Consumer product design of the year

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Drusilla Stokes
10 years ago
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1 Consumer product design of the year General Description Pedalite is a non battery-dependent bicycle pedal light utilising an energy storage capacitor and micro generator rather than any form of chemical battery. Minimising the issues of battery disposal and subsequent environmental impact, Pedalite provides a free safety feature 24 hours a day, 7 days a week. Flashing LEDs in each pedal provide 360 visibility. Flashes white to the front, red to the rear and amber to the side. Operates automatically when ridden (fit and forget). Energy is stored enabling the pedal to flash when the cyclist freewheels or stops. Provides a unique light 'signature'. Provides information for the first time on a cyclist's distance, relative position and speed. Easy to fit. No batteries to purchase or throw away.

Flashing LEDs in each pedal provide 360 visibility. Flashes white to the front, red to the rear and amber to the side. Operates automatically when ridden (fit and forget).

2 Materials Selection; Choice criteria; DuPont Delrin (Acetal) - dimensional stability, good wear properties. Duralon (Polycarbonate) - impact properties, dimensional stability (clarity for Nose Inner Moulding) Elastolan (PU Elastomer) - toughness, appearance, wear properties DuPont Zytel (Nylon) - mechanical properties Chosen materials Pedal Body; Zytel 80G14 Nylon Nose Overmould Assembly; - Inner Moulding; Duralon VR 2000 Polycarbonate - Over Moulding; Elastolan 1185A PU Elastomer Reflector Housing; Lustran M202AS ABS Spindle Seal; Elastolan C90A PU Elastomer Bearing Support Moulding; Delrin 100ST Acetal Gearbox Enclosure; Duralon IR2200 Polycarbonate Gearbox Enclosure Cap; Duralon IR2200 Polycarbonate Gearbox Drive Train; Delrin 100P Acetal Large Spindle Pulley; Delrin 100ST Acetal Drive Belt; Polyurethane with Polyester Reinforcing Spindle Bearings; Iglidur G Standard Igus flange bearing Spindle Seal Bearing Support Moulding Pedal Body Spindle Bearings Large Spindle Pulley Standard Reflector Gear Box Drive Train Reflector Housing Nose Overmould Assem Drive Belt Gearbox Enclosure Cap

mechanical properties Chosen materials Pedal Body; Zytel 80G14 Nylon Nose Overmould Assembly; - Inner Moulding; Duralon VR 2000 Polycarbonate - Over Moulding; Elastolan 1185A PU Elastomer Reflector

3 Aesthetics Designed to look good both on the bike and the shop shelves, Pedalite is purposely styled to be 'soft' preventing grazing injuries to both children and adults. Pedalite's 'form follows function', carefully wrapping considered plastics around the central spindle and the off-set generator / gearbox and PCB assembly. Aggressively styled grips provide the detail to stop a wet shoe from slipping off the Pedalite. Pedal design is severely restrictive; adhering to global legislation Pedalite is designed to use standard approved reflectors. The 24/7 light output does not replace existing lighting, but supplements it with an additional lighting feature providing a unique light 'signature' (lights moving up and down) helping the motorist judge the distance to the cyclist.

Aggressively styled grips provide the detail to stop a wet shoe from slipping off the Pedalite.

4 Design for Manufacture Designed by Product Partners, in conjunction with the client (Pedalite Limited), toolmaker / moulder (ENL Limited), gearbox manufacturer (Davall Gears) and polymer distributor (Distrupol Limited). A close working partnership with ENL ensured Product Partners ideas were successfully translated through the design, development and toolmaking process ensuring 'right first time' product. The technically challenging combined Nose Over-mould Assembly, for instance, was approved at the first-off tool trials. To ensure the gearbox concept was feasible Davall Gears were partnered to provide their expertise with; gear ratios, gear detail design, materials specification and manufacture. Delrin 100P was specifically chosen for its exceptional wear characteristics and self-lubrication properties. Exploded Gear Box Assembled Gear Box

A close working partnership with ENL ensured Product Partners ideas were successfully translated through the design, development and toolmaking process ensuring 'right first time' product.

5 Distrupol's expertise provided assistance with materials selection and Moldflow analysis. This relationship enabled positive feedback into the developing design to modify the components in CAD and reduce potential moulding issues of sinkage, flow marks, weld lines, etc. Fill Time Plastic Flow Skin Weldlines

This relationship enabled positive feedback into the developing design to

6 Market Reception Patented world wide and launched at Interbike, Las Vegas in October 2004, Pedalite received a great interest from the public and distributors - agreements have been made with distributors in; Europe, USA, Australia and Japan. Targeted 'rider groups' for Pedalite standard issue include; The Post Office, Police forces and leisure hire businesses. Stocks of Pedalites are currently being manufactured to coincide with the March, 2005 'on sale' date. In the UK Pedalites will be available through Ergonomics Aggressively styled grips provide the detail to stop wet shoes from slipping off the Pedalite. The generator / gearbox 'power bulge' enables the cyclist to feel pedal orientation through their shoe ensuring correct use. An orientation 'double check' can be achieved with a quick glance at the pedal to check the red orientation LED is positioned to the rear. The combination of the tough Nylon Body and Polycarbonate Nose with over moulded 'soft' PU elastomer, enhances the purchasing experience providing a quality tactile feel to the pedal. Styled Grips Power Buldge Orientation LED

Stocks of Pedalites are currently being manufactured to coincide with the March, 2005 'on sale' date. In the UK Pedalites will be available through www.pedalite.

7 Fitness for Purpose A 'free' safety device, once fitted the cyclist can be seen 24 hours a day, 7 days a week for only 0.5% (0.3W) of their propelling energy. Easily assembled, all internal electro/mechanical components are simply 'dropped' into the rugged pedal body and sealed from the elements by the Nose Over-mould Assembly. Intelligently designed, the Nose Over-mould Assembly comprises a clear Polycarbonate lens to maximise light output, whilst the over-moulded PU Elastomer not only provides impact, scuff and abrasion resistance to the lens but also the watertight seal to the pedal body.

Easily assembled, all internal electro/mechanical components are simply 'dropped' into the rugged pedal body and sealed from the elements by the Nose

8 Speed to Market The design of the polymer Pedalite commenced in February 2004 and followed all the usual design and development processes of: Concept development February 2004 CAD development March/April Finite Element Analysis April Rapid prototyping May Test May Moldflow June CAD finalisation June Toolmaking July/August/September First off trials October Product launch October Tool development November/December Product on sale March 2005 Design for Sustainability Sustainable design is a fundamental to Pedalite philosophy. Pedalite's are designed to: 'Last for life' utilising 'fit and forget' principles with a non battery-dependent power source. Maintain life, ensuring cyclists are visible 24 hours a day, especially in those early morning and late afternoon 'half light' hours when battery powered lights are often switched off to save money. Minimise the issues of battery disposal and subsequent environmental impact. Utilise minimum energy; a cyclist will expend less than 0.5% (0.3W) of their propelling energy to energise a pair of Pedalites. Be easily transferred to another bicycle or recycled at the end of their working life.

development November/December Product on sale March 2005 Design for Sustainability Sustainable design is a fundamental to Pedalite philosophy.

The State Government recognises. areas, and regulates bicycle

cycling & THE LAW rules introduction for roads The State Government recognises The cycling South Australian as a legitimate Road Traffic form of Act including transport the Australian and an increasingly