1 Eighth Lecture Design and Product Evaluation Method Instrumentation and Product Testing.

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Eighth Lecture

Design and Product Evaluation Method

Instrumentation and Product TestingInstrumentation and Product Testing

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Product Design and Development Guidelines:

1. Design to remove unsafe aspects

First and foremost, the product or service must be designed without a possible danger or hazard.

To play safe, similar products or services on the market should be studied (reverse engineering).

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2. Guard against unsafe use

If the danger cannot be designed out of the product, or if the product is inherently dangerous, the second step a designer should take involves guarding the user against the danger. Guards prevent users from gaining access to the area that would cause them injury.

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3. Provide product warnings

If the product hazards cannot be designed or guarded, then a designer’s final resource is to warn the user. Warnings must be specific and must describe the consequences of their being ignored.

Warnings should be highly visible and easily comprehensible.

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A Laser Pointing Device

The Warning Label

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The Warning Label

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4. Design to standards

A product should be designed to comply with industry standards (such as the requirements of dimensional, physical, mechanical, electrical properties).

While designing to standards does not ensure a safe product, standards do tend to create safer products.

What is a standard?

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A dictionary indicates that a number of meanings can apply to word “standard”. In engineering measurement and product testing, usually two will be used:

• The basis (physical record) for a measure of distance, weight, etc.

• The norm for common or accepted practice.

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BSI – British Standards Institute

BS 1363

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Pao Yue-kong Liabrary

Standards (Closed stacks): Major industrial standards are kept in closed stacks of the Special Collections. Standards are indicated by the abbreviation [STD] before the call number on the OPAC. Indexes and full-text/image version of national and international standards, including the British Standards, ISO Standards, American National Standards, Japanese Industrial Standards etc., are available on the Internet at IHS Standards Expert and the Australian Standards.

Podium Floor

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Standards

ANSI American National Standards InstituteASTM American Society for Testing and MaterialsBSI British Standards Institution (includes EN, i.e. BS EN)CNS Chinese National Standard (Taiwan)CS Chinese Standard (People’s Republic of China)CSA Canadian Standards AssociationDIN German StandardsIEC International Electrotechnical CommissionIEEE The Institute of Electrical and Electronics EngineersISA Instrument Society of AmericaISO International Organization for StandardizationJIS Japanese Industrial StandardsMIL Military StandardsSS Singapore Standards

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Benefits in the use of standards:

• Reduce the possibility of accidents• Reduce the possibility of liabilities, lawsuits, and other legal

actions. Proof that an accepted standard was observed can be accepted and viable defense in a lawsuit for product liability

• Indicate the accepted practice in an industry• Present previously evaluated methods of safe design• Ensure proper adherence to laws, codes, and other legal

criteria• Observance lessens cost of insurance premiums• Ensure compatibility of parts, materials, and processes• Ensure similarity of suppliers and reduces quotations for, and

costs of, equipment and supplies• Permit worldwide interchange of products and parts

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5. Advertise and market wisely. Occasionally, a company creates potential product misuse situations though its advertisements, marketing materials, and sales personnel. Product liability loss prevention is not the sole responsibility of the product designer or manufacturer; misrepresentation and exaggeration in advertisements and marketing materials may also be involved.

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Voluntary and Mandatory Standards

Mandatory standards are issued by governmental agencies. Violations are treated as criminal acts and the violators are subject to fines and/or imprisonment. It usually indicates the lowest safety level the government will accept.

A voluntary standard is usually prepared by representative from industry, the government, and the general public. The acceptance of these standards bases on the consensus of these parties. A voluntary standard indicates the lowest safety level an industry or manufacturer intends to meet in the product it supplies.

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Product Testing

According to a product’s nature, specifications and international regulations, various types of tests such as

• Safety tests• Life tests (reliability)• Functional tests, and • Packaging tests

must be preformed to assure conformance and quality.

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There are many different types of products and their associated tests.

Test Categories   

• Chemical Testing • Construction Materials • Electrical and Electronic Products • Food • Textiles and Garments • Toys and Children's Products, etc

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Manufacturers in gaining access to key international markets such as North America, Europe, Japan and Australia, their products must be in compliance with international regulations and standards. You may have seen some of the following marks/labels.

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At the beginning of 1992, the European Single Market was created. A series of Directives are intended to provide controls on product design, with the principal objective being to provide ‘common’ standards for product safety requirements across the European Community.

CE Markinghttp://www.conformance.co.uk/CE_MARKING/ce_content.html

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The act of fixing the CE mark to the product, and signing the Declaration of Conformity, constitutes a declaration by the manufacturer that the product meets the requirements of all the Directives (official instructions) which apply to it.

The CE Marking is a legal requirement for products covered by one or more of the European Union (EU) Directives stipulating its use. It signifies that the supplier of the product has verified that the product complies with the requirements of the relevant Directives.

