The document describes the development of a portable power station called the Powerstation. It goes through phases of problem finding, research, concept development, and finalizing the concept. The Powerstation aims to address issues with temporary jobsite power by accommodating multiple battery chargers and cords in a secure and portable unit. It draws power from the existing temporary power source and allows workers to charge tools and work within a 15 foot radius of the single power supply. The modular design stores cords and tools securely while providing easy access to power.

1. The Powerstation
Phase 1: Problem Finding
Aaron Pierce

2. Construction Site Research
Jobsite: Shelby Engineering Partition teams 1&2

3. Construction Site Research
Plug it in, plug it in… Partition teams 1&2

4. Phase 2: Problem Research + Initial Concepts
Aaron

5. Plug It In: jobsite cord management:
Plugging in and getting the power you need to get the job done right.
Construction Site Research
Partition teams 1&2

6. Plug it in & Charge it Up…
Addressing the issues of charging
more than one Li-Ion battery and
plugs that supply power to 3 or
more separate extension cords.
Construction Site Research
Partition teams 1&2

7. Is there a better way to do this?
While self-built power boxes provide
temporary power, they increase the
risk of blowing breakers, with the
possibility of electrocution.
Construction Site Research
Partition teams 1&2

8. Can we appeal to smaller scale
construction?
Commercial site renovations
encounter the same problem as
larger build-outs , but on a smaller
scale.
They need to be able to deliver the
equivalent amount of power from a
smaller junction box.
Construction Site Research
Partition teams 1&2

9. OSHA Requirements:
Keep cords free from walkways
and standing or flowing water
Battery Charging:
Battery charging installations must be located in areas
designated for that purpose. When batteries are being
charged, vent caps must be maintained in functioning
condition and kept in place to avoid electrolyte spray.
Also, charging apparatus must be protected from
damage...
Construction Site Research
Partition teams 1&2

10. Goals…
Use established temporary power.
Accommodate multiple batteries
and cords.
Deliver more power , more
efficiently.
Construction Site Research
Partition teams 1&2

11. The Fit:
Address the issues found from OSHA to safely provide electricity from a temporary power source
Accommodate existing power cables, multiple outlets and battery chargers, in a rugged and durable way.
Construction Site Research
Partition teams 1&2

12. Criteria
Easier to use than existing methods
of “jerry-rigging” electrical
connections.
Multiple cord and battery bays.
More efficiently use available
temporary power.
Construction Site Research
Partition teams 1&2

13. Professionals
Multipurpose Charger
Market Research
Where is everybody? Specialized Variety
Tool Base:
Specialized or Tool Variety
Audience:
Professional or DIY
DIYers
Construction Site Research
Partition teams 1&2

14. Battery Product Analysis…
Companies…
Makita
$25 - $170
12v-18v Single Battery Chargers
Automotive Application
Construction Site Research
Partition teams 1&2

15. Battery Product Analysis…
Companies…
Bosch
$30 - $100
Single and Dual Bay Battery
Chargers
Automotive Application
No Cord Management
Or powerstrip capacity
Construction Site Research
Partition teams 1&2

16. Battery Product Analysis…
Companies…
Milwaukee
$25 - $160
Single to Triple Bay
Li-ion Battery Chargers
Limited cord management
No power strip capacity
Construction Site Research
Partition teams 1&2

17. Battery Product Analysis…
Companies…
DeWalt
$25 - $160
Single to Triple Bay
Li-ion Battery Chargers
Jobsite Radio
Light cord management
Construction Site Research
Partition teams 1&2

18. Initial Sketches: Power Station
Criteria…
Invincible
Multiple Li-Ion/Nickel Cadmium
Battery Chargers
Cord & Plug Management
Powered by 120V Power Source
OSHA Compliant
Construction Site Research
Partition teams 1&2

19. Initial Sketches: Power Station
Criteria…
Invincible
Multiple Li-Ion/Nickel Cadmium
Battery Chargers
Cord & Plug Management
Powered by 120V Power Source
OSHA Compliant
Construction Site Research
Partition teams 1&2

20. Phase 3: Concept Development
Aaron Pierce

21. Plug It In: Jobsite cord management:
Plugging in and getting the power you need to get the job done right.
Construction Site Research
Partition teams 1&2

22. The Scenario…
Electricians are required to install
the temporary power on many
jobsites.
They wire up a few GFCI outlets
from the junction box, to provide a
semi-reliable power source for the
contractor to use.
Construction Site Research
Partition teams 1&2

23. A power struggle…
As the workers use cordless tools
more, more battery chargers are
needed.
These added chargers drain the
needed power supply for corded
tools, resulting in tripped
breakers.
Construction Site Research
Partition teams 1&2

24. Time and money wasted…
Repetitious building and tearing
down temporary power.
Outlets in an unmanaged way
creating problems for battery
chargers and corded tools.
Workers having to walk back and
forth from chargers.
Chargers being stolen.
Construction Site Research
Partition teams 1&2

25. Critical To Qualities…
Use established temporary
power methods.
Accommodate multiple batteries
and cords in a modular fashion
Deliver power more efficiently.
Save the electrician time and
money by eliminating menial
installation problems
Construction Site Research
Partition teams 1&2

26. The Concept Goals:
Accommodate the issues seen on jobsites with temporary power installation and usage with a new kind of
product.
Manage existing power cables, multiple outlets and battery chargers, in a rugged and durable way that is
transportable from either vehicles or gang boxes.
Construction Site Research
Partition teams 1&2

