Group 2 - Powered Mobile

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Contents

GATE - 1: Request for Proposal

Work Proposal


      Our product for the project is a Fisher Price Children’s toy – Musical Mobile. This toy has a mechanical motor connected at the top, which rotates slowly with the help of two batteries. This product is completely manufactured out of plastic and has more than 10 parts. But, there are 5 main parts which makes this product complex.

The five main parts are:

1. The motor
2. The hinge (in the middle of the stem to bend the products).
3. The remote (also operates with the help of the AA-batteries).
4. The plastic casing/housing.
5. Build-in musical system.

Tools we would require to disassemble the toy:

1. 3/16 philiphead screw-driver.
2. 3/8 philiphead screw-driver.
3. 1/8 philiphead screw-driver.
4. Small pick.
5. Large pick.

Approach for Disassembly:

1. We will start with taking the housing apart, a 3/16 and 1/8 philiphead screw driver and pick will be used. There are more than 10 visible screws on the housing.
2. After the screws are removed the housing can be carefully pried open using the pick and a screwdriver, while doing this we will remove the installed level and disconnect the motor.
3. The motor wires will be disconnected from the base. Once we finish separating the motor wire from the battery slots or motor, we will move on to disassembling the main components of     the toy.
4. We will then disassemble the hinge, which is connected to the two stems.
5. After that we will move on to the top part where the rotational motor and the music mechanism is installed.
6. For the top part, we first have to take the top case cover/housing apart to disconnect the power button wires connected to the motor and the wires connected to the music mechanism.
7. After removing the housing we have can take apart the motor and the music mechanism.
8. Removing apart the motor and the music mechanism, now we can take apart the housing which is attached to the motor. We have to be very careful in this step, as the motor is really     delicate and can break.

      Working as a team disassembling this product would probably take us around 4 hours. We have discussed the disassembly procedure and think that we won’t face any major hurdles, if we follow the procedure step by step. The only problem we might face will be the top part of the toy where the rotational motor mechanism is installed.

      Our group is well balanced. There are no present weaknesses in our group skills to disassemble the Fisher Price Children’s toy – Musical Mobile. Each member has been assigned a task, and assigned to be in charge of different parts in this project. Everyone in our group is excited and willing to take up this challenge as a group.

Management Proposal


Main Contacts for Group 2

Tarandeep S Sodhi.
E-mail: tssodhi@buffalo.edu
Brain.
E-mail: bpb4 @buffalo.edu

Goal for this Project:

To learn how to work as a team and get hands on experience. Help other team members if they are facing difficulties in their part and to complete the assigned tasks on time to make this project a success.


Group Members and Responsibilities


Brain - Group Leader and Main Contact (Update: Resigned the course)

Brain will be in charge of organizing the project and distributing the workload of the project in a fair and even manner. Brain will distribute the work among the group members by their interests, strengths and weaknesses. Brain will be the in charge of outlining each part of the project and putting it up on wiki. The meeting timings will be set up by Brain considering the availability of other group members. Brain will also be helping out the group members of the project when help is required.


Tiffany - CAD Modeling Coordinator (Update: Resigned the course)

Tiffany will be in charge of the CAD modeling aspect of this project. Tiffany is good in CAD modeling and has some experience with it. She has access to a CAD modeling program. This helps our group look professional. Tiffany will also help other group members to accomplish their task in this project.


Tarandeep.S.Sodhi - Dissection and Reassembly Manager

Tarandeep will be responsible for the dissection and reassembly of this project. He will be responsible for taking down the notes and will create hand rough sketches when needed. He will know most of the dissection of this project. He will be helping out other group members to make this project a success.


Gantt Chart


Group2.jpg


Initial Product Assessment


            The Ocean Wonders Mobile was developed by Fisher-Price for home use. Its many functions including ceiling projected light patterns, soothing lullabies and ocean sounds, and floating, rotating fish are designed to calm babies in their cribs as they go to sleep. It also features a remote control so that it can be turned on and off from a distance so the child is not disturbed or woken. Its adjustable pivoting swing arm allows for mounting anywhere from the rails of a crib, to a dresser top.

