Orbito, Hand Orbital Machine

Random Orbital Buffer for automotive polishing(for domestic use)Vidhi Mehta | Product Design | 6th Semester | NID | Guide : Bhaskar Bhatt & Gourab Dhar

What is a buffing?

The smoothing and brightening of a surface by an abrasive compound pressed against it by a soft wheel or belt. Buffing may be used to enhance the looks of certain parts on cars, motorbikes, handrails, cookware, kitchenware, and architectural metal applications. Pharmaceutical, dairy, and water pipes are buffed to maintain hygienic conditions and prevent corrosion.

Buffing can be done by using:

Hands A thin, straight line of polish is directly applied to the paint, then a micro fiber towel or applicator pad is used to polish the paint. Hand buffing must be done in small sections at a time, part by part. The polish is rubbed into the surface using circular, overlapping motions. It is then let to dry, then removed with a clean, soft micro fiber or terry towel.

Electrical Buffer It uses electricity as its power source. The electric tool is encumbered with its motor and related components. Electric models are quiet and generally not very expensive. Electric buffers are further classified into high-speed rotary and random-orbital. Rotational Buffers: The high-speed buffer’s simple circular motion, combined with continuous high revolutions per minute (RPMs), thus creating heat and allowing uniform corrosion. This heating action allows for correction of extensive damage such as heavy oxidation and deep scratching.The speed at which the pad rotates and the size of the pad is directly proportional to the amount of polishing action.

Random Orbital Buffers: The wheel of a random-orbital buffer, operates with two separate motions: a slow circular motion combined with an orbital motion. That is, as the wheel spins, it also orbits slightly off-center around a central point. This action essentially imitates hand motion, making the random-orbit buffer virtually no more dangerous to use than your hands, yet much faster with increased consistency of results.

Compressed air Buffers The source of power is supplied by a separate compressed air source, has none of the motor components. Pneumatic machines are light and requires very less maintenance. Pneumatic devices offer varried control of speed adjustment (revolutions per minute) and are not subject to the shock hazard of combining electricity with wet working conditions.

How electric random orbital buffer works?

The machine operates by orbiting the polishing pad around a center spindle while the pad freely spins on its own axis. A counter-weight on the opposite side of the center spindle dampens vibration for smooth operation.The tool head action, often called orbital, prevents the creation of holograms (symmetrical buffing marks), paint burns and other forms of paint damage often associated with high-speed buffing machines. The polishing action of the machine closely mimics that of circular hand polishing. Imagine being able to make 2,500 to 6,000 tight hand circles in a single minute and you’ll have a pretty good idea of how the Orbital buffer does its job. It works just like your hand, only at super-human speed!

Features:

Power 120 VAC, 50-60 HZ/120 VDCMotor 110 volt, 3.7 ampSpindle Thread Accepts 5/16 - 24Weight 9.6 kgsBacking Plate 4.75” diameter, flexible, with hook & loop (Velcro) backing

Electronic variable speed 2,500-6,000 rpm Highly impact heat-resistant ABS shell

Porter Cable 7424XP with the Backing Plate Removed Exposing the Counterweight and Free Rotating Spindle Assembly

Meguiar G110 with the Backing Plate Removed Exposing the Counter-weight and acœrandom orbital mechanism

Inside a Random orbital buffer

Random Orbital Mechanism

Inside a Random Orbital Machine

DeWalt DW443 Right Angle Random Orbital SanderAmpere - 4.3RPM - 4000 - 6800Orbit Diameter / Stroke - 3/16”Weight - 2.6 kg (approx.)Pad Size - 6” diameter

At Haily’s Car Spa, Akota, Vadodara

This is armature

This part is driven by the armature. It attaches to the fan

This part is the fan, it is driven by the driveshaft protuding from the bottom. The hole in the middle is not centered but is instead offset from the drive shaft axis by 3/16”. So, as it circum navigates the shaft, it creates a pat tern that measures 3/16” in diameter. (twice the distance by which the shift occurs. This part also has a counter balance mechanism in order to ensure center of weight. (picture in the previous page)

Shaft with 2 bearings fit inside the fan. The shaft spins independent of the driveshaft. The backing plate and then the polishing pad are mounted on this. The backing plate is attached using 4 screws.

