Final Submission - Team 19 Lidar Installation Report
1. TEAM 19 INDUSTRIAL
PROJECT 2014
LIDAR INSTALLATION
Andy Thomson
Chris McTeague
Kerrie Noble
Ruairidh Fraser
Mungo Hay
2. 1 Statement of Academic Honesty
We declare that this submission is entirely our own original work.
We declare that, except where fully referenced direct quotations have been included, no aspect of
this submission has been copied from any other source.
We declare that all other works cited in this submission have been appropriately referenced.
We understand that any act of Academic Dishonesty such as plagiarism or collusion may result in
the non-award of our degree.
Signed …………………….………… Signed ………………………………...
Signed …………………….………… Signed ………………………………...
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Dated …….…………………
3. Team 19 SgurrEnergy 2014
2 Acknowledgements
Throughout the duration of the project there have been many instrumental people involved with
the development of the project that the team would like to take the time to thank at this point in
time.
Firstly the team would like to extend their thanks to the client, SgurrEnergy, namely Craig
McDonald, Michael Moir and Will Laird. Thank you for the enthusiasm, encouragement and
support provided through every stage of the project progression. Without this much needed
support and involvement the outcome of the project would certainly have been less impressive.
We would also like to thank SgurrEnergy for providing us with the opportunity to work with the
company in developing this product; it has been a worthwhile and enjoyable experience for all the
team members involved.
Secondly we would like to mention Brian Loudon, Andrew Wodehouse and Kepa Mendibil for
their support and supervision of the project. The team have certainly learnt a lot through their
input and guidance throughout their time as supervisor and we would like to take the time to
thank them for this support.
Thank You.
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3 Executive Summary
The project concerned the development of a robust solution to address the issues experienced
throughout the lidar installation process. The differentiating feature between this newly
developed product and the current solution would be the elimination of manual handling risks
associated with prolonged lifting of heavy objects, a key issue highlighted with the deployment of
a lidar on site.
This report outlines the key stages within the design and development of this product. The
research phase, the specification phase, the concept design phase, the detail design phase and the
manufacture phase of the product development process are all discussed within this report.
The research phase summarises some initial information surrounding the features associated
with the lidar, an overview of the installation process and an identification of key issues recurring
within this process. This is combined with other information gathered through research
techniques such as observational studies, where the operation of the current product was
analysed and an overview of other available technology was generated in order to identify key
technological features which could be incorporated into an innovative solution to solve the
defined problem with the installation process. The result produced help to further establish the
need for this project.
The specification phase provides a summary of all key research data and customer requirements
to provide a technical guidance for use in further development of conceptual ideas within the next
stage of the project.
The concept design phase starts at initial concept generation and progresses through to the
selection of a final solution for the defined problem area. This section is a combination of concept
generation, evaluation, prototyping, testing and validation techniques, utilised in an iterative
converging and diverging manner to ensure thorough exploration of conceptual ideas throughout
this phase of the project. Techniques such as brainstorming, force fitting, controlled-convergence
and weighting and ratings matrices were used to provide a key structured approach to this
essential and important stage of the project.
The detailed design phase utilises key engineering knowledge and principals and applies this in a
practical manner to ensure the functionality and integrity of the final design solution. Throughout
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this stage key design areas will also be highlighted and fulfilled, namely; corrosion resistance,
DFMA, safety and user assembly.
Finally the manufacture stage of the project outlines how the final concept design might be
manufactured with key consideration given to the client’s needs and capabilities. This also
includes information with regards to future recommendations, an overview of key business
implications and a detailed technical drawing pack.
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4 Contents
1 Statement of Academic Honesty........................................................................................................................1
2 Acknowledgements.................................................................................................................................................2
3 Executive Summary.................................................................................................................................................3
5 Project Overview................................................................................................................................................... 16
5.1 Galion Deployment ..................................................................................................................................... 16
6 Problem Definition............................................................................................................................................... 18
6.1 Project Aims................................................................................................................................................... 18
6.2 Project Objectives........................................................................................................................................ 18
6.3 Project Deliverables ................................................................................................................................... 18
6.4 Target Market ............................................................................................................................................... 19
6.4.1 SgurrEnergy......................................................................................................................................... 19
6.5 Constraints/ Legislation/ Regulations...............................................................................................19
6.6 Competitors ................................................................................................................................................... 20
6.7 Testing Methods........................................................................................................................................... 20
6.8 Key Stakeholders......................................................................................................................................... 21
6.9 Project Methodology.................................................................................................................................. 22
6.10 Summary......................................................................................................................................................... 22
7 Observational Visit to SgurrEnergy Workshop and Scene Capture from You Tube Video.....24
7.1 Aims ..................................................................................................................................................................24
7.2 Objectives........................................................................................................................................................24
7.3 Discussion and Outcomes ........................................................................................................................24
7.4 Reflection........................................................................................................................................................ 24
7.5 Summary.........................................................................................................................................................25
8 Manual handling Literature Review.............................................................................................................. 26
8.1 Aim..................................................................................................................................................................... 26
8.2 Scale of the Problem...................................................................................................................................26
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8.3 Hierarchy of Measures .............................................................................................................................. 27
8.3.2 Summary of Relevant General Principles ................................................................................28
8.3.3 Summary of risks and injuries associated with the lidar installation process.........28
8.3.4 Discussion of Risk Reduction – Solo and Team Lift............................................................. 29
8.4 Summary......................................................................................................................................................... 30
9 Technological Review.......................................................................................................................................... 32
9.1 Aims ..................................................................................................................................................................32
9.2 Objectives........................................................................................................................................................ 32
9.3 Outcomes & Discussion............................................................................................................................. 32
9.4 Reflection........................................................................................................................................................ 32
9.5 Summary......................................................................................................................................................... 33
10 Product Autopsy............................................................................................................................................... 34
