Assignment_1 Task.

Engineering Design

ElectroTech007

1. The product design specification contains some serious errors. Identify these errors and provide detail of what is wrong. The extract from the Aquaspeed electric kettle PDS is shown below with identified errors:
*Please refer to note numbers within the table. Detailed explanations follow the table.

Assignment_1 Notes

Engineering Design

ElectroTech007

1. 1 litre of water could not be boiled in 90 seconds by a kettle with a 1KW power rated heating element. Explanation: The energy needed to heat water is 1Kcal per litre for every C rise in temperature. Therefore: Total Kcal = Capacity (L) x Temperature Difference (C) In our example: Total Kcal = 1L x (100C - 20C) = 1L x 80C = 80 Kcal We know that Therefore: 1 Kcal = 4186.8 Joules Total Energy Needed in Joules = 80 Kcal x 4186.8 J = 334944 J (335 kJ)
NB we have assumed water temp at room temperature to be 20C

To calculate the amount of time it would take to boil 1 litre of water in our kettle we would divide the energy needed by the power rating of our kettle, shown as follows: 334944 joules / 1 kW = 334.944 seconds (5.58 minutes) Therefore we can clearly see that our kettle is not capable of boiling 1 litre of water in 90 seconds, but achieves this in nearer to 6 minutes. The actual boiling rating we would need to achieve this in 90 seconds would be: 334.9 kj / 90 seconds = 3721 Watts (approx 3.7 kW)

Assignment_1

Engineering Design

ElectroTech007

2. Going by the physical dimensions of the kettle, the capacity would be incorrect.

Diagram showing approx dimensions of kettle as stated in PDS.(Microsoft office: Powerpoint) NB - the base of the kettle has been included in the total height, therefore the volume will be slightly less than my calculation suggests below

To find the approx capacity of the kettle we must first find the volume. To do this we will use the volume formula for the frustum of a cone: ) ) ) )

To find the capacity we divide the volume by 1000 to get litres: = 3.32 Litres We can see that the capacity of the kettle for the dimensions given in the PDS would be much closer to 3 litres than 1 litre.

Assignment_1

Engineering Design

ElectroTech007

3. The cost seems to be over optimistic due to the impending 5 colour production run. To enable the production of 5 colours it would be most likely that 5 separate production lines would need to be constructed one for each colour. Each production line would consist of a number of plastic processing machines, extra production operatives and not to mention the extra cost incurred by overheads, such as electricity. This extra machinery, raw materials and man power would dramatically increase the per unit selling price of the kettles. The reason being that, for the company to break even development and production costs need to be less than or equal to the total sales value. To enable the company to break even either more than the 10,000 initial production run would need to be manufactured and sold, or the per unit selling cost would need to be increased. The danger being if the kettle is overpriced it could be priced out of the market with the result of the company making a loss due to poor sales. Overall looking at the maximum selling price stated, the total sales would only be around 200,000 max (20 x 10000 units), this figure seems small when considering the fact of the extra cost incurred by setting up 5 production runs, which would indicate that a loss would be made. 4. The weight of the kettle when full is not a realistic interpretation when 1 litre of water is added. The PDS states that: Weight when empty (kettles mass) = 0.25 Kg Weight when full (kettles mass + water) = 0.95 Kg Therefore the waters mass according to the PDS will be: Waters mass = 0.95 Kg 0.25 Kg = 0.7 Kg This is incorrect. It is scientifically known that 1 Litre of water is approximately equal to 1 Kg With this in mind 1 Kg 0.7 Kg = 0.3 Kg (the PDS is out by around 0.3 Kg) Another point here is that we calculated previously that going by the given dimensions for the kettle, this indicated that the kettle actually holds around 3 litres of water, meaning that 3 Kg 0.7 Kg = 2.3 Kg (the PDS is actually out by around 2.3 Kg). It can clearly be seen that the stated weight of the kettle when full is unrealistic.