This is the backing plate

Inside a Random Orbital Machine

Parts of a Random Orbital Machine

base for drive shaft

top view base for drive shaft

bottom view base for drive shaft

base mounting for backing plate

> A motor-driven driveshaft that is used to propel the backing plate mounting point around the driveshaft axis> A backing plate mounting point> A free-spinning bearing that allows the backing plate mounting point to rotate in either direction> A backing plate> A counterbalance (perhaps not necessary to create the motion, but necessary for extending machine life, increasing user comfort, and offset balancing the movement of all other moving components )

Working

Motion of Random Orbital

Buffers are used for car buffing and polishing. They are quite effective in maintaing car paints and to keep them looking shiny. Rotary Buffers are very effective in removing car scratches and can remove even deep scratches with professional assistance.

Euro Carz SpaPlot No. 13 / 311, Nr. Varsha Flats,Vishwa Kunj Char Rasta, P.T. College Road,Paldi, Ahmedabad - 380 007Gujarat, India.

Studying Present users of Buffer in India : Car Detailers

Task Analysis

1 2 3

4 5 6

1. Car is throughly washed and dried 2. All edges and openings are sealed using tape 3. Polishing sealant is applied 4. Orbital buffer assists in spreading it uniformly till a hazy finish is achieved 5. Extra care on the scratched areas 6. Once sealant dries it is polished using polishing pad

Car detailing of Optra at Carzspa, PaldiThe car is first washed and dried, bonnet lines, areas near headlights are sealed with tape and then liquid wax was applied and buffed with orbital buffer. Process time: 30-40 minutes

Applications of Orbital Buffer

>Clean glass

>Polish floors and tiles

>Remove tough stains from tapestry

>Polishing artifacts

>Rust removal

> Automotive buffing and polishing

“The age at which people buy cars and drive cars have reduced drastically. It is not a surprise to see a late 20s Professional pick up a semi-luxury sedan these days – Scoda and the Hondas. These are all mostly self-driven cars, which means they don’t have a driver, which also means there is no one to clean these cars in the morning everyday. So one option is to appoint a person who washes your car every morning because for a professional working in an IT company, or anyone in a 9-5 job, this can be quite an effort. I know this, because I suffer from the same. Else there is an option of going to an automated car clean service. Professional car cleaning is great but it is not affordable on regular basis. http://vijaysblog.wordpress.com/2007/08/08/ideas-to-toss-car-wash/

“The western part of the world have evolved much earlier in this field and they have moved from calling this body of knowledge Automobile detailing from the generalized “car care” but in India, it is still at a nascent stage, with car care slowly moving out of the dingy accessory shops in narrow alleys into elegant “state of the art” detail shops, car washes and osten-tatious service stations fully equipped to handle all the “World cars” that the Indian market offers.Virtually, every car will have some kind of detailing done to it. To start with, it will receive a new car prep (A simple wash and a polish) at the dealer showroom before it is sold. Unfortunately for some cars in this country, this is the only time they are cared for. A well-groomed car should receive washing, polishing and waxing on a regular basis by its owner until the point in time when it is no longer fit to be on the road.

”

”Carzspa Franchisee owner, Anckur SharmaChain of Car Detailing Workshop in Ahmedabad(Photo borrowed from newspaper article, The Franchinsing World, 2009)

Market for orbital buffer in Indian context : Automotive Detailing

Car care has been around in some form since the invention of cars but now you will find that car care becoming not only a huge business but also a fun thing to do on a lazy Sunday morning. The sustained growth of the Indian automobile sector will sure that car care will soon be the norm than a luxury. Further, easy access to finance, younger age of ownership and introduction of contemporary "world cars" in India has seen India move from the era of drab-looking "Ambassadors" to swanky "Optras". From the dinosaurian "FIAT" to the nimble "HONDAY CITY VTEC". Having a good-looking car is be-coming important to Ahmedabadi people.

