Group 21 - Jeep® Wrangler Power Wheels 1 - Gate 3

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Contents

Project Management: Coordination Review

At this point in the project the individuals of Group 21 have successfully learned how to work as a well functioning team. This success can be directly attributed to the corrective action that group has taken along the course of the project. However, this is not to imply that the group is perfect. Despite the actions taken to correct problems within the group prior to this gate, there still exist adversities that need to be overcome.

Successful Corrective Action

There is one primary case where Group 21 has taken action to improve the means of the group's productivity. Prior to this gate the group has adopted the policy of the group leader dividing up each gate into individual components and delegating them to each of the members. This strategy appeared to have the most potential in terms of productivity. However, the way in which the group carried out this strategy could have been much more efficient. The way in which it was initially done was that the group leader would break up the work and ask each member if he or she could complete it. No where in this plan was each member consulted on what they would or would not rather do. This has changed. Now at every new gate meeting, the group convenes and discusses the assignment as a whole as well as individual pieces. Each member describes the component of the assignment that he or she believes they would be the best at completing. This simple alteration betters the quality of each individual component by allowing the member with the best specific knowledge needed to complete said component, do so.

Need For Further Corrective Action

It is clear that the one group flaw that still needs resolution is procrastination. As the end of the semester approaches, the work load and frequency of exams increase for all classes. This fact makes it difficult to balance the work load of all classes, which leads to assignments with the later due dates getting delayed. Gate 3 began with the intent of completing the entire assignment a week prior to the due date to allow optimal time for fine tuning the final product. Unfortunately due to a week of multiple exams and heavy homework assignments for all members in Group 21 this goal gradually became unachievable. Deadlines set by the group became second priority to assignments in other classes that were due sooner. In the future, this must be avoided. To prevent procrastination, mandatory weekend meetings will be instituted if need be. During this time the group can delegate a window of time specifically for being productive on the project. These meetings will also allow group members to converse and help one another while they proceed with their delegated individual components.

Product Archaeology: Product Evaluation

Complexity Profile

The Component Complexity scale show in Table 1 was created by examining our components and setting standards for which we thought was the most complex to least complex. We used the functional model and component summary to see what each component was involved in. From this we created the scale and set a number to each component.


Table 1: Component Complexity Rating Scale


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The Subsystem Complexity Scale was created by examining the interactions between the components. This allowed us to break down what is actually flowing from component to component and create a scale of what is more complex to less complex.


Table 2: Subsystem Complexity Rating Scale


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The Component function, manufacturing method and component form affect the complexity of each part in its overall rating. Depending on the intricacies of the manufacturing, the overall functionality of the part and how it was manufactured the part got an appropriate rating. For example a simple yet vital part of the steering subsystem is the steering rod. It received a 2 in out rating scale due from the movement it needed to have in order to fulfill its task. It has a very simple manufacturing method and form yet because of its function it received a 2. A less complex component is the Battery Cover (and “spark plugs”) it received a 1 on the scale due to its lack of significant function. Although a much more complex form and manufacturing process the cover is a very simplistic component.

Steering

Steering wheel (top and bottom) - The steering wheel is not a complex component at all. It is of simple make, created of molded plastic and a hollow inside. In a scale of 1 through 5, this system would receive a 2. Its purpose is to translate a signal from a human user and send it to the steering column and provide a comfortable grip to the user.
Steering column – This component is a simplistic component in a scale of 1 through 5 it would receive a 2. This component is used only to carry the signal given from the human user to the front axle in order to create a steering system.
Front axle - The front axle rates as a 2 in a scale of 1 through 5. This component is what completes the steering subsystem by connecting the wheels to the signal given from the user. Its manufacturing is slightly more complex than the other components in the subsystem but is still relatively simple.
Steering subsystem: The overall subsystem is a very simplistic part of the Jeep, rating at a 2 in a scale of 2 through 5. Due to the needed signal for the user and multiple moving components.

