Universal Plug Holder
Jonathan RajkowskiBenjamin Dean
Jonathan Fitzwater
Problem Statement
Electrical appliance users in the US are potential victims of short circuiting, injuries, fires, and possibly death caused by the misuse or exposure of the prongs of an electrical plug by dislodging it from the electrical socket
Statement of Purpose
The purpose is to create a mechanism which prevents the dislodging of a plug from an outlet
Justification
Approximately 4,900 electrical fires, 3,900 injuries, 360 deaths, and the loss of $995 million occur each year
The Universal Cord Holder can prevent these occurrences from happening
Survey Results
20% of survey participants were unaware that nearly 5,000 electrical fires occur each year due to plugs
100% utilize appliances with plugs on a regular basis
89% stated they have found a plug partially dislodged from the socket
71% would be willing to purchase a solution to the problem
33% would spend 6-10 dollars on this solution
Existing Solutions
Patent No. 8,021,174- Cord Securing Cover for an Electrical Outlet◦Utilizes a hinged cover over each outlet which
contains a single prong that holds the plug in place when the cord is pulled
Existing Solutions (cont.)
Patent No. 3,838,383- Device for Preventing Disengagement of Electrical Cord from Wall Outlet◦A stopper is held in place next to the
existing plugs on an outlet face and the cord is looped into a hole in the metal prongs which functions to keep the plug connected to the wall when the cord is pulled
Requirements/Specifications
Needs to hold plug in wall when force is unintentionally put onto it
Needs to be cost efficient in order to be purchased by anyone
Needs to be safe and easy to useMust fit regular faceplate dimensionsMust hold twenty pounds of force
Decision Matrix
WEIGHT
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Potential Cost 2 2 4 1 2 2 4 2 4 3 6 2 4 1 2 2 4 2 4
Durability 3 1 3 2 6 2 6 2 6 3 9 2 6 3 9 2 6 3 9
Ease of Use 3 3 9 2 6 3 9 1 3 2 6 2 6 2 6 3 9 2 6
Appeal 1 3 3 2 2 2 2 1 1 2 2 1 1 2 2 2 2 2 2
Potential Effectiveness 4 2 8 2 8 2 8 2 8 2 8 2 8 3 12 1 4 3 12
Safety 2 0 0 3 6 3 6 3 6 3 6 3 6 2 4 2 4 2 4
TOTAL 27 30 35 28 37 31 35 29 37
Top 3 Solutions
Two hooks are attached to side of faceplate to hold plug in by holding cord
Top 3 Solutions (continued)
Three prongs “snap” the plug into place
Top 3 Solutions (continued)
Plastic clamps encase the plug and hold in into the socket
Chosen Solution
Sketches
Prototype Construction
Prototype Construction (continued)
Consumer Instruction Manual
Universal Plug Holder Instruction Manual Step 1: Shut off electricity for chosen outlet.
Step 2: Remove previous faceplate.
Step 3: Screw hooks into new faceplate.
Step 4: Install new faceplate.
Step 5: Plug appliance into electrical outlet.
Step 6: Place wire in the hook.
Testing Procedure
Test Procedures
1. Attach faceplate to test site. (one-hooked) 2. Hook force sensor to faceplate hook. 3. Pull with steadily increasing force, watching the amount of force. 4. Once the faceplate breaks, record the value. 5. Remove broken faceplate from site. 6. Repeat steps 1.-4. using new faceplate on lower bank. 7. Attach faceplate with both hooks to test site. 8. Choose the ¼” two prong cord. 9. Wrap cord firmly around force sensor handle. 10. Plug cord into outlet/ test site. 11. Hook cord around hook of product. 12. Pull with steady, increasing force until the allotted force ( 20 lbs.) is reached of the product fail
point, meaning the cord is unplugged from the outlet. 13. Record maximum value of force required to cause failure, or that it exceeds the designated
value. 14. Unplug cord, unwrap from the force sensor. 15. Repeat steps 8.-14. for the other six cords.