According to me Indian people still prefer the old method of appointing a person to clean your car every morning. This costs much less than an automated car clean at a service station and will ensure that car gets cleaned regularly without any extra effort besides ofcourse paying the guy. Its very convinient, he comes home, takes your keys, cleans the car, you dont have to do any thing. Another system that I have observed is car servicing at the office site, there are companies who do washing of 2 & 4 wheelers in office locality. Its a better model for IT Parks, since many of the bikes, cars are being parked for about 8 hours. There is a microenterprise over here.

Where is the problem in the system then?

The style of washing and waxing achieved by automated or professional car detailers never damage and make any scratches in cars, compare it to inexperienced car cleaner who are most likely driver, office boy or watch man.

Solution

Equipping “unprofessional”, or not so trained car cleaner better by providing them with a product to give you almost professional detailer like results. A product that helps them to give that extra finishing touch to the car and also remove minor scratches etc.

Target group:

Buyer of the product would mostly be the car owners (segment of men late 20s to 50s). Also young entrepreneuring people who want to make car cleaning as a micro business as suggested earlier. They would get an edge over the regular ones that only use a bucket and sponge.User group of this product is definitely our watchman, house or office worker who is usually our car washer.

Market for orbital buffer in Indian context

Office Employee cum car washer, Kanu Bhai (sample user)

He works as a peon in the office. One of his weekly morning chores includes washing and cleaning the car. He takes about 15-20 minutes to do this job.

What do they use?

bucketlocal shampoo (doesnt know the name) sponge - to apply soap over the carcloth (terrycotton cloth, one used to make floor rags) - to wipe the car drywater (usually a tap in the basement)

Starts with first pouring water over the car and then slowly applying soap using the sponge, (soapy water is made in the buck-et) next water is poured over the car again. Glasses are dried with clean cloth and then painted surface and headlights.

Main aim is to remove dust, mud and bird droppings.

Interior of the car is cleaned later. Dus

Cars get cleaned 2 times a week

Unknown to the idea about car buffers or waxing cars.

User Persona of the Product User

User Persona of the Product Buyer

Young enthusiastic car ownerswho want to maintain their cars but dont have enough time to do so themselves, Car is a prized possession for them

USER FEEDBACK (from potential buyers)

Mr. Haresh Kamdar ( mid 40’s ) No one likes to use a dirty looking car, washing a car every 2-3 days makes sense. Buffing, waxing cars is like extra pampering your car. I also don’t see a point in buying a buffer for my home car washer, I am not sure if he will be able to correctly use it either. Unless the buffing proves to show some extra result ofcourse, I am not quite aware of its advan-tages.

Mr. Brijesh (24 year old, first car) : Why not? If it is affordable, it’s worth one time investment. Should be battery operated though, finding access to power will be pointless. Also it should always stay inside the car. It shouldnt be a very complicated process for my car washer to learn.

Ms. Sania (28yrs) : Processes like buffing and polishing are done abroad to keep your car scratch free. Looking at how people drive in India, I ll keep getting scratches every few days, maybe we have just grown used to them and don’t really bother about them.

I wash my car with a good shampoo every 3 days, polishing is usually a monthly affair, mainly because of the expense. Probably if I invest in a good buffer I would wax my car more often, say once in 2 weeks.

I would rather prefer a multi purpose cleaner than just a waxing tool, if it helps in removing glass stains etc.

