Pole Clamp - Philips Color Kinetics
Problem -
Develop ideas for a pole clamping mechanism that fixes to an existing LED lighting fixture.
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This project started with a competitive analysis to find areas of the market that were not being exploited
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The findings of this analysis showed that it would be a good idea to offer pole mounting accessories for some of the existing architectural LED lighting fixtures
Lighting Fixture
Pole
Clamp
Clamp
Bolts
Process -
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In order to create initial concepts, I explored production methods based on predicted sales volumes
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Manufacturing methods were narrowed down to casting or bent sheet metal
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I created a some models of what a final design could look like
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While exploring design, I had to make sure to look at wind loading and random vibration requirements using Solidworks Simulation (FEA) and Solidworks Flow Simulation (CFD)
Pole Clamp Exploded View
Point Load
Solution -
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I made sure that the potential designs could meet all standards necessary
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I prototyped a few scale models with 3D printing and laser cut cardboard
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I developed the business case for the designs with another coop to present to a salesperson
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The preferred solution was a sand cast design because aesthetics were considered to be very important and volumes were estimated to be appropriate
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The other possible solution was a bent sheet metal design which would be cheap, but less aesthetically pleasing
Wind Loading Simulation (CFD)
Random Vibration Simulation (FEA)
Sand Cast
The tooling costs would make this option less feasible at low volumes, but after reaching a certain threshold, this option becomes financially attractive. It can also be designed to fit the pole more seamlessly.
What I learned -
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Industrial design
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Surfacing in CAD
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Business case development and strategy
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Product development life cycle
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Different manufacturing techniques
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Random vibration and modal simulation
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Wind loading flow simulation