Electric Bug Zapper

Introduction of Electric Bug Zapper


  • More formally known as an electric insect-control system or electrical-discharge insect-control system.
  • A device that attracts and kills flying insects that are attracted by light.
  • Works by attracting bugs and insects to the violet and ultra-violet light emitted by the lamp and then electrocutes them.
  • Major parts in a bug zapper: Housing, UV/ Fluorescent Light Source, Wire Gauze and Transformer.


Problem Statements

Original Design for This Project

For my case, I studied on the bug zappers that have been used at MAMAK's restaurants or any food stalls. So, here are a few problems that have been detected:
  •  Bug Zapper on the table will consume space
  • The food on the table might contaminated
  • But most of the bug zappers that we can see at the MAMAK's restaurants were installed far from the critical zone (such as under the table)


Objective

The objective of this project is to make users life easier which is by making the Electric Bug Zapper more efficient, which are by
  • saving the space of the table
  • preventing diseases


Criteria Tree



Product Decompositions for Original Product



Product Specifications

Establishing specification takes on traditional importance and is substantially more challenging when developing a highly complex product consisting of multiple sub-system designed by multiple development teams. After getting the whole picture what our product supposed to have, the product specification will be included all this.




Product Comparisons



Concept Generation

The concept generation is based on the customer needs and target product specification. It is a synthesis process based on the analysis done to date. In this chapter, idea is generated and represented in a rough sketch or with some small explanations written down on the sketch to describe the function of the feature and part represented. This can make the people more understanding what the idea about.

First Design Concept


Advantages
  • High aesthetic value
  • Have hanger to clamp at the edge of table
  • Have trapper to cover bugs’ dead bodies
  • Have trapper to fill mosquito attractant
Disadvantages
  • Hard to clean
  • Consume storage space
  • Not all the table are suitable to clamp
  • Trapper is small
Second Design Concept


Advantages
  • Easy to store and clean
  • Safe to use
  • Have trapper to fill mosquito attractant
  • Have trapper to cover bugs’ dead bodies
  • Have hanger to clamp at the edge of table
Disadvantages
  • Not all the table are suitable to clamp

Third Design Concept


Advantages
  • Easy to store
  • The bugs and mosquitoes dead bodies are covered
  • Safe to use
Disadvantages
  • No table clamp/hanger to clamp at the edge of the table
  • Hard to clean the interior part
  • No specific container to collect bugs and mosquitoes dead bodies
  • Consume table space


Design Concept Selection

Concept selection is the process of evaluating concepts with the respect to customer needs and other criteria, comparing the relative strengths and weakness of the concepts, and selecting one or more concepts for further investigation, testing or development. Individual concepts were put together and proposed in the concepts selection. The features of these concepts were presented. All the concepts features of each of the designs, their strengths and weaknesses are analyzed. Pugh Method Screening and Weightage Scoring Method are used to analyze and evaluate the concepts in order to select the most suitable design of the bug zapper. These methods are playing an important role to simplify the scope into final concept. From the methods, the best concept is able to choose through the process. At this stage, a meticulous comparison for each engineering parameter and the importance of criteria selection will be focus on.

Concept Screening (Pugh Method)



Concept Scoring (Weightage Method)

Concept scoring is a concept of marking the score on each concept designs. The result is based on the weighted score by using formula as below:
Sj = Σi=1 rijwi
Where
rij = raw rating of concept j for the i th criterion
wi = weighting for the i th criterion
n = number of criterion
Sj = total score for concept j










Final Concept



 Final Design Specification and Features

Part / Feature
Detail
Engineering Parameter
Hanger cover
Function:
-        To hang the Electric Bug Zapper at the end of table.


Material : ABS
Height : 50 mm
Length : 125 mm
Thickness : 1 mm
Trapper
Function:
-        To gather the remains of bugs killed.
-        To fill attractant for mosquitoes
Material : ABS
Height : 6.7 mm
Length : 125 mm
Thickness : 3.0 mm
Housing
Function:
-        To cover the electrical components.
Material : ABS
Height : 136mm
Length : 82 mm
Thickness : 2mm
Filter
Function:
-        To avoid bugs from escaping from the zapper.
Material : ABS
Height : 15.8 mm
Length : 80 mm
Thickness : 1mm
Tenon-Mortise joint
Function:
-        Work as the joint
Material : ABS
Height : 3.4 mm
Diameter : 3.0 mm