            The remote control features a single on off button. It uses chemical energy from batteries which is converted to electrical energy. When the button is pressed a signal is emitted from the remote control by way of LED infrared pulses. A receiver built into the mobile component receives the pulses of light. The mobile component also runs off of chemical energy which is supplied by batteries, which is converted to electrical energy and used in various ways to run the different functions of the mobile. Some of the electrical energy is used to run a tiny motor which converts the electrical energy into mechanical energy in order to spin the head of the mobile and the hanging objects. Another portion of the electrical energy is converted into light energy in the upper portion of the head component to project the patterns onto the ceiling. The third use of the electrical energy is used to power the speaker which converts the energy into a rhythmic mechanical energy to produce sound waves.

            The mobile appears to be in good working order; however a few tests should be run in order to confirm that it is running at its full potential.

            Overall this mobile does not appear to be very complex. There are many functions that can be performed by the product, but the components that it uses are not to complex and are packed into a small product. The make up of the product is mostly plastic. The inner workings would be comprised of some small circuit boards, an infrared sensor, a small motor, some speakers, and small light bulbs.

            The mobile is very user friendly. It has clearly marked switches to adjust the volume of the music and ocean sounds, brightness of the lights, and on/off switches. The remote control has one button simply used to turn the product on and off. The only maintenance required would be to replace the batteries in both the main unit and the remote control which each only require the removal of a couple phillips head screws for child safety purposes.

            There are many different alternatives to this mobile made by Fischer-Price and many other companies. Many alternatives could be found at a cheaper price than this specific mobile. There are many benefits to this product including the ability to vary the sound an light intensity, and also the convenience of the remote control.


Gate - 2: Preliminary Design Review

Causes for Corrective Action


The work plan has been followed perfectly. By following these steps it gave us a good start for our disassembly plan, and made this project very manageable.

The management plan quite didn’t work for our group as we decided on. The members assigned to do work didn’t finish it on-time due to lack of communication. And the end result of it was that it became an individual project from a group project as the members of the group resigned this course.

But, I am ready to take up all the challenges and duties required to finish this project.


Product Dissection Plan


The product for this project is Fisher Price Children’s toy - Ocean Wonders Mobile with Remote Control. It is a very reliable product which fulfills all the needs of the customer. This product is made under lots of engineering analysis such as, stress and strain calculations on the arm which supports the weight of the hub. It is build to be a very sturdy toy; to make sure that all the parts in the product remain in place and do not cause a safety hazard. But, it is fairly easy to disassemble it. We rated it a 7 out of 10 on the complexity of disassembly, 1 being the easiest and 10 being the hardest.


In our work proposal we have stated the tools we would require to disassemble the product are:

1. 3/16 philiphead screw-driver.
2. 3/8 philiphead screw-driver.
3. 1/8 philiphead screw-driver.
4. Small pick.
5. Large pick.

As it turned out, we need just few tools:

1. 5/8th philiphead screw driver.
2. 3/8th philiphead screw driver.
3. Long nose plier.
4. Small pick.

Parts Overview


Group2partpic.jpg

Mobile Features with in the Hub


Group2partpic1.jpg

1. Light Dome: Projects bubbles, fish, and swirls onto baby’s celling.

2. Start Button: Starts or restart music and soothing lights.

3. Light Selection Button: Choose dome light, night light, both light or no lights.

4. Song selection Button: Press to choose from five different songs.

5. Power/Volume Switch: Choose high volume, low volume, no sound or power off.

6. Receiver Dome: Accepts signal from the remote.

7. Night Light: Features softly glowing lights.

Remote Features


Group2remote.jpg

1. Button: Activates the mobile.

2. LED Signal Indicator: Lights when the button is pressed to let customer know that the remote has transmitted a signal to the receiver.

3. Transmitter Window: Remote transmits a signal to the receiver dome on the hub.

4. Handle: Flips up, so that the customer can hang the remote. It snaps around the bottom of the remote when not in use.

5. Battery Compartment: Two double “AA” batteries are used.

Disassembly Procedures


Disassembly procedure of the product (Ocean Wonders Mobile with Remote Control)


Scale for ease of assembly: All values given in comparison to all of the other steps of taking this mobile toy apart. This is with a “1” being a simple task such as unscrewing something and                                             a “5” being taking apart a piece that is breakable and not easy to get at without care.


