Oscillating fan

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==Components:==
==Components:==
As part of the first stage of disassembly, we documented the inner workings prior to removing each individual component.  The first image shows the shredder with the top removed and certain key components labeled.  The second is a detailed close-up of the gear train.  Refer to the table below for more details on individual components identified in these pictures.
As part of the first stage of disassembly, we documented the inner workings prior to removing each individual component.  The first image shows the shredder with the top removed and certain key components labeled.  The second is a detailed close-up of the gear train.  Refer to the table below for more details on individual components identified in these pictures.
-
[[Image:Spring07team7_ComponentMap02.jpg|600px|center]]
 
-
[[Image:Spring07team7_ComponentMap03.jpg|600px|center]]
 
Line 50: Line 48:
* Protects fan blades
* Protects fan blades
* Aesthetics
* Aesthetics
-
|| ?? || Merging of Extruded Parts || [[Image:Fan_Front_Cover.jpg]]
+
|| ?? || Merging of Extruded Parts || [[Image:fan front cover.jpg]]
|-  
|-  
-
| 002 || Switch Housing || 1 ||
+
| 002 || Threaded Cap for Blades || 1 ||
-
* Sets desired functionality
+
* Holds blade unit in place
-
* Houses child safety button
+
* Left handed threading to keep it from loosening
-
|| Plastic || 3" x 1" x 1" || Injection Molding || [[Image:Safety housing (7).jpg|100px]]
+
|| Plastic || Injection Molding || [[]]
|-  
|-  
-
| 003 || Base || 1 ||
+
| 003 || Blade Unit || 1 ||
-
* Houses main components
+
* Circulates Air
-
** Light bulb
+
|| Plastic || Injection Molding ||[[]]
-
** Motor
+
-
** Gear train
+
-
** Blades
+
-
** Operation safety switch
+
-
* Dispense of shredded paper
+
-
|| Plastic || 12" x 5" x 3" || Injection Molding ||[[Image:Base_plate_(7).jpg|100px]]
+
|-
|-
-
|004 || Feeder Lip Top || 1 ||
+
|004 || Set Screw || 1 ||
-
* Guides paper
+
* Centers Blades
-
* Protects user
+
|| Steel || Extrusion ||[[Image:]]
-
|| Plastic || 8" x 2" x 1" || Injection Molding ||[[Image:feeder_lip_top_(7).jpg|100px]]
+
|-
|-
-
|005 || Feeder Lip Bottom || 1 ||
+
|005 || Rear Plate Fastener || 1 ||
-
* Guides paper
+
* Fastens rear plate
-
* Protects user
+
|| Plastic || Injection Molding || [[Image:]]
-
|| Plastic || 8" x 2" x 1" || Injection Molding || [[Image:feeder_lip_bottom_(7).jpg|100px]]
+
|-
|-
-
|006 || Child Safety || 1 ||
+
|006 || Rear Fan Cover || 1 ||
-
* Prevents unintentional use
+
* Protect the user's body parts
-
|| Plastic || 2" x 1" x 1" || Injection Molding ||[[Image:Child_safety_switc_(7).jpg|100px]]
+
* Protects fan blades
 +
* Aesthetics
 +
|| ?? || Merging of Extruded Parts ||[[Image:]]
|-
|-
-
|007 || Electrical & Motor Sub-assembly || 1 ||
+
|007 || Motor Front Cover || 1 ||
-
* Drives gear train (motor)
+
* Protect motor components
-
* Automatic safety switch  (must be sitting on basket properly)
+
|| ?? || cast ||[[Image:]]
-
* Shredding cutoff time-delay
+
-
* Ready LED
+
-
* Off/auto/reverse switch
+
-
* Light bulb 
+
-
* Provides electrical power to the system
+
-
|| N/A || N/A || Purchased ||[[Image:Electrical_&_Motor_Sub-assembly_(7).jpg|100px]]
+
|-
|-
-
|008 || Helical Gear || 1 ||
+
|008 || Swivel Adjustment Knob || 1 ||
-
* Component of gear train
+
* Adjusts DOF's of fan position
-
* Connects to motor
+
