Product Design Process

1
Product Design Process

• By Team Strider

2
Table of Contents

• Introduction
• Customer Needs
• Benchmarking
• Programming Concepts
• Structural/Lift Concepts
• Propulsion Concepts
• Concept Integration
• Gantt Chart/Conclusion

3
Introduction

• Ultimate goal Design and fabrication of an
  autonomous hovercraft
• Product Development Process Two phases
  completed Benchmarking Customer
  Needs Concept Generation

4
Introduction (continued)

• Benchmarking Customer Needs Results
• Several existing models assessed
• Company owner interviewed

5
Introduction (continued)

• Concept Generation
• Hovercraft subsystems divided into three groups
• Structure and Lift
• Propulsion and Power
• Instrumentation Control

6
Introduction (continued)

• Assessment
• Pugh Matrix
• Concept scoring matrix

7
Customer Needs

• By Team Strider

8
Customer Needs Evaluation

• Consulted Bryan Phillips, owner/operator of
  Amphibious Marine, a commercial hovercraft
  manufacturing company
• Amphibious Marine builds hovercraft used in
  industry as well as recreation, for private and
  government customers.
• Important
• Basic functionality
• Reliability
• Relatively Unimportant
• Costs
• Adaptability

9
Benchmarking

• By Team Strider

10
The Benchmarking Process

• Evaluate our competition to obtain knowledge
• Comparative analysis of competitors products.
• Process, methods, and service performance against
  competitors.

11
Existing ProductsltProduct 1gt
Product Description Specifications
Griffon 2000TDX Figure 1 Reference 1 RC Hovercraft Models developed this model with the help of Griffon Hovercraft Ltd, a company for real size hovercrafts. It is a fully operational replication of a full sized craft at 1/30th scale. This model has the ability to independently control lift and thrust. It operates on two channel radio, which enables the thrust motors to be controlled with full forward or reverse thrust at the same time while maintaining throttle control of the lift motor (with the help of a specially built ILC model). The craft has the ability to operate on ice, water, snow and land, and has a water proof body panels and skirts 1. Power 4.8 to 8.4 volt 600mA/Hr and greater capacity (mA/Hr) NiCad, MiMH or Lipoly batteries. Runs on 4, 6, or 7 cell batteries.  Propellers  Thrust 3 inch (0.0762 m) ducted fan Lift 3 inch (0.0762 m) ducted fan   Motors 280 size   Skirt Black Rip-stop Vinyl  Operating Surface Water or Land (will float off of hover and return to full hover)  Will transition from water to land  Radio Requirements 2, 3 or 4 channel land based RC systems ( as used in RC cars and boats)   Speed Controller Requirements 5 Amp 7-8 cell Electronic Speed Controller (ESC). Can use ILC model for 2 channel control with forward/reverse thrust  Craft size   Length 18 inches (0.4572 m) Width  8 inches (0.2032 m) Height 5 inches (0.127 m)  Craft Weight  17 ounces (0.481941893 kg) loaded with battery, ESC and radio equipment (as in our combo) Max speed 30 km/h (8.33 m/s) Range ¼ mile (402.33600 m)
12
Existing ProductsltProduct 2gt
Product Description Specifications
SR.N5 Figure 2 Reference 1 The SR.N5 is a very detailed craft with elevator moldings and a detail engine intake. It has a rear storage bin, puff ports, bifurcated exhaust, and cabin lines. This craft is a fast craft. The SR.N5 has forward and reverse thrust capabilities, and it goes backwards just as fast as it goes forward. It has super lift power and outstanding handling. It features high efficiency twin motors for optimum lift and thrust. The Sr.N5 is known for its efficiency and its durability 1. Craft size   Length 26 inches (0.6604 m) Width  20 inches (0.508 m) Height 11 inches (0.2794 m)  Craft Weight  2.4 Pounds (1.08862169 kg) loaded with battery and radio equipment (as in our combo)  Power 7.2 or 8.4 volt 1700mA/Hr and greater capacity (mA/Hr) NiCad RC car battery.  Motors 400 size   Propellers  Thrust 6 inch (0.1524 m) Lift 4 inch ducted fan (.1016 m)  Skirt Black Rip-stop Vinyl  Operating Surface Water or Land (will float off of hover and return to full hover)  Will transition from water to land  Hover Height 1.5 inches (0.0381 m) (no additional load other than kit as built with 6 cell NiCad)  Speed 10-25 MPH (4.4704 - 11.17600 m/s) depending on terrain and operating conditions    Radio Requirements 2 or 4 channel land based RC systems ( as used in RC cars and boats)   Speed Controller Requirements 20 Amp 7-8 cell Electronic Speed Controller (ESC)
13
Existing ProductsltProduct 3gt
Product Description Specifications
HoverDart Figure 3 Reference 1 The HoverDart is a racing craft design that has the ability to perform under excruciating course conditions. It is said to be an extremely fast craft. It accelerates from a standing start to full speed in an extremely rapid manner. The HoverDart is easy to maneuver, and it loses very little speed due to turning friction. The HoverDart operates on land, snow, water and ice with a two channel control system, and it is suitable for any type of motor although it contains a powerful RC motor for outstanding performance. The HoverDart has a proportional RC throttle on lift and thrust which gives it exceptional power 1. Craft size   Length 24 inches (0.6096 m) Width  16 inches (0.4064 m) Height 9 inches (0.2286 m)  Craft Weight  2.3 Pounds (1.04326245 kilograms) loaded with battery and radio equipment (as supplied in our combo)  Power 7.2 or 8.4 volt 1700mA/Hr and greater capacity (mA/Hr) NiCad RC car battery. Can also be used with LiPoly and NiHM battery packs.  Motor 480 size   Propellers 6 inch (0.1524 m), Ducted  Skirt Black Rip-stop Vinyl  Operating Surface Water or Land (will float off of hover and return to full hover)  Will transition from water to land  Hover Height 1.5 inches (0.0381 m) (no additional load other than kit as built with 6 cell NiCad)   Radio Requirements 2 channel land based RC systems ( as used in RC cars and boats)   Speed Controller Requirements 20 Amp 7-8 cell Electronic Speed Controller (ESC)
14
Issues with Current Products

