Project PROJECTOR FINAL PRESENTATION SUBMITTED TO THE SANYO
Project «PROJECTOR» FINAL PRESENTATION SUBMITTED TO THE SANYO Electric Co. Ltd. PRESENTED BY Institute of Innovative Design Terms: Beginning: Completion: January 2003 March 2003
Object of Analysis DLP Projector
Main Function To receive modulated on brightness and color light
Project Goals Main Goal Noise level from projector must be less then 22 d. B(A)
Restrictions • Changing Lamp and DLP unit are impossible now. • Size must be be same (or little larger is acceptable).
Innovative Technology of Design Data Gathering Background information Analysis of the Object Functional and Flow models, Evolution Trends, Key Disadvantages, Contradictions Problem Statement Trimming problems, Feature transfer problems, Key problems Function Based Information Gathering Function oriented information ANALYTICAL STAGE Problem Solution Engineering Solutions Supporting Information Gathering Supporting information INFORMATION STAGE Concept substantiation Concepts, Ideas for Further Development CONCEPTUAL STAGE
INFORMATION STAGE
Processing Information stage Info 1 Source information Info 2 Scientific (basic) information Info 3 Functional information Info 4 Support information Analytical stage Conceptual stage Key problems Concepts Legend: Information reply Information request
Information Search Types of Information Used INFORMATION Info 1 INFORMATION SOURCE Ø INITIAL INFORMATION FROM CUSTOMER (DIAGRAMS, SAMPLES, ETC. ) Ø DATA OF COMPETITORS PRODUCTION Info 2 SCIENTIFIC (BASIC) INFORMATION Info 3 Info 4 FUNCTIONAL INFORMATION SUPPORTING INFORMATION Ø BASIC SCIENTIFIC PRINCIPLES OF OBJECT ACTION (PHYSICAL, CHEMICAL, GEOMETRICAL, BIOLOGICAL) Ø OBJECT EVOLUTION Ø PARAMETERS CHARACTERIZING THE OBJECT AND ITS COMPONENTS Ø LEADING AREAS OF ENGINEERING Ø ENGINEERING DEVELOPMENTS AND THEIR COMPONENTS (EQUIPMENT, MATERIALS, ETC. I. E. DATA FORMULATION OF FUNCTIONS) Ø RESOURCES FOR STATED KEY PROBLEMS SOLVING Ø INFORMATION ON SPECIFIC CONCEPTS Ø SCIENTIFIC BASIS, CALCULATIONS Ø REFERENCES
Table of Information Search Fragment Search direction Leading filds of sience and technology 1. Engineering function 1. 1. Problem: Fan generate noise at creation of airflow. 1. 1. 2. Exinguishing of sound by antisound Electronic engineering 1. 1. 3. Noise reduction of fans Aerodynamics Aircraft construction PCs 1. 1. 4. Decrease of turbulence of stream Wings of airplanes Stabilizer of missiles Aircraft construction To create airflow Principle, method, device Generalized engineering function: System of active noise control (electronic cirquit) Screw-propeller engine CPU Fans Possible application to the project To move substance To applay active noise control system in order to reduce noise. To change amount of impellers. To make impellers of special shape Lattice wings To make impelers of fans as littice wings Microrelief on impeller of screw and on fuselage of airplane. Fibrous covering. To make impelers of fans with microrelief or with fibrous covering. Screw-propeller engine To apply a coaxial meyhod of instulling of two impellers. Outside acoustical effect on turbulent flow To apply ultrasonic generator for structuring of turbulent whirlwind and lowering of viscosity of air.
Analytical Stage
Analytical Stage Structure
Component Structural Analysis Super system elements Desk (selling) Screen Optical system Super system elements Power supply Ambient air DLP Projector User Cooling system Electronic circuit Control unit Video signal Projector case Electric current Power cord Intake vents DLP Block Power supply of projector DMD Chip Micromirror Lamp power supply Memory cell DLP case Condenser lens Air duct Axial fan Fan case Fan rotor Lamp unit Lamp Impellers DC motor Color wheel Lamp case Motor of color wheel Lamp house Light absorber Exhaust vents Centrifugal fan case Centrifugal fan rotor Rotor blades DC motor Chassis
Function Analysis Fragment of function table Element 7. Intake vents 8. Exhaust vents 9. DLP case 10. Micromirror 11. Memory cell Function Rank 7. 1 To direct ambient air A 1 7. 2 To decelerate ambient air H 8. 1 To decelerate airflow H 8. 2 To pass out luminous light H 8. 3 To output airflow A 3 9. 1 To hold condencer lens A 2 9. 2 To decelerate airflow H 9. 3 To hold light absorber A 2 9. 4 Not emit out luminous light A 1 9. 5 To hold memory cell A 2 9. 6 To absorb infrared and ultraviolet of luminous light H 10. 1 To produce modulated light B 10. 2 To absorb luminous light H 10. 3 To modulate luminous light B 10. 4 To heat memory cell A 1 11. 1 To decelerate airflow H 11. 2 To heat DLP case H
Results of functional model The amount of basic functions providing performance of main useful function is – 4 The amount of auxiliary functions is – 108 The amount of harmful functions is – 94
Diagnostic Analysis Element for trimming Trimming problems Rotor blades 1. How to create airflow by centrifugal fan rotor without rotor blades? Impellers 2. How to create airflow by axial fan rotor without impellers? DC motor of axial fan DC motor of centrifugal fan Air flow 3. How to create airflow by electric current without fans? 4. How to cool the elements of DLP projector by projector case without air flow?