|| Plastic/Steel || Injection Molding/Extrusion ||[[Image:]]
-
* Quieter than spur gears
+
-
|| Plastic || 1" x 1" || Injection Molding ||[[Image:helical_gear_(7).jpg|100px]]
+
|-
|-
-
|009 || Large Spur Gear || 1 ||
+
|009 || Nut for Swivel Adjustment Knob || 1 ||
-
* Component of gear train
+
* Fastens bolt of adjustment knob
-
* Reduce Speed/Increase Torque
+
|| Steel || Stamped ||[[Image:]]
-
|| Plastic || 3" x 1" || Injection Molding ||[[Image:large_spur_(7).jpg|100px]]
+
|-
|-
-
|010 || Small Spur Gear || 1 ||
+
|010 || Fan Head Coupling || 1 ||
-
* Component of gear train
+
* Attaches fan head to stand
-
* Reduce Speed/Increase Torque
+
|| Plastic/Steel || Injection Molding/Extrusion ||[[Image:]]
-
|| Plastic || 1" x 1" || Injection Molding ||[[Image:small_spur_(7).jpg|100px]]
+
|-
|-
-
|011 || Output Spur Gear || 1 ||
+
|011 || Speed Selection Knob || 1 ||
-
* Drive shaft
+
* Turns on power
-
|| Plastic || 1" x 1" || Injection Molding ||[[Image:output_spur_gear_(7).jpg|100px]]
+
* Selects speed of fan
 +
* Interfaces with switch
 +
|| Plastic || Injection Molding ||[[Image:]]
|-
|-
-
|012 || Light Bulb Reflector || 1 ||
+
|012 || Switch || 1 ||
-
* Increases intensity of light
+
* Turns on power
-
|| Plastic+Aluminum || .5" x .5" x 1" || Injection Molding and Sheet Foil||[[Image:light_bulb_(7).jpg|100px]]
+
* Selects speed of fan
 +
* Interfaces with speed selection knob
 +
|| Plastic/Copper || Injection Molding/Stamped||[[Image:]]
|-
|-
-
|013 || Delay Trigger Housing || 1 ||
+
|013 || Motor Housing || 1 ||
-
* Houses the shredding cutoff time-delay
+
* Covers
-
|| Plastic || 3" x 1" x 1" || Injection Molding ||[[Image:safety_housing_(7).jpg|100px]]
+
** Motor
 +
** Shaft
 +
** Electrical Components
 +
|| Plastic || Injection Molding ||[[Image:]]
|-
|-
-
|014 || Cutoff Switch Time-Delay Trigger || 1 ||
+
|014 || Capacitor || 1 ||
-
* Triggers cutoff switch time-delay
+
* Stores electrical potential energy
-
|| Plastic || 1" x 1" x .5" || Injection Molding ||[[Image:cutoff_switch_time-delay_trigger_(7).jpg|100px]]
+
|| Plastic/Other || N/A ||[[Image:]]
|-
|-
-
|015 || Spring for Child Safety Switch || 1 ||
+
|015 || Electrial Wire || 7 ||
-
* Hold the safety switch in position
+
* Connects electric components
-
|| Spring Steel || 1/8" x .5" || Winding ||[[Image:spring_(7).jpg|100px]]
+
|| Plastic/Copper || Drawn ||[[Image:]]
|-
|-
-
|016 || Bow-Tie Washer || 1 ||
+
|016 || Oscillation Gear Casing || 1 ||
-
* Attaches automatic safety switch to the base cover
+
* Holds the gears that control oscillation
-
|| Plastic || 1" x 1" x 1/8" || Injection Molding ||[[Image:bowtie_(7).jpg|100px]]
+
|| ?? || Cast ||[[Image:]]
|-
|-
-
|017 || Main Shaft Base Plate  || 1 ||
+
|017 || Gear Casing Cap  || 1 ||
-
* Hold axes aligned
+
* Protects gears
-
|| Plastic || 3" x 3" x 1/4" || Injection Molding ||[[Image:main_shaft_base_plate_(7).jpg|100px]]
+
|| Plastic || Injection Molding ||[[Image:]]
|-
|-
-
|018 || Cover Plate for Shaft Alignment || 1 ||
+
|018 || Oscillation Control Knob || 1 ||
-
* Hold axes aligned
+
* Toggles oscillation mode
-
|| Plastic || 2" x 2" x 1/4" || Injection Molding ||[[Image:Plastic_top_cover_(7).jpg|100px]]
+
|| Plastic || Injection Molding ||[[Image:]]
|-
|-
-
|019 || Gear Train Housing Base Plate || 1 ||
+
|019 || Transmission Gear  || 1 ||
-
* Holds gears
+
* Transfers rotation from shaft to gear 1
-
* Holds axes aligned
+
|| Plastic || Injection Molding ||[[Image:]]
