Siphon

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! Part Number !! Description !! Quantity !! Function !! Material !! Weight !! Manufacturing Process !! Image
! Part Number !! Description !! Quantity !! Function !! Material !! Weight !! Manufacturing Process !! Image
|-  
|-  
-
| 001 || Top Cover || 1 ||
+
| 1 || Siphon Attachment Converger || - ||
-
* Protect the user from moving parts
+
* [Insert function description here]
-
* Aesthetics
+
|| Clear Plastic || 0.6 oz || Forged || [[Image:Siphon_1.JPG|100px]]
-
* Support the shredder on basket
+
-
* Houses the on/off switch
+
-
* Informs the user of acceptable inputs
+
-
* Houses item entrance for shredding
+
-
|| Plastic || 12" x 5" x 1" || Injection Molding || [[Image:Top cover (7).jpg|100px]]
+
-
|-
+
-
| 002 || Switch Housing || 1 ||
+
-
* Sets desired functionality
+
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* Houses child safety button
+
-
|| Plastic || 3" x 1" x 1" || Injection Molding || [[Image:Safety housing (7).jpg|100px]]
+
-
|-
+
-
| 003 || Base || 1 ||
+
-
* Houses main components
+
-
** Light bulb
+
-
** 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 ||
+
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* Guides paper
+
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* Protects user
+
-
|| Plastic || 8" x 2" x 1" || Injection Molding ||[[Image:feeder_lip_top_(7).jpg|100px]]
+
-
|-
+
-
|005 || Feeder Lip Bottom || 1 ||
+
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* Guides paper
+
-
* Protects user
+
-
|| Plastic || 8" x 2" x 1" || Injection Molding || [[Image:feeder_lip_bottom_(7).jpg|100px]]
+
-
 
+
-
|-
+
-
|006 || Child Safety || 1 ||
+
-
* Prevents unintentional use
+
-
|| Plastic || 2" x 1" x 1" || Injection Molding ||[[Image:Child_safety_switc_(7).jpg|100px]]
+
-
 
+
-
|-
+
-
|007 || Electrical & Motor Sub-assembly || 1 ||
+
-
* Drives gear train (motor)
+
-
* Automatic safety switch  (must be sitting on basket properly)
+
-
* 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 ||
+
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* Component of gear train
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-
* Connects to motor
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* Quieter than spur gears
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-
|| Plastic || 1" x 1" || Injection Molding ||[[Image:helical_gear_(7).jpg|100px]]
+
-
 
+
-
|-
+
-
|009 || Large Spur Gear  || 1 ||
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* Component of gear train
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* Reduce Speed/Increase Torque
+
-
|| Plastic || 3" x 1" || Injection Molding ||[[Image:large_spur_(7).jpg|100px]]
+
-
 
+
-
|-
+
-
|010 || Small Spur Gear  || 1 ||
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* Component of gear train
+
-
* Reduce Speed/Increase Torque
+
-
|| Plastic || 1" x 1" || Injection Molding ||[[Image:small_spur_(7).jpg|100px]]
+
-
 
+
-
|-
+
-
|011 || Output Spur Gear  || 1 ||
+
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* Drive shaft
+
-
|| Plastic || 1" x 1" || Injection Molding ||[[Image:output_spur_gear_(7).jpg|100px]]
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-
 
+
-
|-
+
-
|012 || Light Bulb Reflector  || 1 ||
+
-
* Increases intensity of light
+
-
|| Plastic+Aluminum || .5" x .5" x 1" || Injection Molding and Sheet Foil||[[Image:light_bulb_(7).jpg|100px]]
+
-
 
+
-
|-
+
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|013 || Delay Trigger Housing || 1 ||
+
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* Houses the shredding cutoff time-delay
+
-
|| Plastic || 3" x 1" x 1" || Injection Molding ||[[Image:safety_housing_(7).jpg|100px]]
+
-
 
+
-
|-
+
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|014 || Cutoff Switch Time-Delay Trigger  || 1 ||
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* Triggers cutoff switch time-delay
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|| Plastic || 1" x 1" x .5" || Injection Molding ||[[Image:cutoff_switch_time-delay_trigger_(7).jpg|100px]]
+
-
 
+
-
|-
+
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|015 || Spring for Child Safety Switch  || 1 ||
+
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* Hold the safety switch in position
+
-
|| Spring Steel || 1/8" x .5" || Winding ||[[Image:spring_(7).jpg|100px]]
+
-
 
+
-
|-
+
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|016 || Bow-Tie Washer  || 1 ||
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* Attaches automatic safety switch to the base cover
+
-
|| Plastic || 1" x 1" x 1/8" || Injection Molding ||[[Image:bowtie_(7).jpg|100px]]
+
-
 
+
-
|-
+
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|017 || Main Shaft Base Plate  || 1 ||
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* Hold axes aligned
+
-
|| Plastic || 3" x 3" x 1/4" || Injection Molding ||[[Image:main_shaft_base_plate_(7).jpg|100px]]
+
-
 