I think an attachment to the car or bike, that can be docked and removed and used at ease will be useful

A rust remover for chrome parts, or for bicycle spokes

//Essentials: users do not regularly use power tools, something that is easily accessible within vehicle range, concern : domestic washers will find electric tool complex, pads need to be reuseable - used for more than one use cycle, changing pads should not be complex - should not need screwdriver or tools, should not damage car, wires and need of electric supply make it difficult to use

Price Finding

Market Research and Price Comparison

Ace Hardware Workpro Orbital BufferRs 1650

Titan Products 6" Random Orbital Buffer/Polisher3,500 (OPM)Rs 1500

Carrand 94000AS AutoSpa 6" Orbital Professional Automotive PolisherRs 1350

Griot's Garage Rs 8500

Dewalt Tools DW443 POLISHER RANDOM ORBIT4.3 Amp motor4,300-6,800 rpmRs 8750

Kawasaki 6in. Heavy Duty Orbital PolisherRs 2,300

The Indian market hardly has orbital buffers for domestic use. Although the market is flooded with DIY auto detailing kits. These include waxes and polishes and anti scratch sprays. But a machine to use them is rare find with a car owner. These polishes are usually only used by car owners itself as a weekend project over holidays. Professional car detailing packages costs something between Rs 3000- 7000/- per service for sub-compact, compact, mid-size, luxury and ultra-luxury cars. This package includes jet car wash, buffing, polishing, sealing, car interior cleaning, chassis degreasing and cleaning.The product will compete in its price range based on the professional detailing service rates and orbital buffers used by them.Presently I have see these orbital buffers with car detailing studios.

Miracle Electric Orbital Buffer 220 Volt 10” Pad Rs 4800 (produced in India)

*details from ebay

DESIGN BRIEF

> To design an orbital buffer to be bought by upper middle class car owners. Although keeping in mind that the potential users of the product would include car washers, domestic helpers

> It shall have a motor component that runs on an rechargeable DC battery

> It will be a light weight object and will try to not look like a power tool, i.e. look compact and less machine like.

> Easy storage for home.

> It will be made foolproof. Since most of the user group have never used a buffer before, it shall have a very small range of rotational speeds. RPM will be in the range on 1000-3000.

> It shall have a quick to change power switch to ensure full user control.

> It shall have a automatically controlled wax dispenser unit attached to its body itself.

> It shall be ergonomically designed for easy and comfortable hold and use scenarios.

> Make pads easily removable and washable

**The product is not meant to be used in car detailing studios or for big tasks like bus, vans, building floor cleaning etc. As firstly it will not give the required finish for detailing studios. Secondly, the bigger vehicles have a lot of surface area for buffing and a small machine like this will not be effective.

Key Essentials: foolproof mechanism - no damage to car, easy to use for first time users, small and compact, easy storage and accessibility, attached dispenser unit, battery operated - no source of electricity at cleaning point i.e. parking space

deliverables

deliverables

fool-proof technology

one product with all attachments together

Washable and reusable pads

not intimidating

attached dispenser unit

easy to learn and use

easy storage

docking feature

small compact size

not to be charged via car battery

no electrical plugpoint in garage or open shed where cars are parked

rechargeable battery

If the orbital buffer is switched ON before touching the surface of the car, there are chances that the head (buffing pad and/or backing plate detaches itself from the machine and falls off)

Most ammateur DO NOT end up holding pad parallel to surface which leads to swirl marks on surface.

Most battery operated (Ni-Cad) are heavy. Battery is usually placed in a vertical stack manner, or on the grip handle. Grip handle one makes counter balancing of weight for the motor difficult. The vertical stack makes the top heavy, difficulty in using the machine at an angle, to polish sides of car

problem areas

ATTRIBUTES DOODLING




not intimidating



easy storage

docking feature

small compact size







not intimidating



easy storage

docking feature

small compact size




ATTRIBUTES DOODLING




not intimidating



easy storage

docking feature

small compact size




ATTRIBUTES DOODLING

GRIPS FOR EASY USE




not intimidating



easy storage

docking feature

small compact size




ATTRIBUTES DOODLING

MECHANISM

Torque: 13.6mNmOutput Power: 12.25WSpeed(RPM): 3000~30000Voltage(V): 9v

3M(TM) Hookit(TM) Disc Pad 02700, 3 x 1/2

Bosch BAT181 BlueCore 18-Volt 2.4 Amp Hour NiCad Battery

Sensor switch that starts the orbital buffer only once the pad is pressed firmly to the surface of the car

Motor shaft moves the spur gears, they in turn rotate the drive shaft mechanism (little off centered by the pitch 5/32”), encased in aluminium housing, and a shaft coming out of the housing connects to the backing plate which moves with the pad.

