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SE-4000 Portable Eye Wash
Spray Fixture
The Speakman CompanyUniversity of Delaware Team:
Wes Doyle Nate Griffith Matt Jaskot Jason McKnight
Overview
• Present the problem• State our goals• Reveal the project constraints• Traverse the design process• Reveal the problem solution• Validate the problem solution
Existing design
– Complicated and expensive brass valve
– Many parts high assembly labor costs
– Significant room for cost reduction in spray arms
Current Design Components 1 |__ G20-1894-RCP Valve Assy For Se-4000& 577-Sd 1 G20-1894-RCP 1 51.77 | |__ G05-0666-L-RCP Left Outlet Arm Assembly 1 G05-0666-L-RCP 1 10.71$ 10.71$ | |__ G05-0666-R-RCP Right Outlet Arm Assembly 1 G05-0666-R-RCP 1 10.71$ 10.71$ | |__ G20-1815 Valve Mechanism Assy 1 G20-1815 1 2.71$ | | |__ 14-0039-RCP Valve Tailpiece Grvty Flow 1 14-0039-RCP 1 1.86$ 1.86$ | | |__ 20-0949 Plunger-6 Fin For Valve 1 20-0949 1 0.25$ 0.25$ | | |__ 37-0077 Valve Spring Grvty Flow 1 37-0077 1 0.12$ 0.12$ | | |__ 49-0162 #202 O-Ring (Epdm 70 Dur) 1 49-0162 1 0.02$ 0.02$ | |__ 01-0806 13/16 Hex Locking Nut 2 01-0806 2 0.45$ 0.90$ | |__ 03-0504 Spindle Saddle Clip 1 03-0504 1 0.09$ 0.09$ | |__ 03-0529 Valve Spindle W/Thrd Ends 1 03-0529 1 6.99$ 6.99$ | |__ 20-0952 Valve Body For Swing Down Vlve 1 20-0952 1 7.60$ 7.60$ | |__ 45-0707 1.035 X .707 Nylon Washer 2 45-0707 2 0.04$ 0.08$ | |__ 48-0354 10-24 Dog Pt Cap - .355 Lgth 2 48-0354 2 0.60$ 1.20$ | |__ 48-0356 10-24 Cup Pt Set Screw W/Patch 2 48-0356 2 0.17$ 0.34$ | |__ 49-0080 #111 0-Ring, Buna N, 70 Duro 2 49-0080 2 #N/A | |__ 49-0083 #112 0-Ring 2 49-0083 2 #N/A |__ G38-0347 Spray Head/Gravityflo 2 G38-0347 2 3.29$ 6.58$ | |__ 07-0088 Neoprene Spray Head Guard 2 07-0088 2 1.08$ 2.16$ | |__ 38-0251 Spray Head Base-Gravityflo 2 38-0251 2 0.55$ 1.10$ | |__ 38-0252 Spray Head Cap-Gravityflo 2 38-0252 2 0.55$ 1.10$ | |__ 49-0147 #029 O-Ring 2 49-0147 2 0.19$ 0.38$ |__ 01-0781 Lock Nut/2nd Generation Valve 1 01-0781 1 0.49$ 0.49$ |__ 05-1928 Foam Grip 2 05-1928 2 0.98$ 1.96$ |__ 21-0186 In-Line Strainer/Se-4000 1 21-0186 1 0.21$ 0.21$ |__ 45-0580 1 1/4 X 7/8 X 1/16 Ss Washer 1 45-0580 1 0.30$ 0.30$ |__ 51-0073 Rivet-M/P #61apr 25075-B 1 51-0073 1 0.07$ 0.07$ |__ 56-0108 Ratchet ¢Inch Clamp 1 56-0108 1 0.53$ 0.53$ |__ 56-0110 Supply Tube Clamp 1 56-0110 1 0.12$ 0.12$ |__ 63-0026 Pre-Formed Supply Tube 1 63-0026 1 4.34$ 4.34$ |__ 66-0112 Internal Tooth Lockwshr 718id 1 66-0112 1 1.14$ 1.14$
43 54.77$
Sponsor’s Problem• High cost model in a low cost Market
• Seeks to reposition eyewash at appropriate cost level
More Features- Higher Cost
Low Cost Commodity competition
Our Task
• Reduce cost of Spray-Arm Assembly under $15
• Maintain compliance with ANSI flow requirements
Sponsor’s Wants
• Utilize existing tank tooling
• Aesthetic appeal• Minimize changes to
shipping container• One year Return on
capital expenditure
