DeWalt Powerstation Design Presentation

Phase 1: Problem FindingAaron Pierce

The Powerstation

Jobsite: Shelby Engineering Construction Site ResearchPartition teams 1&2

Plug it in, plug it in…Construction Site ResearchPartition teams 1&2

Phase 2: Problem Research + Initial ConceptsAaron

Construction Site ResearchPartition teams 1&2

Plug It In: jobsite cord management:

Plugging in and getting the power you need to get the job done right.

http://www.youtube.com/watch?v=vyMQKQHYcxQ&feature=related�





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.


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.


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.


OSHA Requirements:

Keep cords free from walkwaysand 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...


Goals…

Use established temporary power.

Accommodate multiple batteries and cords.

Deliver more power , more efficiently.


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.


Criteria

Easier to use than existing methods of “jerry-rigging” electrical connections.

Multiple cord and battery bays.

More efficiently use available temporary power.


Multipurpose ChargerMarket Research

Where is everybody?

Tool Base:Specialized or Tool Variety

Audience: Professional or DIY

Professionals

Specialized

DIYers

Variety


Battery Product Analysis…

Companies…Makita$25 - $170

12v-18v Single Battery Chargers

Automotive Application



Companies…Bosch$30 - $100

Single and Dual Bay Battery Chargers

Automotive Application

No Cord ManagementOr powerstrip capacity



Companies…Milwaukee$25 - $160

Single to Triple BayLi-ion Battery Chargers

Limited cord management

No power strip capacity



Companies…DeWalt$25 - $160

Single to Triple BayLi-ion Battery Chargers

Jobsite Radio

Light cord management


Initial Sketches: Power Station

Criteria…

Invincible

Multiple Li-Ion/Nickel Cadmium Battery Chargers

Cord & Plug Management

Powered by 120V Power Source

OSHA Compliant


Initial Sketches: Power Station

Criteria…

Invincible


Cord & Plug Management


OSHA Compliant

Phase 3: Concept DevelopmentAaron Pierce


Plug It In: Jobsite cord management:

Plugging in and getting the power you need to get the job done right.






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.


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.


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.


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


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.


Concept Direction : Lithium Battery Charger

Pros…

Invincible


Multiple Battery chargers


OSHA Compliant


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.

Concept Competing Products…

The 10C – Multicharger

Ryobi’s Multi-Battery Charger

Knaack’s Job Boxes: Storage

Where does all this converge?



Development…



Initial Sketches

Based on feedback from Jim Watson and the BSCI team, I explored those possibilities through sketches


Initial Sketches

Based on feedback from Jim Watson and the BSCI team, I explored those possibilities through sketching

Feedback on Sketches


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”


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.


Sketch Model Development

Black and Decker Senior Designer Tom Murray visited our studio, providing further feedback into the development of a sketch model


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.”


Sketch Model Feedback

Greg Lanier, owner ofAuburn 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


Sketch Model Feedback

Greg Lanier, owner ofAuburn 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


Final Concept:After choosing the concept that best met the end-user needs, and do so in an attractive way within that context.


Final Concept: The DeWalt PowerStationAfter choosing the concept that best met the end-user needs, and do so in an attractive way within that context.


Strong Sturdy HandlesCarry handles on both ends allow for easy pick up and set down in the bed of a truck, trailer, or gangbox.


SecureIncorporates for a padlock through the snap-latch handle to keep chargers and cords safe.


ModularTwo 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.


Atop-lid Storage

Clear lidded containers for hard-to-find hardware, charging your connectivity devices.


Strong Sturdy HandleHandle extends up to the best height for users, approximately 32”


Snap Latch LidBy squeezing the latch on the front of the Powerstation


Final Solution: The PowerstationAaron Pierce

The problem…Many solutions available to

electricians have to be adapted or modified to install temporary

power on a jobsite.

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

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.

Model DevelopmentAppearance model construction

from welding to painted assembly.

11/19

11/21

11/22

11/29

11/30

Powered Storage ContainerThe Powerstation uses the

power supplied by scope, in a way that is modular. Allowing

the workers to charge and work on the same line.

15’ Working Radii15’ Extension Cords supplied on the unit make working on parts

of the of the building from the same unit possible.

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

quence of use: Step 1 Romex Cables are wired into

ystem, powering the interior et, and modular units

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

Date post:	27-Jun-2015
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DeWalt Powerstation Design Presentation

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