Exercise Device

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This is my team\'s final presentation to our Introduction of Mechanical Engineering Design, Innovation, and Entrepreneurship course at Purdue University. The task was to develop a unique workout device.

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Exercise Device

  1. 1. Peak Performance Engineering
  2. 2. Problem Statement <ul><li>Create Compact Total Body Workout Equipment That Provides Both: </li></ul><ul><li>Cardiovascular Workout </li></ul><ul><ul><ul><ul><ul><li>Weight Loss / Fat Burning </li></ul></ul></ul></ul></ul><ul><li>Strength Training </li></ul><ul><ul><ul><ul><ul><li>Muscle Toning / Muscle Building </li></ul></ul></ul></ul></ul>Peak Performance Engineering
  3. 3. Problem Statement (Redefined) <ul><li>Create Compact Total Body Workout Equipment That Provides Both: </li></ul><ul><li>Upper Body Strength Training Capabilities </li></ul><ul><ul><ul><ul><ul><li>Muscle Toning / Muscle Building </li></ul></ul></ul></ul></ul><ul><li>Lower Body Strength Training Capabilities </li></ul><ul><ul><ul><ul><ul><li>Muscle Toning / Muscle Building </li></ul></ul></ul></ul></ul>Peak Performance Engineering
  4. 4. Market Research Peak Performance Engineering Product Type Retail Sales Percentage of Sales Aerobic Riders $25,000,000 0.66% Aerobic Steps $5,000,000 0.13% Cross-Country Ski Machines $50,000,000 1.34% Elliptical Trainers $600,000,000 16.04% Free Weights $130,000,000 3.48% Home Gyms $540,000,000 14.44% Rowing Machines $5,000,000 0.13% Stair-Climbing Machines $180,000,000 4.81% Stationary Exercise Bicycles $360,000,000 9.63% Treadmills $1,650,000,000 44.12% Weight Benches $195,000,000 5.21% Total $3,740,000,000 100%
  5. 5. Market Research Peak Performance Engineering
  6. 6. Market Research Peak Performance Engineering
  7. 7. Customer Requirements Peak Performance Engineering HOQ
  8. 8. Engineering Requirements Peak Performance Engineering HOQ
  9. 9. Operational Description Peak Performance Engineering
  10. 10. Operational Description Peak Performance Engineering
  11. 11. Operational Description Peak Performance Engineering
  12. 12. Operational Description Peak Performance Engineering
  13. 13. Operational Description Peak Performance Engineering
  14. 14. Operational Description Peak Performance Engineering
  15. 15. Operational Description Peak Performance Engineering
  16. 16. Individual Parts <ul><li>½” plywood cut to size </li></ul><ul><li>Padding & cover </li></ul><ul><li>Polypropylene straps </li></ul><ul><li>Aluminum sheet metal bent to desired shape </li></ul><ul><li>Locating guides for pulleys welded to inside </li></ul><ul><li>of box, with pulleys on </li></ul><ul><li>Cable tie-off welded to outside of box </li></ul><ul><li>Positioning hanger with locating hole welded </li></ul><ul><li>to top of box </li></ul>Peak Performance Engineering
  17. 17. Individual Parts <ul><li>Nylon 6/6 reinforced with glass fibers </li></ul><ul><li>Material injection molded to create part </li></ul><ul><li>Nylon 6/6 reinforced with glass fibers </li></ul><ul><li>Material injection molded to create part </li></ul><ul><li>Rubber attached at end for sealing purposes </li></ul>Peak Performance Engineering
  18. 18. Individual Parts <ul><li>Square aluminum tubing </li></ul><ul><li>Holes drilled and ends bent </li></ul><ul><li>for attachment to Resistance Box </li></ul><ul><li>Aluminum sheet metal </li></ul><ul><li>Bent to desired shape </li></ul><ul><li>Slots machined on sides for cable </li></ul><ul><li>Holes machined on end for buttons </li></ul><ul><li>Holes drilled for attachments </li></ul>Peak Performance Engineering
  19. 19. Bill of Materials
  20. 20. Performance Analysis <ul><li>Engineering Models </li></ul><ul><ul><li>Piston-Cylinder Model </li></ul></ul><ul><ul><li>Pulley-Weight System </li></ul></ul><ul><ul><li>Spring System </li></ul></ul><ul><ul><li>Exercise Wheel Design </li></ul></ul>
