Umbrella

Contents
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1 Executive Summary 2 Usage and Usability 3 Parts List 4 Major Stakeholders and Needs 5 DFX o 5.1 DFA o 5.2 DFM o 5.3 DFE 5.3.1 EIO-LCA 6 FMEA o 6.1 Summary 7 Mechanical Analysis o 7.1 Problem Definition o 7.2 Assumptions o 7.3 Fundamental Equations o 7.4 Calculations o 7.5 Finite Element Studies 7.5.1 Axial Compression/Tension 7.5.2 Buckling Analysis

o 7.6 Analysis Conclusions 8 Design Variants o 8.1 Golf Umbrella o 8.2 Purse Umbrella 8.2.1 Collapsable Arm Design 8.2.2 Telescoping Shaft Design o 8.3 Auto Open Close 9 Team Members & Roles o 9.1 Roles o 9.2 Design Process 10 References

Executive Summary
The basic umbrella is a simple device designed to protect the user from inclement weather. It is mass produced and takes advantage of many optimizations to reduce manufacturing and assembly cost. Basic assemblies are identically repeated and joined together, taking advantage of many economies of scale in production and simplifying the assembly process. The arm assembly is repeated eight times, and the two rider latches are also identical. A FMEA table showed a few major potential problems. These are canopy tears, arm failure, and handle degradation. Of those, the most common type of failure is arm failure, which impairs product usability or in the worst case renders the umbrella useless. Performing life cycle analysis using the online EIO-LCA tool shows that the largest portion of greenhouse gas emissions due to umbrella manufacturing come from power generation. This sector accounts for .0009 metric tons of CO2 equivalent (MTCDE) , about a third of the .0028 MTCDE produced in total. There are no emissions directly related to umbrella usage. End-of-life considerations should also be made, given the relative frequency of umbrella failure. A mechanical analysis showed that the force required to buckle the arm supports is approximately ten pounds. This gives a good indication of its relative strength in cases where the arms are strained, for example in strong winds. With eight supports each capable of supporting a ten pound load, the standard umbrella should be fairly wind resistant. There are several problems with the basic umbrella which other, more complex umbrellas attempt to address. Improvements have been made to reduce the umbrella's footprint and to make it easier to open and close. These modifications increase part count and make assembly more difficult. Our initial finds show that it will be difficult to make improvements strictly on the manufacturing side, given the variety of ways in which manufacturing and assembly are taken into consideration in the existing design. Instead, most issues with current umbrellas point to usability as the main factor to improve upon.

Usage and Usability

An umbrella's primary purpose is to protect the user from rain, although they are also used in some cases to protect against sun or snow. To do this, an umbrella has a long, slender shaft with a handle on one end and a collapsible canopy on the other, coming to a point at the umbrella's tip. The umbrella's protective canopy is extended as a rider, initially located near the handle,

travels up the shaft towards the tip. In a standard non-collapsible umbrella such as ours, the rider's motion is started by releasing the rider latch on the handle end of the shaft and manually moving the rider upwards until the rider engages a second latch on the tip end of the shaft, locking the rider and canopy in place. Some improvements on the standard umbrella design have been made to overcome some of the standard umbrella's flaws. The rider mechanism in many umbrellas, such as the golf umbrella, is spring loaded to provide one-handed automatic opening. This is an improvement over the two-handed opening that the standard umbrella offers. The canopy must be forced closed and the spring must be manually reset after use. Because an umbrella has a very specific intended usage environment- outside, in rain - there are times when the umbrella will not be in use but must be carried for later use, such as indoors. It is beneficial to the user for the umbrella to be lightweight and have a small footprint when not in use. One popular variation on the standard umbrella is the purse umbrella. This umbrella has a hollow telescoping shaft. The footprint of the umbrella and its weight are reduced substantially, enough that the umbrella fits conveniently into a purse or backpack and can be carried at all times. This decrease in size comes with an increase in component complexity, as the shaft cannot be a single piece of material and the arms must be folded as well. Additional joints are needed, and the overall strength of the umbrella is reduced. The most complex variant on the classic umbrella is an automatically opening and closing umbrella. This extends the functionality of the purse umbrella by using an additional mechanism to automatically close the canopy with a button press. While the canopy is automatically closed, the spring must still be manually reset. Even with these improvements over the standard umbrella, some issues remain unaddressed. All of the umbrellas designed for personal use must be carried by hand, and even the most complex umbrellas must be forced closed manually after use. This can be a difficult task for people with motor or joint disabilities, such as Parkinson's disease or arthritis. The umbrella's circular canopy is generally held by the user. Because the canopy is held to the side of the user, rather than directly overhead, the coverage is not uniform for a single user, and about half of the canopy is unused on average. Offset umbrellas which maximize the usable coverage area exist, but are rare and significantly more expensive, in part due to lost efficiency because the umbrella is not radially symmetric.