Snap-fit Calculation





Advantages, Disadvantages and Design Limitations

Description
  • Has hanger to hang the bug zapper at the edge of the table for space saving
  • Geometric cubic housing for modern aesthetics and easy for storage purpose
  • Has half diamond-shaped filter to prevent the bugs from escaping
  • Has non-transparent trapper to trap and hide the bugs’ dead bodies
  • Has adjustable hanger so that the hanger can fit perfectly at any types of table
  • Can be used for both light-attracted bugs and mosquitoes (mosquito does not attracted by light but attractant).
Advantages
  • Hygienic
  • Safe to use
  • Can be used for both bugs and mosquitoes
  • Easy to store and clean
 Disadvantages
  • Need refill the mosquito attractant from time to time
  • Need remove the bugs’ dead bodies manually by removing the trapper

Design Modelling

Parts and Detail Drawing

Before going to the 3D printing, the part of each of the components was drawn with aids of CatiaV5. There are seven parts were drawn and their details information was labeled with respect to their tolerance calculated. Below are the example of calculation for tolerance analysis:

DIM
+ve
-ve
Tolerance
Dim1
136

0.1
Dim2

20.5
0.05
Dim3

113
0.05
Dim4

18
0.05
Dim5

15
0.05
Dim6

2.7
0.05
Total
136
134.5
0.35

The gap distance between AB:
The minimum distance = (136-134.5) – 0.35 = 1.15mm
The maximum distance = (136-134.5) + 0.35 = 1.85mm

Model/ Mockup Fabrication

The drafting were saved in .stl mode and printed out with using the 3D printing machine. There were some problem within the modelling process, which that not each parts of the project was printed due to the limited time and machinery problem. Finally, only three main parts was successfully printed and one part was fabricated by using the custom cut acrylic sheet.

 Filter
The filter was fabricated by using the custom cut acrylic sheet. First, the acrylic sheet was labeled properly. Secondly, cut-off the shape with knife. Then, glued to form shape with hot glue. Finally, the filter was done!

Housing frame
The housing frame was fabricated with 3D printing machine. When it was done printing, there was
some surplus attach on the product. Thus, with aids of art-use-scissors, the surplus was cut-off and finished with sand paper. Below was the process of finishing:


 Cover
The cover was fabricated with 3D printing machine. When it was done printing, there was some surplus attach on the product as shown in Figure 5.3(C). Thus, with aids of art-use-scissors and knife, the surplus was cut-off and rub with sand paper to make it smooth. Below was the process of finishing:


Trapper
The trapper was fabricated with 3D printing machine. The project was rubbed with sand paper to make it smooth. Below was the process of finishing:

Assembly of the parts:


The figure above shows the assembly process of the bug zapper. First, install the filter into the trapper. Second, install the housing frame onto the trapper. Third, install the electronic components or as known as the transformer onto the housing frame. Then, cover the housing frame with the cover. Thus, the assembly done!


Sustainability Analysis

The material used to make the product was take into consideration and checked its sustainability with the aids of Solidworks2014. There were two material used to conduct this analysis, which were Acrylonitrile butadiene styrene (ABS) and PP Copolymer.


 PP Copolymer made bug zapper.


Figure 12 shows that the redesigned bug zapper was generated its sustainability with using the Solidwork2014. There was some basic information was given, which that the product was exported from Asia to North America and the exportation required a shipping distance of 1.24x104km. Also, its recycle rate was only 15%. However, the weight for the product was 100.79g, which is lighter than the usual bug zapper.


The result in Figure 13 shows that the water eutrophication was 2.8x10-4 kg PO4, air acidification was 3.6x10-3 kg SO2, carbon footprint was 0.489 kg CO2 and the total energy consumed by the product was 9.9MJ.

ABS made bug zapper

Figure 14 shows that the redesigned bug zapper was generated its sustainability with using the Solidwork2014. There was some basic information was given, which that the product was exported from Asia to North America and the exportation required a shipping distance of 1.24x104km. Also, its recycle rate was only 15%. However, the weight for the product was 115.51g.


           Figure 15 shows that the water eutrophication was 4.3x10-4 kg PO4, air acidification was 4.5x10-3 kg SO2, carbon footprint was 0.747 kg CO2 and the total energy consumed by the product was 13MJ.

