Gate 3: Product Analysis - Harley-Davidson® Rocker™ Power Wheels

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Contents

Project Management: Coordination Review

Cause for Corrective Action

Figure 1: Call Chart

Some unresolved challenges that our group is facing are, a lack of communication and overshooting the internal deadlines that we set for ourselves. Besides just not talking to each other, there has been confusion about who is supposed to take care of which part of the assignment. We are going to address these problems by clarifying individual assignments and making sure that our fellow group members are staying on top of their work. This will be done by setting up a system where each member is assigned to call another member (figure 1). By doing this it will not only increase the communication within the group but will make sure that the work is done on time. A major challenge that we have addressed as a group was that the time for our weekly group meeting was not convenient for a majority of the group members. Because of the inconvenience, attendance at previous meetings was very poor. To solve this issue we have changed the time of our weekly meetings to 5pm on Fridays.

Product Archaeology: Product Evaluation

Product/Component Analysis and Summary

Part Complexity

  1. Low, One simple manufacturing process used, little thought required to make
  2. Medium, May consist of semi complex or multiple manufacturing processes, requires previous knowledge of other connecting parts
  3. High, Multiple production steps, requires knowledge of electrical components, cannot be disassembled by inexperienced person without specialized tools without permanently damaging or destroying.

*An inexperienced person is one that has not had training to take apart the component or similar components

*L stands for length and D stands for diameter

*All components are primarily 3 dimensional

* All components have a smooth finish for safety and to be more aesthetically pleasing except the wheels, which have a different finish to gain more traction

4 Amp Internal Fuse Battery

4 Amp Internal Fuse Battery

Part Number: 00801-1457

Quantity: 1

Part Function: Provides electrical energy to power the product

  • Functional or Cosmetic: Functional. Plastic casing of battery is cosmetic. Color matches product.

Material: Lead, Acid, Plastic

Material Selection Purpose: The component is a lead-acid battery to allow for recharging. The battery is enclosed in a hard plastic casing to help prevent contact with the toxic materials within the battery.

Manufacturing Process: The process used to create the casing was injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: Casing appears to be made of a few separate

joined pieces

  • Identifying marks: Gate Marks

Complexity: 2 - The battery stores chemicals and goes through the process of storing energy within itself. It is not an incredibly difficult component to manufacture, but transfers energy back and forth and also contains very dangerous and toxic materials, making it very complex.

Associated Flows: Electric

Environment: Meant to be used on land, not meant to be submerged in water.

Dimensions: 4.25 in x 2.75 in x 1.75

Shape and Properties: Rectangular prism

Approx. Weight: between 2 and 3 lb

Right Frame & Left Frame

Right Frame

Part Number: N/A

Quantity: 1

Part Function: Protects the interior components from physical forces as well as from dust, debris, and the elements. The right frame also provides anchoring points for the internal components.

  • Functional or Cosmetic: The two frames are both functional and cosmetic. They provide environmental protection as well as anchoring points for the proper placement of the other components. They also give the products body the look of a motorcycle, and the blue color shows that the product is intended for use my little boys.

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use and abuse during play. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

Left Frame
  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 1 - Large oddly shaped piece possesses a slight amount of complexity

Associated Flows: None

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions:

  • Right: 25.5 in x 14 in x 9.5 in
  • Left: 25.5 in x 14 in x 9.5 in

Shape and Properties: Unidentifiable odd shape

Approx. Weight: between 1 and 2 lb

Console Panel

Console Panel

Part Number: N/A

Quantity: 1

Part Function: Holds the control switch in place

  • Functional or Cosmetic: Has both functional and cosmetic purpose. The console panel is designed to look like the console of a motorcycle. It even has a place for a speedometer decal.

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use and abuse during play. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 1 - It is small and has an odd shape, showing very little complexity

Associated Flows: None

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions: 9.5 in x 6 in x 3.75 in

Shape and Properties: T-shape, symmetrical

Approx. Weight: less than 1 lb

Right Engine & Left Engine

Right Engine

Part Number: N/A

Quantity: 1

Part Function: N/A

  • Functional or Cosmetic: Parts are purely cosmetic.

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use and abuse during play. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
Left Engine
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 1 - Serves no function and is essentially not needed, but is oddly shaped, showing little to nearly no complexity

Associated Flows: None

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions:

Right: 11.5 in x 4.75 in x 2.75 in

Left: 8.5 in x 6 in x 2.25 in

Shape and Properties: Odd shape

Approx. Weight: between 0 and 1 lb

Rear Axle

Rear Axle

Part Number: P5065-4519

Quantity: 1

Part Function: Connects the two rear wheels through their rotational axes so that they rotate at the same velocity.

