Exploded view 1
In the picture the exploded view of the inner workings of the toaster are shown. Clicking on the picture enlarges it.
Buttons & Lights
In order to change the settings on the toaster for the ultimate piece of toast, a few buttons were needed. I used the standard buttons that were already placed on the circuit board. To make it possible to actually press them I created a few button parts that guided the button to the outside. Besides that I also guided the turning button to the outside. Because its important to know what setting is selected I also created some light guides. These light guides endings move along with the outside of the toaster giving it a great look.
To solve the problem that I had with the connectivity points i made them a lot thinner. This not only solves the problem I had with the fact that the part was to large, but also saves material. This at the same time means that it saves costs.
To connect the sides of the toaster to the bottom I had to draw connectivity points. For the first try I created A thickening into the corners. In this thickening a hole could be drilled so that a screw could connect both parts. There is just one problem; that it is to thick compared to the rest for injecting molding. Because of this reason I need to find another method.
Yesterday I had a conversation with my mentor in which I explained to him that I don’t think I can finish my project(‘s) on time. Because I have an internship planned for the next and last two periods of this year, I asked him what I should do. For him to decide what the next step should be he told me to fill in the evaluation paper, giving a clear overview of my current progress.
So that’s what I did. In the link below I attached a PDF file of the evaluation paper, filled in by me.
The past 2 weeks I had a Christmas break.
Today I had a conversation with my mentor Jan-Willem Cremers. I showed him the new shape of my toaster and told him about how it was split. He liked the way it looked and told me to go onto the next step.
I chose to split my skeletonpart up into 3 parts the reason behind this is that it s easy to produce this way by injection molding. The left and right part are the same part which makes it more cost efficient. Also both parts can be produced with a 2 part mold.
Today I had a conversation with my mentor Otto Donkers, talking about how to shell my skeleton part. The reason we had to talk about it was because no matter the thickens I set it wouldn’t shell. The first advise he gave me was setting the shell thickness very low but when this didn’t work he gave a look at it. After a try on his pc we found out what the problem was. The only reason there was a problem was because my laptop didn’t have the power to process it.
Skeletonpart 6th Try
I showed the skeletonpart to my mentor Jan-Willem and he gave me some orders to change its appearance. He told me to make the edges from the corner on the side sharper as well as bring the curve more to the middle. If this is the shape he is looking for its time for the next step, otherwise I still have to create a 7th version.
Skeletonpart 5th Try
Once again I am starting over. This time I built it a bit different; This time I only used projected curves to build surface lofts. These lofts I then connected with boundary surfaces.
This way was the correct way according to my mentor. I finally did it!
But this wont be the last version because the shape doesn’t match enough to the clients sketch.
So without further ado lets create the 6th version.
Skeletonpart 4th Try
Trying to create the toaster again for the 4th time it worked better time than the last time but its still not where it should be. I showed it to my mentor Jan-Willem and he told me to start over again. I also showed him my third try of which I thought it was also a good option. But according to him I wouldn’t have enough control over it. So the next step will be making a 5th version.
Skeletonpart 3rd Try
Getting stuck on the 2nd try I decided to start over again. this time working with surface sweeps. This seemed successful and gave me a good looking toaster. By creating this toaster I got some ideas about how I could improve my 2nd try and maybe bring it to a success. So I am going to try this for a 4th version, if that doesn’t work I am going to stick with the 3rd version.
Skeletonpart 2nd Try
With the second try I started working with surfaces again. This time instead of basing the surfaces upon sketches I based them upon but instead of basing the surfaces upon sketches drawn on a sketch plane I based them on project curves. By basing a surface on a curve its possible to eliminate all the straight lines.
Skeletonpart 1st Try
I started out by drawing out a simple floor plan of the toaster. This was done to give me an idea of the size it was going to be. After this I started creating my toaster with surface modeling. After asking a question to my mentor Jan-Willem he told me that all the edges should be curved and that I needed to start over from the start.
Covering It Up
I drew a sheet metal case that holds all the inner workings of the toaster. It got holes for the rotation axis as well as for the circuit boards. Around this case i’ll need to create a plastic housing based upon the sketch that was provided by the client.
In the video below its shown how the magnet release system works.
The Holy Grail
After a lot of work and suggestions from my mentor I finally managed to get my magnet release system to work in SolidWorks.
The magnet is connected to a punched out slab in the middle of the heat blocking part. By locating the magnet below the slab it will never intersect when the bread is released.
