project «projector» submitted to the sanyo electric co. ltd. presented by institute of innovative...
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Project «PROJECTOR»Project «PROJECTOR»
SUBMITTED TO THE SANYO Electric Co. Ltd.
PRESENTED BY Institute of Innovative Design
Terms:Beginning: January 2003Completion: March 2003
FINAL PRESENTATION
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Object of AnalysisObject of Analysis
DLP ProjectorDLP ProjectorDLP ProjectorDLP Projector
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Main FunctionMain Function
To receive modulated on To receive modulated on brightness and color lightbrightness and color light
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Main Main GoalGoalNoise level from projector must be less Noise level from projector must be less
then 22 dB(A)then 22 dB(A)
Project GoalsProject GoalsInstitute of Innovative Design
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RestrictionsRestrictionsInstitute of Innovative Design
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• Changing Lamp and DLP unit are impossible now.
• Size must be be same (or little larger is acceptable).
• Changing Lamp and DLP unit are impossible now.
• Size must be be same (or little larger is acceptable).
Innovative Technology of Design
Innovative Technology of Design
Supporting InformationGathering
Supporting information
Supporting InformationGathering
Supporting information
Analysis of the ObjectFunctional and Flow models,
Evolution Trends, Key Disadvantages, Contradictions
Analysis of the ObjectFunctional and Flow models,
Evolution Trends, Key Disadvantages, Contradictions
Problem SolutionEngineering Solutions
Problem SolutionEngineering Solutions
Data GatheringBackground information
Data GatheringBackground information
Function BasedInformation Gathering
Function orientedinformation
Function BasedInformation Gathering
Function orientedinformation
CONCEPTUAL STAGEINFORMATION STAGE
ANALYTICAL STAGE
Concept substantiationConcepts,
Ideas for Further Development
Concept substantiationConcepts,
Ideas for Further Development
Problem StatementTrimming problems,
Feature transfer problems, Key problems
Problem StatementTrimming problems,
Feature transfer problems, Key problems
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INFORMATION STAGEINFORMATION STAGE
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Processing InformationProcessing Information
Information replyInformation request
Legend:
Conceptual stage
Information stage
Info 2 Scientific (basic)
information
Info 1 Source
information
Info 3 Functional information
Info 4 Support
information
Analytical stage
Key problemsKey problems ConceptsConcepts
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Information Search Types of Information Used Information Search Types of Information Used
INFORMATION
Info 4SUPPORTING INFORMATION
Info 3FUNCTIONAL
INFORMATION
Info 1INFORMATION
SOURCE
INFORMATION ON SPECIFIC CONCEPTS
SCIENTIFIC BASIS, CALCULATIONS
REFERENCES
LEADING AREAS OF ENGINEERING ENGINEERING DEVELOPMENTS AND THEIR COMPONENTS (EQUIPMENT, MATERIALS, ETC. I.E. DATA FOR FORMULATION OF FUNCTIONS) RESOURCES FOR STATED KEY PROBLEMS SOLVING
BASIC SCIENTIFIC PRINCIPLES OF OBJECT ACTION (PHYSICAL, CHEMICAL, GEOMETRICAL, BIOLOGICAL) OBJECT EVOLUTION PARAMETERS CHARACTE- RIZING THE OBJECT AND ITS COMPONENTS
INITIAL INFORMATION FROM CUSTOMER (DIAGRAMS, SAMPLES, ETC.)
DATA OF COMPETITORS PRODUCTION
SCIENTIFIC (BASIC)
INFORMATION
Info 2
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Table of Information Search Fragment
Table of Information Search Fragment
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Search direction Leading filds of sience and technology
Principle, method, device Possible application to the project
1. Engineering function
To create airflow Generalized engineering function:
To move substance
1.1. Problem: Fan generate noise at creation of airflow.
1.1.2. Exinguishing of sound by antisound
Electronic engineering System of active noise control (electronic cirquit)
To applay active noise control system in order to reduce noise.
1.1.3. Noise reduction of fans
AerodynamicsAircraft construction PCs Screw-propeller engine
CPU Fans
To change amount of impellers. To make impellers of special shape
1.1.4. Decrease of turbulence of stream
Wings of airplanesStabilizer of missilesAircraft construction
Lattice wings To make impelers of fans as littice wings
Microrelief on impeller of screw and on fuselage of airplane. Fibrous covering.
To make impelers of fans with microrelief or with fibrous covering.
Screw-propeller engine To apply a coaxial meyhod of instulling of two impellers.
Outside acoustical effect on turbulent flow
To apply ultrasonic generator for structuring of turbulent whirlwind and lowering of viscosity of air.