  • Functional or Cosmetic: Functional

Material: Steel

Material Selection Purpose: Steel is a strong rigid material that resists deformation.

Manufacturing Process: Extrusion Molding, Grinding

  • Reasons for manufacturing process: Creates a continuous length of material with a uniform cross-section.
  • Affect of material on process selection: Steel is a strong material that can be shaped using this process.
  • Affect of shape on process selection: An axle is a long cylindrical bar which makes this component perfect for extrusion.
  • Identifying Marks: There are continuous parallel marks running the entire length of the component.

Complexity: 1 - Very simple shape and mainly hold two wheels together, allowing the product to stand and move, showing little complexity

Associated Flows: Mechanical Rotational Energy

Environment: Should be operated in a dry environment to avoid rust

Dimensions: D = .5 in, L = 24.25 in

Shape and Properties: A long cylindrical shape, axis symmetry

Approx. Weight: between 0 and 1 lb

Right Rear Wheel & Left Rear Wheel

Right Rear Wheel

Part Number: P5065-2159 and P5065-2169

Quantity: 1

Part Function: Rotation of the wheels move product forwards or backwards

  • Functional or Cosmetic: Functional

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use and abuse during play. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection Molding and Welding

Left Rear Wheel
  • Reasons for manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials. Parts are created in two pieces and need to be joined together.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks and Melted Seam

Complexity: 1 - Moves the vehicle with traction converting mechanical rotational energy to translational kinetic energy showing some complexity

Associated Flows: Mechanical Rotational Energy, Translational Kinetic Energy

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle, should be used on flat surface. Meant to be used on cement or grass.

Dimensions:

  • Right: D = 8.25 in, L = 5 in
  • Left: D = 8.25 in, L = 5 in

Shape and Properties: Short, thick cylinder with holes, symmetrical

Approx. Weight: between 0 and 1 lb

Rear Wheel Cover

Part Number: P5065-2499

Quantity: 2

Part Function: To simulate the appearance a hub cap

  • Functional or Cosmetic: Cosmetic

Material: Plastic

Rear Wheel Cover

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use and abuse during play. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection Molding

  • Reasons for manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials. Parts are created in two pieces and need to be joined together.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The geometry must match up with that of the wheel it is covering.
  • Identifying Marks: Gate marks and Parting Lines

Complexity: 1 - Fits into the rear axle with a rectangular hole and into the wheels, transferring mechanical rotational energy to the other rear wheel cover through the axle and then to the other wheel, showing some complexity.

Associated Flows: Mechanical Rotational Energy

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions: D = 6.75 in, L = 1 in

Shape and Properties: Thin cylinder with strange extrusions, symmetrical

Approx. Weight: between 0 and 0.25 lb

.437 Retainer

.437 Retainer

Part Number: 0801-0226

Quantity: 2

Part Function: Holds the rear wheels on the rear axle

  • Functional or Cosmetic: Functional

Material: Plastic, Steel

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use and abuse during play. Plastic is also easy to mold into shapes with complex geometry. Steel is a strong and rigid material the has a excellent resistance to deformation.

Manufacturing Process:' Metal Stamping and Injection Molding

  • Reasons for manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials. Parts are created in two pieces and need to be joined together. The small and thin steel piece makes it convenient to just use stamping instead of something more costly.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The geometry must cover the end of the axle, and be small.
  • Identifying marks: Gate Marks

Complexity: 2 - The component is actually two pieces and keeps the rear wheels on the rear axle and is placed there using a machine, making it quite complex.

Associated Flows: None

Environment: Should not be used in a hot environment allowing easy deformation of the plastic and metal or a cold environment that causes the plastic to be more brittle.

Dimensions: D = .75 in, L = .5 in

Shape and Properties: small cone-like shape, axis symmetrical

Approx. Weight: between 0 and 0.25 lb

Wheel driver 10 RIB

Wheel driver 10 RIB

Part Number: 74460-2249

Quantity: 1

Part Function: Transfers the mechanical rotational energy from the gearbox to the wheels

  • Functional or Cosmetic: Functional

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 1 - Transfers mechanical rotational energy from the gearbox to the wheels, essential to the function of the product, showing some complexity.

