Design with Composites - Composites CIS - О …composites-cis.com/proceedings2013/ru/16.pdf ·...
Transcript of Design with Composites - Composites CIS - О …composites-cis.com/proceedings2013/ru/16.pdf ·...
Design with Composites
with special reference to
Applications in Indian Railways
Presentation
for
K. Munshi Professor, Emeritus Fellow Industrial Design / Mobility & Vehicle Design IIT Bombay
© K.Munshi
Traditional Composite Materials
Grass Reinforced Mud / Dung Composite Huts
Steel Rienfoced Concrete Bridges
& Buildings
Modern Composite Materials
Plywood Wood +
Phenole formaldehyde resin
14’ square Plywood house
Eames Plywood Chair
Wood based
Composite Materials
Conventionally
application of FRP is
limited to industry -
substitute for steel,
aluminum
profiles, castings,
pipes, fabrications,
panels, drums etc.
FRP –
Consumer
application
limited to
Door panels,
window frames,
Roofing etc.
Beach Cabin in FRP
© K.Munshi Beach Cabin A
The potential of FRPs is immense -
yet to be explored
Creative design
inputs can make all
the difference to make
composites a truly
wonder material
Fiber Reinfoced Plastic (FRPs)
FRP Bridge
Glass
Carbon
Poly propylene
Nylon
Jute
Cotton
Bamboo
Hemp …….
Polyester
Epoxy
Nylons
ABS
Phenol formaldehide
Rubbers ……
Apart from material & process SHAPE is an important factor
Desert
Cooler
Panel
A/C Panel
Wash basin Panel + water tank
Panel with shelves Storage panel Panel with hooks & pegs Panel with built-in seats / tables
Panel with toilet seat & cistern etc.
COMPOSITES -
Designer Materials - can
be tailor-made to have
properties to suit the
application in mind.
‘Industrial design’ can
have a very close connect
with composites - to
realize the immense
potential of composites.
This presentation will
explore this connect with
cases from India
MODULAR PANEL
with Amenities
Powai Lake during Monsoon…… IIT Bombay
IDC IIT Bombay offers a 2-year program M Des Industrial Design
Visual communication
Interaction Design
Animation Design
Mobility & Vehicle Design
The program is meant to develop Knowledge, skill & aptitude to become creative problem solvers and to bring about innovation in the manufacturing and communication industry
© K.Munshi
Micro Battery
Chargers
Solar Rice Cooker
Sanitation Products
Emphasis on socially
relevant projects
© K.Munshi
DESIGN INTEGRATION
Structure & Configuration
Culture & Context
Production & Technology
© K.Munshi
’Design utilisation can be classified into two user
segments. One is design for industry which include big
public and private sector undertakings as well as small
scale sector. This design is already taking place but the
pace at which it is going on, its perceptible and social
impact is limited. The other segment which is fertile for
design inputs is the design for utilities and services which
include transportation, traffic, health, communications etc.
The design inputs in this segment can make perceptible
and immediate impact. The improvements can be seen
quickly and widely. For example Indian Railways can
become biggest receiver of design services if it recognizes
the need for improvement in speeds, carriages, rolling
stock, passenger facilities etc.’
Dynamics of Design & Technology - An Indian Overview, Invited lecture at
International Confrence on Development & Design in South & Southeast Asia,
organised by University of Honk Kong, Honk Kong, Nov.1988
Technology Missions -
Dr. Abdul Kalam Principal Scientific Adviser to Govt. of India
Composites Mission
TIFAC – DST
INDIAN RAILWAY –
RDSO &
Rail Coach Factories
VENDOR –
Hindustan Fibre Glass
Works
IIT BOMBAY –
Ind. Design Centre
Aerospace Engg.
12 Years later…………….
© K.Munshi
© K.Munshi
TIFAC Technology Information Forecasting & Assessment Council
ran
A unique mission –
Advanced Composite Program (ACP)
to promote the use of composites in the country.
Its policy of involving end users and supporting user
industry through easy finance and providing high quality
expertise through consultants ensures success for the
projects of which they have created many examples.
Problems are
Huge!!
What can
designers do?