-
|| Metal || 4" x 2" x 1/4" || Stamped ||[[Image:gear_base_plate_(7).jpg|100px]]
+
|-
|-
-
|020 || Gear Train Housing Top Plate || 1 ||
+
|020 || Small Ball Bearing || 1 ||
-
* Holds gears
+
* Prevents free motion of transmission gear
-
* Holds axes aligned
+
|| Steel || Cast ||[[Image:]]
-
|| Metal || 3" x 1" x 1/4" || Stamped ||[[Image:gear_top_plate_(7).jpg|100px]]
+
|-
|-
-
|021 || Attachment Aligner for Motor Base Plate || 1 ||
+
|021 || Small Spring || 1 ||
-
* Holds motor to gear train housing top plate
+
* Prevents free motion of transmission gear
-
|| Plastic || 1" x 1" x 1/4" || Injection Molding ||[[Image:motor_top_plastic_cover_(7).jpg|100px]]
+
|| Steel || Extrusion||[[Image:]]
|-
|-
-
|022 || Screws || 31 ||
+
|022 || Gear 1 || 31 ||
-
* Fastening
+
* Transfers rotation from transmission gear to gear 2
-
|| Steel || #10-20 || Machined||[[Image:basket_(7).jpg|100px]] In the background
+
|| Plastic || Molded ||[[Image:]]  
|-
|-
-
|023 || Helical Blade || 104 ||
+
|023 || Gear 2 || 1 ||
-
* Cut paper in diamond shape
+
* Transfers rotation from gear 2 to plastic shaft
-
* Feeds paper
+
|| Plastic || Injection Molding ||[[Image:]]
-
|| Steel || .5" x 1\32" || Stamped ||[[Image:Helical_blade_cutters_(7).jpg|100px]]
+
|-
|-
-
|024 || Flat Blade || 8 ||
+
|024 || Plastic Shaft and Oscillation Linkage || 1 ||
-
* Feeds paper
+
* Interfaces gear 2
-
|| Steel || .5" x 1\32" || Stamped ||[[Image:flat_blade_cutters_(7).jpg|100px]]
+
* Transfers rotation to oscillation linkage
 +
|| Plastic || Injection Molding ||[[Image:]]
|-
|-
-
|025 || Paper Aligners || 54 ||
+
|025 || Oscillation Linkage || 1 ||
-
* Ensures proper feeding of paper
+
* Transfers rotational motion to angular motion of fan oscillation
-
|| Plastic || 1/2" x 1/4" x 1" || Injection Molding ||[[Image:white_aligner_(7).jpg|100px]]
+
|| ?? || Cast ||[[Image:]]
|-
|-
-
|026 || "Paper Aligner" Aligning Rod  || 2 ||
+
|026 || Shaft || 1 ||
-
* Aligns aligners
+
* Transmits motor power to fan and oscillation gearing
-
|| Metal || 1\4" x 8" || Extrusion ||[[Image:cutting_assembly2_(7).jpg|100px]] Gold rod
+
|| Stainless Steel || Extrusion ||[[Image:]]  
|-
|-
-
|027 || Long Main Shaft || 1 ||
+
|027 || Permanent Magnet || 1 ||
-
* Driven by gear train
+
* Uses electromagnetic force to rotate shaft
-
* Turns blades
+
|| Ferric Material || Coiled Wire ||[[Image:]]
-
* Aligns blades
+
-
|| Steel || 10" x 1/4" || Machined||[[Image:cutting_assembly2_(7).jpg|100px]] Center rod
+
|-
|-
-
|028 || Short Main Shaft || 1 ||
+
|028 || Rear Shaft Support and Bearing || 1 ||
-
* Driven by gear train
+
* Supports and allows smooth rotation of shaft
-
* Turns blades
+
|| ?? || Cast ||[[Image:]]  
-
* Aligns blades
+
-
|| Steel || 9" x 1/4" || Machined||[[Image:cutting_assembly_(7).jpg|100px]] Center rod
+
|-
|-
-
|029 || Basket || 1 ||
+
|029 || Front Shaft Support and Bearing || 1 ||
-
* Collect shredded waste
+
* Supports and allows smooth rotation of shaft
-
* Houses tab
+
|| ?? || Cast ||[[Image:]]
-
* Shredder assembly rests on top of basket
+
-
* Keeps shredder assembly aligned
+
-
|| Steel || 12" x 12" x 5" || Stamp ||[[Image:basket_(7).jpg|100px]]
+
|-
|-
-
|030 || Tab || 1 ||
+
|030 || AC Motor Block || 1 ||
-
* Press safety switch
+
* Holds motor coils and electromagnets
-
|| Steel || 1/2" x 1/2" x 1/2" || Stamped ||[[Image:basket_(7).jpg|100px]] On the basket
+
|| Steel || Cast/Rolled ||[[Image:]]  
|}
|}

