The Process
“The trick to having good ideas is not to sit around in glorious isolation and try to think big thoughts. The trick is to get more parts on the table.”
― Steven Johnson
Expectations/Goals
the main goal of our group is to produce a product/products that both satisfy the outcome and the expectations set by our client(s).
Goal 1
We, the operators/agents, must produce a product that enables our client to be able to
“kick” a ball.
Goal 2
We, the operators/agents, must be able to create four kicking machines, a number set by
our client(s), that are fully functional, portable, and safe.
Goal 3
We, the operators/agents, must use a design and materials that are cost-effective and
within the set expense the client(s) have set for us.
Design
Our design for the requested product is a remodel of a product that was already made. We merely changed a few things that can fulfill the client(s) criteria as well as be mass-made.
Original model
The original model was made up of metal posts, PVC pipes, and wheels. Its size was made in consideration of being compatible with a wheelchair. When it is used, the function of the machine works within expectations; the shoe kicks the ball with considerable strength, the trajectory of the ball it almost perfectly straight, and the set up is somewhat simple. The problem with this model was that it was quite heavy for the adults to move it around when needed. Even with the addition of wheels, its mobility is greatly hindered. Another problem would be the permanent parts of this model. One factor would be the shoe, which is used to kick the ball. Over time, with constant usage, the sturdiness of the shoe becomes weak which then affects the contact force between the shoe and the ball. As the shoe is placed onto the machine in a way that it will stay, the action of replacing the shoe is impossible. The last problem with the original model is its set up. Though it is simple, it is not as easy for the adults to set it up. In order to connect the shoe to the handle, two adults are sometimes required.
Criteria/Constraint
The constraints and criteria are used in subsequent steps of the design process to determine which of many possible designs should be implemented.
Constraint/Criteria 1
The product must be safe for the students (i.e. no loose or uncovered screws, no jagged sides, no pointed edges, no sharp parts)
Constraint/Criteria 2
The product must be fully completed and usable by March, before the date the presentations are being held.
Constraint/Criteria 3
The product must be portable and not too heavy. It must be able to moved by a single individual.
Constraint/Criteria 4
The product must be durable. It cannot have any loose parts and it must be fully glued/screwed.
Process
A series of actions/steps we took in order to complete our project
In the start of the project, we spoke with our stakeholders in order to determine what they wanted from our group. Once our next course of action was set, we brainstormed and researched the best possible way our product should be designed, structured, safe, and used. We asked questions in order to see if an idea was possible, such questions like “what material could we use to replace the metal material? Can we make our product both stationary and portable? How do we keep the product stationary when the product itself is light?”. After much contemplation, we have formed a basic list of ideas that we could begin our process from. The first thing on the list was the design of our product.
As we were creating a product with functions similar to the original machine, we decided to remodel our product after it. Our next action was to measure the original model, as its measurements was compatible with size of the wheelchairs. Once we had recorded the measurements and the design of the original machine, we then pondered what material(s) we would use to build our product. After extensive research, we felt that PVC pipes would be the most suitable material that fit all the constraints and criterias of our product. The other materials we considered for our product were shoes, PVC glue, bungee cords, and PVC joints. With all of our materials compiled, the list was sent to our stakeholders who would be the ones to buy what we required. When we received all of our materials, we began to build our product.
The first thing we did was measure out the PVC pipes to the measurements we recorded from the original model. Next, we cut the PVC pipes, either by a hack saw or by the band saw. With all of our parts cut and prepared, it was moderately easy to put the product together with the PVC glue and joints. With the structure completed, our next step was to put in the shoe. While working on the shoe we used a metal stick and screwed it in at the end of the handle as it work as the connector between the two apparatus. Once we finished with the shoe and “hook”, our first product was completed. Before making our second product, we tested the first one, to test its effectiveness.
The testing was fairly successful; we faced some difficulty in setting up the product, but overall it was able to smoothly kick the ball. With the successfulness of the first product we proceeded to make the rest of the products, repeating the steps we used. After many trial and errors, we finally completed all four kicking machines.
Testing
The measures we took to check the quality, performance, or reliability of (something), especially before putting it into widespread use or practice.
Throughout the whole process of building our products, many tests were done in order to insure the successfulness of each criteria set by our client(s), the effectiveness of each of the products, and the compatibility with the user. We tested the setup of the product (in its level of difficulty and the practicality of it), the function of the kicking apparatus - the shoe and its swing- (to see if it kicks the ball the way we want), the mobility (in it that it is both stationary and portable), the durability (if it can withstand impact and mishandling), and lastly it’s repairability (were we able to change or correct parts?).
Trial and Error
The process we took to find the best means/method and eliminate the faulty ones by experimentation, investigation, and testing.
Error #1
The contact between the shoe and the handle - the metal stick of the first product was easily bent.
Refinement: We replaced the metal stick with metal coat hooks.
Error #2
The bungee cords we used to create force were either too short or too long.
Refinement: For the long bungee cords, we double-wrapped it around the kicking apparatus. For the short bungee cords, we moved the distance between the kicking apparatus and the placement of the cords.
Error #3
The shoe of the kicking apparatus would not stay as we wanted. It kept moving around and it was not stable enough.
Refinement: We replaced the PVC pipe
originally used on the apparatus with a wooden dowel. We then put a hole in the
shoe in order to stick the wooden dowel through it. At the bottom of the shoe, we
used a flat wooden block. With the hole in the wooden block, we placed the end
of the wooden dowel and with the use of wood glue, secured the shoe in
place. At the other end of the dowel, we used a PVC pipe to connect the apparatus
to the structure.
Error #4
The measurements of some of the PVC pipes were wrong, so when we were trying to piece together the rest of the products, some of the parts would not fit together.
Refinement: We had to cut more pieces of the PVC pipes in order to make our products be more stable. We also sometimes had to cut down some
pipes when some of them were a little too long.
Error #5
The PVC glue we used to keep the product together did not work. When we assumed that we had completed our products and were in the process of delivering them to our stakeholders, two of the four products fell apart.
Refinement: We had no choice but to find another alternative to hold the product(s) together. We decided to use screws at the connectors.
Error #6
The screws failed to keep the product(s) together.
Refinement: We went back to using the PVC glue, but it was a brand new one and also consisted of two steps (primer and then cement).