Casing

Body of vehicle – 1 out of 5
Grille- 1 out of 5
Hood- 1 out of 5
Battery Cover (and “spark plugs”) - 1 out of 5
Dash-1 out of 5
Windshield-1 out of 5
Windshield frame- 1 out of 5
Hood latches (2) - 1 out of 5
Activity panel- 1 out of 5
Instrument panel- 1 out of 5
All components of the Casing system receive a rating of 1 due to their stationary position and singular function in that they are completely for aesthetic purposes or provide structural support. Overall this sub-system receives a 1 in the 1 to 3 scale due to the simplistic nature of the components

Translational motion

Motor- The motor is the most complex component of the Jeep, receiving a 5 out a 1 through 5 scales. It includes many small moving parts that must act in complete synchronization in order to complete its function of turning electrical signals to translational movement.
Gearbox – This component is a fairly complex component the overall function, in a Scale of 1 through 5 it would rate at a 4. It does not need to convert any electrical or human signals to perform its task, which is to take high speed rpm motor and convert it to a lower speed with higher torque. This is done by a smaller gear turning a slightly larger gear that turns an even larger gear.
Battery- The battery is a fairly complex component; it provides a power source for the motor and would receive a rating of 4 out of the scale of 1 through 5.
The translational motion subsystem is the most complex part of the Jeep with a rating of 3 out of 3 in the rating scale. This is due to the multitude of complex components residing inside of the subsystem. Also performing multiple tasks in side of the subsystem such as transforming electrical energy to rotational energy then creating low speed torque out of a high rpm motor.

Wheels

4 of the following:
Wheels – A simplistic part receiving a rating of 2 out of 5 for their singular function and movement in the overall function
Traction Bands – receive a 1 out of 5 due to their singular function of providing traction to the whole system
Wheel Bearings – receive a 1 out of 5
Red Caps – receive a 1 out of 5
Washers – receive a 1 out of 5
White drive shaft in the back driver side wheel – receives a 2 out of 5 allowing the gear box to transfer power to the wheel
The wheels subsystem : Receives 2 out of 3 due to the number of moving parts inside of the subsystem and function.

Component Summary

Steering

Steering Wheel

Component Name: Steering Wheel

Quantity: 1, a bottom and top half

Main Function: Allows child to move the Jeep

Other Functions: None

Flows: Human energy to rotational mechanical energy by having the user turn the steering wheel, which makes the steering column rotate.

Environment: Not extremely hot weather because it’s black and could get hot to the touch, and not wet because it could get slippery and hard to turn the steering wheel.

Complexity Rating: 2


Steering Wheel Cap

Component Name: Steering Wheel Cap

Quantity: 1

Main Function: To cover the locknut that holds the steering column in place connected to the steering wheel.

Other Functions: Helps to keep the child safe because it keeps the locknut hidden, and protects it from rusting.

Flows: None

Environment: Any

Complexity Rating: 1


Steering Column

Component Name: Steering Column

Quantity: 1

Main Function: To turn the front axle of the Jeep when the steering wheels is turned, which will then turn the Jeep.

Other Functions: None

Flows: Rotational mechanical energy by turning when the steering wheel is turned, which then turns the front axle.

Environment: Dry because it is metal so it could rust, which is why it is underneath the plastic part of the Jeep.

Complexity Rating: 2


Front Axle

Component Name: Front Axle

Quantity: 1

Main Function: To turn the wheels and make the Jeep move in the desired direction.

Other Functions: It also holds the front wheels in place, which allows the wheels to rotate and move the vehicle.

Flows: Rotational mechanical energy from the steering column to the axle, which turns to make the Jeep move in a certain direction.

Environment: Dry because it is metal so could rust, which is why plastic parts cover it. It can come in contact with grass because the Jeep is supposed to be driven outside, but it is not supposed to be driven on rough terrain because rocks could fly up and break it.

Complexity Rating: 2


Plastic Axle Protectors

Component Name: Plastic Axle Protector

Quantity: 2

Main Function: To connect the front axle to the bottom of the vehicle.

Other Functions: To protect the front axle from the terrain the Jeep is driving over.

Flows: None

Environment: Any

Complexity Rating: 1


Casing

Body of Vehicle

Component Name: Body of vehicle

Quantity: 1

Main Function: To hold the child (driver).

Other Functions: Helps to transport the child by providing him/her with a place to sit and be able to drive the car. It also connects and protects all components so the Jeep can drive.