+
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|-
+
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|018 || Cover Plate for Shaft Alignment  || 1 ||
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* Hold axes aligned
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-
|| Plastic || 2" x 2" x 1/4" || Injection Molding ||[[Image:Plastic_top_cover_(7).jpg|100px]]
+
-
 
+
-
|-
+
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|019 || Gear Train Housing Base Plate  || 1 ||
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* Holds gears
+
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* Holds axes aligned
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|| Metal || 4" x 2" x 1/4" || Stamped ||[[Image:gear_base_plate_(7).jpg|100px]]
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-
 
+
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|-
+
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|020 || Gear Train Housing Top Plate || 1 ||
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* Holds gears
+
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* Holds axes aligned
+
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|| Metal || 3" x 1" x 1/4" || Stamped ||[[Image:gear_top_plate_(7).jpg|100px]]
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-
 
+
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|-
+
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|021 || Attachment Aligner for Motor Base Plate || 1 ||
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* Holds motor to gear train housing top plate
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|| Plastic || 1" x 1" x 1/4" || Injection Molding ||[[Image:motor_top_plastic_cover_(7).jpg|100px]]
+
-
|-
+
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|022 || Screws  || 31 ||
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* Fastening
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|| Steel || #10-20 || Machined||[[Image:basket_(7).jpg|100px]] In the background
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-
 
+
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|-
+
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|023 || Helical Blade  || 104 ||
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* Cut paper in diamond shape
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* Feeds paper
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|| Steel || .5" x 1\32" || Stamped ||[[Image:Helical_blade_cutters_(7).jpg|100px]]
+
-
 
+
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|-
+
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|024 || Flat Blade  || 8 ||
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* Feeds paper
+
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|| Steel || .5" x 1\32" || Stamped ||[[Image:flat_blade_cutters_(7).jpg|100px]]
+
-
 
+
-
|-
+
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|025 || Paper Aligners  || 54 ||
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* Ensures proper feeding of paper
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-
|| Plastic || 1/2" x 1/4" x 1" || Injection Molding ||[[Image:white_aligner_(7).jpg|100px]]
+
-
 
+
-
|-
+
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|026 || "Paper Aligner" Aligning Rod  || 2 ||
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* Aligns aligners
+
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|| Metal || 1\4" x 8" || Extrusion ||[[Image:cutting_assembly2_(7).jpg|100px]] Gold rod
+
-
 
+
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|-
+
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|027 || Long Main Shaft  || 1 ||
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* Driven by gear train
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* Turns blades
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* Aligns blades
+
-
|| Steel || 10" x 1/4" || Machined||[[Image:cutting_assembly2_(7).jpg|100px]] Center rod
+
-
 
+
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|-
+
-
|028 || Short Main Shaft || 1 ||
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* Driven by gear train
+
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* Turns blades
+
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* Aligns blades
+
-
|| Steel || 9" x 1/4" || Machined||[[Image:cutting_assembly_(7).jpg|100px]] Center rod
+
-
 
+
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|-
+
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|029 || Basket || 1 ||
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* Collect shredded waste
+
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* Houses tab
+
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* Shredder assembly rests on top of basket
+
-
* Keeps shredder assembly aligned
+
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|| Steel || 12" x 12" x 5" || Stamp ||[[Image:basket_(7).jpg|100px]]
+
-
 
+
-
|-
+
-
|030 || Tab  || 1 ||
+
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* Press safety switch
+
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|| Steel || 1/2" x 1/2" x 1/2" || Stamped ||[[Image:basket_(7).jpg|100px]] On the basket
+
-
 
+
|}
|}

Revision as of 17:53, 22 September 2007

This product is a component of the analysis for the aquarium pump project.

Contents

Product Purpose

Customer Needs

Stakeholders

Consumer Demographics

Product Function

Product Use

Bill of Materials

Part Number Description Quantity Function Material Weight Manufacturing Process Image
1 Siphon Attachment Converger -
  • [Insert function description here]
Clear Plastic 0.6 oz Forged

Failure Mode and Effects Analysis (FMEA)

The table below details our assessment of the most common failures that we anticipate the bilge pump to experience. This assessment explains how product parts may fail and what the consequences, detectability, and probability of occurence those failures implicate. Addressing these possibilities will allows future designs of this product to be more reliable. Using the Suggested Evaluation Criteria (as found on the FMEA wiki page), we were able to rank the severity from 1-10 (10 being the highest). For the occurrence parameter, we then were able to rank the probability of failure again from 1-10 (with 10 being the highest). Finally, we were able to rank detectability from 1-10 (with 1 being the most detectable). From these three numbers, we were able to multiply them together, which results with the Risk Priority Number (RPN).

