COMPONENT PACKAGING: PART II // Power, Light and Flexibility

 

 
Be sure to check out Component Packaging: Part I  for more packaging considerations within the project.
 

 

Battery (Power) & Light

As the light intensity and run time are intrinsically linked to the battery, these points have been combined.

The run-time of the product from fully charged was proposed to be within the 3-4 hour range as a minimum. This time would allow for the majority of mechanic tasks to be performed without having to cycle out the unit/s during work. A standard rechargeable AA battery was intended to be used. 

From having sampled existing torches, a light with an output of 20 lumens was seen as the minimum light output (Also keeping in mind there would be a point where there was simply too much light).

Simple tests were conducted with varying battery and LED varieties.


 
 
 
Some aspects of the test were extremely positive: The light output from a single LED was sufficient to light an area under or within the car, and the battery provided enough power to sustain the light for over 48 hours - more than 12x the minimum specified.

 

 
 

Other aspects were not so great. At this stage it became apparent that rechargeable AA  batteries did not supply the voltage required to run an LED. However, rechargeable CR123A and CR2 batteries could be found with the required voltage (3v+). The capacity on these batteries was usually only 1/2 to 1/3 of that as a AA (800-1200mAh compared to 2500mAh). This would still guarantee a run time of 20+ hours, and the physical size of these batteries were also much smaller.
 

Flexibility

Initially, the ability to bend near to 90°'s was seen as a key innovation within the product. With all of the components required in the product, the ability for it to bend was initally seen as somewhat of a hard obstacle to overcome. How and where do you put the mechanism? What components are easier to hold in idividual sections of the unit? These were the questions we were asking ourselves.
 
It wasn't until the creation of several form studies that it clicked.
 

 
 
 
We were directly inspired by a common ball joint found within Lego. Its ability to seperate on a whim, while still being solid enough to support the required weight had 3 key advantages to our previous ideas.
 
  1. The ball joint provided sufficient strength to hold the object in place at all angles, and allowed for free axis movement.
  2. It promoted the seperation of all electrical components from the non-electrical. No power had to run through the ball joint.
  3. The ball joint attachment could be removed and replaced with various accessories.
Although this system did not allow a full 90°'s of rotation, our product testing concluded that the bending was more than adequate.
 
In Component Packaging: Part III, we will detail the next steps in the project, specifically focusing on refining and detailing all of the components and packaging within a CAD system.

COMPONENT PACKAGING: PART I // Induction & Magnets


Having gained some direction after Phase I of the project, our first task was to resolve the design of the light itself. There is intended to be tight integration between the lights and the charging station, so it is vital to always keep the user experience of the product forefront in our minds. While designing the packaging for the light, there were several key points to keep in mind.

  1. The design must include an induction coil for hassle-free charging.
  2. The design must include a magnet which allows the product to be secured to metals parts on a car.
  3. The design must include a source of power.
  4. The design must include a source of light output.
  5. The design must include a mechanism that allows the product to bend near 90°'s in one direction.

Several other points were also being considered.

  1. [MAYBE] The design should include an on/off button OR always be on except when charging.
  2. [MAYBE] The design should include a mechanism that allows the user to see when the light is charged.
  3. [MAYBE] The design should include mounting points to allow it to work with other accessories.

This post will focus on points 1 & 2.

Induction Coils

Specifically we are focusing on those used in inductive charging. The two main types of coils being considered are the flat coil and solenoid coil.






The solenoid coil is commonly found in electric tooth brushes, while the flat coil is found in many new products (Especially smart phones) utilizing the Qi standard of inductive charging. In terms of performance they are relatively similar. The size and shape will be the deciding factor as to which is used in the design.

Magnets

Magnets come in a huge range of shapes, sizes and strengths. Ideally the magnet should have slightly more strength than is needed to hold the product onto a steel bolt (generally the smallest ferromagnetic object on a car). The magnet used will therefore reflect on the shape, size and weight of the product.



Coercivity

All magnets lose some of their strength over time. Coercivity measures how resistant the magnet is to becoming demagnetized. Over time, magnets need to be re-magnetized by being introduced to a stronger magnetic field (In industrial applications, a DC current is run through a nearby coil). Luckily,  modern magnets such as Samarium-cobalt and Neodymium have high coercivity values (as little as 1% loss over 10 years), hopefully negating the need for re-magnetization.

Induction Coils & Magnets

Unfortunately, magnets disrupt the flow of energy to an induction coil. We had to know exactly what implications this would have in our design, so we tested just how much of an effect a magnet would have by utilizing a setup borrowed from an electric toothbrush. We placed a moderate strength bar magnet at locations within, above and nearby the coil, and then charged the unit for 1 minute. We then documented the run time after each charge.


Luckily, the only placement that had a significant effect was when the magnet was inside the coil. Although the results look reasonably promising for allowed flexible placement of both the magnet and the coil, we must remember that the effects of all placements would be worsened if using a more powerful magnet.



In Component Packaging: Part II, I will be discussing points 3-5. Later posts will discuss general design elements, material and process selection, product usage analysis and more, so be sure to check back.


CRITERIA FOR SUCCESS // Helping Define a Project & Maintaining Focus


In those times when the designers behind a project start to lose focus, having a defined "Criteria for Success" can help.

Our criteria for success focuses on ensuring our product meets the needs of both professional and hobbyist mechanics by being practical in operation, adaptable to any likely situation, and durable over prolonged periods of time.

USER RESEARCH: PART I // A Day at the Mechanics


As I idled into the bay area of [redacted] Motors, curious mechanics stood onlooking from afar. I turned the ignition key into the off position, and slowly opened the door. 

A mechanic approached. "How can I help?", he greeted warmly. I explained the reason for my visit. What I was not expecting, however, was the almost instantaneous validation of my chosen design problem.

"Lighting is one of the single biggest problems we have". I have never been so joyed at others misfortune.

Around the shop I went, the mechanics enthusiastically (?) describing the light-related problems they encounter each day. They were eager to show the lights they utilize (including custom-built rigs), and to talk of the flaws in existing solutions. As I suspected, many of the problems I faced at home were also faced by these mechanics. 

Interviewing strangers can be a daunting, but ultimately rewarding process.




Some key points:
  • Every mechanic stated lighting was a *huge* problem.
  • No amount of overheard or fixed lighting helps when working within the engine bay or interior - "The darkness swallows you up"
  • Lights are "the most abused tool in the shop". Durability is a huge problem, even on expensive models.
  • Positioning and angling existing solutions was completely impractical or downright impossible depending on the design.
  • Corded lights were frustrating and problematic to use.
  • They resorted to using custom-built solutions in many cases, but these had their own problems.

BUSINESS CARD // Brand Identity Refinement


This business card was created to further refine the VAAN design language in terms of printed and digital media.




Some defining characteristics:
  • Logo aside, typography is portrayed in Century Gothic.
  • Blue / Pale Blue is the main identifying color of the brand (Exact blue TBA).
  • Layouts are kept clean and simple.
  • Lightly textured materials should be utilized in print media (I.e. No glossy photo paper).

POST ONE // 09.08.2013


Please refer to the BRIEF and ABOUT pages for more information regarding this project.

 As the project progresses more information will be added to the main feed including research, concepts, prototypes and more.