• Speed
• Products rarely exceed the 30 35 km/h barrier
• Can be overcome by
• Increasing Size and Number of Fans
• Minimizing the Weight/ Size of Product
• Maneuverability
• Reduced Performance in Reverse
• Can be overcome by
• Implementing a Dual Fan Propulsion Assembly
• Safety
• Exposed Fan Blades
• Can be overcome by
• Protective Screens Placed at Ends of Ducted Fans
• Durability
• Brittle and Vulnerable Components
• Can be overcome by
• Additional Layer of Rubber Applied to the Body

15
Project Specifications

• Circular Base 13 inches
• Height 3.5 inches
• Weight lt 2.5 lbs.
• Payload Capacity gt 5 lbs.
• Volume 618.5 cubic inches
• Footprint 176.71 square inches
• Top Speed 30 km/h

16
Programming Concepts

• Hovercraft Programming Concept Design
• By Team Striders Programming Team

17
Introduction to Concept Generation

• Navigation
• Most important. The hovercrafts ability to
  navigate the course based upon sensor location
  and types of sensors accounts for 25 of the
  weight. It is most important that the hovercraft
  be able to navigate the course and complete the
  main objective
• Sensitivity
• Weighted at 20. Without perfectly functioning
  sensors, there would be no hovercraft, being that
  malfunction in the hovercrafts sensors would
  create a significant handicap in its mobility. It
  would interfere with the programming and
  therefore, make the hovercraft incapable of
  follow commands.
• Durability
• Weighted at 20, it focuses on the durability of
  the sensors. It is imperative that the sensors
  are durable for the reasons mentioned above. So
  when selecting the final concept we had to
  account for the placement of the sensor that will
  allow them to last and not to be exposed to
  collisions.
• Ability to be integrated
• Integration was weighted at 15. When selecting a
  concept we analyzed which concept would have the
  ability to facilitate our integration phase
  without interfering in any way with other
  subsystems.

18
Introduction to Concept Generation

• Versatility
• Versatility was weighted at 10. We had to focus
  on those concepts that would enable us to make
  the programming of the hovercraft system more
  versatile. We are mainly searching for
  versatility in the programming section that makes
  the craft adaptable. This versatility will
  somewhat depend on the sensors placement on our
  hovercraft.
• Sensor balance
• The sensor balance accounts for 5 of the weight.
  The sensor balance deals with equal distribution
  of the sensors placement accounting for every
  side of the hovercraft. Though ballasts could be
  used to counter any weight inconsistencies, it is
  preferable not to need them and keep weight down.
  When we focused on the criteria, we focused on
  the concept that would provide us with the most
  balance.
• Sensor stability
• The stability of the sensor also accounted for 5
  of the weight. It is important that the sensors
  are positioned on the hovercraft on a spot where
  they would not fall off or be subjected to
  movement, and risk the chance of being ruined, or
  displaced.