10.1 Introduction................................................................................................................................................... 34
10.2 Aims ..................................................................................................................................................................34
10.3 Objectives........................................................................................................................................................ 34
10.4 Discussion....................................................................................................................................................... 34
10.5 Outcomes........................................................................................................................................................35
10.6 Reflection........................................................................................................................................................35
10.7 Summary......................................................................................................................................................... 36
11 Scale Model Prototyping................................................................................................................................ 37
11.1 Introduction................................................................................................................................................... 37
11.2 Aims ..................................................................................................................................................................37
11.3 Objectives........................................................................................................................................................ 37
11.4 Discussion....................................................................................................................................................... 37
11.5 Outcomes........................................................................................................................................................ 37
11.6 Reflection........................................................................................................................................................ 38
11.7 Summary......................................................................................................................................................... 38
12 Still Motion Capture – Identification of Issues..................................................................................... 39
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36.2.1 6.2.1 End-Result ...............................................................................................................................137
References .......................................................................................................................................................................139
37 Appendix 1 – Manual Handling Literature Review ..........................................................................140
37.1 General principles for reducing manual handling risks..............................................140
37.1.1 Defining area of focus.................................................................................................................140
37.1.2 Mechanical Assistance................................................................................................................141
37.1.3 Appropriate Steps.........................................................................................................................142
37.1.4 Summary of Relevant General Principles........................................................................143
37.2 Practical advice on assessing and reducing risks in manual handling................144
37.2.1 The Task - Risks.............................................................................................................................144
37.2.2 The Task – Reducing the Risk.................................................................................................147
37.2.3 The Load.............................................................................................................................................149
37.2.4 On the Environment and Individual Capability ...........................................................152
38 Appendix 2 – Product Autopsy.................................................................................................................153
38.1.1 Feature & Functions Discussion................................................................................................153
39 Appendix 3 – Product Design Specification Version 1....................................................................155
40 Appendix 4 – Brainstorming......................................................................................................................160
41 Appendix 5 – Force Fitting .........................................................................................................................164
41.1.1 Analogous Products.....................................................................................................................164
41.1.2 Abstract Products .........................................................................................................................168
41.2 Outcomes................................................................................................................................................174
41.2.1 Analagous Products.....................................................................................................................174
41.2.2 Abstract Products .........................................................................................................................175
42 Appendix 6 – Intuition Evaluation ..........................................................................................................179
42.1.1 Tank Tracks........................................................................................................................................179
42.1.2 Walking Leg........................................................................................................................................179
42.1.3 Wheelbarrow.....................................................................................................................................179
42.1.4 Forklift/Pallet Truck.......................................................................................................................179
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42.1.5 Scissor Lift...........................................................................................................................................179
42.1.6 Lifting/Pulling...................................................................................................................................179
42.1.7 Assorted...............................................................................................................................................179
43 Appendix 7 – Product Design Specification Version 7....................................................................180
1 Updated PDS..........................................................................................................................................................180
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5 Project Overview
SgurrEnergy is a leading independent engineering consultancy specialising in worldwide
renewable energy projects. They work from the early stages of site selection, feasibility and
design through to project management of the construction phase and operation and maintenance.
Their clients include private users, financiers, developers and many other public and private
sector organisations. They have the capability to deliver at every phase of a project, from the early
stages of site selection, feasibility and design right through to project management of the
construction phase and operation and maintenance. Their multi-disciplinary consultants have
extensive sustainable energy experience worldwide. To date they have assessed over 110GW of
renewable energy developments internationally and this figure is growing rapidly every month.
[1]
This project is concerned with the installation of SgurrEnergy Galion wind lidar anemometer.
SgurrEnergy use, rent and sell the Galion in the measurement of wind profiling, flow and complex
configurations associated with design and development of onshore and offshore wind farms. The
device is sophisticated, expensive and to a large degree fairly easy to deploy. The main difficulty
arises when deployment teams are faced with uneven ground or complex topography- moving
this around can be tricky unless a full team of staff and/or tracked plant/equipment is available.
The project will have a particular focus on the deployment of this equipment and this is discussed
further throughout this report.
5.1 Galion Deployment
The Galion is deployed across a range of environments, terrains and climates. The current
deployment process requires two technicians to deploy and setup both the power source and the
Galion lidar. Both pieces of equipment are shipped to the required location and transported by
lorry until they have reached their destination. Upon reaching this destination, technicians will
remove the power supply and lidar from the transportation lorry and begin moving both pieces
of equipment to their final setup position. This can be a great distance from where the equipment
is off-loaded from the transportation lorry and across rough, uneven terrain.
The movement of the Galion requires a combination of different frames which can be used in
conjunction with main body of anemometer. For helping with the movement of the Galion lidar
during deployment there are currently two frames which are used in conjunction with the lidar
to provide handles and lifting points for the technicians in the field; these are the original frame
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which accompanies the lidar and an additional, optional frame, which has recently been developed
and offered as an option for helping with deployment by SgurrEnergy.
The original frame, which is sold with the lidar, undergoes three key phases;
• Travel legs
• Small adjustable legs for deployment
• Adjustable legs of varying heights for use after deployment
The initial phase concerns the state in which the Galion is transported to the final destination
before deployment occurs.
SgurrEnergy want to explore a simple method of moving this around following unload from a
vehicle. A carrying frame has been commissioned to address some aspects of manual handling,
but a robust solution that will reduce the risk of injury, damage to the machine and make
deployment easier and quicker for technical staff is still required.