Associated Flows: Mechanical Rotational Energy

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions: D = 3.875 in, L = 2.5 in

Shape and Properties: Cylinder with pattern within, symmetrical

Approx. Weight: between 0 and 1 lb

Bushing .437 Long Black

Bushing .437 Long Black

Part Number: 73610-2689

Quantity: 4

Part Function: Assists in securing the wheels in place

  • Functional or Cosmetic: Functional

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks and Parting Lines

Complexity: 1 - Small component, but does do a job, showing a little complexity

Associated Flows: None

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions: D = .5 in, L = 1.5 in

Shape and Properties: Small cylinder with wider head, axis symmetrical

Approx. Weight: between 0 and 0.25 lb

Footboard Assembly

Footboard Assembly

Part Number: P5065-9359

Quantity: 1

Part Function: Controls the direction that the motor runs

  • Functional or Cosmetic: Functional

Material: Plastic and Copper

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry. Copper wire provides a good conductor for electricity to travel to and from the motor.

Manufacturing Process: Injection Molding and Drawing

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials. Drawing is the most efficient way to make wires.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity. Copper is ductile and malleable, allowing it to be easily worked and drawn into wire.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 2 - Activates the motor using electrical energy and also has a very complicated shape to prevent movement, showing complexity

Associated Flows: Electrical Energy

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle, should avoid being used in a wet environment to avoid the risk of electric shock.

Dimensions: 4.5 in x 4.125 in x 2.5 in

Shape and Properties: Rectangle with other rectangles coming out of it

Approx. Weight: between 0 and 0.5 lb

Control Switch with Black Buttons

Control Switch with Black Buttons

Part Number: 00801-0873

Quantity: 1

Part Function: Controls the direction that the motor runs

  • Functional or Cosmetic: Functional

Material: Plastic, Copper

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry. Copper wire provides a good conductor for electricity to travel to and from the motor.

Manufacturing Process: Injection molding, Drawing

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials. Drawing is the most efficient way to make wires.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity. Copper is ductile and malleable, allowing it to be easily worked and drawn into wire.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: N/A

Complexity: 2 - Sends electrical energy to signal the direction of movement to the motor showing complexity.

Associated Flows: Electrical Energy

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle, should avoid being used in a wet environment to avoid the risk of electric shock.

Dimensions: 1.25 in x 1 in x 1.5 in

Shape and Properties: Small cylinder with wider head, axis symmetrical

Approx. Weight: between 0 and 0.25 lb

#3 Motor Pinion Assembly

#3 Motor Pinion Assembly

Part Number: 00968-1700

Quantity: 1

Part Function: Coverts electrical energy into mechanical rotational energy

  • Functional or Cosmetic: Functional

Material: Steel

Material Selection Purpose: The motor is potentially the most dangerous part of the product because if the electrical energy running through it and converted into mechanical energy. These dangerous parts must be encased in a strong material so that there is a minimal amount of danger. Steel is a strong enough substance to withstand a lot of impact without much damage.

Manufacturing Process: Die Casting

  • Reason for this manufacturing process: There is no need for using other manufacturing processes so there are no other costs to make it. It also gives the material a lot of strength.
  • Affect of material on process selection: Steel has been cast for hundreds of years and can heat quickly, allowing for faster heating and cooling than other metals. This allows the manufacturing process to happen more quickly.
  • Affect of shape on process selection: Casting gives the component a smooth surface finish and has great dimensional accuracy.
  • Identifying Marks: Riser marks

Complexity: 3 - Converts electrical energy into mechanical rotational energy in a small cylinder with ridges showing a lot of complexity

Associated Flows: Electrical Energy

Environment: Should avoid being used in a wet environment to avoid the risk of electric shock.

Dimensions: D = 1.5 in, L = 3.25 in

Shape and Properties: Small cylinder with smaller cylinder with ridges, axis symmetrical

Approx. Weight: between 0 and 0.5 lb

Gearbox 3B with Insert

Gearbox 3B with Insert

Part Number: 74550-9279

Quantity: 1

Part Function: Transmits power from the motor to the wheel driver and reduces the rotational speed.

  • Functional or Cosmetic: Functional

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 2 - The mechanical rotational energy is transferred through the gears in the gearbox and is reduced to reduce speed for safety, showing exceptional complexity

Associated Flows: Mechanical Rotational Energy

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle.

Dimensions: 6.75 in x 3 in x 4 in

Shape and Properties: Pear-shaped component with a circular protrusion, symmetrical

Approx. Weight: between 0 and 1 lb

4 Amp 6Volt Charger

4 Amp 6Volt Charger

Part Number: 00801-1483

Quantity: 1

Part Function: Recharge the 6 volt battery

  • Functional or Cosmetic: Functional

Material: Metal, Plastic, Copper

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry. Metal is required to be used as the conductor for the electricity. Copper wire provides a good conductor for electricity to travel through.

