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SE-4000 Portable Eye Wash Spray Fixture The Speakman Company University of Delaware Team: Wes Doyle...
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SE-4000 Portable Eye Wash
Spray Fixture
The Speakman CompanyUniversity of Delaware Team:
Wes Doyle Nate Griffith Matt Jaskot Jason McKnight
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Overview
• Present the problem• State our goals• Reveal the project constraints• Traverse the design process• Reveal the problem solution• Validate the problem solution
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Existing design
– Complicated and expensive brass valve
– Many parts high assembly labor costs
– Significant room for cost reduction in spray arms
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Current Design Components 1 |__ G20-1894-RCP Valve Assy For Se-4000& 577-Sd 1 G20-1894-RCP 1 51.77 | |__ G05-0666-L-RCP Left Outlet Arm Assembly 1 G05-0666-L-RCP 1 10.71$ 10.71$ | |__ G05-0666-R-RCP Right Outlet Arm Assembly 1 G05-0666-R-RCP 1 10.71$ 10.71$ | |__ G20-1815 Valve Mechanism Assy 1 G20-1815 1 2.71$ | | |__ 14-0039-RCP Valve Tailpiece Grvty Flow 1 14-0039-RCP 1 1.86$ 1.86$ | | |__ 20-0949 Plunger-6 Fin For Valve 1 20-0949 1 0.25$ 0.25$ | | |__ 37-0077 Valve Spring Grvty Flow 1 37-0077 1 0.12$ 0.12$ | | |__ 49-0162 #202 O-Ring (Epdm 70 Dur) 1 49-0162 1 0.02$ 0.02$ | |__ 01-0806 13/16 Hex Locking Nut 2 01-0806 2 0.45$ 0.90$ | |__ 03-0504 Spindle Saddle Clip 1 03-0504 1 0.09$ 0.09$ | |__ 03-0529 Valve Spindle W/Thrd Ends 1 03-0529 1 6.99$ 6.99$ | |__ 20-0952 Valve Body For Swing Down Vlve 1 20-0952 1 7.60$ 7.60$ | |__ 45-0707 1.035 X .707 Nylon Washer 2 45-0707 2 0.04$ 0.08$ | |__ 48-0354 10-24 Dog Pt Cap - .355 Lgth 2 48-0354 2 0.60$ 1.20$ | |__ 48-0356 10-24 Cup Pt Set Screw W/Patch 2 48-0356 2 0.17$ 0.34$ | |__ 49-0080 #111 0-Ring, Buna N, 70 Duro 2 49-0080 2 #N/A | |__ 49-0083 #112 0-Ring 2 49-0083 2 #N/A |__ G38-0347 Spray Head/Gravityflo 2 G38-0347 2 3.29$ 6.58$ | |__ 07-0088 Neoprene Spray Head Guard 2 07-0088 2 1.08$ 2.16$ | |__ 38-0251 Spray Head Base-Gravityflo 2 38-0251 2 0.55$ 1.10$ | |__ 38-0252 Spray Head Cap-Gravityflo 2 38-0252 2 0.55$ 1.10$ | |__ 49-0147 #029 O-Ring 2 49-0147 2 0.19$ 0.38$ |__ 01-0781 Lock Nut/2nd Generation Valve 1 01-0781 1 0.49$ 0.49$ |__ 05-1928 Foam Grip 2 05-1928 2 0.98$ 1.96$ |__ 21-0186 In-Line Strainer/Se-4000 1 21-0186 1 0.21$ 0.21$ |__ 45-0580 1 1/4 X 7/8 X 1/16 Ss Washer 1 45-0580 1 0.30$ 0.30$ |__ 51-0073 Rivet-M/P #61apr 25075-B 1 51-0073 1 0.07$ 0.07$ |__ 56-0108 Ratchet ¢Inch Clamp 1 56-0108 1 0.53$ 0.53$ |__ 56-0110 Supply Tube Clamp 1 56-0110 1 0.12$ 0.12$ |__ 63-0026 Pre-Formed Supply Tube 1 63-0026 1 4.34$ 4.34$ |__ 66-0112 Internal Tooth Lockwshr 718id 1 66-0112 1 1.14$ 1.14$
43 54.77$
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Sponsor’s Problem• High cost model in a low cost Market
• Seeks to reposition eyewash at appropriate cost level
More Features- Higher Cost
Low Cost Commodity competition
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Our Task
• Reduce cost of Spray-Arm Assembly under $15
• Maintain compliance with ANSI flow requirements
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Sponsor’s Wants
• Utilize existing tank tooling
• Aesthetic appeal• Minimize changes to
shipping container• One year Return on
capital expenditure
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ANSI Requirements– Minimum flow of 0.4 GPM for 15 minutes– Hands free operation– Nozzles protected from airborne contaminants– “On to Off” in 1 second or less– Nozzle at least 6” from nearest obstruction– Must not leak & operate reliably every time– Both eyes flushed simultaneously at safe water
velocities
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Design Subsystems3 Subsystems Spray-Arms perform:
- Regulation of flow on/off (valve)
- Direction of flow to user’s eyes (nozzles)- Attachment to tank (threaded nut)
Any new design must perform these 3 functions at low cost- Attachment to tank and flow direction are relatively easy to do- Focus on flow regulation
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Concept generation
- Initial ideas for flow regulation
Ball Valve Linear Valve Snap-on Nozzle Caps
- Low-cost design easy to prototype quickly, cheaply
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Ball Valve Prototype
• Estimated Cost ~$30 (ball valve expensive, assembly costs)
• One Attachment Point, Low Strength• Ugly.
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Pull-Off Caps Prototype• Estimated Cost Near $15 Target• Attached with Bolts / Screws (Stronger)• T-Handle Connected to Caps
Sharp Metal Edges
Plastic Molded Design(it is a safety product)
