Final Project

MAE377

Jason Martz Person#: 3472-5814 December 14, 2009

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Table of Contents 1. Introduction....................................................................................................... 3

2. Problem Statement........................................................................................... 3

3. Existing Product Research ............................................................................... 3

4. Product Management ....................................................................................... 4

4.1 Gantt Chart ................................................................................................. 4

4.2 Alternative Designs ..................................................................................... 4

4.3 Design Comparison..................................................................................... 8

5. CAD Models ..................................................................................................... 8

5.1 Sub-Assembly & Parts ................................................................................ 8

5.1.1 Locking Tilt Mechanism Sub-Assembly................................................ 8

5.1.2 Wheel Sub-Assembly ......................................................................... 10

5.1.3 Pump Sub-Assembly.......................................................................... 12

5.1.4 Other Parts ......................................................................................... 14

4.2 Main Assembly.......................................................................................... 18

6. Manufacture Analysis ..................................................................................... 20

6.1 Bill of Materials.......................................................................................... 20

6.2 Cost Analysis ............................................................................................ 21

6.3 2D Drawings ............................................................................................. 22

7. Service Analysis ............................................................................................. 26

7.1 User Manual.............................................................................................. 26

7.2 Product Animation..................................................................................... 27

7.3 Product Life Analysis................................................................................. 27

8. Conclusion...................................................................................................... 27

9. References ..................................................................................................... 28

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1. Introduction The final project had us create a new product from scratch. We had to go through the full design process. First we had to come up with an idea and set goals for the design process with a Gantt chart. Then we had to survey similar existing products. Before designing the final product, alternative sketches were created and the final design was decided among them. Then the product and all of its parts were created in a CAD program (Pro/E). Using those CAD models, we created parts drawings, a bill of materials, renderings and animation. We also created a user’s manual for our final product.

2. Problem Statement The purpose of this project was to create an entirely new product from scratch. I focused on the innovative aspect of creating an entirely new product. So I created an office chair designed for both work and relaxation. I created an office chair with an inflatable cushion, so its softness could be varied. The chair to be created should be comfortable for relaxation, yet professional for work.

3. Existing Product Research Product name Picture Features Price Executive Office Chair, Boss Office Products

· Upright locking position · Pneumatic gas lift seat height adjustment · Adjustable tilt tension control

$131.65

Leader Office Chair, Zuo

· Adjustable Height: from 18" to 21" · Locking Tilt Mechanism · Rolling Casters

$197.23

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Deluxe Office Chair w Back Leather & Wide Padded Arms, Mayline Group

· Easy assembly - no tools required · Top Grain leather on all seated surfaces · Accented with gathered seams on seat and back · Padded leather loop armrests · Durable steel frame construction · Deluxe knee-tilt control

$493.20

Figure 1: A few existing office chairs and their features & Price

4. Product Management

4.1 Gantt Chart To plan our progress for this progress we had to create a Gantt Chart, which plans out when each part is worked on.

Figure 2: The Gantt Chart

4.2 Alternative Designs Before designing the final product, I created multiple design alternatives from which to choose the final design.

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Pro’s Con’s

• “Classic” design • Separate cushions Figure 3: The 1st alternative sketches and its pro’s and con’s

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Pro’s Con’s

• Single Cushion • Comfortable appearance

• Too much cushion (not as much for work)

• Leg rest too big Figure 4: The 2nd alternative sketches and its pro’s and con’s

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Pro’s Con’s

• Single Cushion • Stylish

• Leg rest allows alternative leg positions

Figure 5: The 3rd alternative sketches and its pro’s and con’s

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4.3 Design Comparison To decide which alternative design to use, I used a point-based system that gives each design points for different categories. The design with the most points will be used. Design Ease of

manufacture Appearance Comfort Work

Appropriate Originality Total

1 1 1 1 10 1 14 2 10 5 10 1 5 31 3 5 10 5 5 10 35

5. CAD Models I created the chair and all of its parts in Pro/Engineer

5.1 Sub-Assembly & Parts

5.1.1 Locking Tilt Mechanism Sub-Assembly

(a) (b)

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(c) (d) Figure 6: The locking tilt mechanism shown from different views, (a), (b), (c), and (d)

(a) (b) Figure 7: The Seat column shown from different views, (a) and (b)

(a) (b) Figure 8: The tilt mechanism housing shown from different views, (a) and (b)

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(a) (b) Figure 9: The spring shown from different views, (a) and (b)

(a) (b)

Figure 10: The lock key shown from different views, (a) and (b)

5.1.2 Wheel Sub-Assembly

(a) (b)

Figure 11: The wheel sub-assembly shown from different views, (a) and (b)

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(a) (b)

Figure 12: The wheel housing shown from different views, (a) and (b)

(a) (b)

Figure 13: The wheel axel shown from different views, (a) and (b)

(a) (b)

Figure 14: The wheel shown from different views, (a) and (b)

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5.1.3 Pump Sub-Assembly

(a) (b)