Parts List

Here is an overview of some of the main components of the umbrella:

The standard umbrella is composed of the following parts: Par t# 1 Part Name Shaft Qt Weigh y t (g) 1 59 Function Main support unit for umbrella Manufacturin Material g Process Laminated, turned Wood Picture

Handle

70

Provides a comfortable grip for shaft

Laminated, warped

Wood

Tip

1.5

Protects shaft & injection Aesthetic molded

Plastic

Top Cap

1.9

Holds canopy to Stamped shaft

Steel

Top Cap Retention Pin

<.1

Attaches top cap to shaft

Formed

Steel

Top Cap Skirt

.1

Prevents water leakage around top cap

Woven

Nylon

Rider Limit Pin

.1

Prevents upper assembly rider from traveling out of range

Formed

Steel

Rider Latch

1.6

Locks rider in place at top and Stamped bottom of range

Steel

Rider Latch Pin

<.1

Attaches rider latch to shaft

Extruded

Steel

10

Canopy section

7.1

Keeps water from entering area below umbrella Thins trap to wrap around canopy when closed Allows canopy latch strap to attach to itself

Woven

Nylon

11

Canopy Latch Strap Canopy Latch Strap Velcro

.9

Woven

Nylon

12

.3

Velcro

13

Upper Hub

3.1

Attaches arms to shaft

injection moulded

Plastic abs?

14

Hub Pin

.4

Attaches upper hub to shaft

Formed

Steel

15

Bumper

1.9

Reduces jarring at end of rider travel, prevents injection contact between moulded Arm Mainshaft and Shaft

Rubber

16

Connectin 2 g wire

.3

Attaches arms to upper hub and rider

Extruded

Aluminu m

17

Rider

8.5

Attaches arm support rod to shaft; allows injection motion along moulded shaft and attaches to latch

Plastic

18

Arm 8 Mainshaft Arm Support Rod

14.9

Attaches Extruded, canopy to upper stamped hub Attaches rider to arm mainshaft Stamped, formed

Steel

19

4.8

Steel

20

Arm Support 16 Rod Insert

.1

Inserts into end of support rod; Extruded adds strength at crimp point

Steel

21

Arm Endcap

.7

Covers exposed end of arm Die cast mainshaft Loops between canopy and arm mainshaft/endca Spun p to provide attachment

Steel

22

Short string

16

<.1

Cotton

23

Arm Joint 8 Connector

.5

Connects arm mainshaft and Stamped, support rod, crimped allows rotation between the two

Steel

24

Arm Joint Connector 8 Pin

<.1

Connects arm joint connector to support rod

Extruded

Brass

Major Stakeholders and Needs

Customer o Dryness o Ease of use / ergonomics o Speed of operation o Portability o Reliability - includes non-umbrella usage (cane) o Cost o Accessibility o Aesthetics o Safety o Mildew/rust resistance low maintenance Umbrella accessory manufacturers o Standardization (size) o Cost Umbrella manufacturers o Material cost o Manufacturing cost o Part standardization o Ease of assembly o Meeting customer needs Competing rainwear manufacturers o Market differentiation from umbrellas o Satisfying consumer needs, especially reliability and ease of use Retailers o Standardization (size) o Cost / margin o Aesthetics / product differentiation o Ease of storage and inventory o Reliability / few returns o Customer satisfaction

