full load design review. outline original problem statement new problem statement product...

Full Load Design Review

Outline

• Original problem statement

• New problem statement

• Product specifications

• New design

• Features/Cost

• Benefits/Concerns

Original Problem Statement

The problems to be addressed with the PCSys are as follows:

• High cost

• Poor user interface

• Not ready for mass production

New Problem Statement

• The truck drivers cannot see to guide themselves while loading.

• It is difficult for the harvester operator to allocate his attention effectively.

View from 10 and 18 Wheelers

Existing Product/Sugar Beet Harvest

Product SpecificationsThis product will:• Provide position information to the truck driver while

loading• Ensure that the truck is positioned for proper loading• Be competitive in cost and function with existing

technology• Eliminate unneeded workload for the harvester

operator

The final outcome will be to form a corporationwhich will manage the manufactured product tobe sold to the mass market.

Breakdown of Communication

Concept Testing

Camera Mounted on front of truck bed Camera view on monitor

Potential Camera Locations

Positioning options for the camera

1. Above the harvester in line with the boom, looking down on the truck bed.

2. At the rear corner of the harvester closest to the truck.

3. At a front and back corner of the truck bed.

4. Above the cab of the tractor.

Feature List for the New PCSys

• One or two cameras available for visual communication

• Wireless video screen

• Hands-free radio communication system to backup visual system

Cost of new system

Item Cost

6 Inch LCD Panel $150

900 MHz Wireless Camera & Transmitter

$80

900 MHz Wireless Receiver $40

2-Way Radio System $80

Voice Activated Mic & Headset $20

Injection Mold Enclosure $25

TOTAL $395

Benefits of new system

• Eliminates input from harvester operator

• Provides a backup system

• Meets the farmer’s needs

• Uses existing technology

Feasibility Issues

• Environmental issues– Dust– Moisture

• Night-time operation

• Power supply

• Durability – Vibrations– Impact

Timeline

Questions?

Project Background

• Current design replaces each hand signal with one input on the transmitter

– Doesn’t eliminate any work load for harvester operator

• Develop a new PCSys to eliminate the manual inputs from harvester operator

Design Issues/Alternatives

•Truck driver can’t see the operation/ Digger driver is performing too many operations.

•There still needs to be another form of communication besides the visual.

•Cost Competitive

Situation

For tuber and sugarbeet crops:• Simultaneous harvesting and loading• Trucks are required to make position

changes relative to combine to fill uniformly

• Truck and combine operators rely on hand signals to communicate specific actions relating to the proper loading

Existing Technology

• Hand signals

• Two-way radios

• Home built signaling systems

Design Issues/Alternatives

•Mounting

•Input/Output Interfaces

•Multiple Frequency

•Electronic Design

•Cost Competitive

Mounting in the Tractor

Mounting in the Truck

Receiver Mounting Designs

Hangs from the back of receiver from the top mirror bar outside of truck.

Wrap-around clamp onto mirror on the outside of truck.

Hangs from the side of receiver from top mirror bar outside of truck.

Transmitter Mounting Designs

Clamp will allow for a variety of attachment methods.

Description: Flange wraps around rod attached to top of digger controls

The angle bracket attaches to side of digger controls & side of transmitter.

Input Designs

These input configurations address our human factor issues.

Output Designs

Multiple Frequency

• Eliminates crossed signals between multiple combines and trucks in the same fields

• Could accommodate large farms and industrial operations with numerous frequencies

Designing Electronics

• Hire professional EE

• Recruit EE student(s) from the EE Senior Design Course

• Consult faculty/graduate students

Additional Features• Relative Velocity Sensors

– Truck could match the speed of the harvester

• Load Sensors– Harvester operator could load the truck

evenly and accurately to prevent overloading

• Accelerometers– Automate the STOP! signal transmission

Market Possibilities

• Preparing a product package

• Tradeshows

• Finding a buyer/investors

Price Plan and Strategies

* Based off of 1000 units produced.

•Estimated unit cost of manufacturing: ~$82–Outsourced circuit Board: $20/ unit–Outsourced display panel: $10/ unit– Input Devices: $20/ unit– Injection Mold Enclosure: * $30/ unit–Assembly labor: $2/ unit•Estimated unit cost of marketing: ~$15

•Suggested retail –Transmitter: $147/ unit•- Reasonable profit margin is set at $50.00 per transmitter–Receiver: $147/ unit•- Reasonable profit margin is set at $50.00 per transmitter–1 Transmitter – 2 receivers package: $411•- Reasonable profit margin is set at $40.00 per component

Additional Industry

• Additional product models?

• Signal Automation?

• Other industrial applications?– Road construction– Aviation

Project Budget

Component Cost

Electronic components $5,000Hardware components $1,000Enclosure components $4,000Other expenses $2,700

Total amount $12,700

Management Plan