19
Concept Generation
20
The Concepts (continued)
21
The Concepts (continued)
22
The Concepts (continued)
23
Weighted Criteria
Sensor Balance (5) Durability (20) Sensitivity (20) Versatility (10) Sensor Stability (5) Ability to be Integrated (15) Navigation of Course (25)
Concept 1 5 1 7 7 1 1 4
Concept 2 3 6 3 3 6 5 1
Concept 3 2 7 2 2 7 6 2
Concept 4 4 5 4 4 5 4 3
Concept 5 7 2 5 5 2 3 6
Concept 6 6 3 6 6 3 2 7
Concept 7 1 4 1 1 1 7 5

24
Pugh Chart
  Concept 1 Concept 2 Concept 3 Concept 4 Concept 5 Concept 6 Concept 7
Balance 0 0 0 -- -- --
Durability 0 0
Sensitivity -- -- -- 0
Versatility -- -- --
Stability 0 0 0
Compatibility -- -- -- 0 0 0
25
Concept Selection
Images care of Microsoft Office Clipart
26
Concept Selection (continued)
Images care of Microsoft Office Clipart
27
Structural/Lift Concepts

• Hovercraft Programming Concept Design
• By Team Striders Structural/Lift Team

28
Figure 1

• Frisbee-like circular base
• Centrifugal fan

29
Figure 2

• Square, styrofoam base
• Piston based air pump
• Distributed arrangement

30
Structure/Lift Figure 3

• Thin Metal or Balsa wood base with axial symmetry
• Axial fan
• Dispersed load

31
Centrifugal Fan axial fan ducted fan air pump square base circular base axial symmetry
Strength 0 - - 0 0 0
Durability 0 - - 0 0 0
Balance - 0 - 0 0 0
Ease of Construction - 0 0 - - - 0
Availability of materials 0 0 - - 0 0 0
Cost - 0 0 0 0 0
Safety 0 0 0 - 0 0 0
Weight - 0 0 - 0
Size - 0 0 - - 0
Payload assisting - 0 - - - 0
Sum 's 2 0 3 0 1 2 0
Sum 0's 2 10 2 4 6 5 10
Sum -'s 6 0 5 6 3 3 0
Net Score -4 0 -2 -6 -2 -1 0
Rank
Continue ? No Yes No No No No Yes
Structure/Lift Pugh Chart
32
styrofoam frisbee balsa wood rubberizer spray sheet metal vertical arrangement distributed arrangement large volume small volume
Strength - - - - 0 - 0 - 0
Durability - - - - 0 - 0 - 0
Balance 0 0 0 0 0 - 0 0 0
Ease of Construction 0 - 0 - 0
Availability of materials 0 0 0 0 0 0 0 0 0
Cost - 0 - 0 0 0
Safety 0 0 0 - 0 0 0
Weight - 0 - 0 - 0
Size - 0 0 0 0 - 0 - 0
Payload assisting - - - 0 0 - 0 - 0
Sum 's 4 2 3 3 0 0 0 0 0
Sum 0's 2 3 4 5 10 1 10 4 10
Sum -'s 4 5 3 2 0 9 0 6 0
Net Score 0 -3 0 1 0 -8 0 -6 0
Rank
Continue ? Combine No No Combine No No Yes No Yes
Structure/Lift Pugh Chart
33
All-Terrain VehicleUnited States Patent 6845833

• Rectangular/trapezoidal shape with a main cabin
• Lift engine supplies lift to the backside of the
  main body. Separate from propel
  engine.
• Incorporated various structural shapes in our
  concept generation.
• Assumed the lift engine to be separate from the
  propel engine.

34
Vehicle Assisting FabricUnited States Patent
6955192

• External fabric utilized to support vehicle in
  snow, sand, or mud.
• When using fragile materials, such as Styrofoam,
  for the base, rubberized spray can be applied to
  reinforce the structure.

35
Air Cushion VesselUnited States Patent 6672234

• Weight supported by varying elements such as
  surfaces, different volumes, air cushions, and
  pressure.
• Size/arrangement are designed to achieve the best
  effect for lift and motion.
• Incorporated concepts like size of volume and
  need for strong powered lift fan to provide air
  cushion.
• Recognized need for distributed arrangement to
  create balance for lift and motion.