27. Concept Direction :
Lithium Battery Charger
Pros…
Invincible
Multiple Li-Ion/Nickel Cadmium
Battery Chargers
Multiple Battery chargers
Powered by 120V Power Source
OSHA Compliant
Construction Site Research
Partition teams 1&2

28. Concept Direction :
Lithium Battery Charger
Cons…
Patented by Ryobi
Lack of security
No storage or cord management
Not modular
Not enough plugs, batteries are still
distant from workers in one location.
Construction Site Research
Partition teams 1&2

29. Concept Competing Products…
The 10C – Multicharger
Ryobi’s Multi-Battery Charger
Knaack’s Job Boxes: Storage
Where does all this converge?
Construction Site Research
Partition teams 1&2

30. Development…
Construction Site Research
Partition teams 1&2

31. Construction Site Research
Partition teams 1&2

32. Initial Sketches
Based on feedback from Jim Watson
and the BSCI team, I explored those
possibilities through sketches
Construction Site Research
Partition teams 1&2

33. Initial Sketches
Based on feedback from Jim Watson
and the BSCI team, I explored those
possibilities through sketching
Construction Site Research
Partition teams 1&2

34. Feedback on Sketches
Construction Site Research
Partition teams 1&2

35. Feedback on Sketches
Based on feedback from Michael
Schumacher, a general contractor
“My electricians can use this, the
cords just get ‘thrown’ into the
back of the truck, and get
tangled. This would give the cords
a place to go at the end of the
day”
Construction Site Research
Partition teams 1&2

36. Sequence of Use
After reviewing the sequence of
use, It became obvious that I was
creating more steps to the process
than making each step more
efficient. These concepts became
simpler.
Construction Site Research
Partition teams 1&2

37. Sketch Model Development
Black and Decker Senior Designer
Tom Murray visited our studio,
providing further feedback into the
development of a sketch model
Construction Site Research
Partition teams 1&2

38. Sketch Model Development
Black and Decker Senior Designer
Tom Murray visited our studio,
providing further feedback into the
development of a “sketch model”
“…avoid a functionless, flat lid A
5-gallon bucket recess would add
further functionality, along with
charger bays for cell phones or
iPhones.”
Construction Site Research
Partition teams 1&2

39. Sketch Model Feedback
Greg Lanier, owner of
Auburn Electrical Construction Co., Inc.
Conversation Notes:
-Wire Size to Amperage
-Breakers and GFCI outlets
-Thinner Wheels
-Jobsite Security Problems are #1
-DeWalt Tools vs. everyone else
Construction Site Research
Partition teams 1&2

40. Sketch Model Feedback
Greg Lanier, owner of
Auburn Electrical Construction Co., Inc.
Model Notes
-iPad/Smart phone compatibility
-No need to link multiples
-Lockable and Secure
-More Storage on the lid and back of
station
-Larger, Sturdier Handle
-Thinner wheels, like a bike
Construction Site Research
Partition teams 1&2

41. Final Concept:
After choosing the concept that best
met the end-user needs, and do so in an
attractive way within that context.
Construction Site Research
Partition teams 1&2

42. Final Concept:
The DeWalt PowerStation
After choosing the concept that
best met the end-user needs, and
do so in an attractive way within
that context.
Construction Site Research
Partition teams 1&2

43. Strong Sturdy Handles
Carry handles on both ends allow for
easy pick up and set down in the bed of
a truck, trailer, or gangbox.
Construction Site Research
Partition teams 1&2

44. Secure
Incorporates for a padlock through the
snap-latch handle to keep chargers and
cords safe.
Construction Site Research
Partition teams 1&2

45. Modular
Two modular units nest on either side of
the DeWalt Powerstation provide two
outlets and a multi-chemistry battery
charger with a 15’ cord wrapped at the
back of the uniit.
Construction Site Research
Partition teams 1&2

46. Atop-lid Storage
Clear lidded containers for hard-to-find
hardware, charging your connectivity
devices.
Construction Site Research
Partition teams 1&2

47. Strong Sturdy Handle
Handle extends up to the best height for
users, approximately 32”
Construction Site Research
Partition teams 1&2

48. Snap Latch Lid
By squeezing the latch on the front of
the Powerstation
Construction Site Research
Partition teams 1&2

49. Final Solution: The Powerstation
Aaron Pierce

50. The problem…
Many solutions available to
electricians have to be adapted or
modified to install temporary
power on a jobsite.

51. The “traditional” way…
Most large commercial jobsites
construct Spider boxes that are
heavy and cumbersome to
relocate.

52. The interface problem…
Cordless Drills use batteries that
are plugged into chargers.
These must be in an easy and
time-saving location to the
workers.

53. 11/21
11/19 11/29
11/22
Model Development
Appearance model construction
from welding to painted
assembly.
11/30

54. Powered Storage Container
The Powerstation uses the
power supplied by scope, in a
way that is modular. Allowing
the workers to charge and work
on the same line.

55. 15’ Working Radii
15’ Extension Cords supplied on
the unit make working on parts
of the of the building from the
same unit possible.

56. Portable, Secure Storage
The Powerstation makes it easier to
take down the equipment at the
end of the day, locking up with the
extension cords, batteries and
chargers.

58. quence of use: Step 1
Romex Cables are wired into
ystem, powering the interior
et, and modular units

59. Sequence of use: 2
Pull out the modular units. plug in
any other tools. Begin working.