Manufacturing Process: Drawing, Plastics Extrusion, Injection Molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials. Drawing is the most effective way to make wires and plastic extrusion allows the most effective way to make the wire insulation because of how it has the same shape going straight through it from end to end.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity. Copper is ductile and malleable, allowing it to be easily worked and drawn into wire.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges. The wire insulation has a continuity of shape from end to end.
  • Identifying Marks: N/A

Complexity: 1 - The component transfers electrical energy into the battery and shows some complexity.

Associated Flows: Electrical Energy

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle, should avoid being used in a wet environment to avoid the risk of electric shock.

Dimensions: 2.5 in x 1.75 in x 1 in, wire length = 72 in

Shape and Properties: Small rectangular prism with two smaller protruding rectangular pieces and a long oval-type cylinder with another rectangular prism at the end, symmetrical

Approx. Weight: between 0 and 0.25 lb

Motor Clamp

Motor Clamp

Part Number: P5065-2239

Quantity: 1

Part Function: To hold the motor in place so that the motor stays stationary while the product is moving

  • Functional or Cosmetic: Functional

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 1 - Has the function of holding the motor in place, and shows no other complexity, but still overall showing some complexity

Associated Flows: None

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions: 4.375 in x 1 in x .75 in

Shape and Properties: Rectangular-shape with curved edges and two circular protrusions at the ends, symmetrical

Approx. Weight: between 0 and 0.25 lb

Rear Fender

Rear Fender

Part Number: N/A

Quantity: 1

Part Function: To simulate the appearance of a fender

  • Functional or Cosmetic: Cosmetic

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 1 - Has no large function, but provides a comfort for the user and is a large component, showing some complexity

Associated Flows: None

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions: 12 in x 7.5 in x 18.25 in

Shape and Properties: Odd unidentifiable large shape, symmetrical

Approx. Weight: between 0 and 1 lb

Seat For Harley Rocker

Seat For Harley Rocker

Part Number: P5065-9309

Quantity: 1

Part Function: Provide comfort for the used by giving a place to sit as well as serving as the top to the battery compartment

  • Functional or Cosmetic: Functional

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 1 - Give user a place to sit, which is important, and also covers the battery, showing some complexity.

Associated Flows: None

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions: 7.5 in x 5 in x 8.25 in

Shape and Properties: Oval-like curved shape, symmetrical

Approx. Weight: between 0 and 0.5 lb

Head Light

Head Light

Part Number: 3800-8822

Quantity: 1

Part Function: To simulate the appearance of a heat light and hold the front wheel assembly together

  • Functional or Cosmetic: Functional and Cosmetic

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 1 - Keeps the front fork from disconnecting from the frame showing some complexity

Associated Flows: None

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions: 8.5 in x 6.5 in x 3.75 in

Shape and Properties: Small rectangular shape with small curved cylindrical protrusion, symmetrical

Approx. Weight: between 0 and 0.5 lb

Front Axle

Front Axle

Part Number: P5065-4529

Quantity: 1

Part Function: Holds the front wheel in place and allows it to rotate

  • Functional or Cosmetic: Functional

Material: Steel

Material Selection Purpose: Steel is a strong rigid material that resists deformation.

Manufacturing Process: Extrusion Molding

  • Reasons for manufacturing process: Creates a continuous length of material with a uniform cross-section.
  • Affect of material on process selection: Steel is a strong material that can be shaped using this process.
  • Affect of shape on process selection: An axle is a long cylindrical bar which makes this component perfect for extrusion.
  • Identifying Marks: There are continuous parallel marks running the entire length of the component.

Complexity: 1 - Very simple shape and mainly hold a wheel in place, allowing the product to stand and move, showing little complexity

Associated Flows: Mechanical Rotational Energy

Environment: Should be operated in a dry environment to avoid rust

Dimensions: D = 0.375 in, L = 7.5 in

Shape and Properties: Small, thin, long cylinder, axis symmetrical

Approx. Weight: between 0 and 0.5 lb

Front Wheel Spacer

Front Wheel Spacer

Part Number: P5065-4529

Quantity: 2

Part Function: Holds the front wheel in place by keeping it centered on the front axle and unable to move sideways

  • Functional or Cosmetic: Functional

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 1 - Keeps the front wheel at the center of the front axle showing some complexity.

Associated Flows: None

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions: D = 1.375 in, L = 1.125 in

Shape and Properties: Small cutoff cone-shape with ridges, axis symmetrical

Approx. Weight: between 0 and 0.25 lb

Front Fork

Front Fork

Part Number: P5065-2239

Quantity: 1

Part Function: Holds the front axle and front wheel

  • Functional or Cosmetic: Functional

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 1 - Hold the front wheel and axle and controls the general direction of movement, showing complexity.

