Small tracker unit
UNIQUE CASE STUDY – SPECIAL PROJECT : extremely short product development and industrialisation cycle. This was a requirement because the client needed the product to be completed for an international sporting event. Once committed, the client had to deliver the products by a specific date.
Requirements brief by client (Tracker)
The unit had to be waterproof (IP67).
The entire unit had to be compact.
Enclosure had to be opened by the user without special tools.
A waterproof access flap had to be incorporated into the design for an electronic interface.
This product was visible to the public, so good styling was an important criteria.
A very short development and industrialisation timeline was specified.
Timeline
November:
The design brief was given in early November and the contract was awarded to Retief Vorster of Realise Product Design and Manufacturing (RP).
The design was completed by RP and approval was given by the client before the end of November.
December:
Immediately on approval of the design, RP placed the order for the tooling with the toolmakers. The toolmakers submitted designs for the tooling, after which RP commissioned the toolmakers to start.
January:
By themiddle of January, the tooling had been completed, and the first off samples were run on the
tooling. RP flew to China in mid-January to inspect the first off samples.
Minor design changes were done by RP and the the tools were modified immediately. The final samples were run by the end of January and approved by RP before leaving China. At the end of January, RP ordered the first batch of 1500 units for the client.
February:
Bymid-February, the first batch of 1500 units was delivered to the client in Gauteng, well in time for the upcoming sporting event.
Break-down of the components whichmake up this product:
Main housing
End cover
Locking disks and clips used to hold the end cover in place
Rubber gasket
Rubber flap
Rubber button cover
Conclusion
The products were not only designed by the required date – the tooling was developed and the first-off production run had also been done in record time. The product performance exceeded the client’s requirements and the entire project was a success.
Waterproof electronic enclosure:
CASE STUDY – SPECIAL PROJECT : very specific end user requirements.
Requirements brief by client (Scope Electronics)
The housing had to beWaterproof (IP67)
An external cable would be permanently connected to device.
End user product, so styling had to be excellent
Ease of assembly
Unique design features this product has
- A longitudinal split line
- Clip-in mechanism : only 2 fasteners are required to assemble the main housing.
- An overmoulded bayonet system for locking the wire harness in place
- Additional locking mechanism which doubled up as a cable grip and a locking mechanism for the main housing.
- A gasket which doubles up not only as a seal for the main housing and cable, but is also used as a locator for the internal PC Board.
Break-down of the components which were developed for this product
Main housing
Lid
Locking ring for securing cable and lid
Rubber gasket
Conclusion
The design for this electronic housing product turned out to be a huge success. The housing was waterproof, rugged and stylish and exceeded the clients requirements.
Medicine cabinet for home use:
CASE STUDY – This development was very much an end user product which would probably become a household or office product. It had to be very functional and at the same time be aesthetically pleasing.
Due to the large size of the product, it deemed to be much easier to let the cabinet be made up of flat panels which would be assembled to make up the final cabinet.
Furthermore, the cabinets would only be made in one size – if users would want a larger cabinet, they would be able to purchase another one and it would clip/lock onto the original one. They could expand the cabinet by adding units onto the sides or the top of the original unit.
To develop tooling for various sizes of cabinets would be prohibitively expensive, this is why a modular approach was followed.
Requirements brief by client
RP had to design and develop a cabinet with drawers which could be locked. The unit had to be
compatible as a first aid kit as well as a medicine cabinet.
Easily removable drawers for full access to the contents.
Ease of assembly –minimal fasteners had to be used to assemble the unit.
Modular design : one or more units needed to be clipped together – either side by side and/or above and below each other. In this way, one set of tooling could be used for small or large cabinets.
A child proof locking mechanism, which did not require a key, had to be incorporated into the design.
Material – engineering plastic.
Special research and development done for this product
Research and development had to be done to find a suitable design for the locking mechanism.
The locking mechanism had to be tested to ensure it was child proof for an 8 year old child. Various designs were considered: these were then refined, developed and prototypes were grown for testing. Full functionality tests were done with life size components which were grown on 3D printers. In this way, the locking mechanism could be tested to help select the best option for the application.
Break-down of the components which were developed for this product
- Drawers
- Casing – : the casing was made up of loose panels which would clip together to form the main housing. Some of the panels are interchangeable – this was done to minimize the number of individual parts which had to be developed, thereby reducing the overall tooling cost.
- Locking mechanism –made up of a number of smaller components
- All these components were injection moulded parts.