Analytical StageAnalytical Stage
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Analytical Stage Structure Analytical Stage Structure Institute of Innovative Design
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STATEMENT OF KEY PROBLEMS
GENETIC ANALYSIS
COMPONENT-STRUCTURAL ANALYSIS
FUNCTIONAL-PARAMETRIC ANALYSIS
PARAMETRIC ANALYSIS
DIAGNOSTIC ANALYSIS
INTEGRATION OF ALTERNATIVE SYSTEMS
CAUSE-AND-EFFECT ANALYSIS
Problems
Undesirable effects
Denotations:
STATEMENT OF PROBLEMS DIRECTION OF
SOLUTION OVERMODELING
Component Structural Analysis
Component Structural Analysis
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DLP Projector
Projector case
Intake vents
Exhaust vents
DLP Block
DLP case
DMD Chip
Micromirror
Memory cell
Condenser lens
Color wheel
Motor of color wheel
Light absorber
Electronic circuit
Chassis
Power supplyof projector
Lamp power supply
ScreenScreen ElectriccurrentElectriccurrentUserUserDesk
(selling)Desk
(selling)Ambient
airAmbient
airVideo signalVideo signal
Lamp case
Lamp house
Air duct
Centrifugal fanAxial fan
Power supplyOptical system
Lamp unit
Lamp
Cooling system
Centrifugal fan case
Centrifugal fanrotor
Rotor blades
DC motor
Fan case
Fan rotor
Impellers
DC motor
Controlunit
Power cord
Super system elements Super system elements
Element Function Rank
7. Intake vents 7.1 To direct ambient air A1
7.2 To decelerate ambient air H
8. Exhaust vents 8.1 To decelerate airflow H
8.2 To pass out luminous light H
8.3 To output airflow A3
9. DLP case 9.1 To hold condencer lens A2
9.2 To decelerate airflow H
9.3 To hold light absorber A2
9.4 Not emit out luminous light A1
9.5 To hold memory cell A2
9.6 To absorb infrared and ultraviolet of luminous light H
10. Micromirror 10.1 To produce modulated light B
10.2 To absorb luminous light H
10.3 To modulate luminous light B
10.4 To heat memory cell A1
11. Memory cell 11.1 To decelerate airflow H
11.2 To heat DLP case H
Function AnalysisFragment of function table
Function AnalysisFragment of function table
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Results of functional modelResults of functional modelInstitute of Innovative Design
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52%
46%
2%
Basic functions
Harmful functions
Auxiliaryfunctions
The amount of basic functions providing performance of main useful function is – 4
The amount of auxiliary functions is – 108
The amount of harmful functions is – 94
Diagnostic AnalysisDiagnostic AnalysisInstitute of Innovative Design
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Element for trimming Trimming problems
Rotor blades 1. How to create airflow by centrifugal fan rotor without rotor blades?
Impellers 2. How to create airflow by axial fan rotor without impellers?
DC motor of axial fan
3. How to create airflow by electric current without fans?DC motor of centrifugal fan
Air flow 4. How to cool the elements of DLP projector by projector case without air flow?
Cause-and-Effect Chains Analysis
Cause-and-Effect Chains Analysis
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Friction of airflow with surfaces of projector
components and exhaust vents
Voltaic arc in mercury vapor
Modulation of light by selective reflection
Method of creationof monochrome light
Method of transformation of electric energy into mechanical
Action of electric current emitJoule heat
Radiation of IR and UV rays
Heating of projector components
Absorption of visible light by colour filter
Cooling of projector components by airflow
Acceleration of airflow
Inhomogeneity of airflow
Aerodynamic noise
Rigid junction of fan with projector case
Transmission of vibration through projector
components
Mechanical noise
Rotation of DC motor rotor
NOISEDiscrete noise
Internal friction of airflow (viscosity)
Deceleration of airflow
Rotation of rotor blades (impellers)
in air
Absorption ofvisible light
Absorption IR and UV rays
Physical properties of substances
Statement of Key Problems
Statement of Key Problems
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Key problemAmount of key
problems
Direction 1. The noise reduction with the minimum changes in system 3
Direction 2. The noise reduction of discrete noise in fans 2
Direction 3. The change of method of airflow creation 1
Direction 4. The change of method of cooling of projector’s components
2
Direction 5. The reduction of heating of projector’s components 1
Direction 6. The change of a physical operation principle of projector 5
List of ProblemsList of ProblemsInstitute of Innovative Design
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Key problemConcepts solving key
problems
Direction 1. The noise reduction with the minimum changes in system
1.1. How to provide rigid junction of fan-motor case with case of projector, which does not transmit vibration from fan-motor?
