reverse engineering of an oster waffle maker
TRANSCRIPT
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Oster DuraCeramic Belgian Waffle Maker
JECK EngineeringJordan CrandallCyrus VakiliKen PondEddie Krische
Team 1, Section 56-1WTSN 103
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Outline● Appliance Description
o Overviewo Solid Edge Modelso Bill of Materials/Functional Decomposition
● Problems● Redesign
o Possible Modifications o Evaluations (Pugh/Paul & Beitz)o Solid Edge Models of Final Solutiono Bill of Materials/Functional Decomposition of Final
Solution● Conclusion
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Oster Waffle Maker
Advertised as:● Makes good waffles● Economically efficient● Easy to use● Safe to use
o Problem - burns user
http://www.target.com/p/oster-duraceramic-waffle-maker/-/A-14678520
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Problem Statement
● The Waffle Maker doesn’t allow the user to access the finished waffle without the serious danger of being burned.
http://unifiedconstructs.com/wp-content/uploads/2011/05/bigstock_Safety_First_Vector_7506065.jpg
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Solid Edge Assembly
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Solid Edge Exploded View
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Bill of Materials IPart Number Part Name Classification
(Custom or Standard)Quantity Material
1 Black Phillips head screw Standard 4 18-8 Stainless Steel
2 Silver Phillips head screw Standard 3 18-8 Stainless Steel
3 Cover for leg with three screws Standard 1 Polypropylene
4 Short silver flips head screw Standard 9 18-8 Stainless Steel
5 Leg with the two screws Custom 1 Phenol - formaldehyde resin
6 Bottom metal cover Custom 1 18-8 Stainless Steel
7 Small sliver Philips head screw Standard 13 18-8 Stainless Steel
8 Horse-shoe shape heating element cover
Custom 2 Weaved Phenol -Formaldehyde Resin
9 Tiny washer Standard 3 Black Ox - Stainless Steel
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Bill of Materials IIPart Number Part Name Classification
(Custom or Standard)Quantity Material
10 Metal clamp Custom 1 Aluminum - 3200
11 Clear Crimp-Style Wire Nuts Custom 2 Plastic Aluminum - 3200
12 Power cord Standard 1 Copper 10100 Polypropylene Brass
13 Leg with three screws Custom 1 Phenol -formaldehyde resin
14 Handle Custom 1 High Density Polyethylene
15 Top element cover Custom 1 18-8 Stainless Steel
16 Metallic cover of wires Custom 1 Phenol-formaldehyde resin
17 Temperature controlling unit Custom 1 Phenol -formaldehyde resin
18 Handle fastener Custom 1 18-8 stainless steel
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Bill of Materials IIIPart Number Part Name Classification
(Custom or Standard)Quantity Material
19 Bigger washer Standard 1 Black Ox - Stainless Steel
20 Big Phillips head screw Standard 1 18-8 Stainless Steel
21 Wire Ties Standard 3 Nylon 6
22 Heating metal Custom 2 Copper 10100
23 Lights Custom 2 Ceramic
24 Dial Custom 1 18-8 stainless Steel Copper 10100
25 Metal Body Custom 2 Duraceramic
26 Wire with cover Custom 3 Nylon 6
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Handle Detail Drawing
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Top Cover Detail Drawing
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Functional Decomposition SpreadsheetPart Input(s) Function(s) Output(s)
Black Screw Mechanical Force Connects top and bottom of the metal body Mechanical Force
Silver Screw Mechanical Force Connect legs to metal covering Mechanical Force
Cover Applied Force Provides a stable bottom for the legs Stable Force
Short Silver Screw
Applied Force Connects many different parts in different areas
Normal Force
Leg Applied Force Holds the metal body above the ground and makes it stable
Stable Force
Metal Housing/Cover
Metal Body Protects the wires and heating elements of the metal body
Metal Body
Handle Mechanical Motion Allows for metal body to move up Mechanical Motion
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Functional Decomposition Spreadsheet IIPart Input(s) Function(s) Output(s)
Tiny washer Screw Prevent damage on the object the screw is going into
Screw
Clamp Wires Keeps wires organized Wires
Wire Cover Wires Protect the fragile parts of the wire Wires
Power Cord Electrical Energy Brings in the electrical energy from the socket to the waffle maker
Electrical Energy
Small Silver Screw Applied Force Connects many different parts in different areas
Stable Force
Temperature Controlling Unit
Mechanical Energy Moves and protects the dial Mechanical Energy
Heating Cover Thermal Energy Stores thermal energy Thermal Energy
Handle fastener Handle holds handle in place Handle
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Functional Decomposition Spreadsheet IIIPart Input(s) Function(s) Output(s)
Bigger Washer Screw Prevent damage on the object the screw is going into
Screw
Big Screw Applied Force Connects top and bottom of the metal body
Normal Force
Ties Mechanical Energy holds wires together Mechanical Energy
Heating Metal Electrical Energy Converts electrical energy to thermal energy
Thermal Energy
Lights Electrical Energy Converts electrical energy into light
Light Energy
Dial Mechanical Motion Separate and join contacts Mechanical Motion
Metal Body Materials Holds the waffle batter while the batter heats
Materials
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Waffle Maker Functional Flowchart
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Waffle Maker Schematic