Design for People
© K.Munshi Modular Toilet for Rail coaches - prototype (exterior)
Case 1
© K.Munshi Modular Toilet for Rail coaches - prototype (interior)
Case 1
© K.Munshi
Modular Toilet for Rail coaches - schematic
Factory built modules
Easy assembly
Maintenance free
Low weight
Long life
Hygienic
Case 1
New Projects:
- Diesel Locomotive Driver’s Cabin
- 3 Tier Sleeper Coach
Indian Railways Increasing appreciation of Design Contribution
for passenger amenities, driver comfort & Safety
….2004 - 05…
© K.Munshi
Case 2
Upper berth –
Descending sequence
1 2
3 4
© K.Munshi
Research in human factors
Case 2
53 c
m
30 c
m
152 cm male
Research in human factors © K.Munshi
Case 2
3 Tier Sleeper Coach - Mock up
© K.Munshi
Case 2
3 Tier Sleeper Coach - Prototype © K.Munshi
Case 2
3 Tier Sleeper Coach - Prototype / Mechanisms
© K.Munshi
Case 2
Integrating human, aesthetic & cultural
factors with materials & Technology
3 Tier Sleeper Coach - Modular Construction
© K.Munshi
Removed
metal support
structures to
reduce weight
& complexity
Integrated FRP modules to
provide overall strength
Case 2
Diesel Loco Driver’s
Cabin
DESIGN OF
DIESEL LOCO DRIVER’S CABIN
for
INDIAN RAILWAYS
Case 3
Diesel Loco Driver’s
Cabin
Case 3
Diesel Loco Driver’s
Cabin
Case 3
Diesel Loco Driver’s
Cabin
Case 3 Investigation of Issues
Diesel Loco Driver’s
Cabin
Case 3
Diesel Loco Driver’s
Cabin
Case 3
Diesel Loco Driver’s
Cabin
DESIGN OF
DIESEL LOCO DRIVER’S CABIN
CONCEPTS
&
STUDY MODELS
Case 3
Diesel Loco Driver’s
Cabin
Most of the panels shall be identical
thereby bringing down variety and hence
cost of tooling and product Diesel Loco Driver’s
Cabin
Case 3
Diesel Loco Driver’s
Cabin
The panels shall be clad on to the existing
structures
Diesel Loco Driver’s
Cabin
Case 3
Diesel Loco Driver’s
Cabin
CONTROL PANEL
1. Present panel seems to have evolved with time and
hence has not integrated all the items into a single
console
2. Proposed panel : integrate all controls and display
into a smaller, more visually and physically
reachable console .
3. All Brakes shifted to console, leg pedal to be part
of console accessible from the seat.
Case 3
Diesel Loco Driver’s
Cabin
Identical console module with duplicate
controls and displays for both users
VIEW FROM OUTSIDE THE WINDOW
Diesel Loco Driver’s
Cabin
Case 3
Diesel Loco Driver’s
Cabin
And displays more readable Control are now more accessible
Reachable…... Diesel Loco Driver’s
Cabin
Case 3
Diesel Loco Driver’s
Cabin
ALTERNTIVE LAYOUT - 1
Integrated consoles oriented so as to give
more room.
Diesel Loco Driver’s
Cabin
Case 3
Diesel Loco Driver’s
Cabin
And also aid access of all consealed
equipment for maintenance
Diesel Loco Driver’s
Cabin
Case 3
Diesel Loco Driver’s
Cabin
Integrated console is made less taller
now will help drivers see each other, communicate and
coordinate better.
Diesel Loco Driver’s
Cabin
Case 3
Diesel Loco Driver’s Cabin
Case 3
CONTROL CONSOLE PROTOTYPE
Diesel Loco Driver’s
Cabin
Case 3
Diesel Loco Driver’s
Cabin
Case 3
Indian Railway
Completed Projects
In FRP
Composite Interiors for Railway
Passenger Coaches
Composite Interiors for Drivers' Cabin
in Diesel Locomotive for Railways
Composite Sky Bus Coaches
FRP Main Door for Passenger & EMU
Coaches
FRP Modular Toilet Units for Railway
Passenger Coaches
Energy Efficient Axial Flow FRP Fans
FRP Gear-Case for Railway
Locomotive
Composites Sleepers for Railway
Girder Bridges
HOUSE BOAT For
Kerala Tourism
© K.Munshi
Research :
Life-style,
Environment,
Ecology & culture
Case 4
© K.Munshi
Case 4
1st Prototype
Luxury Houseboat for Kerala Tourism - Exterior
4.5 M
X
25 M
3.5 M
Luxury Houseboat for Kerala Tourism – Prototype Building
© K.Munshi
Case 4
Luxury Houseboat for Kerala Tourism - Interior
© K.Munshi
Case 4
Luxury Houseboat for Kerala Tourism
Modular Construction- 5 Modules for super structure
© K.Munshi
FRP Hull & Super-structure
Self-supporting interlocking
modules (no metal supports)
Factory built panels
Expandable system
Easy, Fast & Economic assembly
Case 4
Frangible Cabin in FRP For Bangalore
International Airport
© K.Munshi
……. With built-in weakness
Case 5
Frangible Cabin in FRP For Bangalore
International Airport
Modeling & Analysis to ensure it collapses
on impact with aircraft
© K.Munshi
Case 5
Designed to Collapse
Case 6
Single unified
Body design in FRP
integrating
Styling,
Ergonomics,
Engineering
All the components
are mounted on the
load-bearing FRP
body
Electric Vehicle
© K.Munshi
No metal chassis
Light weight
Vibration & Fatigue
resistance
www.ctechlab.com
Mentoring for new product development, leading teams of
developers. Hand-holding till the prototypes are made
Introducing Methodologies & product development strategies (analytical
tools, creativity tools etc.) to achieve high certainty of success
Motivating & Challenging for higher levels of creativity
Monitoring product development process to create products for
high productivity of design effort
4 M Strategy …… ????
Methodology
Mentoring
Monitoring
Motivating
,
Innovation
Development
Company
……..creative design strategies, appropriate engineering
concepts, combined with humanistic approach help
develop innovative products, which also address the
concerns of the users effectively and make these products
successful in the market place …..
The power of ‘holistic & integrated
design’ approach can unleash the great
potential of Composites as a material
and be the driver for its future growth….
……..creative design strategies, appropriate engineering
concepts, combined with humanistic approach help
develop innovative products, which also address the
concerns of the users effectively and make these products
successful in the market place …..
The power of ‘holistic & integrated
design’ approach can unleash the great
potential of Composites as a material
and be the driver for its future growth….
Thank You