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6 Problem Definition
The current methods of deployment for the Galion lidar are awkward, time consuming and in
some cases can be dangerous for the staff and the safety of the Galion itself. This is because of the
Galion’s weight and size which can be difficult to carry, the terrain adds to these difficulties being
unpredictable, unstable and uneven.
The challenge for the team is therefore to perform a complete review of the installation process,
with a focus on ergonomics and flexibility. Subsequently generating a number of concepts that
will improve the installation process and tackle the issues mentioned above. Once a concept has
been chosen in conjunction with SgurrEnergy for further development, this will result in a fully
functional prototype capable of significantly reducing the risk to the staff and the Galion lidar
throughout the installation process.
6.1 Project Aims
Four main aims have been identified for this project and are outlined below;
1. To design a product that will enable Sgurr employee’s easy and safe transportation of the
Galion Lidar.
2. To design a product that is viable and profitable to the business.
3. To design a product that is easily and cost effectively manufacturable.
4. To create a fully functional prototype to prove the project success through testing.
6.2 Project Objectives
The main objectives for this project, with a key focus being placed on reducing the manual
handling risks associated with the deployment process are;
1. Review the cliental and business strategy of SgurrEnergy.
2. Review of installation process, with ergonomic issues highlighted, and an environmental
review of the average installation.
3. Design a set of concepts for handling and installation of Galion.
4. Prototyping and testing of concept.
6.3 Project Deliverables
The main deliverables for the client and the project have been identified as;
1. A4 project report detailing solution, process and business case against original project
objectives.
2. A3 folio, including technical drawing pack.
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3. Working Prototype.
4. Presentation of the project outcome at the Industrial Project Presentation day 2nd of May.
6.4 Target Market
The target market is detailed below in relation to SgurrEnergy and how this project may affect
future sales in relation to their clientele.
6.4.1 SgurrEnergy
SgurrEnergy use the Galion lidar to suggest where to place wind turbines and assess the wind flow
in a certain areas. They may use this product themselves, or rent and sell to other companies that
would use this product. Therefore there is a small diversity in which this product is used as it is
specialised product. Some of the key clients for the developed product will be;
• Engineering Company
• SgurrEnergy’s Clients
• Tertiary Market, construction
6.5 Constraints/ Legislation/ Regulations
Some of the main constraints surrounding this project are detailed in the following section.
3.5.1. Constraints:
Because this project is University lead, it means that there are certain constraints on the outcome.
The budget given from the client is substantial enough to produce a final working prototype,
although there will be a low number of iterations of this design due to time constraints. Lab
technicians and University staff will be required to help manufacture prototypes for the project,
therefore they also have their own schedule and deadlines to meet. The time constraints will also
have an impact on the research section of the project. 1st hand research should be gathered on the
terrain and use of the Galion lidar, but an in-depth business review is not necessary, a brief
overview shall suffice for this project. The reason is that this project is a specialised, non-
commercial product that will be used by SgurrEnergy and their clients.
3.5.2. Legislation:
There are a number of health and safety regulations and legislation that must be adhered to in
order for the product to be suitable for use.
• Lifting Operations and Lifting Equipment Regulations 1998 (LOLER)
• Provision and Use of Work Equipment Regulations (PUWER)
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Future work will detail the legislation constraints on the product through an in-depth literature
review in section 8. [2]
6.6 Competitors
SgurrEnergy currently use a very basic frame with handles to carry the Galion for deployment.
The current method can be seen below, and is the benchmark that this project should aim to
improve upon.
The frame is very basic and is difficult to use, as it can be awkward to navigate terrain with. This
is because the handles still offer little room for the arms to move and the lifting puts strain on the
back. As a team we believe there is a better solution to this problem, and this project aims to
discover test and validate this idea. With the help of SgurrEnergy and the University of Strathclyde
a suitable solution will be generated to aid in the deployment of the Galion lidar.
6.7 Testing Methods
The testing methods outlined below will be implemented throughout the project and will be key
in the final success and validation of any idea/solution generated as a result of this project;
• Test the product mechanisms with simulation environments in the labs or elsewhere.
Carrying out the assembly process to assess the reliability and robustness of the project.
• Simulate lidar implementation scenario, with SgurrEnergy employees testing the concept.
Rating concepts for further development.
Appropriate risk assessment and ethics approval will be performed for these testing methods.
Figure 1: Current Carrying Frame
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6.8 Key Stakeholders
The Key Stakeholders can be seen below:
• SgurrEnergy
• SgurrEnergy Staff
• SgurrEnergy’s Clients
• Home Owners Using Energy Supplies
• Farm Owners
• Strathclyde Team 19
The main Stakeholder is SgurrEnergy as they are the company commissioning the project. There
are several other stakeholders that will be affected by the resulting product, mainly the staff from
SgurrEnergy that carry and deploy the Galion lidar. The product will hopefully make their job
easier and decrease the risk of injury during deployment. Other stakeholders such as the home
owners and farm owners on/near the deployment sites of Galion will be affected due to the
increased efficiency of the deployment of the Galion. The faster this can be achieved the more
scope there is to increase productivity and the use of renewable wind energy.
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6.9 Project Methodology
The project methodology that is chosen for this project is an adaption of Pugh’s from Total Design
[3].
The methodology is an adaptation of
Pugh’s. The main focus is on the
concept design phase which ensures a
fully developed and suitable final
outcome. There are phases of
convergence and diverging scope to
enable suitable amount of
development. An initial brainstorming
exercises will create a wide variety of
less detailed concepts that will then be
narrowed down through further
research. Detailed and structured
generation tools will then be used to
create more detailed concepts to be
evaluated through dot sticking. To
further develop and understand the
concepts quick prototyping will be
carried out and evaluated. This should
result in a final concept that detail design will be applied to and a product will be ready for
manufacturing. DFX’s will be applied thorough the process as it is central to good design.