People around umbrella users o Unobtrusive (size) open and closed o Low sound signature o Low leakage post use o Safety o Aesthetics

DFX
DFA
Umbrellas are a high production part and as a result a great deal of effort has been put into design for assembly. With respect to assembly, the umbrella is broken into three sub assembles: the shaft, the arms and the canopy. By breaking it into these individual sub sections this arms can be assembled independently of the shaft which can be assembled independently of the canopy, saving assembly time. Design for assembly has been considered within each sub assembly by designing the joints and parts such that there are generous tolerances with respect to part location and by designing the joints such that they are easy to make. With respect to the arms, all of the joints except that connecting the Arm Support Rod to the Arm Joint Connector are crimped connectors to reduce assembly time and part count. Additionally, all of the 8 umbrella arms are identical which improves the ease of assembly and reduces the part count of the umbrella. With respect to the shaft, design for assembly has been considered in the use of identical components for the Upper and Lower Rider Latches. Making these components identical prevents confusion during assembly and the parts are designed such that they are simply hammered onto the shaft to reduce assembly time. Also, assembly tolerances were considered with respect to attaching the Handle to the Shaft. While glue is required for this joint, there is a large tolerance with respect to how deep the shaft has to be placed inside the handle, reducing the time that is required to assembly this joint. Along with being easy to assemble individually, the umbrella sections are designed to be easy to assemble to one another, with the arms attaching to the shaft using two pieces of wire. This attachment method makes it easy for the umbrella to be assembled quickly and simply.

DFM
In order to reduce the manufacturing cost and effort the individual components of the umbrella have been designed with Design for Manufacture in mind. The majority of the metal parts on the umbrella are made through stamping premanufactured flat or round stock into the desired shape. This process is fast, efficient and removes the need for time intensive machining thereby dramatically reducing the associated manufacturing costs. Additionally, by replicating components such as the Rider Latches and the arm components manufacturing costs are reduced. Similarly all of the plastic parts on the umbrella are injection molded for quick manufacturing time and reduced material cost. The umbrella also uses off the shelf fasteners where possible such as in attaching the top cap and upper hub to the shaft. Both of the fasteners involved in this assembly are standard brad nails which, because they do not need to be manufactured specifically for the umbrella and can instead be purchased in bulk from a supplier, reduce the cost of manufacturing the umbrella.

DFE

The choices made in the design and manufacture of a standard umbrella have a variety of environment consequences. Since umbrellas have a short life cycle, it is important to consider how these products will be disposed of/recycled. Since there are a large variety of umbrella designs, these issues may be different depending on the model and manufacturer. These comments pertain only the standard umbrella that we studied. Main Materials Used

Wood (treated) o Natural wood is bio-degradable, however this wood appears laminated and chemically treated/coated to produce a desirable surface finish, which will likely impede biological degradation o Due to the lamination process, it is unlikely that returning these products to the manufacturer would result in recycling of materials. Plastic (Thermoplastic) o Thermoplastics can be recycled if returned to the manufacturer o Does not appear to be made of out of commonly recycled materials, so recycling on a large scale may be impeded. o Non-Biodegradable Steel o Non-Biodegradable o Stamping process used to create the piece is lower energy compared to other forming techniques

EIO-LCA Because there is no category that deals specifically with umbrella manufacturing, the closest applicable category is #420000, 'Wholesale Trade.' This would not be a very accurate estimate since that category is very broad and covers a large number of different products. By breaking down an umbrella into its major components, a better estimate can be reached. The percentages were estimated as a percentage of total product value. The following categories and weights were used to determine how greenhouse gases are produced during manufacturing:

#33999A, Buttons, pins and all other misc. manufacturing - 5%, joint and fasteners within the umbrella #332999, Miscellaneous fabricated metal product manufacturing - 20%, major metal components such as the arms #313100, Fiber, yarn, and thread mills - 10%, the canopy and canopy latch strap #420000, Wholesale trade - 25%, product assembly and other misc. #321999, Miscellaneous wood product manufacturing - 40%, the shaft and handle