Associated Flows: Mechanical Rotational Energy

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions: 17.75 in x 8.5 in x 4 in

Shape and Properties: A cylinder with odd protrusions connected to a u-shape with protrusions, symmetrical

Approx. Weight: between 0 and 1 lb

Front Axle Retainer Right & Front Axle Retainer Left

Front Axle Retainer Right

Part Number: P5065-2259 and P5065-2289

Quantity: 1

Part Function: Holds the front axle to the front fork

  • Functional or Cosmetic: Functional

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Front Axle Retainer Left

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 1 - Hold the front axle to the front fork, showing some complexity.

Associated Flows: None

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions:

  • Right: 3.5 in x 2.25 in x 0.5 in
  • Left: 3.5 in x 2.25 in x 0.5 in

Shape and Properties: Small curved oval-shape with a protruding rectangular-shape and 2 holes, symmetrical

Approx. Weight: between 0 and 0.25 lb

Front Wheel

Front Wheel

Part Number: 3800-9016

Quantity: 1

Part Function: Rotation of the wheel moves product forwards or backwards

  • Functional or Cosmetic: Functional

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding and Welding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks and Melted Seam

Complexity: 1 - Moves the vehicle with traction converting mechanical rotational energy to translational kinetic energy showing some complexity

Associated Flows: Mechanical Rotational Energy

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions: D = 11 in, L = 2.5 in

Shape and Properties: Short cylinder with a hole, symmetrical

Approx. Weight: between 0 and 1 lb

Front Wheel Cover

Front Wheel Cover

Part Number: 3800-9016

Quantity: 2

Part Function: To simulate the appearance a hub cap

  • Functional or Cosmetic: Cosmetic

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks and Parting Lines

Complexity: 1 - Fits into the front axle, little to nearly no complexity.

Associated Flows: None

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions: D = 9.25 in, L = 0.5 in

Shape and Properties: Thin cylinder with strange extrusions, symmetrical

Approx. Weight: between 0 and 0.25 lb

Right Headlight Retainer & Left Headlight Retainer

Right Headlight Retainer
Left Headlight Retainer

Part Number: P5065-2339 and P5065-2329

Quantity: 1

Part Function: Holds the headlight in place

  • Functional or Cosmetic: Functional

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 1 - Hold the headlight and keeps the front fork in place, showing some complexity.

Associated Flows: None

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions:

  • Right:6.5 in x 2 in x 1.5 in
  • Left: 6.5 in x 2 in x 1.5 in

Shape and Properties: Curved rectangular shape

Approx. Weight: between 0 and .25 lb

Handle Bar

Handle Bar

Part Number: P5065-2349

Quantity: 1

Part Function: Aids the user in rotating the front wheel

  • Functional or Cosmetic: Functional

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 1 - A large piece allowing the product to change direction quickly and easily, showing complexity.

Associated Flows: Mechanical Rotational Energy

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions: 18 in x 7 in x 3.5 in

Shape and Properties: A bent cylinder with protrusions attached to a oval shaped cylinder, symmetrical

Approx. Weight: between 0 and .5 lb

Handle Bar Clamp

Handle Bar Clamp

Part Number: P5065-2469

Quantity: 1

Part Function: Holds the handle bar in place

  • Functional or Cosmetic: Functional

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 1 - Hold the handle bar in place, showing some complexity.

Associated Flows: Mechanical Rotational Energy

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions: 5.5 in x 2.5 in x 1.25 in

Shape and Properties: Cut-in-half cylinder with its sides curve out, symmetrical

Approx. Weight: between 0 and .25 lb

Hub Cap

Hub Cap

Part Number: K0452-2349

Quantity: 2

Part Function: Cover the .437 retainers on both ends of the the rear axle

  • Functional or Cosmetic: Cosmetic

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 1 - Covers the .437 retainer which does not accomplish anything useful, showing little or nearly no complexity

Associated Flows: None

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions: D = 1.5 in, L = 0.75 in

Shape and Properties: Half a sphere with slits and a ole in the middle, axis symmetrical

Approx. Weight: between 0 and .25 lb

Frame Brace Top & Frame Brace Bottom

Frame Brace Top
Frame Brace Bottom

Part Number: P5065-2389 and P5065-2399

Quantity: 1

Part Function: Holds together the front of the right frame and left frame

  • Functional or Cosmetic: Functional

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks and Melted Seam

Complexity: 1 - Hold the front of the right and left frame together, showing some complexity.