The methodology as a whole suits this project as it is structured tending towards a more
mechanical project. Pugh’s structure will help the team stick to a structure, and ensure that
deadlines are met. This is something that less structured methodologies tend not to do, they do
not suit team work because the team can get distracted from the critical path of the project.
6.10 Summary
A number of key conclusions were drawn from the initial outlining of the project. The project
brief was agreed and defined the problem as:
“The current methods of deployment for the Galion lidar are awkward, time consuming and in
some cases can be dangerous for the staff and the safety of the Galion itself. This is because of the
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Galion’s weight and size which can be difficult to carry, the terrain adds to these difficulties being
unpredictable, unstable and uneven.
The challenge for the team is therefore to perform a complete review of the installation process,
with a focus on ergonomics and flexibility. Subsequently generating a number of concepts that
will improve the installation process and tackle the issues mentioned above. Once concept will be
chosen in conjunction with SgurrEnergy for further development, which will result in a fully
functional prototype.”
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7 Observational Visit to SgurrEnergy Workshop and
Scene Capture from You Tube Video
This section discusses the process and issues arising from the deployment of the Galion, identified
during a visit to the SgurrEnergy workshop and also through analysis of a SgurrEnergy
promotional video showcasing the Galion lidar (currently available through You Tube) [4]. These
activities are illustrated and discussed on pages 10-15 of the supporting folio.
7.1 Aims
The aim was to gather a detailed understanding of the deployment process and the issues
surrounding the particular areas of the process.
7.2 Objectives
The objectives for this section of the project were;
• Outline the full process of deployment for the Galion lidar from workshop to workshop.
• Identify the key issues with regards to the movement of the lidar and in particular health
and safety issues surrounding manual handling in the project specific context.
7.3 Discussion and Outcomes
The discussion and observation which occurred between the design team and the client during
the workshop visit is discussed and illustrated at length on pages 10-15 of the folio and
subsequent outcomes and conclusions have a particular significance and are discussed further in
the function means tree section of this report, which follows later.
7.4 Reflection
Overall the conclusions reached from the completion of these activities and the advice gained from
the client was invaluable to the project. Without this information it would have been impossible to
picture or fully understand the process, the size of the product and the scale, in terms of lifting
requirements and distances covered while carrying the lidar.
The only negative reflection occurring from these activities was the regret associated with not being
able to arrange the workshop visit sooner. This was mainly due to client and team commitments
which led to having to postpone the visit a couple of times. If the team were to repeat the project it
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would have been more beneficial to organise a visit before starting in order to ensure the first
meetings were more fruitful in terms of lessons learnt and progress being made.
7.5 Summary
An observational visit to the SgurrEnergy workshop was conducted to investigate and visualise
the deployment process associated with the Galion lidar. This is illustrated throughout the
research section of the folio and accompanied by a storyboard, which was taken from a company
promotional video. Through completing these activities the team were able to firmly establish the
stages within the deployment process and gather detailed information with regards to key issues
arising within the process which were related to injuries occurring through manual handling.
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8 Manual handling Literature Review
The current design project with SugrrEnergy is not in direct response to any previous manual
handling injuries, though this has been identified as an area of concern. The complete literature
review is available for viewing in Appendix 1 and examines literature from the UK Health and
Safety Executive, specifically: “Manual Handling Operations 1992”. This literature gives general
guidance on the Manual Handling Operations Regulations 1992 [10], as amended by the Health
and Safety Regulations 20021 (‘the Regulations’).
8.1 Aim
The aim of this literature review is to identify any relevant Manual Handling regulations which
might impact the design project. It is understood that not all of the literature within these
regulations will have relevance to the current project; the appropriate sections are identified and
reflected upon throughout this section.
The design team feels that, although only one source has been used, the Health and Safety
Executive is a sufficiently reliable source from which to draw conclusions and make assumptions
which can impact the direction of the design project. The sheer volume of relevant information
cannot be dismissed due to a lack of corroborating sources.
8.2 Scale of the Problem
The most recent survey of self-reported work related illness estimated that 1.1 million people in
Britain suffered from musculoskeletal disorders (MSDs) in 2001/2002 (correct as of 2004),
including those caused by manual handling. These account for around half of all work-related ill
health. As a result of MSDs an estimated 12.3 million working days were lost in that year. In
1995/96, MSDs cost society £5.7 billion. With specific regard given to the risk of MSDs, the key
messages from this literature are that:
• There are things that can be done to prevent or minimise MSDs;
• The prevention measures are cost effective;
• You cannot prevent all MSDs, so early reporting of symptoms and proper treatment and
suitable rehabilitation is essential.
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The first two of these points are particularly relevant. By investing in preventative measures now,
SgurrEnergy can save themselves money in the future. This literature will help to both assess risks
and explore how those risks might be reduced or eliminated.
8.3 Hierarchy of Measures
The Manual Handling Regulations establish a clear hierarchy of measures:
a) Avoid hazardous manual handling operations so far as is reasonably practicable. This
may be done by redesigning the task to avoid moving the load or by automating or
mechanising the process.
b) Make a suitable and sufficient assessment of any hazardous manual handling operations
that cannot be avoided.
c) Reduce the risk of injury from those operations so far as is reasonably practicable.
Where possible, mechanical assistance should be provided, for example, a sack trolley or
hoist. Where this is not reasonably practicable then changes to the task, the load and the
working environment should be explored.
