full load design review. outline original problem statement new problem statement product...
Post on 22-Dec-2015
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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