A Smart Plug that fulfills all requirements was produced during this degree project. The Smart Plug design consists of fourteen parts; a socket, plug, isolation sheet, button, shutter, shutter casing, spring, PCB assembly, female- and male ground spring, terminal pins, light guide, M2-screws and 2.5x10 M2-screws. The Smart Plug is about 70 mm in height, 52 mm in length and 45 mm in width. The size of the Smart Plug is small and does not take up more area than needed.
The Smart Plug will be manufactured by injection molding, by using the environmentally friendly material PLA.
A few alterations should be performed on the design of the Smart Plug, which was discovered after impact simulations were performed. Certain parts of the Smart Plug absorb an excessive amount of stresses during impact when dropped from a distance of 1 m. The stresses absorbed by the casing of the Smart Plug reaches, or surpasses, the yield stress of the selected material.
This could cause plastic deformation of the Smart Plug, which should be avoided. These alterations mainly regard the design of the plug, but also the design of the button and socket.
6 Future work
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Design alteration in order to reduce the stress absorption during impact simulations.-
Injection mold a few samples so prototype testing and verification can be performed.Proper prototype testing should be performed on the product design which is manufactured with the determined manufacturing technique with the selected material in order to rely on the results.
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Calculate the cost for manufacturing the Smart Plug.-
Create technical drawings of the designed parts.-
This degree thesis work was limited to only examine the casing of the Smart Plug. A study could be made regarding the male and female ground spring, as well as the two terminal pins.References
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Appendices
Appendix A. Socket standard
A sample of the DIN 49440:1989-12
Appendix B. Plug standard
A sample of the DIN 49441:1972-06
Appendix C. IP Classifications
Appendix D. FMEA
in open position 4 Visual
Inspection 4 160 10 – Hazardous – Without warning
9 – Hazardous – With warning 8 – Very high Responsible: Nadia Samson FMEA Date (Orig.):
FMEA
Process/Product Name: Smart Plug Prepared By: Nadia Samson
DETECTION (1 - 10) RPN