8.3.1.1 Discussion
Considering point a), the current manual handling process, that is the movement of the Galion LIDAR
to its deployment position, cannot be avoided. This is a necessary activity which is considered to be a
fixed constraint within the project. Automation or mechanisation of the process should be considered
during the concept generation stage.
Considering point b), the design team understands that the deployment process cannot be avoided.
The regulations recommend that an employer make a “suitable and sufficient assessment” of
unavoidable operations. The design team can adapt this regulation for use during the design project.
The current deployment process will be thoroughly assessed and examined so that the current risks
and requirements may be fully understood. A full understanding of the current situation should allow
the team to develop a comprehensive and effective design solution.
Considering point c), this point mirrors the established aims and objectives of the project. Solutions
which incorporate mechanical advantage should be explored in the concept generation phase. It is
not expected that changes to the “task, the load and the working environment” should be feasible.
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8.3.2 Summary of Relevant General Principles
The Manual Handling Operations Regulations has outlined some general principles for the
reduction of manual handling risks. Those principles which are relevant to this design project are:
• It is deemed likely that the load and an individual’s capability will be the most
important factors associated with the reduction of manual handling risk. This is due to
the changing environment associated with global outdoor deployment.
o In addition to these two factors, the task and the working environment must also
be considered. While it is less likely that improvements can be made to these two
factors in this situation it is important that they not be neglected.
• The literature emphasises the importance and effectiveness of manual assistance and
manual handling aids. This will likely be a driving factor behind the direction of the
team’s concept generation process.
• The design team will carry out a technology review to fully explore all existing manual
handling aids.
• A recommendation will be made to SgurrEnergy to include any new handling aids or
protective equipment in a planned preventive maintenance programme.
8.3.3 Summary of risks and injuries associated with the lidar installation process
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Table 1
8.3.4 Discussion of Risk Reduction – Solo and Team Lift
Despite the fact that earlier parts of the literature encouraged a focus on the load and the
individual’s capabilities it has proved to be useful to examine the task itself. The literature
Risk Problem Area Potential Injury
Distance of load
from body
Removing LIDAR from
vehicle
Increased stress on back as distance
of load from body increases
Twisting of body
during task
Carrying LIDAR using small
handles – twisting while
walking
Increased stress on back when
manual handling is carried out with
twisted body. Stress increases
further when lifting a load
Stooping Picking up and placing the
LIDAR down
Stress on lower back increases
when handler bends over or leans
forward with the back straight. The
weight of the upper body is added to
the weight of the load being handled
Considerable lifting
or lowering
distances
Picking up and placing the
LIDAR down
Lifts over a great distance tend to
require a change in grip which can
increase the chance of various
injuries. Considerable lowering
distances increase the chance of
stooping injuries
Considerable
carrying distances
The deployment process
inherently involves
considerable walking
distances in some instances
Prolonged physical stress associated
with long moving distances
increases fatigue and the risk of
injury. For distances > 10m the
fatigue caused by the distance
becomes more prominent than the
risk of injury from raising and
lowering
Considerable
pushing or pulling of
the load
Not currently an issue Various possible injuries, primarily
to the back, neck or shoulders.
Entrapment injuries are also
common
Combination of
several risk factors
Several issues have been
identified
The effect of a combination of risks
can be worse than the simple
addition of their affects might
suggest. Individual capability is
greatly reduced when stooping is
combined with twisting or
stretching
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distinguishes between solo and team-handling tasks. The following table summarises the insights
gained from this section of the manual handling regulations:
8.4 Summary
This summary of the manual handling regulations will conclude the literature review. It is
expected that the literature review will be ongoing throughout the project and will require
adaptation and addition as the design team explores new transport methods.
Solo / Team Risk Solution
Solo Back pain Alter the task to take advantage of leg
muscles rather than back muscles
Solo Back pain Replace lifting with controlled pushing
or pulling
Team Team members getting in each
other’s line of sight or
obstructing each other’s
movements
Ensure sufficient space around the load
for safe movement. Also allow adequate
access to the load
Team The load may not have enough
good handholds
Provide a sufficient number of
handholds – ensure correct size and
positioning
Team Lack of clear communication,
perhaps due to loud background
noise
One person should plan and take charge
whilst still ensuring good back and forth
communication
Key Findings
The design team has found that alterations to the task or the load could potentially be the
most effective toward the goal of reducing manual handling risks. Notably the environment is
out of the control of the design team and varies between deployments and cannot be altered
as the guidelines suggest.
The design team should pursue mechanical assistance solutions
The design team will carry out a comprehensive technology review to explore all relevant
mechanical assistance solutions
Not only will the design team have to test and assess their design, SgurrEnergy will also have
to carry out testing to ensure that the risk of injury is being reduced. A recommendation will
be made at the end of the project in this vein
The severity of physical stress caused by prolonged lifting is greater than the severity of
stress caused by periodical heavy lifting
Replacing lifting with pushing or pulling could provide a dramatic reduction in risk
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There are distinct differences between solo handling and team handling: manoeuvrability,
line of sight and communication are vitally important for team handling
Size and weight cannot be changed, but must be considered especially with regards to the
additional weight created by a new frame design – this will impact lifting procedures
Making the load easier to grasp seems to be the most effective way to improve transport and
will be a key focus for the project
Any new design will be conscious of the interaction between frame elements and handlers –
sharp features or any features which could negatively affect posture will be avoided
Personal protection equipment may be necessary depending on the design solution
The environment and personal capability cannot be altered by the design team and thus offer
no new insights.
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9 Technological Review
This section includes a review into existing products that utilise technologies with the specific
purpose of manoeuvring equipment over a wide range of terrains; marsh, gravel, soil, water, sand,
etc. Amongst the researched and reviewed technologies a focus has been placed on several
products that have been developed and marketed as specifically fit for purpose on rough and
varied terrain.