A New Beginning
Today I sketched out the new idea for the magnet release system. This sketch is made to quickly put down my idea on paper so I wont forget it. Now the next step is putting it in SolidWorks to test out the concept.
Today I had my weekly check-in conversation with my mentor Jan-Willem. I showed him the problem that I’ve been having with placing the magnet. I showed him the examples of the attempts I made that had failed. He told me that me that my idea could still work if I moved the rotation point closer to the center of the bread compartment.
Another option is to connect the magnet at the middle of the bread compartment in the next post I’ll show a drawing of the Idea and give further explanation.
Thinking about it with the last try it was obvious that this was not going to work. But this time I tried a 45 deg. angle instead of a 90 deg. for the corner. this gave the same problem as last time; the magnet and the corner intersecting when rotated. After trying this method for the third time I think I’ve hit a dead end.
Because of this I shall have to look for different solutions. I shall also seek advise from my mentor and ask him about his thoughts and ideas, because I can’t help feeling that I’m missing something.
Keep On Thinking
Taking the idea from the first configuration I tried to connect the magnet with a corner again. Even though this time the corner was placed in the right place this time it still didn’t work. This is because it would get stuck on the final corner of the magnet as shown in the image.
The first Idea I had was to create a corner on the heath insulator for the magnet to hold on to. although it was a good idea the corner prevented the compartment from turning so it was a no go.
The Bread compartment turns over an axis in the upper left corner. Because of this there is an entire circle in which nothing an be placed because it would otherwise prevent the compartment from turning.
To create the configurations in Solid works first all the parts have the be created.
In the images below all the parts are shown with their recreated 3D model.
Today I discussed with my mentor that I should go on brainstorming in Solid Works toÂ make sure that my idea’s on paper will work and that I won’t come to the realization that my sketch idea’s wont’t work.
The next idea
When I presented the configurations to the client he liked the first configuration. But he wanted to make one change to it; He wanted the bread compartment to turn out. How this works is shown in a communication sketch below. The idea that he had was by placing a hinge in the corner on which the bread has to turn. Now it is up to me to find a way to realize his idea’s.
Make it work
In order to make his Idea I have to find a way a way to make it work from the inside. The first part I started working on was finding a place for the printed circuit board, responsible for the release system.
this was set out to be a challenge because it can not be placed within the turning radius of the bread compartment. Its also not allowed to change the layout of the printed circuit board or changing the toaster design to make it fit.
As shown in the picture are 2 options; the first one is actually not an option because part of the circuit board wont fit into the toaster. The second picture is an option to place the circuit board on the side of the toaster. But this idea is also not likely to be perfect so I am going to keep on brainstorming.
Together with my mentor Jan-Willem (Also the client) we chose the best configuration, this configuration is configuration 1. But he wanted to make some changes to the toaster to make the design more challenging and more exiting. These changes will be described in the next blog post.
For the first configuration I designed the middle section to pop out to the front. the part that pops out has a slice of bread at each side with a heath element separating them.
this configuration is also the configuration that is chosen with the client. But this configuration will undergo more design changes.
The second configuration works by ejecting the entire front side of the toaster. the main difference with the first configuration is that the slices of bread are further apart and that the heath elements stay inside of the toaster.
The third configuration was designed to be like a drawer that pops out. The two slices of bread would be placed next to each other. with the heath elements staying inside of the toaster.
Together with my mentor Edwin I discussed the progress with my toaster project, I told him that I was having startup problems as I found it difficult to start with CAD. As feedback he told me that if CAD actually was the problem that I should stay in the sketching phase for a longer time period so that I would still be going forward. Until a point later in the project when there is no choice anymore. Hoping that by then my startup problems would be gone.
A Smarter Way To Do Things
The client is on a tight schedule to release his toaster, because of this he provided his own schedule. These due dates need to be met so he can release it with the rest of his product line to be presented in February.
The two sketches below shall be combined into one toaster. How this is done is up to me to find out and to be discussed regularly with the client.
The Design Sketch
The basic sketch is already provided by the client.
The shape of the toaster will need to come as close as possible to this design.
Also the inner workings of the toaster are already chosen by the client. even though he does not know how to make it work he explained it through this simple sketch.
The summer holiday is over and the time of school and waking up early has begun. Because there is no better way to kick-start your day than with a healthy breakfast, I’m going to design a toaster.