Flows: None

Environment: Any, but dry weather is preferred because the plastic could become slippery when wet so the child could become injured while getting in and out of the vehicle. Also, the inside could collect water, making the Jeep heavier, and if it gets too heavy it will not move.

Complexity Rating: 1


Grille

Component Name: Grille

Quantity: 1

Main Function: It is mostly for appearance (to make the Jeep look like a real Jeep).

Other Functions: It provides added protection for the battery, especially if the Jeep collides head-on with something.

Flows: None

Environment: Any

Complexity Rating: 1


Hood

Component Name: Hood

Quantity: 1

Main Function: To protect the battery from rain and damage.

Other Functions: Helps prevent the battery from falling out and injuring the child.

Flows: None

Environment: Any

Complexity Rating: 1


Hood Latch

Component Name: Hood Latch

Quantity: 2

Main Function: To hold the hood in place so it does not fly up when the Jeep runs over a bump.

Other Functions: Helps to prevent the battery from falling out from underneath the hood and injuring the child.

Flows: None

Environment: Any

Complexity Rating: 1


Battery Cover

Component Name: Battery Cover

Quantity: 1

Main Function: To hold the battery in place.

Other Functions: Provides additional protection for battery, and helps prevent the battery from falling out.

Flows: None

Environment: Any

Complexity Rating: 1


Spark Plugs

Component Name: Spark Plugs

Quantity: 1 set

Main Function: To make the Jeep look like a real Jeep, by making it look like there are spark plugs on the engine.

Other Functions: None

Flows: None

Environment: Any

Complexity Rating: 1


Dashboard

Component Name: Dashboard

Quantity: 1

Main Function: To connect components located in the top part of the front of the Jeep (windshield frame, activity panel, instrument panel, and steering wheel) to the Jeep.

Other Functions: Provide a place for the steering column to go through to connect to the steering wheel and the front axle.

Flows: None

Environment: Any

Complexity Rating: 1


Windshield

Component Name: Windshield

Quantity: 1

Main Function: To protect the child if something flies up while driving, like mud, water, or something the Jeep ran into, or if the Jeep stops suddenly.

Other Functions: None

Flows: None

Environment: Any

Complexity Rating: 1


Windshield Frame

Component Name: Windshield Frame

Quantity: 1

Main Function: Hold the windshield in place and connect it to the body of the Jeep.

Other Functions: Protecting the child if something flies up while driving or if the Jeep stops suddenly.

Flows: None

Environment: Any

Complexity Rating: 1


Activity Panel

Component Name: Activity Panel

Quantity: 1

Main Function: To hold the “shifter” and knobs. These are just for appearance and to make the child feel like he/she is driving a real car.

Other Functions: None

Flows: None

Environment: Any

Complexity Rating: 1


Instrument Panel

Component Name: Instrument Panel

Quantity: 1

Main Function: To make the vehicle look like a real car.

Other Functions: None

Flows: None

Environment: Any

Complexity Rating: 1


Battery

Translational Motion

Component Name: Battery

Quantity: 1

Main Function: To send energy to the motor and power the vehicle.

Other Functions: Helps to move the Jeep.

Flows: Gets a signal from the pedal and turns chemical energy to electrical energy, and sends the electrical energy to the motor.

Environment: Dry with a temperature between -10F and 75F.

Complexity Rating: 4


Pedal

Component Name: Pedal

Quantity: 1

Main Function: To tell the vehicle to move.

Other Functions: Helps to move the Jeep.

Flows: Turns human energy from the child pressing the pedal to electrical energy, which sends a signal to the battery.

Environment: Dry and away from gravel/sand/loose dirt that could get underneath the pedal and make it stop working.

Complexity Rating: 2


Plastic Casing

Component Name: Plastic Casing

Quantity: 3

Main Function: To connect the wires to the battery, motor and control switch, and to hold the wires together.

Other Functions: Helps transport electrical energy/signals to tell the Jeep to move.

Flows: Helps send signals from the battery and the control switch to the motor.

Environment: Dry.

Complexity Rating: 2


Wires

Component Name: Wires

Main Function: To send electrical signals and energy to certain parts of the Jeep, telling it how to move.