9.1 Aims
The aim of completing this review was to enable the widest range of knowledge accessible on
existing equipment and technologies currently available for manoeuvring equipment over
terrains to be gained for use within the project.
9.2 Objectives
• Carry out an extensive technological review on current technologies that could be applied
to this problem.
• Summarise the technological review in a table for comparisons.
9.3 Outcomes & Discussion
This technology review has been considered as a dynamic document in relation to the project,
having started in the early stages for inspirational purposes when generating concepts. The
review has been continually improved upon and expanded to include the widest variety of
equipment and technologies available for use. References to equipment and technologies revealed
by the technology review can be found throughout the design project
This can be seen on Folio Pages 16-17, technologies researched have been summarised into a
table.
9.4 Reflection
It is felt by the team as a whole that the completion of this technology review helped to increase our
knowledge on the types of equipment and technologies available for manoeuvring equipment of any
size and weight.
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By continually referring to the review throughout the research and generation stages it is felt by the
team that the research has enabled us to create a wider variety of concepts than possible without the
gaining of this knowledge.
By treating the review as a dynamic document, continually referring to it and updating it as the
project progresses we are ensuring that the most up-to-date and relevant technologies have been
included in the project; offering our client the best suited possible solution to their problems.
9.5 Summary
Through the use of pre-existing knowledge, online journals, published books, and results obtained
from internet search engines, a review into existing products that utilise technologies with the
specific purpose of allowing for equipment to be manoeuvred over a wide range of terrains was
performed. Within the review a focus has been placed on products that have been developed and
marketed as specifically fit for purpose on rough and varied terrain. This technology review has
been performed in an aid to enhance the knowledge on existing equipment and technologies
currently available for manoeuvring equipment over terrains. This knowledge will in turn be
utilised within the project to ensure an appropriate solution is found. Results obtained from the
performing of this task have been summarised into a table for the readers viewing.
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35. Team 19 SgurrEnergy 2014
10 Product Autopsy
In order to effectively generate concepts, it is important to understand what features and
functions the Galion lidar has. The product autopsy research method was used as a means of
improving the team’s knowledge of the Galion lidar product.
10.1 Introduction
The product autopsy research method is a simple method which involves breaking down a
product into its various features and functions and discussing them to improve knowledge of the
product. The method is commonly used to build knowledge of how a product is constructed, what
internal components it has, and also to identify flaws in the design and areas for improvement.
As the team did not have regular access to the product, the product autopsy had to be conducted
without the product at hand. The product autopsy was conducted with the use of the technical
drawings provided by SgurrEnergy, 3D CAD models created using the technical drawings, videos
of the product being deployed and images from the warehouse visit.
10.2 Aims
The aim was to improve overall knowledge of the Galion lidar product by discussing its features
and functions with the aid of annotated images.
10.3 Objectives
The main objectives for this research activity were;
• Create a CAD model of the Galion LIDAR using the technical drawings and videos found
during previous research.
• Use the CAD model of the Galion LIDAR to create annotated images of the Galion LIDAR’s
features and functions.
• Discuss the identified features and functions.
10.4 Discussion
The following section summarises how each of the above objectives were met. The outcome of
this research activity are shown on pages 18-21 of the folio and further information on the key
features identified is available in Appendix 3.
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10.5 Outcomes
The main outcome is the increased knowledge of the product. By establishing better knowledge,
concept generation will be more effective. A secondary outcome which is also very important is
the clear descriptions of the Galion lidar’s functions and features which can be shown to anyone
who assists in collaborative design methods such as dot sticking.
10.6 Reflection
The use of this method proved to be very beneficial for everyone in the team as it helped us
understand why the product has been designed in the way it has. The ability to manipulate a 3D CAD
model of the product was just as beneficial as the written discussion of the product because it could
be looked at from multiple angles.
It would have helped to have access to the product at the time of conducting this method, as we would
have been able to discover many more functions and features which simply are not included on the
existing images, videos and technical drawings.
Feature Function
Main Body Contains the internal components of the product and provides
them with protection from the elements and collisions during
transportation and deployment.
Lidar Lens This part of the product fulfils the main function of the product
which is to analyse wind profiles.
Cleaning Station The cleaning brush and washer allow the lens to be cleaned
autonomously.
Carry Handles The product features two carry handles on either side of the
product. These are to allow two people to carry the product from
a vehicle.
Support Legs Each leg features a levelling foot which can rotate to facilitate
deployment on uneven surfaces.
Adjustable Support Leg
Clamps
The support leg clamps secure the support legs to the main body.
Transport Legs The transport legs are only intended for supporting the product
during transportation and are made out of rubber to dampen any
vibrations experienced during transportation.
SgurrEnergy Aftermarket
Carry Handles
This frame was designed by SgurrEnergy to simplify the
deployment process.
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37. Team 19 SgurrEnergy 2014
10.7 Summary
Product autopsy was used to improve the team’s knowledge of the Galion LIDAR product. The
autopsy was conducted by initially creating a 3D CAD model of the product, then making images
of the CAD model, showing individual product features. The following features were identified:
The main body, LIDAR lens, cleaning station, carry handles, support legs, adjustable support leg
clamps, transport legs and aftermarket carry handles. The functions of each of these features were
then discussed to understand the importance of each feature.
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38. Team 19 SgurrEnergy 2014
11 Scale Model Prototyping
Two scale models of the Galion LIDAR product were made to assist in research efforts and in
concept development prototyping, the prototypes was created using 3D printing technology and
using workshop materials.
11.1 Introduction
Scale models were seen a very beneficial resource to the project as they would assist numerous
research and concept development activities. Two scale prototypes were made, one was 1:6 scale
and the other was full scale.
