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CERTIFICATE
This is to certify that the projects enclosed in this report has been carried out
by Prashant Choudhary (ME11B024) of Indian Institute of Technology
Hyderabad (IITH) as a part of the summer internship programme carried out
in Industrial Design Centre (IDC), IIT Bombay at Design Integration Studio from
May 8th to June 25th.
Prof. K Munshi
Industrial Design Centre
Indian Institute of Technology, Bombay
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ACKNOWLEDGEMENT
I would like to thank this opportunity to express my heartfelt thanks to all those who
helped me in the course of my internship at IDC IIT Bombay.
I would like to thank my esteemed guide Prof. K Munshi for providing this opportunity
for me to work as trainee in “Design integration studio” and to carry out the projects.
I was learnt many aspects of design.
I would like to express my gratitude to Mr. MSG Rajan for this effort in teaching me all
the ways to tackle a design issue and on the usage of IDC facilities to its maximum.
I would also like to thank Mr. Imran, Mr. Swapnil Ghutke and Mr. Raghu for guiding
and helping me in every part as needed in the project work.
Finally I would like to thank all my teachers at IITH for encouraging me to undertake
my summer training at IDC, IITB.
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Table of Contents
About Industrial Design Centre.......................................................................................... 4
About Prof K Munshi............................................................................................................ 5
3 wheeler electric Autorickshaw..................................................................................6-31
Introduction .......................................................................................................................6-7
The existing model snaps ....................................................................................................8
Modeling in solidworks(design stages).........................................................................9-21
Rooftop designs ............................................................................................................22-24
Windshields design.............................................................................................................25
The Final Model .............................................................................................................26-27
Real-time Renderings of the final model...................................................................28-29
Ergonomics Considerations..............................................................................................30
Different Colour suggestions for Autorickshaw.........................................................30-31
‘JUGNOO’ LED Solar Lamp .........................................................................................32-40
Introduction ........................................................................................................................32
Solidworks models .............................................................................................................33
Features...............................................................................................................................34
Real-time renderings ....................................................................................................34-35
Manufacturing Process for different models..................................................................36
Paintings and Finishings................................................................................................37-38
Final model .........................................................................................................................39
New Model suggestion for the lamp..........................................................................39-40
Designing of Table-top circular saw .........................................................................41-46
Introduction............................................................................................................................41
Solidworks models ............................................................................................................42-43
Fabrication Process and model ....................................................................................44-46
Revision1 .....................................................................................................................44
Revision2 ................................................................................................................45-46
Workshop Practices ......................................................................................................... 47
Contact Information .......................................................................................................... 4
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INDUSTRIAL DESIGN CENTRE
Industrial Design Centre (IDC), established in 1969 by the Indian government under
the Indian Institute of Technology Bombay (IITB). In the beginning, only industrial
design course was being offered yet now there is a wide array of the courses being
offered. These courses include studies into areas such as Interaction Design, Mobility
and Vehicular Design, Visual Design, etc. in the world IDC has been named as one
of the best design schools in India.
Admission can only be obtained with a CEED rank followed by personal interview
conducted by a panel of professors from IDC.
As of now only master programmes are provided in 5 disciplines Industrial Design,
Visual Communication, Animation, Interaction Design and Mobility & Vehicle Design.
The design training at IDC is intended to develop an attitude among the students
toward problem solving in design, in order to prepare them to go into the field and
face a wide range of challenges at the end of their training.
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About
Prof. K Munshi
Prof. K Munshi is the founder director of CTech Labs pvt. Ltd.,a joint venture with IIT
Bombay.
Prof. K Munshi has a Bachelor’s degree in Mechanical Engineering from IIT Bombay
and a Post graduation in Product Design from Royal College of Art, London. He was
UNESCO fellow at technical University of Hanover, Germany, Universite de
Technologie de Compiegne, France, and worked with some of the leading design
groups in Europe – Sottsass Associati, Milano, Italy. ENFI Design, Paris, France,
Lindinger & Partner, Hanover, Germany etc.
Professor and former Head of the Department, Industrial Design Centre, IIT Bombay,
Professor of Industrial Design at Oslo School of Architecture & Design, Norway, where
he started the master’s programme in Industrial Design. Professor of Design
Management at Middle East Technical University, Turkey. Visiting professor at Lulea
University of Technology, Swedan.
Management adviser and R&D (Product Developement) Concultant to more than
50 industrial organization including L&T Ltd., IBP Ltd., Godrej & Boyce Ltd.,Ponds India
Ltd., HMT watch Directorate, Crompton Greaves Ltd., Godfrey Philips Ltd., DRDO
Labs, Indian Railways etc. He has been advisor for many DST, Govt. of India funded
projects.
