iPod Charge and Ride SystemFinal Project ReportDevelopment Team:Jay FournierCody HolstegeBrad PeirsonKyle RozemaSchool of EngineeringPadnos College of Engineering and ComputingGrand Valley State UniversitySponsored by:Brian Coleman – Product Design and Manufacturing EngineerDavid Curley – MarketingAaron Wilkerson – Electrical EngineerDecember 12, 2007Contents1 Charge and Ride Mission Statement 22 House of Quality 33 Specifications 44 Funtion Structure Diagram 55 Analytical Models 66 Focused Prototype 77 Final Prototype 88 Evaluation of Prototype 129 Acknowledgments 14List of Figures1 Charge and Ride Signed Mission Statement . . . . . . . . . . . . . . . . . . 22 Charge and Ride House of Quality . . . . . . . . . . . . . . . . . . . . . . . 33 Charge and Ride Function Structure Diagram . . . . . . . . . . . . . . . . . 54 RPM vs. Voltage Generated . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Pro-E Model of Circuit Enclosure . . . . . . . . . . . . . . . . . . . . . . . . 86 Inside View of the SLS Circuit Enclosure . . . . . . . . . . . . . . . . . . . . 97 Outside View of the SLS Circuit Enclosure . . . . . . . . . . . . . . . . . . . 98 Charging Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Storage Circuit in Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010 Pro-E Model of Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 1011 Pro-E Model of Control Unit Underside . . . . . . . . . . . . . . . . . . . . . 1012 Pro-E Model of iPod Dock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1013 SLS Prototype of iPod Dock . . . . . . . . . . . . . . . . . . . . . . . . . . . 1114 SLS Prototype of Dock Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 1115 Pro-E Model of Power Ge nerator . . . . . . . . . . . . . . . . . . . . . . . . 1116 The Charge and Ride System Attached to a Test Bicycle . . . . . . . . . . . 1217 Charge and Ride Bill of Materials with Proposed Production Costs . . . . . 1211 Charge and Ride Mission StatementBecause of the distance between the development team and the ESANi team, the missionstatement was drafted and a copy was sent to ESANi for approval. A scanned copy of themission statement with ESANi approval was then sent back to the development team to bedocumented. Figure 1 shows the mission statement of the Charge and Ride project as signedby ESANi.Figure 1: Charge and Ride Signed Mission Statement22 House of QualityResearch was conducted within the Charge and Ride’s target market. Initial results werenegative to the point that there did not seem to be a market for the product. The majorityof the responses reflected concern over the safety of listening to music while riding a bicycle.ESANi was contacted immediately with the concern and brainstorming sessions were held todetermine potential alternate products. ESANi ultimately decided to move forward with thedevelopment of the Charge and Ride system as the initial market research may have beenexecuted with the wrong demographic. Additional market research was conducted and thepositive feedback was compiled into customer needs. These needs were input into a House ofQuality in order to relate the interpreted customer needs to engineering criteria. The finalHouse of Quality is given in Figure 2. Team Measures (HOWs)Customer Requirements (WHATs)Importance (Scale 1-5)Amount of shock material will take before failureMax # of devices that can be poweredMax energy output of systemManufacturing costDrag created at speedMoisture content in iPod cavityMaximum sizeSound levelTime to installCharge Hold TimeTime to reach desired controlMachining required to mountOur Application = ♠Competitor A Application = ♣Competitor B Application = ♦Voice of the Customer (W hat they want) 1 2 3 4 5 6 7 11 12 13 14 1512345Maximum input efficiency 3.0 ▓ ▓Waterproof 5.0 ▓Durable 4.0 ▓Protective of iPod 5.0 □Good sound 4.0 □Two people can hear 3.0 □ □ ▓Loud 2.0 ▓ ▓Easy to install 3.0 ▪ ▓Lightweight 3.0 □ □ □Safe to use in rain 3.0 □Allows for safe riding 5.0 ▓Inexpensive 3.0 ▓ ▓Harmless to Bike 3.0 ▓Safe to Control 5.0 ▪Organizational Difficulty (1- Easy, 5-Difficult) 4 4 3 3 5 4 2 3 38 Scale (1-10)Atleast 2 devicesAtleast power required by one iPodUnder $10010-15% extra power required at 15 mphZero droplets13 in^3Atleast 70 dB< 3 minutes2 - 3 minutes2 seconds0 paint removalOur Application = ♠ 5Competitor A Application = ♣ 4Competitor B Application = ♦ 321House of Quality KeysRoof Key SymbolStrong Positive xPostive ●Negative ○Strong Negative ▬Main House KeyWeak Correlation ▪Average/Medium Correlation □Strong Correlation ▓Customer Rating (1=worst, 5=best)Engineering Competitive Assessment (1=worst, 5=best)How Much/Target ValuesEasy to UseMarketingDurableSound Quality°xxx°°°°xxxxx°°°°Figure 2: Charge and Ride House of Quality33 SpecificationsThe interpreted customer needs from the House of Quality and the resulting engineeringcriteria were combined to form a set of project specifications. Each specification requiresa metric, a numerical value and a method to test against the specification. The primaryspecifications for the Charge and Ride system are listed below.1. The device will be durable• The device will score an 8 out of 10• The device will be dropped from a height of 2 feet• This specification meets the customer need that the product will withstand impact2. The device will provide sufficient power to power an iPod• The device must be able to provide 5v at 300mA minimum• Tested via a digital multimeter3. The device will be weatherproof• The device will not allow any water within any part of the enclosures• The device will be sprayed with water and a visual inspection will verify wateringress• This satisfies the customer need that the device will be waterproof4. The device will be easy to install• The device will install in 3 minutes or less• Tested via various users attempting to install the system on a bicycle• Satisfies the customer need that the product should be easy to install44 Funtion Structure DiagramBased on the specifications above and the overall goals for the project from ESANi, a functionstructure digram was created …