Revision as of 15:29, 19 September 2007

Contents

Customer Needs

The customer’s primary need is to cool a room by circulating air. More air circulation provides greater air movement and cooling potential. The fan’s noise level is a concern of the customer. Quiet operation, with little to no vibrations is preferred. The customer must also be able to adjust the fan’s rotational speed to best suit the surroundings. This allows for quieter, lower energy, operation when maximum air circulation is unnecessary. Another necessity is the ability to vary the direction of where air is being. This includes altering the vertical orientation as well as providing horizontal oscillation. The fan should also be safe for the user. This involves shielding the fan blades, while still allowing air to pass through. This shielding prevents objects and body parts from coming in contact with the blades. Fans are generally only used during warm times of the year. As a result they must be easy to move and store while not in use.

Function

An oscillating fan cools an area using forced convection thus increasing heat transfer. This is accomplished by spinning three plastic blades which circulates air in the desired direction. The blades are spun by an AC brushless motor, which is powered from a standard 120V wall outlet. The motor’s rotational speed can be adjusted by the user using a circular knob. The fan is also capable of horizontal oscillation. The user starts this movement by pushing a button at the top of the fan casing. This engages a gear train which spins a small plastic linkage. This linkage is connected to an aluminum bar which is attached to the casing. This simple mechanism translates circular motion to oscillatory horizontal motion. The gear train is powered by the same motor and shaft that spin the blades, thus requiring no additional motor.

FMEA

Item and Function Failure Mode Effects of Failure S Causes of Failure O Design Controls D RPN Recommended Action Responsibility and Deadline Actions Taken S O D RPN Motor/Shaft Inhibited Rotation Inefficient Operation 5Debris (e.g. dust) in Fan 4 Run Under Extreme Dust and Debris Conditions 2 40Filter, Accessibility for Cleaning, Better Protection of Rotating Parts Motor Housing - 53230 Swivel Mount Nut Stripping, Plastic Fracture Cannot Adjust Vertical Directoin Fan Cannot Effectively Circulate Air 8 Overtightening, Material Failure 3 Overtightened Screw, Force applied on Swivel Area 1 24 Use Torque Limited Fastening, Using Stronger Plastic Swivel - 8 2 1 16 Oscillation Button Dislocation of Button Cannot Toggle Oscillation 6 Stripped Gear, Button Disengaged 5 Stronger Gears, Improved Connection 2 60 Fatigue Testing Gears and Button - 6 3 2 36 Blade Cover Inhibited Rotation, Blade Fracture Complete Inoperable8 Penetration of Cover 4 Penetrate Repeatedly 1 32 Warning Label, Redesign Cover User - 8 3 1 24 Shaft Non-concentric Rotation Vibration and Noise 5 Broken Bearing, Unbalanced Weight, Shaft Non-Uniformity 2 Quality Control 3 30 Vibration Testing Assembly - 5 1 3 15 Electronics Short Circuit Completely Inoperable 8Exposure to Water 3 Water Exposure Testing 2 48Waterproof Housing of Electronics Housing - 81216

Components:

As part of the first stage of disassembly, we documented the inner workings prior to removing each individual component. The first image shows the shredder with the top removed and certain key components labeled. The second is a detailed close-up of the gear train. Refer to the table below for more details on individual components identified in these pictures.