1. Detach the base from the arm.
     Level of Difficulty: 1


2. Unscrewed the battery cover from the backside of the Base.
     Level of Difficulty: 1


3. Removed the four D-size batteries from the base.
     Level of Difficulty: 1


4. With the help of a small black stick, we were able to take out the back casing of the base.
     Level of Difficulty: 1


5. Removed five screws from the inside of the cover of the base, which helped in detaching the outer blue ring which was attached to the front side of the base.
     Level of Difficulty: 1


6. Removed the plastic decoration from the face of the base.
     Level of Difficulty: 1


7. Removed three screws from the hub to disassemble the three soft toy spokes.
     Level of Difficulty: 1


8. Removed the screws from the bottom of the hub, which helped us in disassembling the top cover of the hub, the buttons and the top light cover of the hub.
     Level of Difficulty: 1


9. Disassembled the light cover from the hub.
     Level of Difficulty: 1


10. Took apart the big gear attached at the bottom of the light cover.
     Level of Difficulty: 1


11. Took apart the design molding inside the light cover.
     Level of Difficulty: 1


12. Removed the screws to disassemble the circuit board cover.
     Level of Difficulty: 1


13. Detached the circuit board from the hub.
     Level of Difficulty: 1


14. Disassembled a socket from the hub machine cover.
     Level of Difficulty: 1


15. Detached the power supplying wires attached to the arm.
     Level of Difficulty: 1


16. Detached the arm from the hub (snap socket).
     Level of Difficulty: 4


17. Disassembled the speaker cover attached to the hub base.
     Level of Difficulty: 1


18. Disassembled the speaker from the hub base.
     Level of Difficulty: 1


19. Disassembled the buttons and the electric circuit board from the hub base.
     Level of Difficulty: 1


20. Removed the rubber belt from the small pulley, which is attached to the motor inside the hub.
     Level of Difficulty: 1


21. Took apart the big pulley attached to the small pulley from the motor cover attached inside the hub.
     Level of Difficulty: 1


22. Removed the small gear socket attached to the gear train under the motor cover.
     Level of Difficulty: 1


23. Took apart the motor cover from the hub.
     Level of Difficulty: 1


24. Took apart the motor bushing attached to the motor cover/board.
     Level of Difficulty: 1


25. Took apart the motor from the hub base.
     Level of Difficulty: 1


26. Took apart the first gear from the gear train attached to the base of the hub.
     Level of Difficulty: 1



27. Disassembled the second gear from the gear train attached to the base of the hub.
     Level of Difficulty: 1


28. Removed two screws to disassemble the hub base from the bottom hub light cover.
     Level of Difficulty: 1


29. Removed a screw attached to the hub base to remove the third gear from the gear train. A small thick gear was attached to the outer bottom of the hub cover and the third big gear was      inside the hub cover.
     Level of Difficulty: 1


30. Disassembled the light snap cover from the outer surface of the hub cover.
     Level of Difficulty: 1


31. Took apart the light with wire attached from the bottom hub cover.
     Level of Difficulty: 1


32. Took apart the top light case from the circuit board cover.
     Level of Difficulty: 1


33. Disassembled the small gear attached on top of the circuit board cover.
     Level of Difficulty: 1


34. Disassembled the spoke from the slots.
     Level of Difficulty: 1


35. Disassembled the transparent light cover from the white bottom light cover.
     Level of Difficulty: 1


36. Removed the transparent decorative multicolor plastic sheet attached to the white bottom of the light cover.
     Level of Difficulty: 1


37. Removed the bushing attached at the center of the white bottom light cover.
     Level of Difficulty: 1



Disassembly procedure of the Crib Adapter


1. Unscrewed the plastic blue cap (Clamp).
     Level of Difficulty: 1


2. Unscrewed two screws at the bottom of the panel.
     Level of Difficulty: 1


3. Removed the small square pieces from the bottom of the panel.
     Level of Difficulty: 1


4. Disassembled the big plastic screw clamped to the base.
     Level of Difficulty: 1


Disassembly procedure of a Remote


1. Unscrew the battery cover.
     Level of Difficulty: 1


2. Removed the battery cover by pulling it upwards.
     Level of Difficulty: 1


3. Removed the AA-batteries from the remote.
     Level of Difficulty: 1


4. Unscrew the three screws at the backside of the remote control.
     Level of Difficulty: 1


5. Pull out the bottom base.
     Level of Difficulty: 1


6. Pull out the green band attached to the top cover of the remote.
     Level of Difficulty: 1


7. Detach the yellow button attached to the top cover of the remote.
     Level of Difficulty: 1


8. Pull out the red signal cover from the bottom cover of the remote.
     Level of Difficulty: 1


Total Time taken to disassemble the product was 2.5 hours.



