Reverse Engineering of an Oster Waffle Maker

Oster DuraCeramic Belgian Waffle Maker

JECK EngineeringJordan CrandallCyrus VakiliKen PondEddie Krische

Team 1, Section 56-1WTSN 103

Outline● Appliance Description

o Overviewo Solid Edge Modelso Bill of Materials/Functional Decomposition

● Problems● Redesign

o Possible Modifications o Evaluations (Pugh/Paul & Beitz)o Solid Edge Models of Final Solutiono Bill of Materials/Functional Decomposition of Final

Solution● Conclusion

Oster Waffle Maker

Advertised as:● Makes good waffles● Economically efficient● Easy to use● Safe to use

o Problem - burns user

http://www.target.com/p/oster-duraceramic-waffle-maker/-/A-14678520

Problem Statement

● The Waffle Maker doesn’t allow the user to access the finished waffle without the serious danger of being burned.

http://unifiedconstructs.com/wp-content/uploads/2011/05/bigstock_Safety_First_Vector_7506065.jpg

Solid Edge Assembly

Solid Edge Exploded View

Bill of Materials IPart Number Part Name Classification

(Custom or Standard)Quantity Material

1 Black Phillips head screw Standard 4 18-8 Stainless Steel

2 Silver Phillips head screw Standard 3 18-8 Stainless Steel

3 Cover for leg with three screws Standard 1 Polypropylene

4 Short silver flips head screw Standard 9 18-8 Stainless Steel

5 Leg with the two screws Custom 1 Phenol - formaldehyde resin

6 Bottom metal cover Custom 1 18-8 Stainless Steel

7 Small sliver Philips head screw Standard 13 18-8 Stainless Steel

8 Horse-shoe shape heating element cover

Custom 2 Weaved Phenol -Formaldehyde Resin

9 Tiny washer Standard 3 Black Ox - Stainless Steel

Bill of Materials IIPart Number Part Name Classification

(Custom or Standard)Quantity Material

10 Metal clamp Custom 1 Aluminum - 3200

11 Clear Crimp-Style Wire Nuts Custom 2 Plastic Aluminum - 3200

12 Power cord Standard 1 Copper 10100 Polypropylene Brass

13 Leg with three screws Custom 1 Phenol -formaldehyde resin

14 Handle Custom 1 High Density Polyethylene

15 Top element cover Custom 1 18-8 Stainless Steel

16 Metallic cover of wires Custom 1 Phenol-formaldehyde resin

17 Temperature controlling unit Custom 1 Phenol -formaldehyde resin

18 Handle fastener Custom 1 18-8 stainless steel

Bill of Materials IIIPart Number Part Name Classification

(Custom or Standard)Quantity Material

19 Bigger washer Standard 1 Black Ox - Stainless Steel

20 Big Phillips head screw Standard 1 18-8 Stainless Steel

21 Wire Ties Standard 3 Nylon 6

22 Heating metal Custom 2 Copper 10100

23 Lights Custom 2 Ceramic

24 Dial Custom 1 18-8 stainless Steel Copper 10100

25 Metal Body Custom 2 Duraceramic

26 Wire with cover Custom 3 Nylon 6

Handle Detail Drawing

Top Cover Detail Drawing

Functional Decomposition SpreadsheetPart Input(s) Function(s) Output(s)

Black Screw Mechanical Force Connects top and bottom of the metal body Mechanical Force

Silver Screw Mechanical Force Connect legs to metal covering Mechanical Force

Cover Applied Force Provides a stable bottom for the legs Stable Force

Short Silver Screw

Applied Force Connects many different parts in different areas

Normal Force

Leg Applied Force Holds the metal body above the ground and makes it stable

Stable Force

Metal Housing/Cover

Metal Body Protects the wires and heating elements of the metal body

Metal Body

Handle Mechanical Motion Allows for metal body to move up Mechanical Motion

Functional Decomposition Spreadsheet IIPart Input(s) Function(s) Output(s)

Tiny washer Screw Prevent damage on the object the screw is going into

Screw

Clamp Wires Keeps wires organized Wires

Wire Cover Wires Protect the fragile parts of the wire Wires

Power Cord Electrical Energy Brings in the electrical energy from the socket to the waffle maker

Electrical Energy

Small Silver Screw Applied Force Connects many different parts in different areas

Stable Force

Temperature Controlling Unit

Mechanical Energy Moves and protects the dial Mechanical Energy

Heating Cover Thermal Energy Stores thermal energy Thermal Energy

Handle fastener Handle holds handle in place Handle

Functional Decomposition Spreadsheet IIIPart Input(s) Function(s) Output(s)

Bigger Washer Screw Prevent damage on the object the screw is going into

Screw

Big Screw Applied Force Connects top and bottom of the metal body

Normal Force

Ties Mechanical Energy holds wires together Mechanical Energy

Heating Metal Electrical Energy Converts electrical energy to thermal energy

Thermal Energy

Lights Electrical Energy Converts electrical energy into light

Light Energy

Dial Mechanical Motion Separate and join contacts Mechanical Motion

Metal Body Materials Holds the waffle batter while the batter heats

Materials

Waffle Maker Functional Flowchart

Waffle Maker Schematic

• Mechanical Force• Flow of Heat• Flow of Electricity

Handle

Heat Control Mechanism

Contains and heats batter

Modified Schematic (View 2)