ANSI Requirements– Minimum flow of 0.4 GPM for 15 minutes– Hands free operation– Nozzles protected from airborne contaminants– “On to Off” in 1 second or less– Nozzle at least 6” from nearest obstruction– Must not leak & operate reliably every time– Both eyes flushed simultaneously at safe water
velocities
Design Subsystems3 Subsystems Spray-Arms perform:
- Regulation of flow on/off (valve)
- Direction of flow to user’s eyes (nozzles)- Attachment to tank (threaded nut)
Any new design must perform these 3 functions at low cost- Attachment to tank and flow direction are relatively easy to do- Focus on flow regulation
Concept generation
- Initial ideas for flow regulation
Ball Valve Linear Valve Snap-on Nozzle Caps
- Low-cost design easy to prototype quickly, cheaply
Ball Valve Prototype
• Estimated Cost ~$30 (ball valve expensive, assembly costs)
• One Attachment Point, Low Strength• Ugly.
Pull-Off Caps Prototype• Estimated Cost Near $15 Target• Attached with Bolts / Screws (Stronger)• T-Handle Connected to Caps
Sharp Metal Edges
Plastic Molded Design(it is a safety product)
Design changes
Design changes
Design changes
Design changes
Design changes
Design changes
Design changes
Design changes
Pull-Off Strap Design• Angled rubber strap
– Allows for user to easily grab onto handle
– Expensive to mold due to complex shape
– Cheaper, effective alternative?
Pull-Off Strap Design• Straight rubber strap
– Less expensive mold– Smaller surface area for
user to grab onto – $6800 Tooling– $3.50 Piece price– Cheap, ergonomic
alternative?...
Pull-Off Strap Design• Inverted rubber strap
– Inexpensive– Prominent– Peeling effect
• Other alternative?– Widen the space between nozzles
for more room
Rapid prototyping/final design
• Final Design
• Rapid Prototyping using Stereolithography
CostReduced Unit Cost
• Cheaper materials• Fewer parts• Easier to assemble
Current/Proposed Design Comparison
Testing• Flow Requirements Met
t = 0 mint = 0 min
t = 1 mint = 1 min
t = 2 mint = 2 min
t = 3 mint = 3 min
t = 4 mint = 4 min
t = 5 mint = 5 min
t = 6 mint = 6 min
t = 7 mint = 7 min
t = 8 mint = 8 min
t = 9 mint = 9 min
t = 10 mint = 10 min
t = 11 mint = 11 min
t = 12 mint = 12 min
t = 13 mint = 13 min
t = 14 mint = 14 min
t = 15 mint = 15 min
t = 16 mint = 16 min
t = 17 mint = 17 min
t = 18 mint = 18 min
t = 19 mint = 19 min
t = 20 mint = 20 min
t = 21 mint = 21 min
t = 22 mint = 22 min
t = 23 mint = 23 min
t = 24 mint = 24 min
t = 25 mint = 25 min
t = 26 mint = 26 min
t = 27 mint = 27 min
t = 28 mint = 28 min
t = 29 mint = 29 min
t = 30 min
Manufacturing Concerns -Fixture
• Molding method-Rotomolding
• Accommodates short production runs
• Low tooling cost compared to blow molding
• Tradeoff-High piece price
Molding Results
-100000
-50000
0
50000
100000
150000
200000
250000
300000
350000
400000
0 1 2 3 4
Series1
Series2
Route to finished product
• Path forward to a marketable product– Packaging – Customer Assembly?– Contour – Precision measurements– Decals – Removing current and replacing– Assembly Jigs – Handle Manufacturing
Before
Now
Future Development
THANK YOU
Questions?
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