Assume 2008 standard retail markup of 45%, the total product value in 2008 dollars is $5.50. Using the deflation calculator from the Bureau of Labor Statistics, the 1997 umbrella product value was $4.03. Sector numbe Sector name GWP MTCDE CO2 MTCDE CH4 MTCDE N2O MTCDE CFCs MTCDE

r Total for all sectors Power 221100 generation and supply 484000 111920 0.00275340 6 0.00087315 9 0.00220602 2 0.00086266 0.00018443 4 3.37757E05 0.00023116 9 0 2.85945E07 0 0.00025072 4 0 2.57351E06 0.00015145 1 6.54906E -05 1.04994E -05 0 0

Truck 0.00018729 transportation 3 Cotton farming 0.00018522 7

Miscellaneou s wood 0.00012153 321999 product 1 manufacturin g 331111 420000 Iron and steel 0.00010156 mills 8 Wholesale trade 9.96767E05

0.00012153 1

0.00010156 8 9.96767E05

0 0

0 0

0 0

Waste management 562000 and remediation services

9.77437E05

1.54527E05

8.21722E05

1.18804E07

Noncellulosic organic fiber 7.14761E325222 manufacturin 05 g Paper and 3221A0 paperboard mills 211000 Oil and gas extraction 5.49042E05 5.43236E05

7.14761E05

5.49042E05 9.1147E-06

0 4.52089E05

As this table shows, the plurality of greenhouse gas emissions comes from power generation and supply. Transportation, farming, and wood product manufacturing are also major contributors. Because an umbrella is unpowered and uses no other resources, no additional greenhouse gases are produced directly by umbrella usage.

FMEA
This below table lists the results of our Failure Modes and Effects Analysis, followed by a brief summary of the major issues that we viewed as the most important. Only components

with an RPM greater than 40 were given corrective action. The top 5 RPN components have been bolded. Item or Failure Func Mode tion R Recom Respon P mended sibility N Actions

Effects of Failure

Causes of Failure

Design Controls

Decreased shaft strength Splinte Potential ring safety hazard to user Shaft

5 Wear

Revised Design/ Engine Coating or 3 4 60 Material ering finish on shaft Selectio Design n Material choice Durability testing

Product is Breaka inoperable ge

Inappropriate 8 stresses on shaft Impact

Material Quality Robust Design

5 40 NONE

NONE

Rot

Reduced Strength

Poor 3 Protective Coating

Coating 1 Process Control Coating or 4 finish on handle

5 15 NONE

NONE

Decreased handle strength Splinte Potential ring safety hazard to user Hand le Product is Breaka inoperable ge Reduced Strength

7 Wear

Revised Design/ Engine 11 4 Material ering 2 Selectio Design n

Material choice Durability testing 7 Impact 1 Material Quality Robust Design Poor 3 Protective Coating Coating 1 Process Control 5 15 NONE NONE 5 35 NONE NONE

Rot

Tip

Loss of Degredatio 2 Wear Protecti n of Shaft on

Material choice Part Design

Revised Engine Material 7 56 ering Selectio Design n

Top Cap

Corrosi Decrease In 2 Oxidation on Aesthetics Bendin Latch fails g to operate 8 Inappropriate Loading

Material 2 choice/Coatin g 1 Part Design

5 20 NONE

NONE

2 16 NONE

NONE

Rider Latch Jammi ng

Latch fails to operate

Corrosion/For eign Tolerance 8 2 Debris/Poor control Assembly

Improve d Quality Manufa 4 64 Control cturing in Assembl y 2 10 NONE NONE

Rider Latch Loss Pin

Potential Loss of Latch

Vibration/Poo Proper 1 r Assembly Assembly

Tear Cano py sectio n

Leak in Umbrella

Improper Material Manufacturing Selection/Man 14 7 /Improper 5 4 ufacturing 0 Storage by Control Consumer

Improve Product d Manufa Quality cturing Control

Seam Leak in Failure Umbrella

Improve Improper Manufacturing Manufa 12 d 7 3 6 Manufacturing Controls 6 Quality cturing Control