11.2 Aims
The main aim of this activity was to create a small scale model of the Galion LIDAR product which
can be used during research and concept development. A second aim was set to produce a 1:1
scale model of the lidar and this will be used in testing and validation phases which are discussed
at a later stage.
11.3 Objectives
The main objectives identified for this activity were;
• Use the CAD model generated during the product autopsy activity to create the
necessary files to rapid prototype the product.
• Rapid prototype the product using the 3D printer available to the team.
• Construct a full scale prototype using materials available in the workshop.
11.4 Discussion
The outcome of the scale prototyping of the lidar is shown extensively on pages 22-23 of the folio
with key features highlighted for clarity and understanding of the product and specific features
which may be of relevance to conceptual design ideas.
11.5 Outcomes
The outcomes of this activity where used to aid research and concept development.
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39. Team 19 SgurrEnergy 2014
11.6 Reflection
Creating both scale models of the Galion lidar has been very beneficial to the project. The small scale
model can be used for a vast number of activities from researching manual handling problems to
allowing us to build prototypes around.
The large scale model took longer than expected to make, however it will allow us to understand the
challenges of lifting and manoeuvring the product. The large scale model could also be used to model
more developed prototypes when we are closer to a fully developed concept towards the end of the
project.
11.7 Summary
Two models of the Galion lidar were made to assist in research and concept development, one was
produced in 1:6 scale using 3D printing technology and one was produced in full scale using wood
and cardboard. The 1:6 scale model allowed the team to conduct a still motion capture activity at
an early stage of the project, this is discussed in the following section of the report.
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40. Team 19 SgurrEnergy 2014
12 Still Motion Capture – Identification of Issues
Still motion capture was used as a means of identifying and highlighting issues when moving and
lifting the Galion lidar product, two 1:6 scale manikins and the 1:6 scale model of the Galion lidar
product were used in this activity.
12.1 Introduction
Still motion capture was a very useful research method as it provided an opportunity to identify
problems and had the potential to identify the causes of problems. It was used in this project
along with scale manikins and a scale model of the Galion lidar product. By manipulating the
manikins into typical body positions when handling the Galion lidar.
12.2 Aims
The aim of this activity is to place scale manikins into positions showing them handling the Galion
LIDAR and take still photographs which could be used to highlight problems and potential causes
of problems.
12.3 Objectives
The main objectives for this activity were defined as;
• Put the scale manikins in a range of positions which a handler could be put in during
deployment of the Galion LIDAR product.
• Take a range of still photographs of the manikins.
• Use Photoshop to highlight problems such as back rotations in the manikins.
12.4 Discussion
The manikins were put into a range of positions along with the Galion LIDAR product, including
the following:
• The various stages of lifting the product
• Walking with the product
• Turning with the product
When in these positions photographs were taken from a pre-set angle maintained through the use
of a tripod and also from other angles which were better for highlighting specific problems.
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41. Team 19 SgurrEnergy 2014
Photoshop was used to highlight problems such as back rotations on the manikins and to highlight
difficult and awkward positions when lifting, walking and turning with the product. The causes of
problems were also highlighted, such as the height of handles, and the distance from the Galion
LIDAR product when lifting.
12.5 Outcomes
The outcome of this activity was a range of images showing various problems and causes of
problems, these are shown on folio page 23 with discussion being made on the individual
problems identified.
12.6 Reflection
In reflection this activity was very beneficial to the progress in the project. As we did not have access
to the Galion LIDAR product or have a full scale prototype at the time of conducting this task, we
were able to identify a range of problems and problem causes at an early stage of the project. Without
this information, it would have been hard to conduct focused research on the problems identified and
also hard to effectively generate concepts.
The experience the team has gained from conducting this activity will be beneficial for conducting
similar activities during concept evaluation and development.
12.7 Summary
The team used still motion capture to identify problems and the potential causes of problems
when lifting and manoeuvring the Galion LIDAR product. Scale manikins and a scale model of the
Galion LIDAR product were positioned together, photographed and then edited using Photoshop
to highlight problems or problem causes. The outcome of this activity was a range of images
showing these problems and causes.
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42. Team 19 SgurrEnergy 2014
13 Product Design Specification
After the completion of an extensive research phase and product design specification (PDS) was
established to outline the key customer requirements in relation to the lidar installation process,
with specific focus on issues and problems which have been highlighted to this point within the
project. The PDS is included in Appendix 3.
Some of the most important specification points have been highlighted below;
• The product must not impact the lens that sits on-top of the main body. This part sits 232
mm above the main body.
• The product must not interfere with the small rubber legs on the bottom of the LIDAR as
they are fixed and used in transit.
• The product must not cover the auxiliary air cooler on the side of the LIDAR and must
provide suitable ground clearance for the fans and air intakes on the bottom.
• Ideally the product leaves room for the PSU to be placed underneath the LIDAR.
• The product must withstand heat changes of at least -30°C to +40°C. Norway is the
lowest temperature experienced.
• The product must be resistant to a variety of weather conditions, from the rain and
cold, to dry heat and dust of the desserts.
• The product must be able to be in a compact state that would fit inside a car for
transportation to the site. Often a Land Rover or a Van.
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43. Team 19 SgurrEnergy 2014
14 Concept Generation
14.1 Introduction
Beginning the concept generation stage, the team have made several adaptions and amendments
to the projects methodology as work has progressed; an amended version of the methodology can
be found detailed below:
Amended Project Methodology
14.2 Discussion
As can be seen in Figure above the concept generation phase began with brainstorming. This
technique was completed to allow the initial creation of a vast range of concepts utilising
information and design ideas from past experiences and preferences. Following on from this the
technique of force fitting was utilised, this technique was chosen as it worked well with the
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44. Team 19 SgurrEnergy 2014
creation of manual handling problems, allowing the creation of both abstract and analogous
solutions. In an effort to reduce the number of concepts, which exceeded 100, duplicate concepts
were removed using design intuition, bizarre unviable concepts were also removed at this point.