Other Functions: Helps move the Jeep.

Flows: Sends signals from the pedal to the battery and the control switch to the motor, and sends electrical energy from the battery to the motor.

Environment: Dry.

Complexity Rating: 2


Forward/Reverse Button

Component Name: Forward/Reverse Button (“control switch”)

Quantity: 1

Main Function: To tell the Jeep to move forward or backward.

Other Functions: None

Flows: Human energy (pressing the button) to an electrical signal sent to the motor.

Environment: Dry.

Complexity Rating: 3


Back Axle

Component Name: Back Axle

Quantity: 1

Main Function: To hold the back wheels, motor, and gearbox.

Other Functions: Helps move the Jeep.

Flows: None

Environment: Dry because it is metal so could rust, which is why plastic parts cover it. It can come in contact with grass because the Jeep is supposed to be driven outside, but it is not supposed to be driven on rough terrain because rocks could fly up and break it.

Complexity Rating: 2


Black and White Spacing Cylinders

Component Name: Black and White Spacing Cylinders

Quantity: 1 of each color

Main Function: To take up space between the back left wheel and the plastic main part of the Jeep.

Other Functions: None

Flows: None

Environment: Any

Complexity Rating: 1


Motor

Component Name: Motor

Quantity: 1

Main Function: To move the Jeep forward or backward.

Other Functions: None

Flows: Electrical energy from the battery is converted to rotational mechanical energy.

Environment: Dry and away from loose dirt, gravel, sand, etc. that could get into the motor and cause it to stop working.

Complexity Rating: 5


Motor Case

Component Name: Motor Case

Quantity: 1 Main Function: To hold the motor and protect it from rocks, water, etc.

Other Functions: None

Flows: None

Environment: Dry is preferred, but any environment will work.

Complexity Rating: 1


Gearbox

Component Name: Gearbox

Quantity: 1 top and 1 bottom half

Main Function: To hold the gears and grease, and to protect the gears.

Other Functions: Helps move the Jeep by holding the gears where they are in contact with the motor and wheel.

Flows: None

Environment: Dry is preferred, but any environment will work.

Complexity Rating: 2


Gears

Component Name: Gears

Quantity: 3

Main Function: To take energy from the motor and send it to the wheel, causing the Jeep to move.

Other Functions: None

Flows: Sends rotational mechanical energy from the motor to the back right wheel.

Environment: Dry, lubricated, and away from dirt/gravel/etc.

Complexity Rating: 4


Wheels

Wheel

Component Name: Wheel

Quantity: 4

Main Function: To rotate and move the Jeep forward or backward.

Other Functions: None

Flows: Back right wheel only - Gets rotational mechanical energy from the gears and which makes the wheel rotate, which causes the other wheels to rotate, which causes translational movement of the Jeep.

Environment: Dry and on flat terrain with few rocks.

Complexity Rating: 2


Traction Band on Wheel

Component Name: Traction Band

Quantity: 4

Main Function: To give the wheels better traction so the Jeep can move forward or backward.

Other Functions: None

Flows: None

Environment: Dry and on flat terrain with few rocks.

Complexity Rating: 1


Component Name: Red Plastic Cap

Red Plastic Cap

Quantity: 4

Main Function: To block the parts inside the wheel so a child cannot take the wheel off or take the smaller parts out and choke on them.

Other Functions: None

Flows: None

Environment: Any

Complexity Rating: 1


Component Name: Black Plastic Cap

Black Plastic Cap

Quantity: 4

Main Function: To additionally block the parts inside the wheel so a child cannot take the wheel off or take the smaller parts out and choke on them.

Other Functions: None

Flows: None

Environment: Any

Complexity Rating: 1


Component Name: Metal Wheel Bearing (.354 Retainer)

Metal Wheel Bearing

Quantity: 4

Main Function: To connect the wheel bushing to the axle.

Other Functions: Helps move the Jeep by holding the parts of the wheel in place so the wheel can rotate.

Flows: None

Environment: Dry.

Complexity Rating: 1


Component Name: Wheel Bushing

Wheel Bushing

Quantity: 4

Main Function: To connect the wheel to the axle.