Assignment_1 5. Fuse rating incorrect for 240V supply

Engineering Design

ElectroTech007

The PDS states that the kettle has a boiling rating of 1 KW. If the kettle was running from a 240V supply it would require a current of: Current (Amps) = Power (Watts) / Voltage (Volts) I = 1000/240 = 4.16 Amps If the kettle was running from an 110V supply it would require a current of: I = 1000/110 = 9.09 Amps This would mean that the stated fuse in the PDS with a rating of 3 Amps would be too small for the kettle, and would most likely blow (open circuit), or cause a fire hazard. According to BS1363 equipment with a power rating below 700 watts will need a fuse of 3 amps, and equipment above 700w must be fitted with a 13 amp fuse. The kettle in our PDS has a power rating of 1 kW, and requires a current of either 4.16 Amps or 9.09 Amps (dependent upon supply voltage); therefore we would fit a 13 amp fuse.

Assignment_1 Task .1

Engineering Design

ElectroTech007

2. The PDS contains some serious omissions. Identify these and state what is missing. There is no stated supply voltage Information on the supply voltage has been omitted; this will determine a variety of factors including where the kettle is to be sold, and what components can be used in the design and manufacture (power/current ratings etc). The most common supply voltages around the world can be seen on the map below.

Map showing world power supplies (http://sites.google.com/site/mechatronicsguy/makerbot-build)

Assignment_1

Engineering Design

ElectroTech007

Target market is not specified Information on whether the kettle is to be sold in the UK only or Europe and the rest of the world has been omitted. There is no information on the target customer, i.e. young, old, what age group? What social background? This information would determine the Aesthetics and ergonomics of the kettle, for example how it is designed, including shape, colour, branding, and ease of use, safety features, and cost. No details are provided about the method for filling the kettle or the type of lid To enable the user to fill the kettle is the kettle lid removable, semi-removable (on a hinge), or non-removable (i.e. the spout is to be the main method for filling or emptying). If the lid is non removable how large should the spout be, and if removable what size should the spout be for easy flow without dripping (non-drip spout). All of this information needs to be provided to enable good design practice. Safety factors do not contain a method for switching off the kettle when the water has boiled The PDS only contains information on the fact that there is an on/off switch; it does not however contain information on whether or not the kettle needs to have an automatic overload cut out switch (using a thermostat), which breaks the circuit once the water has reached boiling point (100C), hence cutting off the supply. This is a common feature on modern electrical kettles, and is both, an energy saving feature and a safety feature. Specification and information on toxicity of materials used is not included The materials to be used in the manufacture to some extent have been provided in the PDS, such as easy clean plastic surface, but this is not enough. Further information such as the temperature profile of the shell material, what the actual material should be, i.e. low density polyethylene (LDPE), polypropylene (PP), or polystyrene (PS)), and details on the electrical components to be used for the heating element, thermostat etc (i.e. tin, aluminium, lead free). Regulations surrounding lead, mercury and cadmium are covered by the Restriction of Hazardous Substances Directive (Rohs). These Regulations implement EU Directive 2002/95 which bans the placing on the EU market of new electrical and electronic equipment containing more than agreed levels of lead, cadmium, mercury, hexavalent chromium, polybrominated biphenyl (PBB) and polybrominated diphenyl ether (PBDE) flame retardants. Manufacturers need to understand the requirements of the RoHS Directive to ensure that their products, and their components, comply. For this reason more detail is required in the PDS, to enable the designers to factor this into the design.

Assignment_1

Engineering Design

ElectroTech007

No mention of conformity with British Standards (following information obtained from trading standards) There is no information in relation to conformity with British standards relating to regulations surrounding domestic electrical equipment. All electrical equipment must be deemed safe for use and conform to the following The Electrical Equipment (safety) Regulations 1994 Applies to all electrical equipment that is designed or adapted for use between 50 and 1,000 volts or 75 and 1,500 volts. The Regulations cover domestic electrical equipment including component parts. The regulations require electrical equipment to Be safe Be constructed in accordance with principles constituting good engineering practice, and in particular protecting against electric shock Conform to the essential safety requirements, which include: Being marked with manufacturer's brand name or trade mark Being designed so that can be safely and properly assembled Having instructions for safe use, either on the equipment, or in an attached document.