Cause-and-Effect Chains Analysis Rigid junction of fan with projector case Method of transformation of electric energy into mechanical Voltaic arc in mercury vapor Transmission of vibration through projector components Rotation of DC motor rotor Rotation of rotor blades (impellers) in air Radiation of IR and UV rays Absorption IR and UV rays Mechanical noise Method of creation of monochrome light Absorption of visible light by colour filter Modulation of light by selective reflection Physical properties of substances Internal friction of airflow (viscosity) Friction of airflow with surfaces of projector components and exhaust vents Heating of projector components Absorption of visible light Cooling of projector components by airflow Action of electric current emit Joule heat Acceleration of airflow Deceleration of airflow Inhomogeneity of airflow Discrete noise Aerodynamic noise NOISE
Statement of Key Problems Key problem Amount of key problems Direction 1. The noise reduction with the minimum changes in system 3 Direction 2. The noise reduction of discrete noise in fans 2 Direction 3. The change of method of airflow creation 1 Direction 4. The change of method of cooling of projector’s components 2 Direction 5. The reduction of heating of projector’s components 1 Direction 6. The change of a physical operation principle of projector 5
List of Problems Key problem Concepts solving key problems Direction 1. The noise reduction with the minimum changes in system 1. 1. How to provide rigid junction of fan-motor case with case of projector, which does not transmit vibration from fan-motor? 1 1. 2. How to provide rotation of DC motor rotor without generation of mechanical noise? 2 1. 3. How to reduce frequency of rotation of fans? 3, 4 Direction 2. The noise reduction of discrete noise in fan 2. 1. How to create airflow by centrifugal fan rotor without blades? 5 2. 2. How to create airflow by axial fan rotor without impellers? 6 Direction 3. The change of method of airflow creation 3. How to create airflow by electric current without fans? 7
List of Problems Key problem Concepts solving key problems Direction 4. The change of method of cooling of projector’s components 4. 1. How to cool projector’s components without airflow? 4. 2. How to cool the elements of DLP projector by case of projector without airflow? 9, 10 8 Direction 5. The reduction of heating of projector’s components 5. How to reduce absorption of IR and UV radiation by projector’s components? 11 Direction 6. The change of a physical operation principle of projector 6. 1. How to reduce absorption of visible light in projector? 12 6. 2. How to reduce a share of IR and UV radiation? 12 6. 3 How to generate visible light without voltaic arc in mercury vapor? 12 6. 4. How to generate modulated light without selective reflections of radiated light? 12 6. 5. How to generate monochrome radiation without absorption of a part of visible light? 12
Conceptual Stage
List of Concepts on Directions Conceptual direction 1: Reduction of noise from projector with minimum changes in system. Concept 1. Fastening of the fan to the case of the projector by magnetic supports Concept 2. The fan bearings with air lubrication. Concept 3. Cooling intake air by thermoelements with Peltier effect. Concept 4. Cooling of intake air by adsorption refrigerator by using heat of lamp. Conceptual direction 2: Rduction of discrete noise of fans. Concept 5. Screw disk-shaped fan. Concept 6. Conic spiral fan. Conceptual direction 3: Change of method of airflow making. Concept 7. Ionic noiseless fan. Conceptual direction 4: Change of method of cooling of projector components. Concept 8. Cooling of lamp unit and DLP block by heat pipes. Concept 9. Heat removal from projector by flexible heat pipe integrated with power cord. Concept 10. Cooling of projector elements by thermoionic semiconductor elements. Conceptual direction 5: Reduction of heating of projector components. Concept 11. Case of projector made of materials transparent for IR beams. Conceptual direction 6. Change of physical principle of projector operation. Concept 12. Laser projector
Conceptual Direction 1 REDUCTION OF NOISE FROM PROJECTOR WITH MINIMUM CHANGES IN SYSTEM The purpose of the given direction: to reduce noise from a projector with minimum changes of existing air cooling system and design of fans. In concepts of the given direction reduction of noise from a projector is achieved by reduction of mechanical and discrete noise from fans.
