Laptop chill mat
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==DFMA== | ==DFMA== | ||
===Design for Assembly=== | ===Design for Assembly=== | ||
| - | Although the design for assembly can be improved on, most aspects of the design have been optimized to enable an easy, cheap assembly process. As for major improvements, the fan containment shell could be joined with the bottom body piece as one piece. There could be certain problems regarding the manufacturing process, but it would improve the design for assembly. In addition, the electric components including the fan and USB component, could be a subassembly that could be manufactured separately. The Logitech logo piece is unnecessary and just adds to the complexity of the assembly. Lastly, joining the felt to the bottom piece provides an assembly complexity as it may require multiple assembly directions or manual assembly. As for minor improvements, screws could be replaced with snap-fit designs and the screws necessary could be standardized. As for the current design, the elastic spacers between two parts are a useful inclusion for variable manufacturing tolerances. The general assembly process seems unambiguous and the assembly surfaces are kept to a decent minimum. | + | Although the design for assembly can be improved on, most aspects of the design have been optimized to enable an easy, cheap assembly process. As for major improvements, the fan containment shell could be joined with the bottom body piece as one piece. There could be certain problems regarding the manufacturing process, but it would improve the design for assembly. In addition, the electric components including the fan and USB component, could be a subassembly that could be manufactured separately. The Logitech logo piece is unnecessary and just adds to the complexity of the assembly. Lastly, joining the felt to the bottom piece provides an assembly complexity as it may require multiple assembly directions or manual assembly. As for minor improvements, screws could be replaced with snap-fit designs and the screws necessary could be standardized. As for the current design, the elastic spacers between two parts are a useful inclusion for variable manufacturing tolerances. Another noteworthy design decision was the fan subassembly. The fan component consisted of a magnet, and it rested over the copper coils, which enables easy assembly without rotating shafts and additional components while being an effective motor. The general assembly process seems unambiguous and the assembly surfaces are kept to a decent minimum. |
===Design for Manufacturing=== | ===Design for Manufacturing=== | ||
Revision as of 22:01, 10 February 2012
Contents |
Executive Summary
Stakeholders Information
DFMA
Design for Assembly
Although the design for assembly can be improved on, most aspects of the design have been optimized to enable an easy, cheap assembly process. As for major improvements, the fan containment shell could be joined with the bottom body piece as one piece. There could be certain problems regarding the manufacturing process, but it would improve the design for assembly. In addition, the electric components including the fan and USB component, could be a subassembly that could be manufactured separately. The Logitech logo piece is unnecessary and just adds to the complexity of the assembly. Lastly, joining the felt to the bottom piece provides an assembly complexity as it may require multiple assembly directions or manual assembly. As for minor improvements, screws could be replaced with snap-fit designs and the screws necessary could be standardized. As for the current design, the elastic spacers between two parts are a useful inclusion for variable manufacturing tolerances. Another noteworthy design decision was the fan subassembly. The fan component consisted of a magnet, and it rested over the copper coils, which enables easy assembly without rotating shafts and additional components while being an effective motor. The general assembly process seems unambiguous and the assembly surfaces are kept to a decent minimum.
Design for Manufacturing
The competitor’s product has been designed well with respect to manufacturability. The product has a low complexity as well as a part count that matches the level of complexity, as it has a good number of parts for its complexity. The most number of parts comes from the number of screws. Although could be lowered by changing from screws to a molded in, snap-fit feature, the screws allows for the part to be assembled easier, have an option to later open the part without breaking it, and keeps the mold simpler and cheaper.
FMEA (Failure Mode and Effects Analysis)
Table
| Failure Modes and Effects Analysis - Laptop Chill Pad | ||||||||||
|---|---|---|---|---|---|---|---|---|---|---|
| Items and Function | Failure Mode | Effects of Failure | Severity | Causes of Failure | Probability of Occurrence | Design Control | Detectability | RPN | Recommended Actions | |
| Fan - spins & cools laptop | Fan stops spinning | Laptop heats up | 0 | Something blocks the fan from spinning | 0 | Protect the fan from foreign objects by having smaller holes so only air can get through | 0 | 0 | None | |
| USB Connector - provides power | Power stops flowing through the USB Connector | Laptop chill pad loses power | 0 | Disconnected from laptop | 0 | Plastic parts within that prevents the movement of the USB Connector from weaker forces | 0 | 0 | Have a smaller connector so that it would be harder to disconnect | |
| 0 | Electronics inside breaks | 0 | Has a metal casing around the electronic parts | 0 | 0 | Have a stronger casing around metal casing for further protection | ||||
DFE
Bill of Materials
The chill pad consists of five simple components: top cover, bottom cover, air intake, grill, and fan subassembly. The assembly is fairly straight forward. There are 16 parts we identified in the assembly. It consists mostly of plastic parts which were manufactured using different molding methods. Several metal screws were used to attach the components together. There are electrical components in the assembly that we did not disassemble such as the motor, switch and the USB connector. In the table below, the parts we identified are listed along with their properties and functions.
List of Components
| Part Number | Part Name | Quantity | Weight (g) | Material | Manufacturing Process | Function | Part Image |
|---|---|---|---|---|---|---|---|
| 1 | Top Cover | 1 | Plastic | Molding | Connects to the top grill and bottom cover. Protects inner workings. | ||
| 2 | Top Grill | 1 | Plastic | Molding | Connects to the top cover. Protects the fan and allows fan blown air to go through. | ||
| 3 | Small Steel Screws | 5 | Steel | Molding | Connects the top cover to the bottom cover. | ||
| 4 | Rubber Screws | 4 | Rubber | Molding | Connects the fan assembly to the top cover. | ||
| 5 | Fan Casing | 1 | Plastic | Molding | Connects to the top cover and the fan. | ||
| 6 | Fan | 1 | Plastic | Molding | Spins and blows air through the grill. | ||
| 7 | Motor | 1 | Copper, Plastic | Connects to the fan. Spins the fan. | |||
| 8 | Felt | 1 | Felt | Glued to the bottom cover. Provides soft interface between the user and product. | |||
| 9 | Bottom Cover | 1 | Plastic | Molding | Connects to the top cover and protects the inner workings. Provides a base for the product. | ||
| 10 | Air Intake | 1 | Plastic | Molding | Connects to the bottom cover. Allows air to flow into the chillpad. | ||
| 11 | Screws | 3 | Steel | Molding | Connects the air intake to the top cover. | ||
| 12 | Rubber Stoppers | 4 | Rubber | Molding | Pushes on the top and bottom cover to provide a space in between. | ||
| 13 | Removable Rubber Gripper | 2 | Rubber | Molding | Connects to the top grill. Provides increased friction between the laptop and chillpad to keep it from moving. | ||
| 14 | USB Connector | 1 | Steel | Stamped | Connects the chillpad to the computer to draw power. | ||
| 15 | Switch | 1 | Plastic, | Molding | Allows the user to control the fan speeds. | ||
| 16 | Wires | 1 | Plastic, Copper | Connects the motor to the switch and then to the USB Connector. |
Team Member Roles
Phase I Team Roles
- Team Leader - James Chon
- DFMA(Assembly) Leader - Jay Kim
- DFMA(Manufacturing) Leader - Mukul Bhatt
- DFE Leader - David Gregor
- FMEA Leader - Brenden Patch