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Design changes
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Design changes
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Design changes
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Design changes
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Design changes
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Design changes
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Design changes
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Design changes
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Pull-Off Strap Design• Angled rubber strap
– Allows for user to easily grab onto handle
– Expensive to mold due to complex shape
– Cheaper, effective alternative?
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Pull-Off Strap Design• Straight rubber strap
– Less expensive mold– Smaller surface area for
user to grab onto – $6800 Tooling– $3.50 Piece price– Cheap, ergonomic
alternative?...
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Pull-Off Strap Design• Inverted rubber strap
– Inexpensive– Prominent– Peeling effect
• Other alternative?– Widen the space between nozzles
for more room
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Rapid prototyping/final design
• Final Design
• Rapid Prototyping using Stereolithography
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CostReduced Unit Cost
• Cheaper materials• Fewer parts• Easier to assemble
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Current/Proposed Design Comparison
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Testing• Flow Requirements Met
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t = 0 mint = 0 min
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t = 1 mint = 1 min
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t = 2 mint = 2 min
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t = 3 mint = 3 min
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t = 4 mint = 4 min
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t = 5 mint = 5 min
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t = 6 mint = 6 min
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t = 7 mint = 7 min
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t = 8 mint = 8 min
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t = 9 mint = 9 min
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t = 10 mint = 10 min
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t = 11 mint = 11 min
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t = 12 mint = 12 min
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t = 13 mint = 13 min
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t = 14 mint = 14 min
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t = 15 mint = 15 min
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t = 16 mint = 16 min
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t = 17 mint = 17 min
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t = 18 mint = 18 min
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t = 19 mint = 19 min
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t = 20 mint = 20 min
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t = 21 mint = 21 min
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t = 22 mint = 22 min
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t = 23 mint = 23 min
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t = 24 mint = 24 min
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t = 25 mint = 25 min
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t = 26 mint = 26 min
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t = 27 mint = 27 min
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t = 28 mint = 28 min
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t = 29 mint = 29 min
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t = 30 min
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Manufacturing Concerns -Fixture
• Molding method-Rotomolding
• Accommodates short production runs
• Low tooling cost compared to blow molding
• Tradeoff-High piece price
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Molding Results
-100000
-50000
0
50000
100000
150000
200000
250000
300000
350000
400000
0 1 2 3 4
Series1
Series2
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Route to finished product
• Path forward to a marketable product– Packaging – Customer Assembly?– Contour – Precision measurements– Decals – Removing current and replacing– Assembly Jigs – Handle Manufacturing
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Before
Now
Future Development
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THANK YOU
Questions?