Simultane Product- & Productieontwikkeling

Voxdale company presentation & Case studies

OMC - October 24th 2013

Koen Beyers – Voxdale

Voxdale • Founded in 2005

• Located in Antwerp, Belgium

• 5 Product Designers (Design, Product architecture, Mechanical engineering) • 6 Engineers (Mechanical engineering, CFD, FEA)

• 1 Business Developer

• Profiles: B.Sc., M.Sc., Lic., Ing., Ir.

Voxdale • Brainstorming, Concept Design & Product Development

• Mechanical Design & Engineering

• Process simulation & Optimization

• Prototyping & Design Validation

Tools

Markets • Medical Devices

• Space & Aerospace • Automotive

• Transportation & Logistics

• Performance sports

• Consumer Electronics

• Industrial installations

• Energy & Environment • Governments

Design Path

Design Path

Design Path

Product/Device development is a multidisciplinary job • Technological aspects

• Material (medical grade, biocompatibility, leachable, extractables, sterlization, …) • Device architecture • Mechanical design – Electronics, hardware (if apl.) – Software, firmware (if apl.) • Prototyping - optimization • Manufacturing technique (moulding, milling, …) • Labling (CE mark, …), technical file

• Economics

• Investment cost/budget • Unit price – manufacturing cost – margin – assembly cost • Market – distribution channels – collaborations (drug – device combination)

• Human Factors - HCD

• Ergonomics – Anthropometrics • Usability – semantics – acceptance • Aesthetics – design • Clinical Trials

Multidisciplinary team / Complementary partners

&

Open Innovation

• Multidisciplinary teams

• Complementary partners

• Radical innovation • Open Innovation

Case studies

Case study - Projector

Case Study: Multi Media Projector (Beamer) Specifications:

• XGA Resolution (1024 x 768 pixels) (800.000) • 800 Ansi Lumens • Ultra Compact: 125 x 95 x 50 mm • € 700 > Listprice

Case Study: Multi Media Projector (Beamer) Technology:

• 80W UHP Lamp • Single Chip DLP (Texas Instruments) - 0.55’’ >> 0.55’’ is the size of a fingertip >> Magnified to the screen size you see now … >> One pixel is 0.011 mm >> Extremely sensitive to dust & particles

Case Study: Multi Media Projector (Beamer) Requirements:

• Dust free • Low Noise Level > 32 dB(A) • Compact • Low Weight • EMI compliant Class B • Robust & Stable (optics) • Optimal thermal management (reliability) >> Material definition is Concept Design, not a choice at the end >> Magnesium

• Top Shell (Mg) • Electronics

• LPS (Lamp power) • PMP (Imaging) • Input Module

• Optical engine

• Lamp • Light Rod • Mirrors • Prism • DLP Chip • Lens

• Fan (1) • Bottom Shell (Mg)

Case Study: Multi Media Projector (Beamer) Enclosed Housing, for:

• Low Noise Level > 32 dB(A) • Dust Exclusion

• Resulting disadvantages:

• Thermal Management? • No cooling slots (with dust filter)

Case Study: Multi Media Projector (Beamer) Magnesium for EMI Shielding

• Hi-Freq Electronics • Image processing for 96 (24x4) XGA images/second • 2 mm metal layer, • versus a thin (15 micron) and expensive Cu or Ni coating (used with plastics)

Case Study: Multi Media Projector (Beamer) Magnesium for (optical) stability & robustness

• Optics mounted in the bottom shell • Portable device (drop test)

• Torsion test (bottom shell) with 1 Nm torque • Comparison of

• 2.0 mm wall thickness Magnesium design, 78g versus • 2.8 mm wall thickness Cycoloy design, 66g

Case Study: Multi Media Projector (Beamer)

Case Study: Multi Media Projector (Beamer)

Case Study: Multi Media Projector (Beamer)

• Torsion test with 1 Nm torque (FEA)

Cycoloy C6200 (PC-ABS) versus AZ91HP

Case Study: Multi Media Projector (Beamer) Magnesium for Thermal Management

• Thermal Conduction

• 100% enclosed housing

• One fan for internal convection and air-flow

• ‘Air-metal-air’ Heat Exchanger in Top & Bottom shell

• Entire Magnesium housing acts as Heatsink.

• About 75W heat dissipation to get out of the product

Case Study: Multi Media Projector (Beamer) Magnesium for Thermal Management

Bottom shell with heatsink/double heat exchanger

Axial Fan

Case Study: Multi Media Projector (Beamer) Magnesium for Thermal Management (CFD Analysis)

Case Study: Multi Media Projector (Beamer) Magnesium for Thermal Management (CFD Analysis)

Case Study: Multi Media Projector (Beamer) Magnesium for Thermal Management (CFD Analysis)

Case Study: Multi Media Projector (Beamer) Magnesium for Thermal Management (CFD Analysis)

Case Study: Multi Media Projector (Beamer) Magnesium for Thermal Management (CFD Analysis)

Temperature plot of projector body in ‘Ceiling Mount’

Case Study: Multi Media Projector (Beamer) Magnesium for Thermal Management (CFD Analysis)

Case Study: Multi Media Projector (Beamer)

Simulation as a design tool : • It all starts at conceptual level!

• Parameters are essential • Rubbish in is rubbish out • Spec sheets (commercial) • Historical measurements • Intuition (10°C or 10.000°C? 0.11 m/s or 11 m/s?) • …

• Therefore: main value is

• Trend research (variant A is 12% better than B) – rather than absolute value • Check initial feasibility of concepts & ideas • Compare dozens of variants overnight + parameter optimization • Pin point! Rather than: ‘good enough, it seems to work’ >> look inside & visualize

Multidisciplinary team / Complementary partners

&

Open Innovation

Where is this going to?

Form Follows Funtion design • Optimized for stress • For thermal management • Use of material • Reliability

• Efficiency

• ‘Design inspiration’

Questions?