iRobot Project - Side Brush
Project Summary
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Studied and tested variables around the negative user feedback on existing side brush
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Calculated the optimum number of brush arms and rotation speed to improve perception of cleaning
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Implemented changes in a drop in replacement with a new gear box and brush head
Project Steps
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Read negative customer feedback on existing products to determine problems (Coverage and debris flicking)
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Created an excel spreadsheet to calculate floor coverage, tip velocity and cost based on RPM, number of brush arms, contact surface area and OD
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Presented findings and design options to stakeholders to get buy in on a final configuration
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Redesigned gear box from scratch and modified brush head to create a drop in replacement
Skills Learned
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Experienced working with user feedback and data
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Exposure to balance customer perception, robot performance and cost
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Learned how to work with and model involute gears
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Video of prototype being tested for floor coverage and debris flick
Excel generated side brush coverage path
Video of prototype gear box running to ensure correct RPM
Assembly of gear box that I designed from scratch
iRobot Project - Mold Design
Project Summary
​Designed reusable, core and cavity molds for casting prototype roller parts in resin
Project Steps​
Moved away from single use "break away molds" that were causing long prototype times and poor quality parts
Designed a reusable molds that would make lengths of stock that could then be cut to the correct size
Iterated design by adding ship-lapped seams to cut down on flash, gate points off the molding surface to mitigate air bubbles, screw bosses to stop the need for clamps and overflow channels to stop excess resin from leaking onto the lab surface
Result​
Created a final design that would cast a pair of mirrored parts with no secondary operations required
Cuts the in house production time and cost in half