Member of various Government of India committees for making recommendations
on ‘Technology Transfer’, ‘Technology Upgradation’, formation of design council,
etc. Member, Human Engineering panel of DRDO, Ministry of Defence, GOI &
National Innovation Foundation. Member, Services selection board (UPSC)
Government of India.
He has been awarded for “Excellence in Design Consulting” by CDC, Government
of India and IF Award in Germany for ‘Good Design’. He has number of patents to
his credits.
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Battery Operated 3 wheeler Auto-Rickshaw
ABSTRACT:
To design and fabricate a 1:1 prototype of the outer body of three wheeler
electric auto rickshaw.
Whole model should be made in a way that it can be ejected from the
mould in single step to reduce the production cost and to make cheaper to
buy.
Courtesy: Google Images
Introduction:
Air pollution due to petrol and diesel is one of the major factors for global warming.
Daily hike in petrol and diesel prices has resulted in reluctance for use of these
vehicles. And the limited amount of these natural sources pushes us to think about
some strong alternative. Designing and developing in the area of battery operated
vehicles and their efficiencies may be a strong alternative to satisfy the need of
power with better efficiency values.
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World is becoming more and more conscious towards the environmental problems
caused by the emissions of the petrol and diesel operated vehicles. Electric vehicle
is the only remedy for this because the batteries can be charged using unending
source of solar or any other clean energy.
The project is focused on designing the outer body of the 250W BLDC motor battery
operated electric auto rickshaw. Whole auto rickshaw had to be made in a way to
reduce the cost and the time with a clean energy source battery powered system.
My project involved-
1. Making sketch of an electrically powered auto-rickshaw for 2 passengers.
2. Making of 3D model in solidworks.
3. Rendering of the model to get a real-time look.
4. Basic structural analysis of the body.
5. Making of a 1:1 thermocol model of the body.
Further the same model with minor changes will be made in clay to make an
FRP (fibre reinforced plastic) final model of the electric auto-rickshaw.
Courtesy: Google Images
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The Existing model
of the three-wheeler:
These outer dimensions were taken as a reference in making the new 3D
model of the auto-rickshaw.
Reverse engineering was done and a 3D model of the existing model was
made in solidworks.
The fork design, the base plank and the side covering with tires and leaf-
spring were made in 3D.
Then on the basis of existing model, a new simple model was generated.
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Mold5:
Simple body design so that whole body can be taken out from the mould in a
single step with the need of only one mould design.
Mold 6:
Driver seat was redesigned aesthetically.
Finished base part giving rigidness to the whole model.
Spacing for front wheel to steer was made.
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Mold 9:
Improvised design of casing for front wheel.
Step for mounting the passenger seat was made.
Driver foot-space area was increased.
Mold 10:
Wide driver seat for driver to put battery inside of it
Redesigning of driver-seat to keep batteries for the electric BLDC motor.
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Mold 15:
Packet for laminated spring suspension was made.
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Mold 17:
Driver seat was replaced with step. Driver seat would be separately attached
to that step according to driver comfort.
The Battery compartment was shifted to the back for safety purposes and the
battery space was increased to keep extra battery.
Mold 19:
Added Draft Allowances, fillets etc.
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Mold 26:
Giving 6mm thickness all around to the model.
Mold29:
Side stepping for preventing water to come in and to give strength to the
base.
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Mold 33:
Uniform side-stepping design merging to both sides smoothly.
Mold 36:
Slot cut was made for full steer of the handle while turning.
To make handle fully steer-able, additional front increment in design was
made.
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Mold 37:
Improvised design for full steer
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Mold 38:
New better design for full steer
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Mold 39:
Engineering revised design for mould to be come out
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Mold 41:
With all drafting allowances and filleting.
Mold 42:
Design re-evaluation according to roof-top design
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Mold 46:
The final model with all surface and edge correction.
Stepping for covering the back-part with a mesh.
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ROOF-TOP DESIGN
Model1
Revision1:
Revision2:
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Revision3:
final
1. Wide vision area.
2. Only need to fix straight glass.
Model2:
Revision1:
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Revision2:
final
o New design for warped glass shield for better un-restricted vision area
for driver.
o Wide back-side glass aesthetically designed for better vision.
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Windshields
Model1:
Model2:
o Variable radius fillet for fine transition with mould body part.
o
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The Final Model
Suggestion1:
with straigth glass surface.
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Suggestion2:
with warped glass surface
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Real-time Rendered images
for the final model of three wheeler electric auto rickshaw
Suggestion1:
With straight glass surface
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Suggestion2:
With warped glass surface
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Ergonomics Consideration:
(taking 95% manikin as a reference)
Transperent look to visualise the sitting position of the passengers and the
driver and to see the position of glass sheild according to driver.