36
Propulsion/Power Concepts

• Hovercraft Programming Concept Design
• By Team Striders Propulsion/Power Team

37
Propulsion Concepts
Figure 4 Reference 2

• Hovercraft Concept Design
• Rear mount Propulsion with rear mount steering
  fan

38
Propulsion Concepts (continued)
Figure 5 Reference 2

• Hovercraft Concept Design
• Dual Propulsion/Steer motor
• Single lift motor

39
Propulsion Concepts (continued)
Figure 6 Reference 2
Hovercraft Concept Design Dual Propulsion/Steer
motors
40
Propulsion Concepts (continued)
Figure 7 Reference 2
Hovercraft Concept Design Dual Propulsion
motors Single lift motor
41
Propulsion Concepts (continued)
Figure 8 Reference 1
Hovercraft Concept Design Rear Facing Propeller
with Rudders
42
Propulsion Concepts (continued)
Figure 9 Reference 1
Hovercraft Concept Design Air Intake and
Directional Expulsion System
43
Propulsion Concepts (continued)
Figure 10
Hovercraft Concept Design Dual Rear Angled
Propellers
44
Propulsion Concepts (continued)
Figure 11
Hovercraft Concept Design Dual Front Mounted
Pulling Propellers
45
Propulsion Concepts (continued)
Figure 12
Hovercraft Concept Design Multi-Directional
Propellers That Pull
46
A. Dual Propulsion/ Steer Motor B. Rear Mount Propulsion w/ Rear Mount Steering Fan C. Dual Mid-mounted Rotating Propellers D. Dual Fixed Mid-mounted Propellers E. (Reference) Rear Facing Propeller with rudder
F. Air Intake and Directional Expulsion System G. Dual Rear Angled Propellers H. Dual Front Mounted Pulling Propellers I. Multi-Directional Propellers
Photos from Reference 1
47
Selection Criteria Concepts Concepts Concepts Concepts Concepts Concepts Concepts Concepts Concepts
Selection Criteria A B C D E F G H I
Size 0 -' 0 0 0 ' 0 -' -'
Minimum Fan Output 0 0 0 0 0 -' 0 0 0
Maximum Fan Output 0 ' ' ' 0 -' ' ' '
Cost 0 -' 0 0 0 0 0 -' -'
Ease of Integration -' -' -' ' 0 -' ' -' -'
Weight 0 -' 0 0 0 ' 0 -' -'
Aesthetics 0 0 0 0 0 ' 0 0 -'
Variable Power ' ' ' ' 0 -' ' ' '
Durability 0 0 0 0 0 0 0 -' -'
of Fans (2 is best) ' -' ' ' 0 -' ' ' -'
Turning Radius ' 0 ' ' 0 0 0 -' '
48
A B C D E F G H I
Sum 's 3 2 4 5 0 4 4 3 3
Sum 0's 8 4 6 6 12 3 7 2 1
Sum -'s 1 6 4 1 0 5 1 7 8
     
Net Score 2 -4 0 4 0 -1 3 -4 -5
Rank 3 7 (t) 4 (t) 1 4 (t) 6 2 7 (t) 9
Continue? Yes No Yes Yes Yes No Yes No No