Associated Flows: None

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions:

  • Top: 4.25 in x 3.75 in x 1.5 in
  • Bottom: 3.75 in x 3.5 in x 1 in

Shape and Properties: Rectangular shape with an attached circle and a large hole in the middle of the circle, symmetrical

Approx. Weight: between 0 and .5 lb

Footswitch

Footswitch

Part Number: 0801-0538

Quantity: 1

Part Function: Allowing the user to activate the motor more easily by providing a larger area to press instead of the small switch

  • Functional or Cosmetic: Functional and Cosmetic

Material: Plastic

Material Selection Purpose: Plastic is a lightweight and impact resistant material. This provides for the durability to withstand repeated use. Plastic is also easy to mold into shapes with complex geometry.

Manufacturing Process: Injection molding

  • Reason for this manufacturing process: Although injection molding has a high upfront cost, it is a quick, cost effective method of forming a high volume of the same parts from meltable materials.
  • Affect of material on process selection: Plastic provides a meltable material of an acceptable viscosity.
  • Affect of shape on process selection: The complex geometry of the parts and smooth edges
  • Identifying Marks: Gate Marks

Complexity: 1 - Pushes the switch, activating the motor, showing complexity

Associated Flows: None

Environment: Should not be used in a hot environment allowing easy deformation or a cold environment that causes the plastic to be more brittle

Dimensions: 3 in x 1.75 in x 1.5 in

Shape and Properties: Rectangular prism attached to a protruding nail, symmetrical

Approx. Weight: between 0 and .25 lb

Battery Retainer

Battery Retainer

Part Number: 74230-4129

Quantity: 1

Part Function: To keep the battery from being removed easily and from bouncing around while the product is moving as well.

  • Functional or Cosmetic: Functional

Material: Steel

Material Selection Purpose:

Manufacturing Process: Extrusion Molding and Forging

  • Reasons for manufacturing process: Creates a continuous length of material with a uniform cross-section and bent ends.
  • Affect of material on process selection: Steel is a strong material that can be shaped using this process.
  • Affect of shape on process selection: The component's thin cylindrical shape makes it perfect for extrusion.
  • Identifying Marks: There are continuous parallel marks running the entire length of the component and being bent.

Complexity: 1 - Stop battery from movement and in turn, danger, showing complexity