Cano Improve Inability to py Seam Improper Manufacturing d Manufa strap 5 3 6 90 Latch Failure Manufacturing Controls Quality cturing umbrella Strap Control Hub Pin Upper Hub Improper Proper not longer 8 Tolerancing/ 1 Tolerancing/ 2 16 NONE attached to Manufacturing Manufacturing shaft 8 Wear 1

Loss

NONE

Conn Arms Breaka ecting disconnect ge wire from shaft

Engine Coating/Mater Revised 6 48 ering ial Selection Design Design NONE

Button Latch more Rider Breaka difficult to 6 Fatigue ge operate

Proper 2 Tolerancing/ 3 36 NONE Manufacturing

Deformed Arm Plastic umbrella Excessive 7 Main Yieldin shape/troub Loading shaft g le closing Arm Plastic Supp Yieldin ort g Rod

Part Engine 16 Revised 6 Design/Materi 4 ering 8 Design al Selection Design

Part Deformed Excessive Design/Materi Engine umbrella 19 Revised 8 Loading/Impa 6 al 4 ering shape/troub 2 Design ct Selection/Man Design le closing ufacturing Revised Manufa Engine cturing ering Specific Design ation Improve d Manufa Quality cturing Control

Arm Endc ap

Partial Disasso Canopy Insufficient Manufacturing ciation 10 Detatchme 7 Crimping/Tole 5 and Assembly 3 from 5 nt/Exposed rances Controls Arm Rod Partial Canopy Detatchme nt Excessive Loading/Defe Material 10 7 ctive 3 Quality/Manuf 5 5 Materials/Poor acturing Manufacturing Part Design/Materi 2 al 2 8 Selection/Man ufacturing

Short Snap string

Arm Joint Improve Conn Seperat Quality ector Impaired Manufacturing ion Improper Control Manufa operation 8 3 and Assembly 3 72 from Manufacturing in cturing of umbrella Controls Arm Assembl y

Plastic NonYieldin smooth g operation

Excessive Loading

NONE

NONE

Summary
The main issues seen in the FMEA deal primarily with three issues:

Plastic Deformation of the umbrella arms Poor Canopy Quality Handle Degradation

The plastic deformation of the umbrella arms is primarily a design issue. By having a better understanding of the kind of loads that are applied to the umbrella, engineering design can redesign the arms to be more robust against yielding issues. This could mean improving the strength of the arms or, conversely, making them more flexible to allowing for more deformation before yield.

Poor canopy quality is primarily a function of the quality of the materials and the manufacturing process. By reducing variation in the quality of unprocessed fabric materials in the supply chain, this issue will be greatly reduced. It is also the job of the Manufacturing department to ensure that the machines used to process the fabric are not detrimental or add variation to the final quality of the product. There should also exist some form of quality control before the product leaves the factory in order to ensure the integrity of the woven materials. Handle degradation is another design issue. By choosing wood as a material, the designers introduced the associated failure modes. By changing the material selection to account for a plastic or metal handle, the designers could have avoided the potential splintering of wood, and might even have been able to reduce the cost of the product. For mass production parts such as umbrellas, the tooling costs for plastic parts would not be cost prohibitive.

Mechanical Analysis
An umbrella is a highly mechanical device with a variety of failure modes and analysis possibilities. Since one of our most highly rated failure modes involves the plastic deformation of the arm support rob (Part 19), we chose to perform a mechanical analysis on this part in order to determine the cause of this failure and extract design principles for our redesign efforts. The work presented attempts to address the problem of part buckling under compression.

Problem Definition
The part itself is fundamentally a U-Channel shaped part, creating through stamping, giving it a uniform wall thickness of 0.016 in The actual cross section of the part can be seen as a combination of a parabola with straight edges, as shown in the below diagram.

For the purpose of easier mechanical analysis, we decided to analyze this cross section using two approximations:

Case I: U-Channel Cross Section using the measured height and width. Case II: Semi-Circle Approximation using the flattened length as the length of the neutral plane.

In addition to our analytical analysis, we performed finite element analysis using COSMOSWorks. For this analysis, we used a cross section that more closely mimicked the actual cross section.

