1. Product Design & Development
Redesign of a Reebok Edge Series Cross Trainer
Foot Plate Linkage
Student Name Tony Ponsonby
Student Number 02968984
Unit Name Product Design And Development
Unit Code 64ET7004 1112 9
Assignment Code 2CWK30
9. Material Selection
SPS Syndiotactic Polystyrene 40% Glass Fiber
Density 1360-1380 kg/m^3
Price 2.58-3.86 GBP/kg
Tradenames
Edgetek; Schulatec; Questra; Xarec
Composition overview
Polystyrene homopolymer
(CH2CH(C6H5))n of regular syndiotactic
stereochemistry with impact modification.
With reinforcing filler.
Thermoplastic : semi-crystalline
Mechanical properties
Young's modulus 10-15.2 GPa
Yield strength 110-147 MPa
Tensile strength 96.5-140 MPa
Compressive strength 92.6-134 MPa
Flexural strength 161-231 MPa
Elongation 0.7-2.04 % strain
Melting point 240-260 °C
Optical properties
Transparency Opaque
Recycle False
Downcycle True
Combust for energy recovery True
Landfill True
Typical uses
Specialized components for automotive,
electrical, electronic, and
consumer/industrial products, such as
connectors and microwave oven parts
Data from CES
10. Design to Standards
BS EN 957 Stationary training equipment —
Part 1: 2005 General safety requirements and
test methods
Part 9: 2003 Elliptical trainers, additional
specific safety requirements and test
Methods
BSEN 15312:2007 Free access multi-sports
equipment
11. Design to Standards
FOOT PLATE SIZE
BS EN 957 Part 9: 2003 clause 5.5 requires that ‘ the foot platforms have a
non slip surface of at least 300mm x 100mm and a friction actor of more
than 0.5 when tested to ISO5904’
13. Design to Standards
BS EN 957 Part 9: 2003 clause 5.5 requires that ‘The footplatform shall have a
guard with at least 30mm height along the inside edge and the front edge’
20. Design to Standards
Classification S - 100KG Loading
Conclusion
SPS is suitable for H classification trainers
SPS not suitable for S classification
trainers
The design could be used for S
classification using a material with a
Young’s Modulus >24GPa
Yield Strength > 150MPa
PP66 with 30% carbon fiber is
suitable for H classification trainers
25. Eco Audit Report
Product Name Reebok Cross Trainer Linkage
Product Life (years) 3
Energy and CO2 Footprint Summary:
Energy Details...
CO2 Details...
Phase Energy (MJ) Energy (%) CO2 (kg) CO2 (%)
Material 176 81.2 12.2 80.0
Manufacture 36.8 17.0 2.76 18.2
Transport 3.59 1.7 0.255 1.7
Use 0 0.0 0 0.0
Disposal 0.321 0.1 0.0225 0.1
Total (for first life) 216 100 15.2 100
End of life potential -171 -11.8
Environmental Report
Downcycle at EOL
Criteria
– Component weight 1.6kg
– Manufactured in China &
transported to
Manchester
– Re-engineered at end of
life
– 15.2kg CO2 required for
a 1.6kg?
– Combustion only returns
10MJ but adds 2.6kg CO2
emissions
27. Design Benefits
Original Design New Design
Number of parts 80 16
Manufacturer assembled components 24 6
User assembled components 56 10
Weight 6.03kg 3.18kg
Cross trainer Classification H H&S
Recycle
Steel Yes -
ABS Downcycle/Combust -
SPS - Downcycle/Combust
28. Future Work
• Rapid prototype
• Physical testing as designated by BS EN957-1;2005
– Load test as per as per clause 5.3.1 in accordance with
clause 6.4
– Fatigue / Cyclic loading as per clause 5.7 in accordance
with clause 6.7
– Friction factor test as per clause 5.5 in accordance with
clause ISO 5904
29. Redesigned using SPS Syndiotactic
Polystyrene 40% Glass Fiber
Reduces user-assembled components by 64
Reduces weight by 2.85kg
Designed for class H (home use) Elliptical
Trainers as per BS EN 957–1:2005Redesign of a Reebok Edge Series
Elliptical Trainer Foot Plate Linkage
Product Design & Development
Tony Ponsonby 14/12/2011