Mechanical Force

Problems Encountered

● Identification of some materials● Difficulty re-assembling

o Many parts broke when rebuildingo ex: “Power” and “Ready” light cover broke

● Difficulty with Solid edge waffle maker part

http://www.magicalexperiments.com/wp-content/uploads/2013/06/problems.jpg

Possible ModificationsMore-open, longer handle

-More space between hand and waffle ironLatch with a Vent

- Latch locks waffle iron close, vent releases excess heatAdditional Cooking Instrument

- Detachable utility (i.e. fork or spatula)Temperature Display

-Indicate Temperature of Waffle Iron

Criteria for Matrices

● Safety (.30)- materials are safe for the user● Cost (.20)- keep the materials at low prices● Heat Efficiency (.15)- produces enough heat to cook

waffle batter● Reliability (.15)- produces crisp, cooked waffles● Portability (.15)- Easy to store and move● Aesthetics (.05)- looks pleasing for the user

Pugh’s MethodHandle Change Addition of a latch w/ a vent Additional Cooking Instrument Temperature display

Safety (+) (+) (+) (+)

Cost S (-) (-) (-)

Heat Efficiency (+) S (+) (+)

Reliability S S S S

Portability S S S (-)

Aesthetics (+) (-) S (-)

(+) 3 1 2 2

S 3 3 3 1

(-) 0 2 1 3

Pahl and Beitz’s Method

Handle ChangeAddition of a latch w/ a

ventAdditional Cooking

Instrument Temperature display

CriterionWeighting Factor (W)

Numerical Value (NV1)

Weighted Value

(W*NV1)Numerical

Value (NV2)

Weighted Value

(W*NV2)Numerical

Value (NV3)

Weighted Value

(W*NV3)Numerical

Value (NV4)

Weighted Value

(W*NV4)

Safety 0.30 4 1.20 3 0.90 4 1.20 4 1.20

Cost 0.20 3 0.60 2 0.40 2 0.40 2 0.40

Heat Efficiency 0.15 3 0.45 3 0.45 3 0.45 3 0.45

Reliability 0.15 3 0.45 2 0.30 3 0.45 4 0.60

Portability 0.15 2 0.30 1 0.15 2 0.30 1 0.15

Aesthetics 0.05 2 0.10 1 0.05 1 0.05 1 0.05

Sum 1 3.10 2.25 2.85 2.85

Modified Solid Edge Assembly

Modified Solid Edge Exploded View

Modified Handle Detail Drawing

Modified Top Cover Detail Drawing

Modified Bill of Materials

Part Number Part Name Classification(Custom or Standard)

Quantity Material

2 Silver Phillips head screw Standard 7 18-8 Stainless Steel

14 Handle Custom 1 High Density Polyethylene

15 Top element cover Custom 1 18-8 Stainless Steel

Modified Functional Decomposition Spreadsheet I

Part Input(s) Function(s) Output(s)

Black Screw Mechanical Force Connects top and bottom of the metal body Mechanical Force

Silver Screw Mechanical Force Connect legs to metal covering Mechanical Force

Cover Applied Force Provides a stable bottom for the legs Stable Force

Short Silver Screw Applied Force Connects many different parts in different areas

Normal Force

Leg Applied Force Holds the metal body above the ground and makes it stable

Stable Force

Metal Housing/Cover Metal Body Protects the wires and heating elements of the metal body

Metal body

Small Silver Screw Applied Force Connects many different parts in different areas

Stable Force

Modified Functional Decomposition Spreadsheet II

Part Input(s) Function(s) Output(s)

Handle Mechanical motion Allows for metal body to move up Mechanical motion

Handle Mechanical Motion Allows user to safely access their waffle Mechanical Motion

Tiny washer Screw Prevent damage on the object the screw is going into

Screw

Clamp Wires Keeps wires organized Wires

Wire Cover Wires Protect the fragile parts of the wire Wires

Power Cord Electrical Energy Brings in the electrical energy from the socket to the waffle maker

Electrical energy

Temperature Controlling Unit

Mechanical energy Moves and protects the dial Mechanical energy

Heating Cover Thermal Energy Stores thermal energy Thermal energy

Modified Functional Flowchart

• Mechanical Force• Flow of Heat• Flow of Electricity

Handle

Heat Control Mechanism

Contains and heats batter

Modified Schematic (View 1)

Mechanical Force

Modified Schematic (View 2)

Conclusion● Problem: User injured by

accessing waffles

● Solution: Longer handle to access cooked waffleso Makes sure user does not

get burned

● Thank you for your time, Questions?

Bibliography ● "Oster Waffle Maker." Target. N.p., n.d. Web. 03 Dec. 2013.● The Role of Magic In Solving Problems. (n.d.). Magical Experiments. Retrieved

December 7, 2013, from http://www.magicalexperiments.com/wp-content/uploads/2013/06/problems.jpg

● Unified’s Safety Management Program. (n.d.). UNIFIED. Retrieved December 9, 2013, from http://unifiedconstructs.com/about-us/approach-safety/