Concept 1. FASTENING OF THE FAN TO THE CASE OF THE PROJECTOR BY MAGNETIC SUPPORTS 2. Conical const magnet 3. Annular const magnet 1. Fan case S N SN S SN N 4. Clips
Concept 2. THE FAN BEARINGS WITH AIR LUBRICATION 1. Axle of fan rotor 2. Teflon porous bushing 3 5. Fan case 4. Piezoelectric ceramic vibration generator 6. Electrodes
Concept 3. COOLING OF INTAKE AIR BY THERMOELEMENTS WITH PELTIER EFFECT Top view Side 1 view
Concept 4. COOLING OF INTAKE AIR BY ADSORPTION REFRIGERATOR BY USING HEAT OF LAMP 15. Fan 16 2 4 1. Condenserreboiler 3. Pipe 5. Adsorbergenerator 8. Flat condenser part A 6 B 9 17. Heat insulator 11 7. Capillaryporous substance + Ca. Cl 2 10. Heat Pipe 12. Flat condenser part 14. Flexible heat pipe 13
Conceptual Direction 2 REDUCTION OF DISCRETE NOISE OF FANS The purpose of the given direction: is to offer a design of fans with a minimum level of discrete noise. In concepts of the given direction the airflow is created by a rotor of fan without blades and impellers.
Concept 5. THE SCREW DISK-SHAPED FAN 1. Fan case 2. Fan rotor 3. Screw disk
Concept 6. THE CONIC SPIRAL FAN 3. Fan case 2. Spiral cone 4. DC motor FN 1. Fan rotor FC FA
Conceptual Direction 3 CHANGE OF METHOD OF AIRFLOW CREATING The purpose of the given direction: to offer a construction of a fan which does not create mechanical and discrete noise. In the concept of the given direction the airflow is created without any mobile parts by an electric field directly.
Concept 7. THE IONIC NOISELESS FAN 4. The positive grid electrode Operating mode 2. Needles 1. Negative grid electrode Storage mode 5. The movable part of a case 3. The movlees part of a case
Conceptual Direction 4 CHANGE OF METHOD OF COOLING OF PROJECTOR COMPONENTS The purpose of the given direction: to offer methods of cooling without a forced circulation of air. In concepts of the given direction heat energy emitted in projector by different methods remove on exterior surfaces of projector components and is dispersed in surrounding medium.
Concept 8. COOLING OF LAMP UNIT AND DLP BLOCK BY HEAT PIPES The cooling system of the lamp unit and DLP block with the central heat sink with one fan
Concept 9. HEAT REMOVAL FROM PROJECTOR BY FLEXIBLE HEAT PIPE INTEGRATED WITH POWER CORD 5. Evaporator part 7. Capillary-porous canal 1. Case 4. Flexible heat pipe 6. Condencer part 3. Wires 2. Contacts 8. Condencer part
Concept 10. COOLING OF PROJECTOR ELEMENTS BY THERMOIONIC SEMICONDUCTOR ELEMENTS 10 11 13 4. Condencer part 7. Air canal 6 9. Thermoionic element 15. Radiator enclosure 7. 1. Heat pipe 14 5 12. Element with Peltier’s effect 3 8. Projector case 2
Conceptual Direction 5 REDUCTION OF HEATING OF PROJECTOR COMPONENTS The purpose of the given direction: to reduce heat absorption by components of projector. In the offered concept elements of case are made of substances transparent for infrared radiation. The heat radiation does not remain inside a projector, but outputs in a surrounding medium.
Concept 11. CASE OF PROJECTOR MADE OF MATERIALS TRANSPARENT FOR IR BEAMS 2. Projector case 3. Lamp unit 1. IR transparent window IR rays
Conceptual Direction 6 CHANGE OF PHYSICAL PRINCIPLE OF PROJECTOR OPERATION The purpose of the given direction: to change a physical principle of operation of projector, to solve a maximum quantity of key problems. In the offered concept the light source with a high efficiency in which are combined functions of light source with the modulator of radiation.
Concept 12. LASER PROJECTOR 7 2 4. Mirror 8. Chip 1. Red semiconductor laser 6 3 5. Micromotor
Concept 12. LASER PROJECTOR WITH MATRICES OF SEMICONDUCTORS MICROLASERS 4. Semiconductor micro lasers 3 1. Control chip 6 7. Mixing prism 5 2
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