TESTINGSuccess
TESTING
TESTINGFailure
TESTING
Test Results
ControlTest Number Plug Length (inches) Number of Prongs Wire Thickness (inches) Trial One (lbs.) Trial Two Trial Three Average5 1 5/8 2 5/16" 6 8 6 6.671 1 2 1/4"x1/8" 8 5 6 6.332 1 7/8 2 1/4" 5 5 5 56 1 3/4 2 3/8" 6.5 7 6 6.54 1 3/4 3 5/16" 7.5 7.25 7.5 7.423 1 3/8 3 5/16"x1/8" 9.5 9.5 10 9.677 2 1/4 3 3/8" 9 8.5 8.5 8.67
With ProductTest Number Plug Length (inches) Number of Prongs Wire Thickness (inches) Trial One(Ibs.) Trial Two Trial Three Average3 1 5/8 2 5/16" max* max* max* max*4 1 2 1/4"x1/8" 14 13 12 136 1 7/8 2 1/4" max* max* max* max*2 1 3/4 2 3/8" max* max* max* max*5 1 3/4 3 5/16" max* max* max* max*7 1 3/8 3 5/16"x1/8" max* max* max* max*1 2 1/4 3 3/8" max* max* max* max*
Breaking Point (lbs.)Upper Hook 50+Lower Hook 50+
Breaking Point for Faceplate
Secure Outlet Faceplate Data 5/4/2012
*Due to the high breaking point of our product, we have established the maximum force required for the success of our product to be 20 lbs.
Extraneous Issues
Can’t hold plug lengths less than 1 ½ inches
Can’t fit wire thickness of more than a half inch
Hook does deform slightly (1/16 of an inch) with repeated testing at 50 lbs. of force
With continuous force, faceplate pulls away from the wall
Data Analysis
All but one type of wire was tested successfully when using the product
Wire plug needs to be longer than 1 1/2” in order to properly work
Some deformation does occur to the faceplate, but goes back to normal after a few moments
Product takes 50 lbs. of force to completely break
Cost of Materials
2 hooks= one dollarFaceplate= 56 centsCost of product should be around $5.56,
yielding $4 profit per item.This costs less money than the amount
the majority of the survey takers said they would pay.
Conclusion
Testing was a success in finding the points at which the product works and fails
It was determined that it works for almost all plugs and will remain sturdy for continual use within 50 lbs. of force
If more time was allotted, product would have been altered so that the force was on the screw rather than on the faceplate
Product was successful in solving problem
Gantt Chart
Task Assigned to
2/15/201
2
2/1
6/2012
2/17/201
2
2/21/201
2
2/22/201
2
2/23/201
2
2/24/201
2
2/27/201
2
2/28/2012
2/29/2012
3/1/2012
3/5/2012
3/6/2012-
3/9/2012
3/12/2012-3/16/2012
3/19/2012-3/23/2012
3/26/2012-3/30/2012
4/9/2012-
4/13/2012
4/16/2012-4/120/20
12
4/23/2012-4/27/2012
4/30/2012-5/4/2
012
5/7/2012-
5/11/2012
5/14/2012-5/18/2012
5/21/2012-5/25/2012
Possible Problems All
Finalize Top 3 Problems All
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Finalize Problem All
Further Anti-Unplug Socket Cover Research All
Create Problem Statement All
Anti-Unplug Socket Cover Market Research All
Brainstorming Solutions All
Refining Solutions (Decision Matrix) All
Selecting Solution (Sketches) All
Technical Drawings All
Business Plan (Materials, Cost, Tools, Etc.) All
Plan Prototype All
Build Prototype All
Develop Testing Procedures All
Test Prototype All
Improve Prototype All
Retest Prototype All
Determine Conclusion All
Documentation and Presentation All
References
http://www.arkansaselectricenergylaw.com/tags/electricity/
http://www.picturesof.net/pages/100112-052670-735042.html
http://students.clipart.com
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