(c) (d) Figure 15: The pump shown from different views, (a), (b), (c), and (d)

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(a) (b) Figure 16: The pump tube shown from different views, (a) and (b)

(a) (b)

Figure 17: The pump handle shown from different views, (a) and (b)

(a) (b) Figure 18: The pump cap shown from different views, (a) and (b)

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(a) (b)

Figure 19: The air pin shown from different views, (a) and (b)

5.1.4 Other Parts

(a) (b)

Figure 20: The base shown from different views, (a) and (b)

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(a) (b) Figure 21: The right arm shown from different views, (a) and (b)

(a) (b) Figure 22: The left arm shown from different views, (a) and (b)

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(a) (b)

Figure 23: The arm cushion shown from different views, (a) and (b)

(a) (b) Figure 24: The seat back shown from different views, (a) and (b)

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(a) (b) Figure 25: The cushion shown from different views, (a) and (b)

(b)

Figure 26: The ¼-ACME, 16 Th’ds per In. bolt shown from different views, (a) and (b)

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(a) (b) Figure 27: The bolt tool shown from different views, (a) and (b)

4.2 Main Assembly

(a) (b)

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(c) (d)

(e) (f) Figure 28: The main assembly shown from different views, (a), (b), (c), (d), (e) and (f)

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6. Manufacture Analysis

6.1 Bill of Materials

Figure 29: The Bill of Materials

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6.2 Cost Analysis Part Price per part Quantity Total Price

Seat Cushion $10.00 1 $10.00 Arm Cushion $3.00 2 $6.00 Seat Back $7.00 1 $7.00 Right Arm Rest $3.00 1 $3.00 Left Arm Rest $3.00 1 $3.00 Tilt Mechanism Housing $6.00 1 $6.00 Tilt Lock $1.00 1 $1.00 Seat Column $4.00 1 $4.00 Tilt Spring $2.00 1 $2.00 Bolt $.50 8 $4.00 Base $5.00 1 $5.00 Wheel $0.50 10 $5.00 Wheel Axel $0.50 5 $2.50 Wheel Housing $2.00 5 $10.00 Pump Handle $2.00 1 $2.00 Pump Cap $1.00 1 $1.00 Pump Tube $2.00 1 $2.00 Air pin $1.00 1 $1.00 Bolt tool $2.00 1 $2.00 Total Price: $76.50

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6.3 2D Drawings

Figure 30: The locking tilt mechanism drawing with parts

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Figure 31: The wheel drawing with parts

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Figure 32: The pump drawing with parts

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Figure 33: The rendered final product

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7. Service Analysis

7.1 User Manual Jason Martz and Co. Air Cushion Office Chair

To Assemble your new Air Cushion Office Chair, just follow these simple steps:

1. Take the left armrest (The bag containing it will be labeled) and align the holes with the holes on the left side of the bottom of the seat

2. Screw in one bolt per hole, and tighten with the included tool 3. Repeat with the right side 4. Forcefully insert each wheel into the outermost holes on the base (make

sure they cannot be pulled out) 5. Forcefully insert the seat column into the center hole in the base 6. Place the base and attached parts wheels-down on floor 7. Align holes on locking-tilt mechanism with holes on bottom of seat 8. Screw in one bolt per hole and tighten with tool 9. Using the hand pump, inflate the seat cushion to desired softness/rigidity

in the hole located in the left/back side of the seat cushion 10. To deflate the seat cushion, just insert the air pin into hole

Warning:

• Do not over-inflate! • Remove sharp objects (keys, etc.) from back pockets when sitting

on chair

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7.2 Product Animation

Figure 34: The product animation screenshot

I created an animation showing how the sub-assemblies are assembled and how the product is assembled by the consumer and how the product works.

7.3 Product Life Analysis The Air Cushion Office Chair should last as long as any other office chair. Its main structure is sound, but the only problem is the cushion. It should last quite long since it will be durable and thick. Since the cushion’s inflation is maintained by the user, when the cushion looses air, it can simply be inflated again.

8. Conclusion The design of the Air cushion Office Chair was successful. Initially, I was only going to create a chair with an inflatable cushion, but I added the locking tilt mechanism and the included hand pump. I also made it so it can be assembled without any other tool (except the one included). I think that if I presented this to a company they would buy it. But that is because when doing this product I tried to create a product that would be marketable today. Creating the product in Pro/E was difficult at times. Since my product contained a lot of parts made up of non-simple shapes, Pro/E would frequently not create the parts for seemingly no

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apparent reason. If I had more time I would have researched and made a pneumatic height adjuster. I also may have made a motorized pump instead of a hand pump, but that would be its own project.

9. References Oberg, E.; Jones, F.D.; Horton, H.L.; Ryffell, H.H., Machinery’s Handbook, 26th ed., McCauley, Christopher J.; Heald, Riccardo; Hussain, Muhammed Iqbal, Ed. New York: Industrial Press, 2000. Mark’s Standard Handbook for Mechanical Engineers,10th ed.,New York: McGraw-Hill, 1996. http://www.officechairstation.com/