New Castle Design Associates Project Proposal

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CREATIVE CARD PLACING MACHINE
presented by
Overkill Inc.
Exerting Maximum Effort For Minimum Results
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PROBLEM BACKGROUND
Business cards are todays person-to-person
marketing tool GDA Digital Media is seeking a
new way of accepting business cards The idea is
to build a creative machine that will highlight
GDAs receptive and down-to-earth approach to
business.
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OUR MISSION
To design, build, and evaluate an innovative,
multi-step machine that accepts business card and
places it randomly in a defined area of the
wall.
Our Approach In the presentation Customers Wants,
Constraints, Metrics Benchmarking Concept
Generation, Evaluation and Refinement Prototype
Testing Modifications Recommendations to the
Customer Budget
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CUSTOMERS
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CUSTOMER WANTS, METRICS, TARGET VALUES
1. Display Creativity No. of Employee
Representations 4 No. of Steps ?7 No. of
Steps That Involve the Card 5 No. of Moving
Parts 7 No. of Dissimilar Actions/Steps
?7 No. of Steps to Start the Machine 1 No.
of Hidden Steps 0 of Card Visible After
Attachment 100 of Card Defaced 0 No.
of Simultaneous Steps 2
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CUSTOMER WANTS, METRICS, TARGET VALUES
2. Reliability Percent complete cycles 95
3. Customers Represented No. of customer
representations 2
4. Limited Run Time Time to completion 45 sec.
5. Limited Machine Size Machine
Length/Width/Height 3ft/2ft/3ft
6. Business Card Compatibility Card size 2.5
x 3 - 3 x 3.5 Weight 1 gram Thickness 0.
012in
7. Simple Reloading Reloading time 15 sec.
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CONSTRAINTS

• Random Placement In Defined Area
• Minimum Five Steps
• No Profane, Indecent, Or Lewd Expressions
• Cost Not To Exceed 250
• No Human Intervention After Startup
• Must Include GDA Logo And Spike Image
• Must Include A South Park Character
• Card Must End Up Face Out

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BENCHMARKING
System Benchmarks Labeling Machine, Auto Feed
Copy Machine, Printing Press
Functional Benchmarks Placement/Positioning Robo
tic Arm Random Generation Computer, Air
Table Machine Initiation Global Bill
Acceptor Rube Goldbergs Theta Tau Wall
Attachment Staples, Tape
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CONCEPT GENERATION
1. Held Brainstorm Sessions for the five main
functions Placement/Positioning
Robotic Arm, Dart Gun, Free Fall, X - Y
Plotter Random Generation Air
Table, Computer, Mechanical Devices - Roulette,
Plinko Machine Initiation
Pinball Plunger, Carrousel, Foosball Player
Rube Goldbergs Elevator,
Conveyor Belt, Chutes, Foosball Wall
Attachment Adhesives, Pushpins,
Velcro, Magnets, Staples 2. Evaluated
brainstorms against our constraints to determine

feasible
concepts.
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METRIC REFINEMENT AND VALIDATION
Lack of Engineering Specifications That Measure
Creativity Presented Concepts to GDA Led to
analysis of individual functions for specifics
that make a design creative Based on
Specifics Developed New Metrics Validated
Existing Metrics
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THE SPECIFICS - METRIC DEVELOPMENT
Some Feedback Highlights Robot Arm more
favorable than Bulletin Board Metric of
hidden steps Tape/glue more favorable than push
pin/pin board Metrics card defaced
card visible after attachment
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THE TOP CONCEPTS
Concept A Initiation Card Placed in car
and shot with pinball Placement Robotic
Arm Random Generation Computer
Attachment Solenoid / Double Sided
Tape Concept B Initiation Card Placed in
car and shot with pinball Placement X - Y
Plotter Random Generation Computer
Attachment Solenoid / Double Sided
Tape Concept C Initiation Card Placed in
car and shot with pinball Placement Hinged
Bulletin Board Random Generation Air
Table Attachment Double Sided Tape
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CONCEPT SELECTION
Metric Highlights Concept A 2 steps to initiate
machine Concept B 2 steps to initiate
machine The X-Y plotter acts in a linear
fashion duplicates an action Concept C 2
steps to initiate machine The Air table hides
attachment of card Has 1 hidden step Hinged
Bulletin Board doubles required Volume 4x
2.5x 2.5
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CONCEPT A
Five Major Functions Acceptance - Two
Steps Place card in car Pinball
Plunger Rube Goldberg Highlights - 12
steps Car down a ramp Card in an elevator and
on conveyor belt Foosball player and
ball Hanging Kenny
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CONCEPT A CONTD
Random Generation Computer Generated
Number Basic Program Use 1 serial port and
1parallel port Placement of Card Card positioned
with robotic arm 2 Degrees of Freedom Planar
Motion Driven by two stepper motors Card held
to arm via vacuum suction Attachment Solenoid
extends Vacuum turns off Tape adheres to wall
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PROTOTYPE EVALUATION
Top Metric Target Value Actual Value No.
of Employee Representations 4 4 No. of Steps
?7 gt7 No. of Steps That Involve the Card
5 4 No. of Moving Parts 7 7 No. of
Dissimilar Actions/Steps ?7 gt7 No. of Steps to
Start the Machine 1 2 No. of Hidden Steps
0 0 of Card Visible After Attachment
100 100 of Card Defaced 0 0 No. of
Simultaneous Steps 2 2
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PROTOTYPE TESTING
Robotics Holding Torque Run Time 25 - 70
sec. Solenoid Activation 100 Vacuum 75
Rube Goldberg Completion - Initiation/Terminatio
n 80 Defacement of Card 0 Acceptable
Card Sizes width to 2.75 length to
3.5 Entire Machine Complete
Cycles Time to Completion 45 - 90
sec. Reload Time 30 sec.
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MODIFICATIONS
Added 900g Counterweight To Arm Moved Solenoid
Off Arm Added Weight To Front of Car Changed
Bearing Sleeve Material In Paddlewheel Added
Guardrail To Conveyor Belt Added Ratchet Style
Brake
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RECOMMENDATIONS

• Pull plunger back to full extension
• Ensure proper arm alignment
• Replace batteries every 6 months
• Always keep vacuum plugged in
• Replace unused tape weekly

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BUDGET
Our spending limit was set at 250. Robot 165
.73 Rube Goldberg Supplies 27.36 Computer 1
5.22 General Materials 40.40 Total
248.71 Many significant materials have been
donated courtesy of UD EE Dept., BikeLine, GDA,
and Dade Behring.
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CONCLUSIONS
System will be installed at the GDA Wilmington
office before April 30, 1999 Team 13 will receive
feedback over the month of May, 1999