Other Functions: Helps move the Jeep by allowing the wheels to rotate.

Flows: None

Environment: Any

Complexity Rating: 1


Component Name: Washer

Quantity: 4

Main Function: To create space between components on the inside of the wheel.

Other Functions: None

Flows: None

Environment: Dry

Complexity Rating: 1


Miscellaneous

Component Name: 3/16th inch Lock Nut

Quantity: 2

Main Function: To hold the steering column in place.

Other Functions: To help steer the Jeep by connecting the steering column to the steering wheel and front axle.

Flows: None

Environment: Dry

Complexity Rating: 1


Component Name: #6x1/2” Screws

Quantity: 11

Main Function: To hold the steering wheel together, to hold the windshield to the windshield frame, and to hold the activity panel to the dashboard.

Other Functions: None

Flows: None

Environment: Dry

Complexity Rating: 1


Component Name: #8x1” Screws

Quantity: 10

Main Function: To hold the steering wheel cap onto the steering wheel, to hold the windshield frame to the vehicle, to hold the dashboard to the vehicle, and to connect the battery retainer to the inside of the hood of the Jeep.

Other Functions: None

Flows: None

Environment: Dry

Complexity Rating: 1


Component Name: 1.25” Screws

Quantity: 2

Main Function: To connect the motor case to the gearbox.

Other Functions: None

Flows: None

Environment: Dry

Complexity Rating: 1


Product Analysis


Standards by which we define one, two, and three dimensional objects:
1. One-dimensional objects would be an object that has only a length, width or height. One-dimensional objects will most likely NOT appear in any of the components.
2. Two-dimensional objects, such as a washer, can be measured in two dimensions, because the third dimension is so small that it can be neglected. Any dimension that is measured to be less than 1/16” can be regarded as negligible.
3. Any component that has a diameter implies that it has at least two dimensions.
4. Anything with length, width and height is considered to be three-dimensional.
5. Any component with a length, width or height accompanied by diameter is three-dimensional.


Electric Motor and Motor Casing

The shape of the motor is cylindrical, with a gear shaft on the end where the motor connects to the gearbox. It consists of three dimensions, diameter and length.

Motor casing:
Diameter = 2.375”
Length = 3”

Electric Motor:
Diameter = 1.375”
Length = 2.25”

Gear Shaft:
Diameter = .375”
Length = .75
Weight: 8 ounces

Current enters the motor and it travels across many coils of wire surrounded by a permanent magnet. The magnet produces a magnetic field on the charged wire and creates a force that spins the wire, creating mechanical energy. The cylindrical shape keeps the copper coil at the same distance away from the magnet at all times. Any other shape, such as a rectangular or triangular prism would not have this benefit. Copper wiring is needed to carry the current inside of the motor that induces the spinning. Copper is a good conductor for its price and its resistivity per unit length, which is why it is commonly used in electrical wires. The strength of the magnet also affects the power of the motor, so when choosing a magnet the manufacturers would be most interested in the magnet that produces the most power for the least cost.

The power of the electric motor was mostly impacted by economic, and societal factors. The engine could have been made more powerful by using more powerful, larger magnets, which would have increased the cost. The more powerful motor may have been more appealing to the child who wants the toy, but standards set by the government may not allow the motor to exceed a certain angular velocity. Also the parents would most likely not want the child from age 1 ½ to 4 driving a Powerwheels vehicle that travels at potentially dangerous speeds.

The motor does not have any aesthetic purpose; it is kept within a black plastic motor protector making it not visible unless the protector is removed. The motor is silver color, which is a result of the metal alloys that are used to make the motor outer shell. The protector is the same shade of black as the gearbox and the wheels, stopping the motor from standing out, which implies that it was never meant to be appealing to the eye. .

Steering Column

1. Long cylindrical shaft
2. Three dimensions consisting of a diameter and a length

Steering Column:
Diameter = .5”
Length = 1.5”
Weight: 1 pound
Material: Steel

There are “keys” that protrude on both sides of the top of the shaft that fit into key slots in the steering wheel that allow the steering wheel to grip the shaft and effectively turn the wheels without spinning the steering wheel around the shaft. The shaft is held in place by two plastic braces that stick out of the underside of the frame. The braces hold the shaft in place just before the bend that allows the shaft to push the axle to the right or left.