Different colour
Suggestions:
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‘JUGNOO’ LED Solar Lamp
ABSTRACT:
To design and fabricate a solar powered lamp for various purposes.
INTRODUCTION:
The project involves the making of a real-time product which should be
environmental friendly and to be related to some social cause. In rural area, where
electricity-supply is not very frequent and after the daytime lot of children cannot
study even due to power cut-offs. A 3D model of an LED solar lamp with a compact
and unique design is made. Then it is fabricated aesthetically and technically in all
respects.
My project involves-
1. Making a 3D assembly model in solid works.
2. Rendering it to get a real-time touch for better visualisation.
3. Drafting the 3D model in Autocad.
4. Making a pattern for model to make outer parts.
5. Painting and finishing of all parts.
6. Assembling it with solar panel.
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Making of 3D model in SOLID WORKS 2010-
Rendering the model in ‘Keyshot 3.0’-
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Salient Features-
No direct LED light on the eyes.
Less power consuming LEDs.
Adjustable wireframe for different angle.
Solar powered battery with a solar panel mounted on back.
Can be hanged on the wall and can be used as a room-light.
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Patterns were made for Vaccum-forming to get an outer casing for lamp-
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Model1:
Model2:
2 models for this LED solar panel are proposed.
2mm thick styrene sheets were used to make this model in vaccum molding to meet
the purpose of design and functionalities.
1mm thick sheets were too thin to hold the all components rigidly. And the 3mm
thickness were not really required for this purpose.
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Final Model-
Model3:
Design simplification on the basis of manufacturing and aesthatically revised.
Solar panel will go inside till the straight cross section and sit on the curvature
part of the model.
Better uniform layer thickness in vacuum forming.
Staggered arrangement of LEDs for the space limitation of compact design.
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Designing a Table-top Circular saw
Abstract:
To design a table mount for a handhold circular saw generally to cut styrene
or plastic sheets.
Introduction:
A handhold angle grinder can be used to cut plastic sheets precisely with the help
of a table mount arrangement. An existing model of BOSCH GWS 6-100 Professional
was taken.
Grinding plate was replaced by a circular cutting saw blade to cut the plastic parts.
The whole system was mounted on a wooden box and other things and
connections were made. The whole assembly was made in that way so that it can
be easily dismantled and can be used as a normal angle grinder.
My project involved-
1. Designing a 3D model of the whole system in SolidWorks.
2. Making a real-appearance of the 3D model in Keyshot 3.0.
3. Making of whole working model in real scale.
4. Attaching a safety guard cover on the blade.
5. Making guide-ways to propagate the sheets in x-y direction with accuracy.
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3D model made in solidworks 2010-
4 holes are made to mount the clamp with M12 allen bolts. The clamp was
made to support the angle grinding machine.
Holes were countersunk to get a planer finish on the working area (the top of
the table).
Countersunk holes in the depth can make plywood weak so an additional
12mm thick wooden plank was nailed-attached in the bottom area of the
plywood.
A 12mm wide and 150mm long slot is made in the 12mm plywood plank for
the circular saw to be come out from the table with a cutting-height of
24mm.
One impression was made to attach a clamp for the safety cover for the
circular saw.
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Designing of safety cover:
Revision1: Solidworks model
Revision2: Nature inspired design for safety guard of the cutting saw.
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Fabrication Process and model:
Revision1:
With metal cage body:
Machine was tightened with 4 M12 allen bolts.
Alignment was made properly to meet the requirements.
All electric connection was made.
One extra ON/OFF switch was given to operate the machine from outer side
of the box.
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Revision2:
Aesthetically revised wooden cage:
Lipping of the boundaries was done for smooth finish.
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Slot for wire was made.
Rectangular boss was made to strengthen the structure.
Nylon stands were put for better gripping the table-top mount.
Since this was made in wooden box so special foam for sound-proofing was
attached in the inner side of the box to reduce the noise.
Leaf design for safety cover was made in acrylic sheets of 3mm via laser
cutting method.
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Workshop Practices
RAPIDBOT 3D printer, Angle grinder, grinding machine, sander, electric arc
welding,
Wood shop- wood cutting machine, sander, grinder, hand drill.
Metal studio- lathe, metal cutting machines (hand operated & leg operated
both), power drilling machine.
Plastic Studio- Vacuum moulding machine, plastic bending machine,
thermocol cutting machine, styrene sheet cutters, sander. Grinder, air blower.
Ceramic studio
Clay studio
Bamboo studio
Paint shop
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Contact Information
Prashant Choudhary
B.Tech Mechanical
3rd year ,
IIT HYDERABAD
Email address:
me11b024@iith.ac.in
Contact Information:
+91-7382-365-794