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The Manufacturer or their legally appointed representative in the EU can be liable to a fine or a prison sentence if the product is found not to comply with the requirements of all the relevant Directives. A challenge can be initiated by anyone who believes a product to be dangerous (including your competitors).

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General Product Testing Procedures

• Raise problems: Emulation of practical using situation (proper and improper uses)

• Confirm test criteria: Directives and Standards

• Plan for the test: Facilities setup and test sequence

• Test implementation: Record and Analysis

A product test should be also designed and performed to comply with industry standards.

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Example: Product Testing for Safety of Toys

•Emulate the users of the toy under various situations (normal and abnormal)

•Analyze and study the features/functions of the toy

•Identify the potential hazards of playing the toy (include packing)

According to the essential safety requirements for toys (Toy Safety Directive 2009/48/EC), there are many requirements and tests to assure the safety of toys. What tests we should do? (Ref: http://ec.europa.eu/enterprise/sectors/toys/documents/directives/index_en.htm)

Step 1

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Step 2. Look up the standards and confirm the test criteria. For example, EN-71 or ASTM F963

BS EN71-1: Mechanical & Physical PropertiesBS EN71-2: FlammabilityBS EN71-3: Specification for migration of certain elementsBS EN71-4: Experimental sets for chemistry and related activitiesBS EN71-5: Chemical toys (sets) other than experimental setsBS EN71-6: Graphical symbols for age warning labellingBS EN71-7: Finger paints requirements and test methodsBS EN71-8: Swings, slides and similar activity toys for indoor and

outdoor family domestic useBS EN71-9,10,11: Organic Chemical CompoundsEN50088: Safety of electric toys

Step 3. Plan for the tests.

Step 4. Perform the tests.

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Case Study: Safety of Toys

(1) Select a toy from the market (Explain why it is selected)(2) Study its packing, features and functions (Must be specific)(3) Identify and explain at least x characteristics/features of the toy

that will be critical to safety concerns. (x = number of subgroup members)

(4) Based on these features, describe briefly the required testing standards, apparatus and procedure briefly.

Each subgroup should give a x-page report (excluding the covering page) and submit the toy selected for this case study.

Submission deadline: Tuesday 3 December 2013.

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Introduction to RoHS and WEEE

RoHS, also known as Lead-Free, stands for Restriction of Hazardous Substances. RoHS Directive 2002/95/EC restricts the use of six hazardous materials found in electrical and electronic products.

• Cadmium (Cd): 100 ppm• Mercury (Hg): 100 ppm• Lead (Pb): 1000 ppm• Polybrominated Biphenyls (PBB): 1000 ppm• Polybrominated Diphenyl Ethers (PBDE): 1000 ppm• Hexavalent Chromium (CrVI): 1000 ppm

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The following product categories are impacted under the RoHS Directive:

1. Large household appliances: refrigerators, washers, stoves, air conditioners

2. Small household appliances: vacuum cleaners, hair dryers, coffee makers, irons

3. Computing & communications equipment: computers, printers, copiers, phones

4. Consumer electronics: TVs, DVD players, stereos, video cameras5. Lighting: lamps, lighting fixtures, light bulbs6. Power tools: drills, saws, nail guns, sprayers, lathes, trimmers,

blowers7. Toys and sports equipment: videogames, electric trains,

treadmills8. Automatic dispensers: vending machines, ATM machines

RoHS impacts the entire electronics industry.

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The following products are currently exempted from RoHS compliance:

1. Large stationary industrial tools2. Control and monitoring equipment3. National security use and military equipment4. Medical devices5. Some light bulbs and some batteries6. Spare parts for electronic equipment in the market before

July 1, 2006.

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Countries work on their own version of RoHS:

• RPCEP (Regulation for Pollution Control of Electronic Products): China

• JGPSSI (Japan Green Procurement Survey Standardization Initiative): Japan

• SB20 (Electronic Waste Recycling Act of 2003): California, USA

• Adopting the EU RoHs Directive: Australia, Canada, Korea, Taiwan

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WEEE Man

WEEE stands for Waste from Electrical and Electronic Equipment. WEEE Directive 2002/96/EC mandates the treatment, recovery and recycling of electric and electronic equipment (90% ends up in landfills).

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Objectives of the WEEE Directive

• to increase reuse, recycling and other forms of recovery, leading to a reduction in the amount of waste going to landfill or incineration

• to improve the environmental performance of all operators involved in the life cycle of electrical and electronic equipment

• to set criteria for the collection, treatment, recycling and recovery of WEEE

• making producers responsible for financing most of these activities - private householders are to be able to return WEEE without charge

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The WEEE Directive requires producers to take a whole-life responsibility for their products and to meet given targets. They will also need to provide data to demonstrate compliance.

The WEEE Directive covers all electrical and electronic equipment with voltages up to 1,000 AC and 1,500 DC

Producers are defined as:

• Manufacturers who sell their own brand • Resellers under their own brand • Importers or exporters into an EU member state

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Please complete also the reading assignment.

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Thank youThank you