Associated Flows: None

Environment: Should be kept in a dry environment to avoid rust

Dimensions: 3.75 in x 0.375 in x 0.375 in

Shape and Properties: A small, bent, long cylinder, symmetrical

Approx. Weight: between 0 and .25 lb

Influencing Factors

Material of Component(s)
or
Manufacturing Process
Component(s) Global Societal Economic Environmental
Plastic Right Frame & Left Frame
Console Panel
Right Engine & Left Engine
Right Rear Wheel
Left Rear Wheel
Rear Wheel Covers
Wheel driver 10 RIB
Bushing .437 Long Black
Gearbox 3B with Insert
Motor Clamp
Rear Fender
Seat For Harley Rocker
Head Light
Front Wheel Spacer
Front Fork
Front Axle Retainer Right
Front Axle Retainer Left
Front Wheel
Front Wheel Covers
Right Headlight Retainer
Left Headlight Retainer
Handle Bar
Handle Bar Clamp
Hub Cap
Frame Brace Top
Frame Brace Bottom
Footswitch
Plastic is a widely available
material. It is used all over
the globe in a countless
number of products so most
regions have no problem with
plastic being used to create
these components.
Plastic is used all over
the globe in nearly every
society and every region.
Using hard plastics for
the components also
makes them relatively
strong, stable and safe.
Using plastic to create
most of the components in
the product will most likely
not affect the number of
consumers significantly.
Plastic is a relatively cheap
material, especially when
bought in bulk.
Plastic can be recycled, but
it is not biodegradable so all
of these components will
eventually end up in a dump.
Manufacturing plastic also
creates many toxic gases,
affecting the people working
with them as well as the
environment.
Steel Front Axle
Rear Axle
#3 Motor Pinion Assembly
Steel is available and
commonly used all around
the globe, because of its
high strength to weight ratio.
Steel is a strong material,
so it will not fail unless put
under a great amount stress.
This increases the safety of
the product to meet regulations.
Steel Prices vary from
location to location.
It is a reusable material that
can be recycled.
Plastic
and
Steel
.437 Retainer Plastic and steel are
widely available materials
that are used in countless
numbers of products around
the world.
See above cells for plastic and
steel
See above cells for plastic and
steel
See above cells for plastic and
steel
Plastic
and
Copper
Footboard Assembly
Control Switch with Black Buttons
See above cell for plastic
Copper is a material used
on a worldwide scale for the
creation of wires
See above cell for plastic;
Copper is a safe material to
use for the conduction of electricity
See above cell for plastic;
The easy handling, forming,
and joining of copper saves
time and money in the overall
cost of production. Also its
long term performance makes
it a cost-effective material.
See above cell for plastic;
Copper is easy to recycle
Lead, Acid and Plastic 4 Amp Internal Fuse Battery Usage varies according to
the voltage regulation of region.
Fits most small/medium size
power wheels.
Very low cost Does not require combustion
to generate power therefore
does not contribute to air
pollution, it can be recycled
at specific locations.
Injection Molding Right Frame & Left Frame
Console Panel
Right Engine & Left Engine
Rear Wheel Covers
Wheel driver 10 RIB
Bushing .437 Long Black
Gearbox 3B with Insert
Motor Clamp
Rear Fender
Seat For Harley Rocker
Head Light
Front Wheel Spacer
Front Fork
Front Axle Retainer Right
Front Axle Retainer Left
Front Wheel Covers
Right Headlight Retainer
Left Headlight Retainer
Handle Bar
Handle Bar Clamp
Hub Cap
Frame Brace Top
Frame Brace Bottom
Footswitch
Method commonly used
around the globe because of its
high production rate.
Good surface finish makes
product more aesthetically pleasing
High initial cost but
cost-effective process when
producing large quantities.
With this process any leftover
material can be remelted and
reused.
Extrusion Molding Front Axle
Rear Axle
Process widely used around
the world to produce components
with a consistent cross-sectional
area.
Gives attractive finishes to the parts Is a method that requires low
tooling cost, and minimizes
the need for secondary
machining processes.
Waste materials from this
process can be reused for
this process.
Injection Molding
and
Welding
Right Rear Wheel
Left Rear Wheel
Front Wheel
See above cell for injection molding;
Welding is a widely used and
simple method of binding two
components together with heat.
See above cell for injection molding;
See above cell for injection molding;
See above cell for injection molding;
Metal Stamping
and
Injection Molding
.437 Retainer See above cell for injection molding;
Commonly used around the world
See above cell for injection molding;
Parts have high tolerance and
precision, increasing the safety
when parts are assembled.
See above cell for injection molding;
It is a very cheap process that can
easily mass produce a component.
See above cell for injection molding;
Very precise process that has a
minimal amount of waste. Waste
materials can use melted down
and reused.
Extrusion Molding
and
Forging
Battery Retainer See above cell for extrusion molding;
Simple method used around the
globe to create components using
heat and pressure.
See above cell for extrusion molding;
Process done quick and easy.
See above cell for extrusion molding;
Cost-efficient production of complex
shapes.
See above cell for extrusion molding;
Minimal metal waste saves material.

Overall Product Analysis

To manufacture this product, plastic must be injection molded, copper must be drawn, and steel must be extruded, stamped and caste. The decision to manufacture the product this way was made based off many thing, including the four factors.

  • Economic: The injection molding is expensive to do, as well as the casting for steel, but it allows for faster manufacturing and lower cost over time. Drawing and stamping are cheaper and doing this with certain components helps save money.
  • Environmental: The injection molding of plastic releases toxic chemicals into the air hurting the environment. Caste steel also contributes to thermal pollution because of the need to cool the component down after being at extremely high temperatures.
  • Societal: The use of steel for the .437 retainers, which holds the rear wheels to the rear axle, instead of other weaker metals was to make sure that there would be no way for the product to fall apart after any collision. This is done because of the social concerns of the American people, safety, especially for children.

Solid Modeled Assembly

The solid modeling images below are of parts that have somewhat complex features; it was a challenge to model these parts since most members did not have prior experience creating solid models in 3D, and those that did had very limited knowledge on the subject. The parts we selected are the axel, the wheel and the wheel cover. These components were picked because the assembly of the wheel is what supports all the weight of the power wheel and it was also intended to help us in our future classes of 3D modeling by going into detail in the wheel and the wheel cover.


Program used for solid modeling: Autodesk inventor professional 2011 trial version. This program was chosen because it is offered free to all students for a period of 30 days, and because it has some nice features, like the extrusion command, that really helps when working on 3D modeling.