The following table contains each individual part present in the product. A brief description of each part and its function will help determine whether any of the components can be refined for future designs to make it less expensive or possibly remove it all together. It can be also be seen that a large, important part of the system is purchased (the motor and electronics).

Part # Part name QTY Function Materials Manufacturing Process Picture
001 Front Fan Cover 1
  • Protect the user's body parts
  • Protects fan blades
  • Aesthetics
 ?? Merging of Extruded Parts Image:fan front cover.jpg
002 Threaded Cap for Blades 1
  • Holds blade unit in place
  • Left handed threading to keep it from loosening
Plastic Injection Molding [[]]
003 Blade Unit 1
  • Circulates Air
Plastic Injection Molding [[]]
004 Set Screw 1
  • Centers Blades
Steel Extrusion [[Image:]]
005 Rear Plate Fastener 1
  • Fastens rear plate
Plastic Injection Molding [[Image:]]
006 Rear Fan Cover 1
  • Protect the user's body parts
  • Protects fan blades
  • Aesthetics
 ?? Merging of Extruded Parts [[Image:]]
007 Motor Front Cover 1
  • Protect motor components
 ?? cast [[Image:]]
008 Swivel Adjustment Knob 1
  • Adjusts DOF's of fan position
Plastic/Steel Injection Molding/Extrusion [[Image:]]
009 Nut for Swivel Adjustment Knob 1
  • Fastens bolt of adjustment knob
Steel Stamped [[Image:]]
010 Fan Head Coupling 1
  • Attaches fan head to stand
Plastic/Steel Injection Molding/Extrusion [[Image:]]
011 Speed Selection Knob 1
  • Turns on power
  • Selects speed of fan
  • Interfaces with switch
Plastic Injection Molding [[Image:]]
012 Switch 1
  • Turns on power
  • Selects speed of fan
  • Interfaces with speed selection knob
Plastic/Copper Injection Molding/Stamped[[Image:]]
013 Motor Housing 1
  • Covers
    • Motor
    • Shaft
    • Electrical Components
Plastic Injection Molding [[Image:]]
014 Capacitor 1
  • Stores electrical potential energy
Plastic/Other N/A [[Image:]]
015 Electrial Wire 7
  • Connects electric components
Plastic/Copper Drawn [[Image:]]
016 Oscillation Gear Casing 1
  • Holds the gears that control oscillation
 ?? Cast [[Image:]]
017 Gear Casing Cap 1
  • Protects gears
Plastic Injection Molding [[Image:]]
018 Oscillation Control Knob 1
  • Toggles oscillation mode
Plastic Injection Molding [[Image:]]
019 Transmission Gear 1
  • Transfers rotation from shaft to gear 1
Plastic Injection Molding [[Image:]]
020 Small Ball Bearing 1
  • Prevents free motion of transmission gear
Steel Cast [[Image:]]
021 Small Spring 1
  • Prevents free motion of transmission gear
Steel Extrusion[[Image:]]
022 Gear 1 31
  • Transfers rotation from transmission gear to gear 2
Plastic Molded [[Image:]]
023 Gear 2 1
  • Transfers rotation from gear 2 to plastic shaft
Plastic Injection Molding [[Image:]]
024 Plastic Shaft and Oscillation Linkage 1
  • Interfaces gear 2
  • Transfers rotation to oscillation linkage
Plastic Injection Molding [[Image:]]
025 Oscillation Linkage 1
  • Transfers rotational motion to angular motion of fan oscillation
 ?? Cast [[Image:]]
026 Shaft 1
  • Transmits motor power to fan and oscillation gearing
Stainless Steel Extrusion [[Image:]]
027 Permanent Magnet 1
  • Uses electromagnetic force to rotate shaft
Ferric Material Coiled Wire [[Image:]]
028 Rear Shaft Support and Bearing 1
  • Supports and allows smooth rotation of shaft
 ?? Cast [[Image:]]
029 Front Shaft Support and Bearing 1
  • Supports and allows smooth rotation of shaft
 ?? Cast [[Image:]]
030 AC Motor Block 1
  • Holds motor coils and electromagnets
Steel Cast/Rolled [[Image:]]


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