Mechanical Design and Optimization Family Friendly, User Friendly ImParaDoors

SUMMARY

This project aimed to optimize the hinge mechanism design for Arçelik's dishwasher doors, adhering to the specified design criteria and standards. The existing hinge mechanism had a crucial limitation: while facilitating door movement, it lacked the required stability to keep the doors open at various angles between 0 and 90 degrees. The project spanned from September 2022 to May 2023, during which a new pulley design was developed while preserving the integrity of other components. The project encompassed essential phases, including needs assessment, concept selection, preliminary and detailed design, progress reporting, and presentations. This report presents the final design, which involved the creation of a unified double-pulley using 3D printing (SLA technology). Rigorous physical tests were conducted by integrating the double-pulley into a standard dishwasher. In the near future, a comprehensive evaluation will be conducted to assess the prospective performance of the unified double-pulley in its ability to support dishwasher doors with a weight capacity of up to 15.2 kg. This assessment aims to determine the pulley's efficacy in effectively sustaining the doors at intermediate angles spanning from 0 to 90 degrees while in an open position. This optimized hinge mechanism design offers promising potential for enhancing
the functionality and stability of Arçelik's dishwasher doors, meeting the desired design objectives and surpassing the previous limitations.

MOTIVATION

The motivation behind this project was to address the crucial limitation of the existing hinge mechanism in Arçelik's dishwasher doors. The lack of stability at different angles posed inconvenience to users, prompting the need for optimization. By developing a new pulley design while preserving other components, the goal was to enhance functionality and stability. Leveraging 3D printing technology provided an opportunity for precision and customization. Ultimately, this project aimed to improve user experience, exceed customer expectations, and solidify Arçelik's reputation as an innovative leader in the home appliance industry.

OBJECTIVE

This project aimed to optimize the hinge mechanism design for Arçelik's dishwasher doors, addressing the limitation of insufficient stability at various angles. The objective was to develop a new pulley design, preserve other components, and enhance functionality and stability. Rigorous testing was conducted using a 3D printed double-pulley, aiming to support doors weighing up to 16 kg and sustain them at intermediate angles from 0 to 90 degrees. The project aimed to surpass previous limitations and meet desired design objectives for improved dishwasher door performance.

METHODOLOGY / DESIGN

The modeling process aimed to minimize the moment on the hinge arm base for preventing door rotation. Constraints on the door's mass, shape, and hinge arm dimensions could not be modified. The existing system lacked sufficient spring reaction and increasing the spring constant excessively had drawbacks. A functional prototype has undergone comprehensive testing, and design adjustments have been made based on feedback. The prototype optimized friction and the force generated by rope tension. The focus is on achieving balance between stability, spring reaction, and customer comfort. Testing and design refinements have driven continuous improvement. The technical drawings were performed using SolidWorks and CATIA V5 R21 CAD programs. The analyses were conducted using the ANSYS simulation and 3D design software tool. The prototype was printed using the SLA printing method with mold resin material, assisted by plastic injection molding.

Capstan Equation Modelling

Capstan Equation Application on Ships

Free Body Diagram of the Dishwasher Door Mechanism

FEATURES

Working Principle

Minimize moment on hinge arm's base to prevent door rotation.

Compensation for Insufficient Spring Reaction

Additional force on the same side of the pivot.

Prototype Testing and Feedback

Iterative design adjustments for improvement.

Phases

Final Design of the Unified Pulley

Final Prototype of the Unified Pulley with Strength Resin

Final prototype of the Unified Pulley with Mold Resin

CRITERIA

Final Assembly

Thorough testing and evaluation of the final design, incorporating a unified doublepulley manufactured through 3D printing (SLA technology), demonstrated significant potential in meeting the desired design objectives and surpassing the previous limitations. Consequently, the optimized hinge mechanism design adequately fulfilled the operational and functional requirements of opening and closing the dishwasher door, ensuring stability at various angles within the designated range. The project’s success can be attributed to multiple contributing factors, encompassing a comprehensive needs assessment, meticulous concept selection, and detailed design phases. Following a systematic approach, the project team maintained regular progress reporting and presentations, fostering effective communication and collaboration.

GROUP G7

 

ImParaDoors

Berkant CEYHAN

Mehmet Can YENER

Ahmet Melih GICIR

Ekin SUMER

Cem ÜNLÜ

Bora ÖZMEN

Industrial Supervisor:
Sultan Ahmet KOÇ

Academic Supervisor:
Asst. Prof. Melih ÇAKMAKÇI

Course Coordinators:
Dr. Müjdat TOHUMCU
Assoc. Prof. Yıldıray YILDIZ

Teaching Assistant:
Emirhan İNANÇ