49
    Concepts - Propulsion Concepts - Propulsion Concepts - Propulsion Concepts - Propulsion Concepts - Propulsion Concepts - Propulsion Concepts - Propulsion Concepts - Propulsion Concepts - Propulsion Concepts - Propulsion
    Dual Propulsion/ Steer Motor Dual Propulsion/ Steer Motor Dual Mid-mounted Rotating Propellers Dual Mid-mounted Rotating Propellers Dual Fixed Mid-mounted Propellers Dual Fixed Mid-mounted Propellers (Reference) Rear Facing Propeller with rudder (Reference) Rear Facing Propeller with rudder Dual Rear Angled Propellers Dual Rear Angled Propellers
Selection Criteria Weight Rating Score Rating Score Rating Score Rating Score Rating Score
Power Requirements 8 3 0.24 2 0.16 2 0.16 3 0.24 2 0.16
Size 10 3 0.3 3 0.3 3 0.3 3 0.3 3 0.3
Minimum Fan Output 5 3 0.15 3 0.15 3 0.15 3 0.15 3 0.3
Maximum Fan Output 5 3 0.15 4 0.2 4 0.2 3 0.15 4 0.2
Cost 10 4 0.4 3 0.3 3 0.3 3 0.3 3 0.3
Ease of Integration 10 2 0.2 2 0.2 4 0.4 2 0.2 3 0.3
Weight 10 3 0.3 3 0.3 3 0.3 3 0.3 3 0.3
Aesthetics 5 3 0.15 3 0.15 3 0.3 3 0.15 3 0.15
Variable Power 14 3 0.42 4 0.56 4 0.56 2 0.28 4 0.56
Durability 5 3 0.15 3 0.15 3 0.15 2 0.1 3 0.15
Number of Fans 8 3 0.24 4 0.32 4 0.32 2 0.16 4 0.32
Turning Radius 10 4 0.4 4 0.4 3 0.3 2 0.2 3 0.3
  Total Score 3.1 3.1 3.19 3.19 3.44 3.44 2.53 2.53 3.34 3.34
  Rank 4 4 3 3 1 1 5 5 2 2
50
Dual Fixed Mid-mounted Propellers
51
Power Concepts
52
Power Concepts
Figure 13 Reference 4
Hovercraft Power Supply Design 4 "AA" Serial
Battery Holders
53
Power Concepts (continued)
Figure 14 Reference 5
Hovercraft Power Supply Design "PP3" Serial
Battery Holders
54
Power Concepts (continued)
Figure 15 Reference 6
Hovercraft Power Supply Design 7.2V Rechargeable
Battery Pack
55
Power Concepts (continued)
Figure 16 Reference 7
Hovercraft Power Supply Design Solar Panels
56
4 "AA" Serial Battery Holders "PP3" Serial Battery Holders (Reference) Battery Pack Solar Panels

Photos from Reference 4, 5, 6, 7
57
Selection Criteria Concepts Concepts Concepts Concepts
Selection Criteria 4 "AA" Serial Battery Holders "PP3" Serial Battery Holders (Reference) Battery Pack Solar Panels
Power Output 0 ' 0 -'
Size '' ' 0 0
Weight '' ' 0 0
Ease of Integration '' ' 0 -'
Cost '' ' 0 -'
Availability ' ' 0 '
         
Sum 's 5 6 0 1
Sum 0's 1 0 6 2
Sum -'s 0 0 0 3
Net Score 5 6 0 -2
Rank 2 1 3 4
Continue? Yes Yes Yes No

58
      Concepts - Power Concepts - Power Concepts - Power Concepts - Power Concepts - Power Concepts - Power Concepts - Power Concepts - Power
      4 "AA" Serial Battery Holders 4 "AA" Serial Battery Holders "PP3" Serial Battery Holders "PP3" Serial Battery Holders "PP3" Serial Battery Holders (Reference) Battery Pack (Reference) Battery Pack (Reference) Battery Pack
Selection Criteria Weight Weight Rating Weighted Score Rating Rating Weighted Score Rating Rating Weighted Score
Power Output 10 10 3 0.3 4 4 0.4 2 2 0.2
Size 20 20 3 0.6 5 5 1 2 2 0.4
Weight 20 20 4 0.8 5 5 1 3 3 0.6
Ease of Integration 20 20 4 0.8 4 4 0.8 2 2 0.4
Cost 20 20 5 1 5 5 1 2 2 0.4
Availability 10 10 4 0.4 3 3 0.3 3 3 0.3
  Total Score Total Score 3.9 3.9 4.5 4.5 4.5 2.3 2.3 2.3
  Rank Rank 2 2 1 1 1 3 3 3
  Continue? Continue? No No Yes Yes Yes No No No











59
4 "AA" Serial Battery Holders
Dual Fixed Mid-mounted Propellers
60
Team Striders Gantt Chart

• Hovercraft Concept Design
• By Team Strider

61
Gantt Chart
62
Conclusion
63
References
Reference 1
Reference 2
US. Patent Bureau www.uspto.gov (1 March, 2006)
Reference 3
Hobby Lobby www.hobby-lobby.com (1 March, 2006)
Reference 4
Thomas Distributing www.thomas-distributing.com
(5 March, 2006)
64
References (continued)
Reference 5
Strikalite Batteries www.strikalite.co.uk (5
March, 2006)
Reference 6
Only Batteries www.onlybatteries.com (6 March,
2006)
Reference 7
Silicon Solar Inc www.siliconsolar.com (3 March,
2006)