PRODUCT ARCHITECTURE

PRODUCT ARCHITECTURE

Styrofoam model of all internal parts, motor, gears and casing, backplate, foam pads and battery. I tried various arrangements of these parts to explore dif-ferent forms that the final form can take.

QUICK SKETCH MODELING

FORM FINDING

Asymmetrical form with the power switch on the left side and the toggle button for wax dispensing in the center, to be gripped by holding its body itself. There is a slight bulge in the top and groove below it to help grip.

1

docking position, in the car storage boot

battery removing for recharging

switching ON and using the buffer

2

buffing vertical areas holding and carrying around

VARIOUS GRIPS, FUNTIONAL CONTROLS AND SWITCH PLACEMENTS

exploring suitable handle grips

3

2”

2” x 1”dia x h 5.5”

7.5”

2.5”

Over user testing and interaction with present orbital buffer users, I have found that it is essen-tial for the product to have a handle / support on top of the hand as there are chances of slip-ping due to vibration otherwise. Also the handle should not have so much prominance that the user of the product is tempted to maneuver it with the handle itself. Thus there should be seam-less integration of the body with the handle so as to ensure that the user intuitively holds it using the the body grip. 4”

3.75”

understanding body grips

styrofoam model

weight modelobservations:motor + casing + battery weight = 1.5 kgs approx.chances of slipping, without the handlestrain at wristsits comfortably on the battery side when not in use.

proof of concept: pictures, physical model video, process of making

A universal joint, universal coupling, U joint, Cardan joint, Hardy-Spicer joint, or Hooke's joint is a joint or coupling in a rigid rod that allows the rod to 'bend' in any direction, and is commonly used in shafts that transmit rotary motion. It consists of a pair of hinges located close together, oriented at 90° to each other, connected by a cross shaft.

A flexible shaft is a device for transmitting rotary motion between two objects which are not fixed relative to one another. It consists of a rotating wire rope or coil which is flexible but has some torsional stiffness. It may or may not have a covering, which also bends but does not rotate. It may transmit consid-erable power, or only motion, with negligible power.

OR

proof of concept : final video

detailing out mechanism oninventor file

Patent search:

1. Random orbital finishing apparatus - Patent number: 6244933 The patent is regarding a 2 pad random orbital mechanism placed with referecnce to conveyor belt, the front end of the conveyor belt recieves the object and the shaft of the random orbit work on the object until it reaches the end of the belt. The apparatus remains stationary and requires the object to be polished to move on the mechanism.

2. Random orbital sander - Patent number: D350886 Design of the casing of a single pad orbital buffer head.

3. Random orbital sander - Patent number: 4854085 Redesign of the mechanism in order to enhance the life of the bearing parts that usually have a short life due to wear and tear of the then existing buffer. This is done by restricting the motion of the free moving bearing in the second axis.

4. Buffing Pad Centering System - Publication number: US 2010/0144253 A1 This is regarding the change in the backplate design such that the pad is centered to the backplate, this allows no unneces-sary errors in the orbit diameter

5. Surface polishing applicator system and method - Patent number: 6547643 Patent is regarding identifying stains by the medium of thin plastic film over hand and then buffing them using a flexi sponge that stores the polishing wax in the sponge.

6. Power tool - Patent number: 7047585\ The patent is with regards to griping and holding the power tool, in particular the buffing/polishing tool while in use. There are 2 handles provided one over the head of the operating tool and the other support handle to assist in the operation.

sketching and detailing of body

Final mock-up model : process pictures

Final mock-up model

Usage scenario pictures

operating the power switch

toggling speed slider

picking up productrefilling wax chamber

removing battery for recharge changing buffing pads

3-D model

3-D model Exploded view

Orbito, Hand Orbital Machine

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