The amended concepts were then evaluated through dot sticking, this method allowed concepts
to be assessed on their specific functional uses allowing for detailed considerations surrounding
the manufacture of different design concepts. Further concept generation was conducted to the
same high standard by completing a morphological chart with each potential function of a
conceptual idea highlighted in detail. More in-depth discussion of the individual concept
generation tools follow on from this section.
14.3 Reflection
By following this methodology it will help ensure that concepts are completed to the level of detail
required with regards to the relevant design stage. Continually diverging and converging the number
of concepts being generated/refined at specific stages within the design process, enables the team to
include concepts with the newest and most relevant information and technologies available to the
project.
The team’s decision to adapt and amend our original methodology was made in accordance to the
following rational;
The technique of force fitting was utilised at an earlier stage because it provided the most stimulation
for idea generation, something we as a team decided was most important at the early stages.
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45. Team 19 SgurrEnergy 2014
15 Brainstorming
32 Concepts were generated through unstructured brainstorming. This was conducted
on an individual basis and the output was combined in in a later design meeting.
15.1 Introduction
To provide a good base of concepts to build upon, brainstorming was conducted. This
consisted of each team member drawing 5 concepts, with no structure or limits to what
they may draw. No further development of the problem was needed for this stage of
concept generation as each team member already possessed a good level of basic problem
understanding which was necessary for concepts concept generation at this stage.
15.2 Aims
The aims of this brainstorming exercise were:
• To ensure that everyone had a basic knowledge of the problem, to generate
concepts you first must understand the problem.
• To give a base or foundation of ideas that would get the entire team thinking and
discussing possible solutions.
• Get the team in the correct mind frame to go further and participate in more
structured and developed concept generation tools.
15.3 Objectives
The objectives of this brainstorming exercise were:
• Design 5 concepts each for discussion so that a foundation of concepts was
generated for the team to move forward with.
• Discuss the concepts and look at them in-depth to ensure each member fully
understands what has been achieved.
• Use the concepts for positive progress, rather than simply generate them without
any facilitated discussion.
15.4 Discussion
There were several limitations to this exercise, mainly that the lack of structure gave little
guidance to team members to generate feasible and innovative ideas. However, one may
look at this from another point highlighting that with no structure, and no constraints the
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46. Team 19 SgurrEnergy 2014
brainstorming exercise gave the team the ability to think outside the box and not limit
emerging ideas to a set of rules and regulations. The brainstorming was conducted on an
individual basis, which may hinder an expansion of ideas during the generation process
through discussions. However, to combat this the team discussed and explained each
concepts, facilitating that helpful discussion that can be used to develop the concepts.
15.5 Outcomes
The outcomes can be seen on page 28-29 of the folio. Each person developed around 5
concepts therefore creating a total of 32 concepts. More detailed explanations of each
concept are included in Appendix 4 for more clarity and understanding which may not be
apparent through the images and descriptions supplied in the folio.
15.6 Reflections
Several conclusions can be drawn from this exercise, there were a number of repeated
concepts, which indicates that it is difficult to create a variety of concepts for this project
without the aid of structured generation methods. This subsequently means that duplicate
concepts should be removed.
More structured generation tools should be used to ensure that the team is as innovative and
creative as possible. Although the brainstorming did give a good basis to work on the next
step in project was to begin more detailed and structured generation tools. In order to
achieve this force fitting was planned, which would force the team to ‘think outside the box’
and create innovative concepts.
15.7 Summary
Brainstorming was conducted in order to generate 32 basic concepts. This gave a
foundation of ideas which could be built and developed throughout the progression of the
project. Duplicate concepts and concepts deemed to be unviable were removed through
a process of design intuition. This was a valuable exercise provoked deeper thinking
about the problem and it will complement the following activity of force fitting well.
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47. Team 19 SgurrEnergy 2014
16 Force Fitting
On completion of the initial brainstorming activity and discussion of the generated concepts it was
felt that the project required a further concept generation phase. It was hoped this second phase
would further expand and diverge the concept generation.
This section outlines the force fitting stage within the plan for concept generation development.
This is the second stage of concept generation conducted within this project.
16.1 Introduction to the Force Fitting Method
This method takes basic objects, like a child’s toy screwdriver, and allows the designer to imagine
how different features and characteristics could be incorporated into the conceptual product.
This method is therefore very successful in enabling ‘out-of-the-box’ thinking.
The exercise was conducted in two sections, analogous products and abstract products, with each
product image utilised in both of those categories being allocated 5 minutes to allow each member
of the team to develop a rough conceptual idea relating to a specific feature or function related to
the analogous or abstract product.
Fast generation of numerous early conceptual ideas may be vague, address different issues at
varying stages of the deployment process or they may also not be feasibly possible.
16.2 Aims
The main aim of this activity was to use existing technology, as previously identified through the
literature review and technology reviews within the research stage of the project to help generate
solutions to the identified problems with the lidar deployment and installation process.
16.3 Objectives
The main objectives for this activity were;
• Identify solutions to various problems at different stages throughout the deployment
process.
• Generate 5 possible solutions for each image used within the force fitting activity.
• Evaluate existing technology and its suitability with regards to the specific problems
identified within the Lidar deployment process.
• Evaluate the generated conceptual ideas to ensure feasibility.
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