DEVELOPMENT & VALIDATION
VALIDATION
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Our validation plan outlines the key requirements we plan to evaluate and the associated activities, resources, criteria, and timeline associated to the tests we aim to conduct. We separated out our validation plan into three dimensions that originally informed our concept design considerations, focused on desirability, viability, and feasibility. In order to first validate the functionality of our beta prototype, we focused first on validating that we could resolve our key design drivers which validates whether our proof-of-concept can actually work. These tests were prioritized for our initial validation plan before additional user testing and research were conducted to examine dimensions of desirability and viability, we are scheduled for the time before Design Expo. Below is a table summarizing the different test requirements we aim to validate.
Design Validation Plan
To ensure validation that our products meet specifications, we analyze and verify the functionality of our product components. Analysis and verification will include our main components, which are the cross frame, hinge, and steel strap; performance tests include whether the above components can withstand the weight of most helmets and components of different materials.
Modularity Check
Strap Testing
Wire Testing
In actual environment
EQUIPMENT- We used CREO Parametric FEA Simulation software to simulate the performance of the cross frame, hinge and steel strap under a load of the typical weight of the average size of the helmet. We also tried manual testing with wires, galvanized steel straps, and non-galvanized steel straps. In order to select the material for the parts under consideration, we used Ansys Granta.
PROCEDURE- To test the best possible size of steel strips in order to arrest the degrees of freedom of the spherical object (helmet) when placed on the cross frame in a locked condition we created jigs and fixtures that resemble our product's functioning. We used glue and clips to join together the metal plates in the V shape and kept the helmet on the measuring board. We did multiple iterations to determine the best angle of strips to hold/ secure the helmet at a place. In order to test the strength of the frame, hinge, and steel strap, we did the simulation to analyze the stress and mesh of the child parts under various load conditions. We also analyzed the material for the frame by plotting the graph for price vs density to determine the best possible combination of both. We also plotted graphs in Granta for mechanical tensile strength vs price.
RESULTS- We observed that flat and wider strips had more surface contact and were able to secure the helmet instead of wires. The best result for the strip angle that came out was -- degrees. Initially, we tried the frame in rectangular shape but it was observed that it created hindrances with the bikes while riding the bike. Therefore, the best possible design was achieved by optimizing the frame in a cross shape. Further, the FEA strength analysis was carried out that passed the structure for the given amount of load. For hinges, the results for the shear force of analysis at the hinge joint passed the test as well.
CONCLUDE- From the results we concluded that the cross shaped frame will generate best results in terms of durability and security of helmet on bike. The steel strap with plastic coating will serve to have better contact of surface than wires and hence will secure the helmet at a place.
REFINEMENTS- Further refinements will have a lock that is a part of the frame and not a separate entity. The cross shape might have the hindrance with the rider therefore further modifications of A-shaped frame is proposed.
SAFETY PLAN- For further safety of plan we propose to have A-shaped frame of product so that it does not hinder the user while riding the bike, this will be generated upon testing of existing one.
PROOF OF CONCEPT VALIDATION- FEA
The structural and mesh simulation analysis of the frame was carried out in Creo Parametric- 9, simulation was done on the basis of applying Aluminum alloy material and fixing the bottom of frame, by applying load of 4lb and the results passed the test.
HINGES - FEA Analysis
At the points of load, we did finite element analysis to evaluate the shear force that will deform the shape upon application of load. With the constraints set for simulation, the results passed the test.
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