Product Design and

Development

C h a r l e s B r o n s o n A

D e e p a k P a n d a

D h a y a l k u m a r . M

H e n r y N e w m a n

G a d a m s e t t y M u r a l i d a r

L a v a P r a s a d . N

Abstract

Designing and developing a

product based on the concepts

explained in the coursework.

Introduction

Ever since the discovery of fire, human beings have been fascinated by the

power it produces one of which is heat. This heat is which supplies people

with hot water to drink, bath etc. It is well known that people like their

drinks hot rather than cold. But there is a dearth of products which enable

people to have hot water or drinks at their disposal or they need to have a

big machine to enable them to do so. This project tries to overcome these

obstacles

Customer Requirements and Statements:

Below are some of the statements as given exactly by the customer

1. Cost is very high. I want cheaper product

2. Power consumption is very high

3. I want temperature indication in my kettle

4. I want to see the contents inside the device.

5. I want to maintain the temperature for sometimes after heating

6. A.C power may not be available always; I want to run it with DC power.

7. I want it to be connected with my laptop for heating.

8. I want chargeable batteries for this device.

9. I want to hold it inside my pocket.

10. I am not satisfied with the aesthetics like colour, shape and size. I want

something new.

11. This is very large in size. So I want smaller size.

Problem Statement

The objective is to design a heating device that is portable, compact and

user friendly with several utility functions like temperature sensor,

temperature regulator etc,

Gathering Information

Kettle:

A kettle, sometimes called a tea kettle or teakettle, is a type of pot, typically

metal, specialized for boiling water, with a lid, spout and handle, or a

small kitchen appliance of similar shape that functions in a self-contained

manner. Kettles can be heated either by placing on a stove, or by their own

internal electric heating element in the appliance versions. `

Functions:

Stores fluid

Insulates the user from hot fluid.

Accommodates the heating coil

Cup:

A cup is any of a variety of drink ware used to consume food or beverage.

Functions

Stores fluid

Used as drinking utensil insulating the user from the hot fluid

Heating coil

A heating element converts electricity into heat through the process of

resistive or Joule heating. Electric current passing through the element

encounters resistance, resulting in heating of the element.

Functions

It heats the fluid.

Concept Generation

Brainstorming

Knowing very well the customer requirements, we henceforth sat for a

brainstorming session within our group and we came up with a mind map

incorporating all functions and ideas for the product.

We used the idea of mind map to clearly lay down our ideas and

creativities using which we can develop our concepts.

Concept Maps/Mind Map

SCAMPER

Using the concept of SCAMPER we developed new concepts.

For e.g;

Modify/Magnify/Minify – Reducing the size of the kettle to the size of a

regular coffee cup.

Adapt – Adopted from kettle and All Out (Mosquitoes Liquidator) into our

cuptle.

Adaptation of temperature sensors and regulators from induction stoves.

TRIZ – Theory of Inventive Problem Solving

We used some of the principles of TRIZ to develop our concepts

Some of the concepts are

Segmentation – Heating element and cup are segregated and kept

separate.

Combining – Combining cup with kettle

Universality- It can be used both as kettle and cup and can be easily taken

from one place to other place

Prior Counteraction – Use of temperature sensors and alarm when the

fluid goes beyond a level while boiling

Product Concepts

Using the various tools/aids in improving creative thinking, and also the

tools for concept generation like SCAMPER and TRIZ. We developed three

new concepts incorporating the customer requirements.

Concept 1:

Features:

Segregated heating coil and cup

Temperature sensors and Timers

Transparent Lid

Concept 2:

Features:

Wired heating element

Transparent and hard lid

Pouring lip in the cup

Concept 3

:

Features:

Wired heating element

A handle to lift the cuptle comfortably

Supporting lower part for better balance during stagnant condition.

Concept Evaluation

Using the principles of TRIZ and SCAMPER we developed three new

concepts for our product cuptle. We had to evaluate the concepts to select

one concept for further development. So we used the principle of

Benchmarking matrix to evaluate the design.

