product design of reebok cross trainer linkage 2
TRANSCRIPT
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Product Design & DevelopmentRedesign of a Reebok Edge Series Cross Trainer Foot Plate
Linkage
Student Name Tony PonsonbyStudent Number 02968984Unit Name Product Design And
DevelopmentUnit Code 64ET7004 1112 9Assignment Code 2CWK30
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Stage 1 CompletionCompletion
Initial Material Selection
Initial FEA
CES Material Selection
Aesthetics Of Design User
Interface
Further FEA
Loading Types
Final Design
Environment Impact
Drawings & Renders
Motion Simulation
Design Selection
3D Refinement
British Standards
Which direction now?
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Proposed Design
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Initial FEAAcetal• 120kg load• Young's modulus 3.54GPa• Tensile strength 73.3MPa• Yield strength 59.3MPa
Possible New Linkage MaterialsPC – polycarbonateABS - acrylonitrile butadiene styreneHDPE - high density polyethylenePEEK – polyetheretherketoneAcetal – POM
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Initial FEAAcetal120kg load Young's modulus 3.54GPaUTS 73.3MPaYield strength 59.3MPa ResultsMax Principle stress - 55.53MPaVon-Mises stress – 72.82MPaDeflection - 7.47mmConclusion - Stronger more rigid material required
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Data from CES software
Material SelectionProperties of Plastic
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Material SelectionCriteria• High Young's Modulus >14GPA• High Tensile strength >50MPA• Low cost <£8/kg• Opaque • Good Processability• Recyclable?
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Material Selection
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Material SelectionSPS Syndiotactic Polystyrene 40% Glass FiberDensity 1360-1380 kg/m^3Price 2.58-3.86 GBP/kgTradenamesEdgetek; Schulatec; Questra; XarecComposition overview
Polystyrene homopolymer (CH2CH(C6H5))n of regular syndiotactic stereochemistry with impact modification. With reinforcing filler.
Thermoplastic : semi-crystallineMechanical propertiesYoung's modulus 10-15.2 GPaYield strength 110-147 MPaTensile strength 96.5-140MPaCompressive strength 92.6-134MPaFlexural strength 161-231 MPaElongation 0.7-2.04 % strainMelting point 240-260 °C
Optical propertiesTransparency Opaque
Recycle False
Downcycle True
Combust for energy recovery True
Landfill True
Typical uses
Specialized components for automotive, electrical, electronic, and consumer/industrial products, such as connectors and microwave oven parts
Data from CES
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Design to Standards
BS EN 957 Stationary training equipment —Part 1: 2005 General safety requirements andtest methodsPart 9: 2003 Elliptical trainers, additionalspecific safety requirements and testMethodsBSEN 15312:2007 Free access multi-sports equipment
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Design to StandardsFOOT PLATE SIZE
BS EN 957 Part 9: 2003 clause 5.5 requires that ‘ the foot platforms have a non slip surface of at least 300mm x 100mm and a friction actor of more than 0.5 when tested to ISO5904’
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MOTION
Design to StandardsFOOT PLATE GRIP DESIGN
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Design to StandardsBS EN 957 Part 9: 2003 clause 5.5 requires that ‘The footplatform shall have a
guard with at least 30mm height along the inside edge and the front edge’
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Design to StandardsTrainer Classification as BS EN 957-1:2005
Load testing to BS EN 957-9:2003
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Design to StandardsLoad testing to BS EN 957-9:2003
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Design to StandardsLoad testing to BS EN 957-9:2003
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Design to StandardsClassification H - 250KG Loading
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Design to StandardsClassification H - 250KG Loading
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Design to StandardsClassification S - 400KG Loading
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Design to StandardsClassification S - 100KG Loading
ConclusionSPS is suitable for H classification trainers
SPS not suitable for S classification trainers
The design could be used for S classification using a material with a Young’s Modulus >24GPa Yield Strength > 150MPa
PP66 with 30% carbon fiber is suitable for H classification trainers
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Shape Optimization
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CURVATURE OF SHAPE
INITIALPROPOSAL
REFINEDDESIGN
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Exploded View
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Eco Audit Report
Product Name
Reebok Cross Trainer Linkage
Product Life (years)
3
Energy and CO2 Footprint Summary:
Energy Details...
CO2 Details...
Phase Energy (MJ) Energy (%) CO2 (kg) CO2 (%) Material 176 81.2 12.2 80.0 Manufacture 36.8 17.0 2.76 18.2 Transport 3.59 1.7 0.255 1.7 Use 0 0.0 0 0.0 Disposal 0.321 0.1 0.0225 0.1 Total (for first life) 216 100 15.2 100 End of life potential -171 -11.8
Environmental ReportDowncycle at EOL
Criteria– Component weight 1.6kg– Manufactured in China &
transported to Manchester
– Re-engineered at end of life
– 15.2kg CO2 required for a 1.6kg?
– Combustion only returns 10MJ but adds 2.6kg CO2
emissions
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Tooling
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Design Benefits
Original Design New DesignNumber of parts 80 16Manufacturer assembled components 24 6User assembled components 56 10Weight 6.03kg 3.18kgCross trainer Classification H H&SRecycle
Steel Yes -ABS Downcycle/Combust -SPS - Downcycle/Combust
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Future Work• Rapid prototype• Physical testing as designated by BS EN957-1;2005
– Load test as per as per clause 5.3.1 in accordance with clause 6.4
– Fatigue / Cyclic loading as per clause 5.7 in accordance with clause 6.7
– Friction factor test as per clause 5.5 in accordance with clause ISO 5904
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Redesigned using SPS Syndiotactic Polystyrene 40% Glass FiberReduces user-assembled components by 64Reduces weight by 2.85kgDesigned for class H (home use) Elliptical Trainers as per BS EN 957–1:2005Redesign of a Reebok Edge Series
Elliptical Trainer Foot Plate LinkageProduct Design & DevelopmentTony Ponsonby 14/12/2011