The shaft must be dense; the steering rod cannot bend or break easily as the child will constantly be twisting the steering wheel. The steering column is silver due to the color of the metal alloy, with a smooth finish. The steering column cannot be seen unless the vehicle is flipped and therefore does not have much aesthetic value. It is smooth for functional purposes, cannot be too rough, as this would make it more difficult for the child to turn the steering wheel.


The shaft is a uniform material throughout, which means it was most likely forged and stamped to form the keys at the end of the shaft. Forging is a practical process for mass production, which is necessary when making toys such as the Jeep Powerwheels.


Steel is a universally used throughout the world, is readily available and can be melted down and reused for any other purpose. .

Wheels (x4)

All four wheels are identical cylindrical shapes that have three dimensions consisting of diameter and width. The properties of the wheels are as follows: Weight: 4 ounces Material: High Density Polyethylene Width = 5” Diameter = 9.5” The plastic band on tire has width, outer and inner diameter. They are the following Plastic Band: width = 1.125” Inner diameter = 9.5” Outer diameter = 10.25"


The shape of the wheel is cylindrical which allows it to rotate, there are protrusions that form treads so the vehicle can have more traction than if it were a perfectly smooth cylinder. The tire is black with treads, and fake plastic nuts. All of these qualities contribute to making the toy vehicle look more realistic. The color black and the fake plastic nuts have no purpose other than their aesthetic value, while the treads actually help the wheels like more like wheels on a real car and help the car gain traction. The plastic the wheels are made of must be rough enough so that they do not just slip, and they must be dense enough so they do not wear away quickly.


The wheels were manufactured by injection molding. Injection molding is assumed based on the circular riser marks found on the wheels surface. The wheels are hollow and very thin because if they were made of solid plastic the cost would be much larger.

Steering Wheel

The steering wheel is circular shaped, at the center it is cylinder shaped with depth. It consists of three dimensions: multiple diameters and depth. Steering Wheel: Material: Polypropylene Weight: .7 ounces Diameter = 6.5” Height of steering wheel from base of steering wheel = 2.5” First Cylinder Diameter = 2.5” Second Cylinder Diameter = 1.5” .

The steering wheel must have key slots so the steering rod can be held in place, which prevents the steering wheel from rotating without turning the wheels. The steering wheel was machined to look like an actual steering wheel to give the child the feel of holding an actual steering wheel. The color of the steering wheel is black, which is a believable color of a steering wheel, adding to the child’s more lifelike experience. The steering wheel finish is somewhat rough, which was made that way so the child could grip the wheel without slipping, and not for any particular aesthetic purpose. The steering wheel was manufactured in two separate pieces by injection molding. Injection molding was assumed because of the circular riser marks that are found on the steering wheel. Injection molding is a very cheap process that is used for mass production, which would be very practical when making parts of a child’s toy.

Gearbox and Gears 1, 2 and 3

All three gears are circular shaped with teeth around the circumference allowing them to function properly as gears. Gears 2 and 3 each have smaller gears in the center of the gear with smaller teeth that slows down the angular velocity of the larger gear 1, which connects to the drive shaft of the wheel. The diameters of the larger part of the gears (D1) and the diameter of the smaller gears (D2) are the following:

Gearbox: Width = 1.25” Length = 6.75” Height1 = 2” Height2 = 3.25”
Gearbox Material: High Density Polyethylene

Gear 1: D1 = 3.25” D2 = 2 “ Height of the component = 1.75”
Weight = .19 ounces

Gear 2: D1 = 2.25” D2 = 1” Height of the component = .75”
Weight = .08 ounces

Gear 3: D1 = 1.75” D2 = .75” Height of the component = 1”
Weight = .035 ounces

Gears Material: Acetal and other plastics


The gears and the gearbox are on the underside of the Jeep, against the rear right wheel. The location of the components does not call for the appearance to be overly aesthetically pleasing. The color of gears, and gearbox are the same shade of black that is consistent throughout the other black components. This stops the gearbox from standing out, which means the designers never intended for this component to be particularly pleasing to the eye. Injection molding was used in the making of the gears and gearbox, because again a large amount of there parts are necessary when mass production of a product needed. This has a direct relationship to the economic factors that are considered when making the parts.

