simultane product- & productieontwikkeling
TRANSCRIPT
Simultane Product- & Productieontwikkeling
Voxdale company presentation & Case studies
OMC - October 24th 2013
Koen Beyers – Voxdale
Voxdale • Founded in 2005
• Located in Antwerp, Belgium
• 5 Product Designers (Design, Product architecture, Mechanical engineering) • 6 Engineers (Mechanical engineering, CFD, FEA)
• 1 Business Developer
• Profiles: B.Sc., M.Sc., Lic., Ing., Ir.
Voxdale • Brainstorming, Concept Design & Product Development
• Mechanical Design & Engineering
• Process simulation & Optimization
• Prototyping & Design Validation
Tools
Markets • Medical Devices
• Space & Aerospace • Automotive
• Transportation & Logistics
• Performance sports
• Consumer Electronics
• Industrial installations
• Energy & Environment • Governments
Design Path
Design Path
Design Path
Product/Device development is a multidisciplinary job • Technological aspects
• Material (medical grade, biocompatibility, leachable, extractables, sterlization, …) • Device architecture • Mechanical design – Electronics, hardware (if apl.) – Software, firmware (if apl.) • Prototyping - optimization • Manufacturing technique (moulding, milling, …) • Labling (CE mark, …), technical file
• Economics
• Investment cost/budget • Unit price – manufacturing cost – margin – assembly cost • Market – distribution channels – collaborations (drug – device combination)
• Human Factors - HCD
• Ergonomics – Anthropometrics • Usability – semantics – acceptance • Aesthetics – design • Clinical Trials
Multidisciplinary team / Complementary partners
&
Open Innovation
• Multidisciplinary teams
• Complementary partners
• Radical innovation • Open Innovation
Case studies
Case study - Projector
Case Study: Multi Media Projector (Beamer) Specifications:
• XGA Resolution (1024 x 768 pixels) (800.000) • 800 Ansi Lumens • Ultra Compact: 125 x 95 x 50 mm • € 700 > Listprice
Case Study: Multi Media Projector (Beamer) Technology:
• 80W UHP Lamp • Single Chip DLP (Texas Instruments) - 0.55’’ >> 0.55’’ is the size of a fingertip >> Magnified to the screen size you see now … >> One pixel is 0.011 mm >> Extremely sensitive to dust & particles
Case Study: Multi Media Projector (Beamer) Requirements:
• Dust free • Low Noise Level > 32 dB(A) • Compact • Low Weight • EMI compliant Class B • Robust & Stable (optics) • Optimal thermal management (reliability) >> Material definition is Concept Design, not a choice at the end >> Magnesium
• Top Shell (Mg) • Electronics
• LPS (Lamp power) • PMP (Imaging) • Input Module
• Optical engine
• Lamp • Light Rod • Mirrors • Prism • DLP Chip • Lens
• Fan (1) • Bottom Shell (Mg)
Case Study: Multi Media Projector (Beamer) Enclosed Housing, for:
• Low Noise Level > 32 dB(A) • Dust Exclusion
• Resulting disadvantages:
• Thermal Management? • No cooling slots (with dust filter)
Case Study: Multi Media Projector (Beamer) Magnesium for EMI Shielding
• Hi-Freq Electronics • Image processing for 96 (24x4) XGA images/second • 2 mm metal layer, • versus a thin (15 micron) and expensive Cu or Ni coating (used with plastics)
Case Study: Multi Media Projector (Beamer) Magnesium for (optical) stability & robustness
• Optics mounted in the bottom shell • Portable device (drop test)
• Torsion test (bottom shell) with 1 Nm torque • Comparison of
• 2.0 mm wall thickness Magnesium design, 78g versus • 2.8 mm wall thickness Cycoloy design, 66g
Case Study: Multi Media Projector (Beamer)
Case Study: Multi Media Projector (Beamer)
Case Study: Multi Media Projector (Beamer)
• Torsion test with 1 Nm torque (FEA)
Cycoloy C6200 (PC-ABS) versus AZ91HP
Case Study: Multi Media Projector (Beamer) Magnesium for Thermal Management
• Thermal Conduction
• 100% enclosed housing
• One fan for internal convection and air-flow
• ‘Air-metal-air’ Heat Exchanger in Top & Bottom shell
• Entire Magnesium housing acts as Heatsink.
• About 75W heat dissipation to get out of the product
Case Study: Multi Media Projector (Beamer) Magnesium for Thermal Management
Bottom shell with heatsink/double heat exchanger
Axial Fan
Case Study: Multi Media Projector (Beamer) Magnesium for Thermal Management (CFD Analysis)
Case Study: Multi Media Projector (Beamer) Magnesium for Thermal Management (CFD Analysis)
Case Study: Multi Media Projector (Beamer) Magnesium for Thermal Management (CFD Analysis)
Case Study: Multi Media Projector (Beamer) Magnesium for Thermal Management (CFD Analysis)
Case Study: Multi Media Projector (Beamer) Magnesium for Thermal Management (CFD Analysis)
Temperature plot of projector body in ‘Ceiling Mount’
Case Study: Multi Media Projector (Beamer) Magnesium for Thermal Management (CFD Analysis)
Case Study: Multi Media Projector (Beamer)
Simulation as a design tool : • It all starts at conceptual level!
• Parameters are essential • Rubbish in is rubbish out • Spec sheets (commercial) • Historical measurements • Intuition (10°C or 10.000°C? 0.11 m/s or 11 m/s?) • …
• Therefore: main value is
• Trend research (variant A is 12% better than B) – rather than absolute value • Check initial feasibility of concepts & ideas • Compare dozens of variants overnight + parameter optimization • Pin point! Rather than: ‘good enough, it seems to work’ >> look inside & visualize
Multidisciplinary team / Complementary partners
&
Open Innovation
Where is this going to?
Form Follows Funtion design • Optimized for stress • For thermal management • Use of material • Reliability
• Efficiency
• ‘Design inspiration’
Questions?