If you faced challenges during dissection outline those challenges and describe how they were overcome.

There were few problems encounters during the whole process of disassembly:

1. All the wires were soldered to the circuit board located inside the hub. Therefore the disassembly of the hub was done very carefully and with right wire management.
2. The arm of the product can’t be disassembled as the plastic joint is factory glued and there is lot of chances of breaking it if forced. So the arm was not disassembled (opened).

Is the product intended to be taken apart easily?

Yes, the product was intended to be taken apart easily. Some, of the parts come disassembled and they are assembled by the user when first bought such as the arm to the hub, spokes which snaps to the hub and the base to the arm.

Special tool required to disassemble the product was the long nose plier which helped in removing the arm from the hub.



GATE - 3: Coordination Review

Causes for Corrective Action


            As of now all my other two group members have resigned this course. I am trying to be on schedule as it is almost the end of the semester and I am doing this whole project by my own. I might be slightly behind than the other groups in my class, but I am doing the best of my ability to carry it by my own.

            The prediction of disassembling of Ocean Wonder would take about two hours, but when I started dissemble it ,it took me more than 2 and a half hours. That was caused by the some unexpected problems during the whole process. The structure of the machine looked really simple and a fun job to do. But as I proceeded with the process, complexion stood in front of me. My misconception of simple changed to a hardworking job as it had more parts as I expected when I saw it .But I was lucky in some of the assumptions I made about the fact that the machine is not supposed to be apart as there was the circuit board and the components were soldered to it. There were other minor difficulties I faced that were disengaging the plastic parts such as spokes from the night light cover and arm from the rub.


Coordination Review


            The main purpose of the coordination review is to analyze the components of Ocean Wonders mobile with remote Control (Mobile). In order to see what mechanism works well, and what can be improved in other forms of analysis for better understanding of the toy. The Component Summary lists all the components of the mobile of the mobile toy , including what material is used and what manufacturing process has been used to manufacture each component .The component summary reflection further discusses what was found inside the Ocean Wonder Mobile. Using these components, solid model can be made to show how part of this mobile toy works or assembled in sequence design revisions can be made based on total analysis of the product. Finally, Engineering Analysis can be used in order to show how further analysis and testing can be done on Ocean Wonders Mobile.

Component Summary


            After disassembly of the product 60 components were found which were used to build this whole product. The components of this product are listed in the table below.

REMOTE - Components of the Mobile
Part # Part Name Quantity Function Material Manufacturing Process Image
1 Outer Upper Cover 1 Protects the inner components from dust. Plastic Injection Molding Media:Group2.jpg
2 Outer Lower Cover 1 Protects the inner components from dust. Plastic Injection Molding  
3 Battery Cover 1 Protects the batteries from the dust Plastic Injection Molding  
4 Springs 2 Helps the Button to swich on/off the mobile. Steel Coiling  
5 Circuit Board 1 Takes power from the batteries and uses it to transfer the signal to the toy. Epoxy Resin, Solder, Polytetrafluoroethylene Board is molded; components attached to board  
6 Remote Button 1 Helps in switching on/off the toy. Plastic Injection Molding  
7 Light Bulb 1 Lights up whenever the button is pressed. Glass    
8 Green Handle 1 Can use to hang the remote at the door knob. Plastic Injection Molding  
9 LED Signal Indicator 1 Transmits signal to the toy and lits up the bulb whenever the button is pressed. Glass    
10 LED Signal Indicator Cover 1 Cover the LED signal Indicator. Protects it from the dust Plastic Injection Molding  
11 Philip round head Screws (3/8") 3 To attach the housing of the remote Steel Machining  


  
   
      CRIB ADAPTER Components of the Mobile      
Part # Part Name Quantity Function Material Manufacturing Process Image
1 Crib Adapter Plate 1 Attaches the toy to the crib. Plastic Injection Molding  
2 Long Crib Screw 1 Gives the toy a stability as it is tightened with the help of the clamp. Plastic Injection Molding  
3 Back small Plate 1 Helps to dis-assemble the Crib Screw from the Plate. And gives the screw stability it requires. Plastic Injection Molding  
4 Clamp 1 Goes on to the crib screw attached to the plate which gives a strong hold to the toy. Plastic Injection Molding  
5 Philip round head Screws (3/8") 3 Connects the crib adapter and the toy. Steel Machining