Manufacturing Methods

Table 3 shows a list of components, the materials used to create them, and the manufacturing methods used to do so.
Table 3: Component Manufacturing


Manufactoring methods gate 3G21.jpg
Below shows a more elaborate description of each Section from Table 3.
Section A


Evidence of Material: Polypropylene. This can be seen because of the waxy surface and relatively hard properties of the part.

Evidence of Method: Injection molding. This is known because riser marks and waste plastic can be seen where the material was injected.

Shape: The simple geometric shapes and choice of using plastic on the parts made it a perfect fit to be injected modeled.

Factors: The societal factor of this manufacturing process is that the product is going to be in high demand and therefore many parts will be needed to fulfill the demand. The economic factor is that injection molding is a high initial price but as more parts are made the better the cost per part is. Fisher price is going to be making thousands of these parts and therefore injection molding is the best choice. The environmental factor in choosing to use this product is how well it can be recycled. Polypropylene can be recycled into many different products such as pegs, bins, pipes, pallet sheets, oil funnels, car battery cases, trays. The Global factor is that this plastic can be easily obtained. Fisher price is a large company which has distribution of materials all throughout the world.


Section B


Evidence of Material: Steel. This can be seen because the parts are light in weight, metal, silver, and magnetic.

Evidence of Method: These parts were made using forming and shaping. Most likely the product started out as a straight rod. For the steering column a bent shape at each end was required. Therefore the ends were most likely shaped to that and then threaded. The required key and rivets on the parts were forded onto it by a machining process. This was determined because the material is the same throughout but the surface finish at these places were different and smoother.

Shape: The bent shape at the end would have been difficult to die cast. The shape of the product could easily be bent and the metal stamped out where necessary.

Factors: The societal factor to use forming and shaping is that this method is the simplest way to produce the component. The economic factor is that the manufacturer can use a simple steel rod which is relatively cheap and then shape it into the required dimensions.


Section C


Evidence of Material: Low density Polyethylene. This can be seen by the flexibility and waxy surface finish of the parts. Also these parts are easily scratched.

Evidence of Method: Injection molding. This is known due to the riser marks and extra plastic left behind.

Factors: Similar Factors to the parts in part A.


Section D


Evidence of Material: Polystyrene. This is known because it is clear and is used frequently as a plastic windshield in toys.

Evidence of Method: Injection molding. Beat blasted. This can be seen due to the parts rough surface finish around the windshield.

Shape: The flat shape of the component allowed for injection molding.


Section E


Evidence of Material: Copper. This is known by looking at the wires in the Jeep.

Evidence of Method: Drawing. This is how copper wire is made.

Factors: The economic factor is that drawing is a cheap way to create copper wire. The societal factor is that this method produces good copper wire which is not fail.


Section F


Evidence of Material: The gears are made from acetal, polybutylene terepthalate (PBT), nylon, polyphenylene sulfide (PPS), and liquid crystal polymer (LCP). These are the most common plastics used in the making of plastic gears.

Evidence of Method: Injection Molding. Riser marks on the gears.

Shape: The circular shape of the gears can easily be made using injection molding.

Factors: The economic factor in using plastic gears is that it is much cheaper than metal gears. Also they are much lighter. The global factor is that the gears are not meant to be used in high sloped or mountainous areas and therefore do not need the strength of metal gears. The societal factor is that the gears will not erode if water gets inside them because they are plastic and therefore the product will last longer. The product is not meant to be exposed to high temperatures and therefore plastic gears are acceptable.


Section G


Evidence of Material: These components are made from High Density Polyethylene. This is supported by the waxy surface finish and the inability to flex these parts.

Evidence of Method: Injection Molding. Riser marks can be seen.

Factors: The societal factor is that these components must be stronger to keep the product working. The economic factor is that injection molding is a good process for a large amount of volume.