Here we compared the products based on the categories like Ergonomics,

Aesthetics, Manufacturability, Eco-friendliness etc.

Parameters Concept 1 Concept 2 Concept 3

Aesthetics 8 6 7

Ergonomics 8 6 7

Portability 8 6 7

Ease in

Manufacturing 6 7 8

Indented Purpose 8 7 7

Cost 7 6 6

Eco Friendliness 6 8 7

Weight 8 6 6

Total 59 52 55

Based on the benchmarking matrix we can find that Concept 1 is relatively

better based on the parameters of comparison. So we take Concept 1 for

further development.

Product Architecture

Product architecture helps in visualizing the arrangement of the physical

elements of a product to carry out its required functions.

Below is the product architecture of our product.

Top

Cover

Cup

Heating

Element

Bottom

Cover

Temp

Sensor

Temp

Regulator

Power

Supply

Regulator

Micro

Controller

USB Battery

AC

Supply

Physical

Signal

Power

Supply

Unit

Handle

Material Selection

Now that the individual functions of the part are clear. We move on to the

step of selecting material for the product based on the individual

constraints and functions.

Top Cover – As it has to be transparent, flexible and also has to withstand

high temperature. Glass fiber fulfills the requirement and is selected as the

material for the top cover

Bottom Cover – As it has to withstand the load/weight of the fluid plus the

added constraint of enclosing the heating element. Steel coated with an

insulating material (preferably hard rubber) is selected for this part.

Cup – It has to be portable, weightless as well as has to insulate the user

from the hot fluid. So the best combination of material which fulfills these

criteria is steel insulated inside with glass

Heating Element – It has to be power efficient as well must be light and

highly thermally conductive. In that case copper is the best material to be

used for this purpose

Handle – Handle must be easy to manufacture as well as to be

ergonomically superior and it also has to be strong as it accommodates the

temperature sensor and regulator. So hard plastic with rubber covering

(better grip) is selected as the material

Final Design

Exploded View

Top Cover

Cup

Heating Element

Bottom Cover

Handle

Assembled View

Top Cover

Slot/Grip for Opening

Features

Transparent material to see through easily

Interference fit so it seals the hotness of the fluid inside.

Bottom Cover

Features

Strong solid steel covered with hard rubber for insulation.

Thread at the inner surface to couple it with the cup.

Covers heating element.

Supports the power supply unit and regulator

Interference fit so it seals the hotness of the fluid inside.

Connected to AC Power Supply

Power Supply Regulator/ USB

Connector

Cup

Features

Strong solid steel insulated inside by glass.

Threaded at the bottom to connect the bottom cover. Here we

used the concept of Segmentation to segregate parts for easy

cleaning.

We also used the concept of Adapt to adapt the feature of kettle

into a cuptle

Holes to connect the handle

Thread to connect the bottom

cover

It can be also used as a kettle as well as a cup incorporating the

concept of Universality

Heating Element

Features

Made from highly polished copper for better thermal

conductivity.

Handle

Display

Temperature

Regulator

ON/OFF Switch

Features

Made from hard plastic covered with rubber (better grip).

Adapt the principle of temperature sensor and regulator from

Induction stoves.

Ergonomically shaped handle for better comfort while holding

Ergonomically placed ON/OFF switch for ease of use.

Summary

In short we used the entire product design and development

process to develop the product.

We identified the problem using customer statements which was

then defined using accurate and brief description. Then we

gathered information about the basic components and concepts.

We then used the tool of brainstorming and concept map to aid in

the creative thinking process in generating concepts. Then

concepts were generated using TRIZ and SCAMPER principles.

The generated concepts were evaluated using benchmarking

matrix, the selected component was then further build upon by

making the product architecture in which the functions of the

individual components were defined. This definition was useful

in selecting the material in the next step. Then we finally

modelled the product using modelling softwares. Thus the entire

scope of this course was used in designing and developing the

product.