This cross section was calculated in SolidWorks to have a moment of inertia of 3.017e-6 in4

Assumptions

Ends of linkage are pinned o No forces are transmitted other than in a purely axial direction - No shear forces

No moments are transmitted - No bending moments Any torsional forces are ignored o No natural operating condition would lend itself to the generation of torsional forces on that part o There exists enough tolerance in the part's interface with the rider and arm joint connector that significant torsional deflection would have to occur before forces started to be transferred in that direction Simplifications are made in cross sectional geometry in order to promote easier analysis. These simplifications are listed in an earlier section.

Fundamental Equations
The following equation was used for the buckling analysis.

where F = maximum or critical force (vertical load on column), E = modulus of elasticity, 3,000,000 psi in case of steel. I = area moment of inertia, l = unsupported length of column, K = column effective length factor, whose value depends on the conditions of end support of the column. In our case, K = 1.0, since both ends are pinned(hinged).

To get the moment of inertia for each case, the following equations were employed.

Case I:

where I = moment of inertia of rectangular area w = width of the rectangular area h = height of the rectangular area

Case II:

where

I = moment of inertia of semicircular area r = radius of the semicircular area

Parallel axis theorem

where Itotal = the area moment of inertia through the parallel axis Ix = the area moment of inertia through the centre of mass of the area A = the surface of the area d = the distance from the new axis to the centre of gravity of the area.

Calculations
Moment of Inertia for Case I and Case II

Case I

Since Case I is the approximation of square U-channel, moment of inertial of outer area, A1, should be subtracted from the inner area, A2. Also, the center of gravity has to be located and the parallel axis theorem is applied to find out the result of moment of inertia of Case I approximation. IA = I1 I2 I1 = Ix1 + A1d1 I2 = Ix2 + A2d2 where I1 : moment of inertia of A1 I2 : moment of inertia of A2 d1 : distance between center of gravity of A and that of A1 d2 : distance between center of gravity of A and that of A2

Case II

Same method for Case I is employed in Case II. The moment of inertia of bigger semicircle is subtracted from the moment of inertia of smaller one to obtain the moment of inertia of donut-shaped area. IB = I1 I2 where I1 : moment of inertia of B1 I2 : moment of inertia of B2

The moment of inertia of real cross-sectional area model can be calculated from the average of IA and IB and turned out to be 0.000003 in4 Based on the obtained moment of inertia of real model and the properties of steel, the compressional load to cause the armshaft to start buckling is 9.996 lb.

Finite Element Studies

Axial Compression/Tension Considering only ideal axial compression along the length of the support arm, you would need 114 pounds of force before plastic deformation takes effect. This case is somewhat trivial, as the member would fail in buckling before it reached the amount of force required to yield the member in compression. It is unlikely that the part would be subjected to a force of this magnitude, since there is no environment or situation where the support arm would be

subject to such forces

Buckling Analysis A far more realistic case, the support arm was tested for buckling by subjecting it to an axial load and numerically calculating solution for the first buckling mode. This analysis, performed in COSMOSWorks, provides an estimate of the axial force required before the member fails in buckling. This analysis was performed with a test load of 1 pound, and resulted in a buckling factor of around 9.29. This means that 9.29 pounds of force are required before the support arm fails in buckling. An actual deformation plot under the first buckling mode is shown below:

This analysis was performed with a mesh size of 12,750 elements and under the assumption that both ends are pinned.

Analysis Conclusions
By using both analytical and numerical methods to determine the buckling load of the support member, we can say that the member would fail in buckling at around 10 pounds of compressive force. These results seem reasonable given the typical conditions present during observed part failure. This level of force is typically brought about either through high wind

situations, or though improper use by the customer. Given the severity of this failure, it is important to observe several design improvements that will help us avoid this issue in our prototype. In order to provide resilience against buckling, it is important to design with part geometry in mind. As can be seen in:

Reducing the unsupported length of the bar has a large impact on the buckling force. Using different end conditions, such as fixed-fixed conditions, would also increase the force required, however this is impractical as the joints need to move freely in order for the mechanism to work as desire. Selecting a material stronger than steel would also increase the required force, however such a material would quickly become cost prohibitive. The last avenue would be to increase the moment of inertia by altering the cross sectional geometry of the part. Instead of using a parabolic shaped channel, using a square closed-wall section would improve resilience to buckling as well as torsion and lateral torsional buckling. Creating a close-walled section would require a substantial change in the manufacturing process, however, making it significantly more expensive to produce the parts. Some important things to consider when interpreting the results are that our assumptions disregard a few potential issues. First, by assuming that the ends are ideally pinned at either end, we are ignoring potential bending moments or shear forces that could also affect the member. This assumption removes the need for shear or lateral torsional buckling analysis. We believe this assumption to be justified, since the pins provide little friction, and the small amount that exists would have negligible effect. Secondly, we ignore the effect of any torsion forces. We believe this to be a valid assumption, as the assembly of the unit provides enough tolerance for significant forces to be a non-issue.

Design Variants
Golf Umbrella
Golf Umbrella makes a big difference by having double layered canopies (top and bottom) to protect umbrella from failing by wind. For this purpose, the umbrella is designed to have wind blow under the umbrella and go out of the canopy through the gaps between top and bottom canopies. Each arm of the umbrella has canopy hook to hold the bottom canopy down to the arms. Possible failure can be occurred from this part when too much force applied on the hook as shown on the figure below the table of parts. The top canopy is attached on side arms bent in the counter-clockwise direction, which is different from the main arms. The size of the golf umbrella is relatively bigger than regular umbrellas and it has a bigger main spring with strong stiffness on the rider to keep the umbrella opened. The shaft of the umbrella is made of carbon fiber and hollow, so that it can reduce the total weight of the umbrella compared to an umbrella with solid shaft. However, the shaft might emit harmful material when it is destroyed since it is made of carbon fiber.

Pa rt #

Part name

QT Weigh Functio Y t(g) n

Manufact Mater uring ial Process

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Main Spring

74.5

Keeps the arms of the Coiled umbrell a opened

Steel

Double 1 Canopy

137

Protects umbrell a from Woven breakin g down by wind Hanging outer canopy to the Injection side Molded arms of the umbrell a Main support unit for umbrell a

Nylon

Canopy 8 Hook

N/A

Plastic

Hollow graphit 1 e shaft

81.4

Woven and Carbo wrapped n fiber

Ergono mic 1 Handle

81.9

Provide sa comfort Injection able Molded grip for shaft Attach bottom canopy on the arms

Rubbe r

Side arm

N/A

Extruded

Steel

Purse Umbrella
The Purse umbrella, also called a Compact umbrella, extends upon standard umbrella design by adding the capability of folding up into a greatly reduced size when closed. This design variation is the result of greater emphasis on customer needs for portability and compactness not typically found in standard umbrellas. The primary features which gives the purse umbrella it's unique ability lies in a complex collapsable arm design and a telescoping shaft. An overview of these two features is provided below: Collapsable Arm Design The basic function of the collapsable arm design involves using a combination of linkages to translate a small amount of vertical movement on the shaft into a large amount of radial movement of the arm tip. Unlike standard umbrellas, which have large shafts on which the rider has a large range of motion, purse umbrellas have limited range along the shaft with which to extend the umbrella arms. In order to accomplish the extension the arm is composed of a series of linkages, connected by pins, which transmit moments to other members creating relative rotation. Pictures of the linkage sub-assembly are included below, as well as a

depiction of how the pieces create relative rotation.

Telescoping Shaft Design

The function of the telescoping shaft is to provide a shaft that has the ability to extend to different lengths depending on the needs of the user. When the umbrella is closed the shaft retracts to a smaller length improving storage and portability. When the umbrella is open the shaft extends to full length allowing the user to comfortable hold the umbrella during operation. The key features of this design include concentric hollow steel shafts with a spring loaded locking feature to maintain the extended position. A few examples of specific design features are pictured below: The telescoping shaft is made up of 5 shafts of decreasing diameters. Each shaft is shown with different lengths, with the associated locking mechanism.