Solid Modeled Assembly

In Figure 1, solid models of the Front Axle, Wheel Bushing, .354 Retainer, Steering Column, Steering Wheel and Wheel. Below that in Figure 2 is a view of the completely assembled steering subsystem. The reason these particular components were chosen for closer analysis is due to the fact they are pertinent to controlling the direction of the vehicle. The CAD package that was used is called Blender. This package was chosen due to the fact that it is a relatively professional looking, free, 3D rendering program. The Blender Official Website can be viewed at: http://www.blender.org/

Figure 1: Solid Models of Individual Components


Front Axle
Wheel Bushing
.354 Retainer
Steering Column
Steering Wheel
Wheel


Figure 2: Solid Model of Assembled Steering System


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Engineering Analysis

Figure 3: Analysis Process


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Design Revisions


Secondary Motor

Mounting of another small electric motor on the other wheel, as seen in Figure 4, will give the jeep an increased power output giving the vehicle a faster velocity. This change will be more appealing to the older users of this toy. Serious considerations also need to be given for the safety of the children. This would greatly impact the economic factor of the Jeep on average a new motor would cost around $15.95 as well as to power this addition you would need either a larger and more powerful battery or a second battery increasing the cost even further. This increase in price could very well turn some consumers off of the product but may give others even more of an incentive to buy, seeing the changes as improvements worth the cost. On a societal level the changes in the product may seem dangerous or too fast for small children from ages 1 ½ to 4. However with the possibility of a faster more “thrilling” ride this revised product could be appeal to an older age group, which could potentially increase sales, depending on consumer reactions to the changes.

Global Factor: None
Economical Factor: An additional of motor would cause the price of the jeep to increase and a decrement of customer, however due to the possibility of attracting a wider range in age of consumer would still balance out the possible lost, if not possible, a higher in net profit.
Environmental Factor: Adding a motor into the production will only bring minimal harm to the environment as most of the materials used to produce the motor are reusable.
Societal Factor: A more entertaining experience for children and increased longevity for the product.


Figure 4: Location of Second Motor


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Replacement of Traction Bands

The traction bands are slotted from the side of the wheel and fixes itself at the middle of the wheel. The current wheels are less than optimal, offering little additional traction. With the addition of some treads like on traditional tires the traction could be greatly increased giving an added safety factor. This would increase friction and weight of the driving system which has some drawbacks, as in stripping the gear boxes or burning out the motor. This again would increase the overall cost of the power wheels upping the quality along with the price. Customers expect a child’s toy to be safe to operate but when a small child driving a power wheels vehicle wipes out due to lack of traction that brand now will carry a new societal stigma as being a dangerous toy to own. Therefore the societal impact of adding a new traction system could greatly benefit Fisher Price.

Global Factor': None
Economical Factor: An additional of motor would cause the price of the jeep to increase and a decrement of customer, however due to the possibility of attracting a wider range in age of consumer would still balance out the possible lost, if not possible, a higher in net profit.
Environmental Factor: By changing the material of the traction belt to rubber, it causes less harm to the environment as rubber is an easily biodegradable material, whereas plastic requires far longer time to do so.
Societal Factor: With higher friction provided by the rubber traction belt, children will be safer while riding the jeep on an incline surface, reducing the risk that a child might face.

Figure 5: Insufficient Traction Band


DesignRevTread.png

Increase Battery Voltage

This is the simplest way of making the Jeep power wheels go faster. The power wheels originally have a 6 volt battery supply, by simply adding another 6 volt battery to the system the power would be doubled. To do this all that would be needed is to create a docking station for the second battery on the vehicle and to wire the two batteries together in series. While in series the car will function but will not charge so a charging state must also be implemented. This is possible with a switch that changes the batteries to be wired in parallel while it is being charged. This adds more power at the least expense to the consumer and the manufacturing company, although it still will increase the price. This will also add to a “Coolness” factor of the Jeep power wheels giving added incentive to older children to want this product and in turn changing societies view on such a product.

Global Factor: None
Economical Factor: The cost of an extra battery is very minimal, with the ‘coolness’ factor added to the jeep, more children will be attracted and the sales will increase, providing fisher price a higher profit.
Environmental Factor: As there are dangerous chemical inside the battery, this idea will certainly bring harm to the environment if it isn’t treated properly.
Societal Factor: A more entertaining experience for children and it last longer through out their childhood.