Assembly (Rear Wheel, Rear Wheel Cover, Rear Axle)

Assembly Pic.jpg Assembly Pic 2.jpg


Rear Wheel

Wheel pic.jpg Wheel pic 2.jpg

Rear Wheel Cover

Cover Pic.jpg Cover Pic 2.jpg

Rear Axle

Rod Pic.jpg Rod Pic 2.jpg

Engineering Analysis

The rear axle is an integral part of the vehicle and if it fails the product would not be able to function. The engineering analysis process can be used in the testing of the axle to figure out what load would cause it to fail. By first figuring this out mathematically it gives an approximation of the real answer. This approximation can be used to choose an appropriate test to use to figure out the load at which the axle will fail.

1. Problem Statement:

What is the maximum force that the axle can take before it fails. The material for the axle is steel and it has a diameter of one half of an inch. The flexural modulus of steel is 20,000 lbf/in²


2. Diagram:

Diagram 1:Diagram for Engineering Analysis


3. Assumptions:

  • The Plastic does not fail first
  • Even distribution of load
  • The force of the wheel comes from the center of the wheel
  • The weight of the axle is negligible compared to the total weight


4. General Equations:

  • A=π r ²
  • Fshear, max=EtA
  • ∑Fy=0
  • Total Loading= LFy+RFy

Max Shear Force occurs between where the force from the wheel and the frame meet. Shear Force for distance x between the Left Wheel and Left Frame.

V=(LWy)

If V≥Fshear, max, then the axle deforms

5. Calculations:

Since load is evenly distributed and the weight of the axle is considered negligible

LWy=RWy=LFy=RFy

Fshear, max=EtA

Fshear, max=Etπr²

Fshear, max=(20000 lbf/in²)π(0.25 in)²

Fshear, max=3,927 lbf

Since V=(LWy) when V≥Fshear, max the LWy is the same as V and since LWy=RWy=LFy=RFy the total maximum load is twice the maximum shear force

Total Loading=3927 lbf+ 3927 lbf=7,854 lbf

6. Solution Check:

The units line up in the end

There are no mathematical errors

The answer makes sense considering the flexural modulus of steel and the cross-sectional area of the axle

7. Discussion

The number determined from this check is liberal because the weight of the axle was considered negligible, the actual values would be slightly lower. Also the chance of the steel axle failing before either the body or the wheels of the Power Wheels is very low and is virtually impossible. This calculation gives the upper end of values that it could be, the real failure load is likely less than the determined value.

Design Revisions

Figure 2: Internal Battery

Internal Battery:

  • The new location of battery and charging port are shown in figure 2. The battery is secured in place by adding a bracket (battery clamp). Wires are clamped to frame to keep them from getting tangled in the axle. By changing the placement of the battery the user no longer needs any direct contact with it and by changing its location, it is no longer necessary to screw the seat onto the frame.
  • There is an economic factor in that while it may increase the initial cost of the product as a new mold needs to be created for the battery clamp. The new higher initial cost can be offset by a slightly higher sales price and now, any service dealing with the battery would have to be done at a service center.
  • This design revision also addresses societal factors through the American obsession with safety and convenience. By not having the need to handle the lead acid battery it makes the product appear safer, and not needing to unfasten the seat to recharge the battery increases convenience.

Forward/Backward Button with arrows:

  • The black forward/backward switch that comes with the original Power Wheels Harley Davidson Rocker is unlabeled and it is very difficult to determine whether the vehicle is in forward or reverse at a glance. This could be changed by placing arrows on the switch to determine which direction the vehicle is going. This modification would be inexpensive and could be done by stamping the plastic buttons with an arrow facing the direction the vehicle would go. This is a societal concern because people like things to be explained to them.
  • The original design was probably due to an economic concern because the product was designed in 2009, during an economic recession, and adding another step would increase the price of the product.
Figure 3: Console w/ On-Off Switch and Directional Arrows

On/Off Switch:

  • Add on/off slide switch above the Control Switch with black buttons, shown in figure 3. The original design of the product has the battery located under the seat, which is fastened with two screws, as well as having the product constantly on as long as the battery is plugged in. The current design prevents the power from being quickly shut off. We would also incorporating an LED next to the switch that will help notify the user that the device is on. Also there may be times when the battery may be plugged in that the owner does not want the device to move and the on-off switch will add this feature. This is a societal concern because Americans, the primary consumers, have high safety expectations. This improvement would cause a slight increase in the price of the product.
  • The original design was probably due to an economic concern because the product was designed in 2009, during an economic depression, and adding another step would increase the price of the product.

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References

[1]"Plastic at your peril." DWS - Dance with Shadows - Your Search Ends Here. Web. 17 Dec. 2010. <http://www.dancewithshadows.com/business/pharma/plastic.asp>.