In order to facilitate the telescoping movement, a brass insert is placed on the inside of the shaft. This brass insert creates lower friction between the shafts, making the telescoping movement easier and more reliable.

Auto Open Close

The Auto Open Close umbrella is a double fold collapsible shaft variant of the standard umbrella which has additional mechanisms in order to allow it to both open and collapse with the touch of a button. The opening of the umbrella is achieved through a large spring which is compressed inside the shaft. When the open close button is pressed a latch releases the upper shaft, causing the spring to extend the shaft. At the same time the umbrella canopy is opened by a string which is latched inside the handle of umbrella. This string passes through the shaft, around a pulley at the top of the umbrella and is anchored inside the lower hub of the umbrella. By this means when the umbrella shaft is extended it causes the string to pull the lower hub upwards, extending the arms and opening the umbrella canopy. The collapsing of the umbrella canopy is achieved through tension springs located in each arm. When the open close button is pressed a latch attached to the button releases the string from inside the handle, this frees the lower hub, causing the tension springs in the arm to compress, collapsing the umbrella canopy.

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Part Part Weight Qty # Name (g) Shaft 1 Spring

Function

Manufacturing Process

Material

Picture

17.2

Causes the Coiled shaft to extend

Steel

Button 1

1.1

Releases umbrella mechanisms Returns the Button to its original position Releases the String Bulb

Injection Molded

Plastic

Button 2 Spring

0.1

Coiled

Steel

Button 1 Tab

0.4

Stamped

Steel

Button Tab 1 Shaft Button Tab 1 Spring

0.3

Attaches Button Tab to Button Return the Button Tab to its original position

Formed

Steel

Coiled

Steel

Shaft Clip

1.2

Locks shaft in the collapsed Stamped position Houses and locates all of the handle mechanical parts Locates and locks Shaft Clip

Steel

Handle 1 Frame

10

Injection Molded

Plastic

Shaft Clip 1 Spring

<0.1

Stamped

Steel

10

String Bulb

0.5

Locks String into handle of Umbrella Locks String Bulb into handle Locks String Bulb into String Bulb Latch Links Lower Hub to Umbrella Handle

Injection Molded

Plastic

11

String Bulb Latch

1.3

Injection Molded

Plastic

12

String Bulb 1 Spring

0.3

Stamped

Steel

13

String

0.7

Woven

Nylon

14

String Guide

4.9

Protects string and pushes Extruded/Injection String Bulb Steel Molded into String Bulb Latch Reduces string frictionand injection moulded Plastic wear Connects Pulley to String Guide prevents String from slipping off Pulley

15

Pulley

0.2

16

Pulley Shaft

0.3

Formed

Steel

17

Pulley Cap

0.1

injection moulded Plastic

18

Lower Hub

6.4

Attaches lower arms supports to shaft. Opens Injection Molded and collapses umbrella by translating along the shaft

Plastic

19

String Clip

0.3

Attaches String to Lower Hub

Injection Molded

Plastic

20

Arm 7 Spring

0.7

Collapses arm when string is Coiled released

Steel

Team Members & Roles

Roles
Ben Berkowitz - Finite Element Analysis, Auto-Open/Close Documentation, DFMA Michael Cushman - Use and Usability, Parts list, EIOLCA Analysis, Regular Umbrella Documentation Mark Fuge - Analytical Analysis, DFE, Purse Umbrella Documentation Changho Oh - Analytical Analysis, Golf Umbrella Documentation All - FMEA, Stakeholder's needs

Design Process
This section of the design process was highly collaborative, involving several meetings each week in order to dissect all 4 umbrellas. Once the umbrellas were each dissected and documented, we used the knowledge gained to populate an FMEA table of common failure modes. Through studying this FMEA table, as well as considering stakeholder needs, our team was able to plan out our user study areas and potential avenues for further investigation. We also used this FMEA table to isolate areas for mechanical analysis, and operated in tandem with each other to conduct both an analytical and computational study of some of our higher severity failure modes.

References
Gross Margin average for clothing accessory stores Bureau of Labor Statistics inflation calculator Category: Design studies

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