Design and manufacturing analysis of a window shading system

Abstract

In this thesis a novel concept for a window shading system was proposed and developed. This concept was created to address issues with an existing Lutron Electronics product. Over the past year and a half, concepts have been generated, tested and refined to produce a fully functional working prototype that meets the product specifications. This thesis focuses upon a manufacturing cost analysis and redesign of a gearbox assembly for the window shading system. This is a logical next step in the product's development. An estimate for the assembly time for the current version of the gearbox assembly is found. The parts are then redesigned for improved assembly time, and hence reduced cost. The parts are also redesigned for mass production processes; injection molding, and die casting. Calculating and then comparing cost estimates for the two processes finds an injection molded integrated design the most cost effective.