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Above Floor Accessory Test Rig

LESSONS LEARNED

Below is a gallery showing the different components involved in the design

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A device used to test accessories to steam mops used to clean above floor surfaces (countertops, windows, tables…)

DESCRIPTION â€‹

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Holds steam accessory in place, above stain, and moves it back and forth to simulate cleaning/scrubbing

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FEATURES​

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Highly flexible with 6-degres of freedom in sample/accessory placement

Can simulate up to 40 lb. of pressure

Fully powered by high torque motor with adjustable speed and stroke

Spring-balanced weight box to concentrate weight on accessory

Custom printed adaptors for specific accessories

  • High quality, steam safe, waterproof aluminum/carbon fiber components

  • Safety guards, pads, labels, and instructions 

  • Waterproof base with feet and handles for transportation

Other Features:

Problem:

Our team wanted to measure performance metrics for new above floor accessories to compare design iterations

Manual Testing: ​

  • No standard test procedures available

  • Manual testing proved highly inconstant 

  • Saw need for accessory rig that constrained:

    • Cleaning motion and speed​

    • Pressure applied 

    • Stain sample

Initial Prototype:

  • Mocked up rough concept in a couple days

  • Presented to team 

  • Got approval to build robust version

CAD:

  • Sketched concept in Creo using a combination of:

    • High quality optical mount parts​

    • Standard hardware

    • In-house supplies

  • In hind sight I should have put more work into this

Initial Assembly:

  • Ordered all parts and assembled them 

  • Many unforeseen challenges:

    • Mounting​ holes not lined up

    • Un-modeld components interfered

    • Needed adjustable sample mounting plate 

    • Weight box not large enough

    • Not enough flexibility for new accessories

    • Many more...

    • Each issues presented more probelms

Final Rig:

  • Months of Iterations 

  • Much more work than anticipated

  • Made many more changes:

    • Added motor 

    • Added scissors jack lifted sample tray

    • Raised everything up for larger accessories

    • Added feat, safety guards, and covered corners, and handles

    • Lighter components

  • One of the largest projects I have worked on

  • Gained experience in test design, prototyping, presentation, buying parts, assembly design in CAD, designing custom printed parts, and many new machine shop skills

  • Learned value of detailed CAD work, planning ahead, and not taking shortcuts

  • Learned the unforeseen challenges in a project like this and how to better estimate timeline

  • Learned the value of involving others and getting feedback in your work

  • Saw the value in proposing your own project and taking on the challenges associated with large projects like these  

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PROCESS

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