All new equipment under this regulation must also contain CE marking and have the related technical information included to show their conformity, such as: a description of the electrical equipment, the last 2 digits of the year in which the CE marking was affixed the name and address of the manufacturer or his authorised representative a reference to the harmonised standards that the equipment complies with, OR if no harmonised standard then other specifications that the equipment complies with, such as being tested by a notified body

The manufacturer holds the responsibility of completing the above therefore the PDS should indicate that the kettle should be aligned toward this. Other regulations that should be mentioned are: Electromagnetic Compatibility Regulations 1992, equipment should be constructed so as not to cause excessive electromagnetic interference or be affected by it. Plugs and Sockets etc. (Safety) Regulations 1994, which includes conformity with BS 1363 relating to plugs

Assignment_1

Engineering Design

ElectroTech007

Plug details missing Information on the type of plug to be used has been omitted. This information will determine if for example adaptors need to be included to enable operation in various countries. There are various standards relating to different plugs used on electrical equipment around the world, which to an extent depends upon supply voltage, current and frequency in the specific country or continent. The main standards can be seen as in the following table with plug type, and supply voltage: Table showing standard, power supply, and plug types in use around the globe (http://www.interpower.com/ic/guide.htm)

Assignment_1

Engineering Design

ElectroTech007

Assignment_1

Engineering Design

ElectroTech007

World map showing location of various the various (http://commons.wikimedia.org/wiki/File:WorldMap_PlugTypeInUse.png)

plug

types

from

the

table

above

Assignment_1 Task.1

Engineering Design

ElectroTech007

3. The PDS contains insufficient detail. Identify at least three items that need improvement and state the nature of these improvements. Not enough detail has been included about the kettles cost. The stated cost is 15 - 20. Other information that should be included is whether the price given is the recommended retail price (RRP), the manufacturing cost only (as in the bill of materials), or the trade price (price at which sold to distributers). Insufficient information is included in terms of maintenance. There are a few replacement parts listed, but no information regarding whether or not a warranty is included, or the length of time component parts are guaranteed. This would have an impact on the selection of components for the kettle (component quality, materials used etc), and ultimately on overall manufacturing unit price, and selling price. Stated boiling time should also include the kettle capacity. The amount of time to boil the kettle is stated to be 90 seconds, but the water capacity that this time refers to is missing. The boiling time should be stated with regards to the capacity of the kettle when full, this is done by simply indicating the capacity i.e. 1 litre, 2 litre etc. Insufficient information is included with regards to environmental usage. The PDS states that the kettle is for domestic use only. Does this specify, in the kitchen, bedroom or bathroom? or would it also be suitable for use in a damp shed in your back garden, all of which are domestic areas. Common sense would tell you that this would not be the case, but ultimately; where the term domestic relates to, should be specified in the PDS. Other information that could have been included would be, whether it is suitable for travelling, and to which countries, the reason being power supplies, and plugs etc vary from country to country, and this needs to be known for safety reasons. Insufficient detail is included with regards to quantity. Only initial production numbers are stated in the PDS (10000 units). Future number predictions would also need to be included, as this will give an indication to the designer about the types of components and materials that need to be used, especially with regards to the most cost effective manufacturing processes which will ultimately have an impact on the cost effectiveness of the business. It is common to include around three years detail of sales prediction i.e. year 1 (10000 units), year 2 (15000 units), and year 3 (20000 units). Insufficient detail about the water level indicator. Has the water level indicator got markings, if so what units are they in, metric or imperial. Is the water level visually seen, or is there a float indicator. This detail must be specified in the PDS.

Assignment_1

Engineering Design

ElectroTech007

Insufficient detail regarding type and position of mains on/off switch. The main on off switch has not been fully specified. Details that may be included could consist of, the type of switch; slider, push button, flicker etc, and the location of the switch i.e. on the bottom of the kettle near the base, or on the upper part of the handle. This type of information should be included.

Assignment_1 Task.1

Engineering Design

ElectroTech007

4. Re-write the extract from the PDS incorporating your answers to the three items above. For the amended PDS opposite, I have calculated the volume of the kettle based on the original physical parameters of the kettle from the previous PDS, this then allowed me to calculate the boiling time and boiling rating for a kettle of that specific size. I have also assumed that the kettle is to be sold in the UK and Ireland only.