1
1.2. How to provide rotation of DC motor rotor without generation of mechanical noise?
2
1.3. How to reduce frequency of rotation of fans? 3, 4
Direction 2. The noise reduction of discrete noise in fan
2.1. How to create airflow by centrifugal fan rotor without blades? 5
2.2. How to create airflow by axial fan rotor without impellers? 6
Direction 3. The change of method of airflow creation
3. How to create airflow by electric current without fans? 7
List of ProblemsList of ProblemsInstitute of Innovative Design
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Key problemConcepts solving key
problems
Direction 4. The change of method of cooling of projector’s components
4.1. How to cool projector’s components without airflow? 9, 10
4.2. How to cool the elements of DLP projector by case of projector without airflow?
8
Direction 5. The reduction of heating of projector’s components
5. How to reduce absorption of IR and UV radiation by projector’s components?
11
Direction 6. The change of a physical operation principle of projector
6.1. How to reduce absorption of visible light in projector? 12
6.2. How to reduce a share of IR and UV radiation? 12
6.3 How to generate visible light without voltaic arc in mercury vapor? 12
6.4. How to generate modulated light without selective reflections of radiated light?
12
6.5. How to generate monochrome radiation without absorption of a part of visible light?
12
Conceptual StageConceptual Stage
List of Concepts on DirectionsList of Concepts on DirectionsInstitute of Innovative Design
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Conceptual direction 1: Reduction of noise from projector with minimum changes in system.
Concept 1. Fastening of the fan to the case of the projector by magnetic supports
Concept 2. The fan bearings with air lubrication.
Concept 3. Cooling intake air by thermoelements with Peltier effect.
Concept 4. Cooling of intake air by adsorption refrigerator by using heat of lamp.
Conceptual direction 2: Rduction of discrete noise of fans.
Concept 5. Screw disk-shaped fan.
Concept 6. Conic spiral fan.
Conceptual direction 3: Change of method of airflow making.
Concept 7. Ionic noiseless fan.
Conceptual direction 4: Change of method of cooling of projector components.
Concept 8. Cooling of lamp unit and DLP block by heat pipes.
Concept 9. Heat removal from projector by flexible heat pipe integrated with power cord.
Concept 10. Cooling of projector elements by thermoionic semiconductor elements.
Conceptual direction 5: Reduction of heating of projector components.
Concept 11. Case of projector made of materials transparent for IR beams.
Conceptual direction 6. Change of physical principle of projector operation.
Concept 12. Laser projector
Conceptual Direction 1Conceptual Direction 1Institute of Innovative Design
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REDUCTION OF NOISE FROM PROJECTOR WITH MINIMUM CHANGES IN SYSTEM
The purpose of the given direction: to reduce noise from a projector with minimum changes of existing air cooling system and design of fans.
In concepts of the given direction reduction of noise from a projector is achieved by reduction of mechanical and discrete noise from fans.
REDUCTION OF NOISE FROM PROJECTOR WITH MINIMUM CHANGES IN SYSTEM
The purpose of the given direction: to reduce noise from a projector with minimum changes of existing air cooling system and design of fans.
In concepts of the given direction reduction of noise from a projector is achieved by reduction of mechanical and discrete noise from fans.
Concept 1. FASTENING OF THE FAN TO THE CASE OF THE PROJECTOR BY MAGNETIC SUPPORTS
3. Annular const magnet
NS NS
NS
NS
1. Fan case
2. Conical const magnet
4. Clips
Concept 2. THE FAN BEARINGS WITH AIR LUBRICATION
1. Axle of fan rotor 2.Teflon porous bushing 3
4. Piezoelectric ceramic vibration generator
6. Electrodes
5. Fan case
Fan Fan
1
2
3
6
7
8
9 1111 121310
+ -
Room temperature air
Cool air
Vap
oriz
atio
n o
fa
cond
ens
ate
Concept 3. COOLING OF INTAKE AIR BY THERMOELEMENTS WITH PELTIER EFFECT
Top view
Side 1 view1
4
5
7
82
Concept 4. COOLING OF INTAKE AIR BY ADSORPTION REFRIGERATOR BY USING HEAT OF LAMP
1. Condenser-reboiler
2
A B
3. Pipe
4
5. Adsorber-generator
6
7. Capillary-porous substance
+ CaCl2
8. Flat condenserpart
9
10.Heat Pipe
11
14. Flexible heat pipe
12. Flat condenserpart
13
17. Heat insulator
15.Fan 16
Conceptual Direction 2Conceptual Direction 2Institute of Innovative Design
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REDUCTION OF DISCRETE NOISE OF FANS
The purpose of the given direction: is to offer a design of fans with a minimum level of discrete noise.
In concepts of the given direction the airflow is created by a rotor of fan
without blades and impellers.
REDUCTION OF DISCRETE NOISE OF FANS
The purpose of the given direction: is to offer a design of fans with a minimum level of discrete noise.
In concepts of the given direction the airflow is created by a rotor of fan
without blades and impellers.