  21. 21. Piston-Cylinder Model <ul><li>Resistance generated by vacuum. </li></ul><ul><li>Force is constant at absolute vacuum. </li></ul><ul><li>Vacuum maintained by vacuum seal. </li></ul><ul><li>Maximum force corresponds to diameter of piston. </li></ul><ul><ul><li>F=P* π *r 2 </li></ul></ul><ul><li>Several cylinders used for resistance skill level. </li></ul>
  22. 22. Peak Performance Engineering Assembly
  23. 23. Parameter Variation Peak Performance Engineering
  24. 24. Assumptions: Pressure inside piston starts at 1 atm, and density is 1.18 kg / m 3 . Dynamic Vacuum seal on piston Constant room temperature Piston/Cylinder Model Peak Performance Engineering h i ≈ 0 d i = 1.32” F = 20lb V i ≈ 0 F = P * A A = π * r 2 r = d i / 2
  25. 25. Comparison Benchmarks <ul><li>Benchmark - Cap Barbell Home Gym System </li></ul><ul><ul><li>- Model outperformed or met customer requirements the same as the Cap Home Gym. (150 lbs vs. 180lbs) </li></ul></ul><ul><ul><li>- Reparability, the only issue for customer requirements. </li></ul></ul>Peak Performance Engineering
  26. 26. Pulley System Model F F F mg <ul><li>Elaborate Pulley System </li></ul><ul><ul><li>Basic Configuration: Force-driven cable connected at one end to external surface, with the cable being wrapped around a pulley linked to a mass. </li></ul></ul><ul><ul><li>Assumptions: Frictionless pulley, constant gravitational acceleration (9.81m/s^2), massless cables, massless pulley. </li></ul></ul>Peak Performance Engineering
  27. 27. Basic Calculations: (2 pulley configuration)‏ F x = 0 A x = 0 F y = 2F – mg = 0 F = (mg) / 2 (m)A y = 2F – mg A y = ((2F) / m ) – g Force mg Pulley System Model Peak Performance Engineering
  28. 28. Peak Performance Engineering Assembly
  29. 29. Comparison Benchmarks <ul><li>Benchmark - Cap Barbell Home Gym System </li></ul><ul><ul><li>Net weight of concept exercise device lower than Cap Barbell Home Gym. (170 lbs vs. 300lbs) </li></ul></ul><ul><ul><li>The ability of foldable bench legs helps in storage under beds or other furniture. </li></ul></ul>Peak Performance Engineering
  30. 30. Assembly Efficiency <ul><li>Goal: Maximize production efficiency, Minimize cost. </li></ul><ul><li>Solution: Design for Assembly worksheet </li></ul><ul><ul><li>Pinpoint faults, areas for improvement. </li></ul></ul><ul><ul><li>Obtain a DFA score </li></ul></ul>Peak Performance Engineering
  31. 31. First DFA Worksheet 46 0 16 10 12 8 Peak Performance Engineering
  32. 32. DFA Evaluation <ul><li>Improvements in overall assembly, part retrieval and part mating. </li></ul><ul><li>Steps to implementation </li></ul><ul><ul><li>Single pulley sizes </li></ul></ul><ul><ul><li>Lighter materials </li></ul></ul><ul><ul><li>Chamfers, round edges </li></ul></ul><ul><ul><li>Hinged legs </li></ul></ul>Peak Performance Engineering
  33. 33. 36 12 66 2 0 16 Second DFA Worksheet Peak Performance Engineering
  34. 34. Assembly Efficiency <ul><li>Simple assembly for consumer. </li></ul><ul><ul><li>Leg Hinges </li></ul></ul><ul><ul><li>Leg Extension Bar </li></ul></ul><ul><ul><li>Exterior Pulleys </li></ul></ul><ul><ul><li>Rail and Box Assembly </li></ul></ul>Peak Performance Engineering
  35. 35. Economic Analysis <ul><li>Purpose: Evaluate financial effectiveness of our product. </li></ul><ul><li>Established Financial Analysis Diagram. </li></ul>Peak Performance Engineering
  36. 36. Peak Performance Engineering
  37. 37. Peak Performance Engineering
  38. 38. Peak Performance Engineering
  39. 39. Other Calculations <ul><li>Net Return on Investment: 55.6% </li></ul><ul><li>Net Rate of Return: 76.9% </li></ul><ul><li>Break-even Thresholds: </li></ul><ul><ul><li>Quarter 7 </li></ul></ul><ul><ul><li>4,488 units (assuming interest) </li></ul></ul>Peak Performance Engineering
  40. 40. Conclusions <ul><li>Unparallel total body workout in a compact design. </li></ul><ul><ul><li>Strong niche in current market. </li></ul></ul><ul><li>Met or surpassed customer needs </li></ul><ul><li>Very profitable, low risk, investment </li></ul><ul><li>Conservative sales assumptions, great entry opportunity </li></ul>Peak Performance Engineering

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