Item and Function Failure Mode Effects of Failure S Causes of Failure O Design Controls D RPN Recommended Actions Responsibility Actions Taken S* O* D* RPN*
Siphon Attachment Converger
  • Joins siphon tube and cleaning attachment
Blockage Erratic operation; fluid movement impinged 7 Sediment buildup; insufficient room for large objects (e.g., aquarium stones); fish or marine life impingement 6 Siphon flows with suspensions of large objects of varying geometries 2 84 Allow greater curvature in converger design; creating brush to facilitate cleaning Design engineer - - - - -
Attachment
  • Cleans aquarium rocks
Cracking or fracture Rocks may exit attachment and would not be cleaned properly 6 Overstressing; applying large forces to plastic outside of normal use 3 Test material strength under high loads 3 54 Improve material strength tests; use more durable plastic Materials engineer - - - - -
Tube
  • Transfers fluid from aquarium to output source
Deterioration or melting Pump will lose efficiency 6 Siphoning corrosive substances or hot liquids; exposure to excessive heat 4 Test under extreme temperature conditions with range of substances 4 80 Use material with greater resistance to high temperatures Materials engineer - - - - -
Deformation Tube may not connect to converger properly or may become dislodged during use 6 Excessive use causes tube diameter stretching 3 Subject tube to repeated tests with larger diameter 2 36 Use material that better permits repeated wear without deformation Materials engineer - - - - -
Wear Hole or rip 7 Overuse; contact with sharp edges (e.g., tank) 5 Test material under extreme use conditions 3 105 Use more durable material in tube construction Materials engineer - - - - -

The highest RPN value for this analysis was 105, which would be caused by overuse. This mode of failure would lead to a hole or rip in the main tube, which transfers fluid from the aquarium to the output source. This failure received a 7 for severity, a 5 for probability of occurrence, and a 3 for detectability. The result of this failure would be the siphon operating inefficiently but perhaps would lead to a complete loss of functionality. From this analysis, it can be concluded that even the most catastrophic failure is not detrimental to the user with respect to his or her physical safety and wellbeing. The worst case scenario is that the siphon would lose its functionality, causing the user to have to purchase another such pump. To fix this failure mode, a possible solution would be to use more durable material in the tube. This example illustrates the fact that the FMEA analysis diagnoses some room for improvement in the overall design of the siphon.

Design for X (DFX)

The concept of DFX refers to considering a specific variable X in the design of a product. Some common variables that are considered are ease of: manufacturing, assembly, use, and maintainability.

Design for Manufacturing and Assembly (DFMA)

DFM and DFA refer to analysis and design strategies that aim to understand how a product is made and how the manufacturing and assembly steps in its production can be improved. The DFMA process is advantageous for a designer’s consideration due to the tremendous cost benefits that accompany the simultaneous analysis of DFM and DFA and the interface between the two methods. The use of these methodological tools can reduce costs, decrease labor, cut production times, decrease part counts, and improve the overall design quality.

Design for Manufacturing (DFM)

The primary goal of the DFM process is to analyze the manner in which the component parts of a product are made. By examining how things are manufactured, this process can be optimized so that parts can be produced efficiently and economically while adhering to design constraints. In order to optimize a manufacturing process, cost factors must be taken into account along with time, labor, environmental, and quality concerns. The list below details some of the ways in which DFM was likely incorporated into the design of the siphon:

  • Tube and attachment are both extruded, which allows for less wasted plastic and ultimately greater efficiency and lower cost in mass production
  • Tolerance between siphon attachment converger and tube is loose enough to allow small expansions of plastic tubing for tight fit in assembly, which prevents parts from being discarded owing to fitting problems
  • Product contains no materials that are difficult or expensive to manipulate in manufacturing process (e.g., rubber, glass, metal)

The analysis above suggests that the product has been designed well for manufacturing. Despite its simplicity, the siphon design manages to reduce manufacturing costs through its choice of materials yet retains a high degree of durability. However, one improvement that might be made is to use an injection molding process to make the siphon attachment converger instead of forging, as this manufacturing switch would allow the process to become more cost effective.

Design for Assembly (DFA)

The objective of DFA is to improve product quality and reduce costs by optimizing a product's design and assembly process. DFA goals are predominantly achieved through simplifying a product, reducing part counts, and designing components that can be easily managed and installed. The follow list describes how DFA was probably applied to the design of the siphon:

  • Product design uses sleeve fitting instead of fasteners to reduce part count, thereby decreasing cost and complexity
  • All components are axisymmetric about radial axis and have enough friction to facilitate handling and manipulation
  • Parts are not too big or heavy due to light plastics used in design, which makes handling easier
  • Stackable nature of siphon attachment converger reduces storage space through compact design
  • Simple and clear product design (with terminals that can only be connected with correct parts) facilitates assembly

From the aforementioned analysis, it is evident that great care has been taken to optimize the assembly process for the siphon. Owing to the straightforward nature of the product design, the design for assembly of the siphon is nearly optimal, as it avoids superfluous complexities and allows for easy handling.

Design for Environment (DFE)

Economic Input-Output Life Cycle Assessment (EIO-LCA)

Quantitative Analyses

Prepared for: 24-441 Engineering Design Course (Fall 2007), Carnegie Mellon University

Retrieved from "https://wiki.ece.cmu.edu/ddl/index.php/Siphon"
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