Concept 5. THE SCREW DISK-SHAPED FAN
1. Fan case
2. Fan rotor
3. Screw disk
Concept 6. THE CONIC SPIRAL FAN
1. Fan rotor
2. Spiral cone
3. Fan case
4. DC motor
FCFN
FA
Conceptual Direction 3Conceptual Direction 3Institute of Innovative Design
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CHANGE OF METHOD OF AIRFLOW CREATING
The purpose of the given direction: to offer a construction of a fan which does not create mechanical and discrete noise.
In the concept of the given direction the airflow is created without any
mobile parts by an electric field directly.
CHANGE OF METHOD OF AIRFLOW CREATING
The purpose of the given direction: to offer a construction of a fan which does not create mechanical and discrete noise.
In the concept of the given direction the airflow is created without any
mobile parts by an electric field directly.
Concept 7. THE IONIC NOISELESS FAN
Operating mode
Storage mode
1. Negative grid electrode
2. Needles
3. The movlees part of a case
4. The positive grid electrode
5. The movable part of a case
Conceptual Direction 4Conceptual Direction 4Institute of Innovative Design
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CHANGE OF METHOD OF COOLING OF PROJECTOR COMPONENTS
The purpose of the given direction: to offer methods of cooling without a forced circulation of air.
In concepts of the given direction heat energy emitted in projector by
different methods remove on exterior surfaces of projector components and is dispersed in surrounding medium.
CHANGE OF METHOD OF COOLING OF PROJECTOR COMPONENTS
The purpose of the given direction: to offer methods of cooling without a forced circulation of air.
In concepts of the given direction heat energy emitted in projector by
different methods remove on exterior surfaces of projector components and is dispersed in surrounding medium.
Concept 8. COOLING OF LAMP UNIT AND DLP BLOCK BY HEAT PIPES
1
2
3
4
5
9 10
10
8
A A
B B
Top view
Heat dissipation
Folding of panel
The element is hot
Working mode
Storage
6 3 4 2 7
5
A-A (section)
B-B (section)
Cappilary–porous material for working
liquid return
Reflector of lamp
The cooling system of the lamp unit and DLP block with the central heat sink with one fan
1112
Intake air
Concept 9. HEAT REMOVAL FROM PROJECTOR BY FLEXIBLE HEAT PIPE INTEGRATED WITH POWER CORD
1. Case
2. Contacts
3. Wires
4. Flexible heat pipe
5. Evaporator part
6. Condencer part
7. Capillary-porous canal
8. Condencer part
Concept 10. COOLING OF PROJECTOR ELEMENTS BY THERMOIONIC SEMICONDUCTOR ELEMENTS
1. Heat pipe
2
3
4. Condencer part
5
6
7. Air canal
7.
8.Projector case
9. Thermoionic element
10
11
12. Element with Peltier’s effect
13
14
15. Radiator enclosure
Conceptual Direction 5Conceptual Direction 5Institute of Innovative Design
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REDUCTION OF HEATING OF PROJECTOR COMPONENTS
The purpose of the given direction: to reduce heat absorption by components of projector.
In the offered concept elements of case are made of substances
transparent for infrared radiation. The heat radiation does not remain inside a projector, but outputs in a surrounding medium.
REDUCTION OF HEATING OF PROJECTOR COMPONENTS
The purpose of the given direction: to reduce heat absorption by components of projector.
In the offered concept elements of case are made of substances
transparent for infrared radiation. The heat radiation does not remain inside a projector, but outputs in a surrounding medium.
1. IR transparent
window
2. Projector case
3. Lamp unit
IR rays
Concept 11. CASE OF PROJECTOR MADE OF MATERIALS TRANSPARENT FOR IR BEAMS
Conceptual Direction 6Conceptual Direction 6Institute of Innovative Design
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CHANGE OF PHYSICAL PRINCIPLE OF PROJECTOR OPERATION
The purpose of the given direction: to change a physical principle of operation of projector, to solve a maximum quantity of key problems.
In the offered concept the light source with a high efficiency in which
are combined functions of light source with the modulator of radiation.
CHANGE OF PHYSICAL PRINCIPLE OF PROJECTOR OPERATION
The purpose of the given direction: to change a physical principle of operation of projector, to solve a maximum quantity of key problems.
In the offered concept the light source with a high efficiency in which
are combined functions of light source with the modulator of radiation.
Concept 12. LASER PROJECTOR
1. Red semiconductor
laser
2
3
4. Mirror
8. Chip
5. Micromotor6
7
Concept 12. LASER PROJECTOR WITH MATRICES OF SEMICONDUCTORS MICROLASERS
1. Control chip
2
3
4. Semiconductormicro lasers
5
67. Mixing
prism