• Mechanical Force• Flow of Heat• Flow of Electricity
Handle
Heat Control Mechanism
Contains and heats batter
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Modified Schematic (View 2)
Mechanical Force
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Problems Encountered
● Identification of some materials● Difficulty re-assembling
o Many parts broke when rebuildingo ex: “Power” and “Ready” light cover broke
● Difficulty with Solid edge waffle maker part
http://www.magicalexperiments.com/wp-content/uploads/2013/06/problems.jpg
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Possible ModificationsMore-open, longer handle
-More space between hand and waffle ironLatch with a Vent
- Latch locks waffle iron close, vent releases excess heatAdditional Cooking Instrument
- Detachable utility (i.e. fork or spatula)Temperature Display
-Indicate Temperature of Waffle Iron
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Criteria for Matrices
● Safety (.30)- materials are safe for the user● Cost (.20)- keep the materials at low prices● Heat Efficiency (.15)- produces enough heat to cook
waffle batter● Reliability (.15)- produces crisp, cooked waffles● Portability (.15)- Easy to store and move● Aesthetics (.05)- looks pleasing for the user
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Pugh’s MethodHandle Change Addition of a latch w/ a vent Additional Cooking Instrument Temperature display
Safety (+) (+) (+) (+)
Cost S (-) (-) (-)
Heat Efficiency (+) S (+) (+)
Reliability S S S S
Portability S S S (-)
Aesthetics (+) (-) S (-)
(+) 3 1 2 2
S 3 3 3 1
(-) 0 2 1 3
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Pahl and Beitz’s Method
Handle ChangeAddition of a latch w/ a
ventAdditional Cooking
Instrument Temperature display
CriterionWeighting Factor (W)
Numerical Value (NV1)
Weighted Value
(W*NV1)Numerical
Value (NV2)
Weighted Value
(W*NV2)Numerical
Value (NV3)
Weighted Value
(W*NV3)Numerical
Value (NV4)
Weighted Value
(W*NV4)
Safety 0.30 4 1.20 3 0.90 4 1.20 4 1.20
Cost 0.20 3 0.60 2 0.40 2 0.40 2 0.40
Heat Efficiency 0.15 3 0.45 3 0.45 3 0.45 3 0.45
Reliability 0.15 3 0.45 2 0.30 3 0.45 4 0.60
Portability 0.15 2 0.30 1 0.15 2 0.30 1 0.15
Aesthetics 0.05 2 0.10 1 0.05 1 0.05 1 0.05
Sum 1 3.10 2.25 2.85 2.85
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Modified Solid Edge Assembly
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Modified Solid Edge Exploded View
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Modified Handle Detail Drawing
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Modified Top Cover Detail Drawing
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Modified Bill of Materials
Part Number Part Name Classification(Custom or Standard)
Quantity Material
2 Silver Phillips head screw Standard 7 18-8 Stainless Steel
14 Handle Custom 1 High Density Polyethylene
15 Top element cover Custom 1 18-8 Stainless Steel
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Modified Functional Decomposition Spreadsheet I
Part Input(s) Function(s) Output(s)
Black Screw Mechanical Force Connects top and bottom of the metal body Mechanical Force
Silver Screw Mechanical Force Connect legs to metal covering Mechanical Force
Cover Applied Force Provides a stable bottom for the legs Stable Force
Short Silver Screw Applied Force Connects many different parts in different areas
Normal Force
Leg Applied Force Holds the metal body above the ground and makes it stable
Stable Force
Metal Housing/Cover Metal Body Protects the wires and heating elements of the metal body
Metal body
Small Silver Screw Applied Force Connects many different parts in different areas
Stable Force
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Modified Functional Decomposition Spreadsheet II
Part Input(s) Function(s) Output(s)
Handle Mechanical motion Allows for metal body to move up Mechanical motion
Handle Mechanical Motion Allows user to safely access their waffle Mechanical Motion
Tiny washer Screw Prevent damage on the object the screw is going into
Screw
Clamp Wires Keeps wires organized Wires
Wire Cover Wires Protect the fragile parts of the wire Wires
Power Cord Electrical Energy Brings in the electrical energy from the socket to the waffle maker
Electrical energy
Temperature Controlling Unit
Mechanical energy Moves and protects the dial Mechanical energy
Heating Cover Thermal Energy Stores thermal energy Thermal energy
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Modified Functional Flowchart
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• Mechanical Force• Flow of Heat• Flow of Electricity
Handle
Heat Control Mechanism
Contains and heats batter
Modified Schematic (View 1)
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Mechanical Force
Modified Schematic (View 2)
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Conclusion● Problem: User injured by
accessing waffles
● Solution: Longer handle to access cooked waffleso Makes sure user does not
get burned
● Thank you for your time, Questions?
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Bibliography ● "Oster Waffle Maker." Target. N.p., n.d. Web. 03 Dec. 2013.● The Role of Magic In Solving Problems. (n.d.). Magical Experiments. Retrieved
December 7, 2013, from http://www.magicalexperiments.com/wp-content/uploads/2013/06/problems.jpg
● Unified’s Safety Management Program. (n.d.). UNIFIED. Retrieved December 9, 2013, from http://unifiedconstructs.com/about-us/approach-safety/