Comparisons



Material
Environmental impact
Carbon Footprint
(Kg CO2)
Water Eutrophication
(Kg PO4)
Air Acidification
(Kg SO2)
Total Energy Consumed (MJ)
Total
Percentage (%)
ABS
0.747
4.3x10-4
4.5x10-3
13
13.8
57.02
PP Copolymer
0.489
2.8x10-4
3.6x10-3
9.9
10.4
42.98
Total
24.2
100
Table 6.2.1: The environmental impact comparison.


        From Figure 16 and Figure 17, the comparison result shows that the PP Copolymer made bug zapper was much better than an ABS made bug zapper in terms of the material, manufacturing, use, end of life and the transportation factors. This mean, a PP Copolymer made bug zapper cause less environmental pollution when compare to the ABS made bug zapper. This happen because the PP Copolymer are much easier to manufacture and beside it is much recyclable. PP Copolymer tends to have better stress crack resistance and low temperature toughness than homo-polymer at the expense of quite small reductions in other properties. The result of the product could be referred to Table below.

Material Analysis for ABS and PP Copolymer
Storage in life cycle
Sustainability strategy
ABS
PP Copolymer
Stage 1:
Extraction and Manufacturing
Embodied energy
Own relatively high embodied energy per unit volume is needed to extract material. Low processing energy to moulded material once extracted.
Own relatively low embodied energy per unit volume is needed to extract material as compare to other plastics. Higher processing energy to moulded material once extracted.
Stage 2：
Product Use
Aesthetics and durability
Excellent aesthetic properties and easy to paint and glue. Durable, good strength and stiffness, good fabricating and machining properties and process low heat conductivity.
Attractive and aesthetically appealing, excellent strength, toughness and flexibility over a wide range of temperatures. Excellent impact strength resistance and good elasticity.
Stage 3：
End of life
Disassemble and Recyclability
Machines with ease, low coefficient of friction, corrosion and abrasion resistant, good chemical resistance and can be recycle
Recyclable. PP Copolymer tends to have better stress crack resistance and low temperature toughness than homo-polymer at the expense of quite small reductions in other properties.

As a result, ABS was not the suitable material use to make the bug zapper especially it was not as recyclable as the PP Copolymer due to it physical and mechanical properties that causing it to be not that easy to melt or degrade. Also, an ABS material usually applied in making shell for electronic component due to its high resistance and high melting point. When comes to making the bug zapper, there was only a very small area will contact with those electronic component such as the transformer. In addition, the bug zapper made with PP Copolymer have better performance because it required low embodied energy per unit volume to extract material, meaning that the PP Copolymer are suitable to manufacture and form shape. Plus, it required lower energy and consume less time to degrade. PP Copolymer tends to have better stress crack resistance and low temperature toughness than homo-polymer at the expense of quite small reductions in other properties. Therefore, the PP Copolymer made bug zapper are much environmental friendly and it reached the sustainability goals.


Economic Analysis

Bill of Materials

Part / Feature
Material
Quantity
Price per Unit ($)
Total Amount ($)
Hanger
ABS
1
0.50
0.50
Trapper
ABS
1
1.00
1.00
Housing frame
ABS
1
2.50
2.50
Filter
ABS
1
1.00
1.00
Connector
ABS
2
0.20
0.40
Wire Gauze
Stainless Steel
1
1.00
1.00
Ultraviolet Light
Borosilicate glass
1
2.50
2.50
Tenon-Mortise joint
Stainless steel
12
0.10
1.2
Transformer
Silicon steel
1
3.00
3.00
Cable (1m)
Conductor: Copper

PVC
1
1.50
1.50
Plug
ABS
1
0.50
0.50
Total
23
13.80
15.1

Variable Cost to Produce 1 Unit of The Product


Fixed Cost


Return of Investment





Product Warranty

Product Quality Dimension

Performance

For the Electric Bug Zapper, the performance of the new design was being compared with the original design based in the current market. A 100% Safe Electric Bug Zapper, no chemicals or potentially harmful sprays to human were embedded in the product. With a size of 81mm x 52mm x 12.8 mm, a single high intensity LED UV bulb, a power voltage of 110V AC, 50 Hz and average power consumption of 2.5 W,  the bug zapper is perfect for taking along during travel due to the compact size.


Durability

The Electric Bug Zapper was designed by using ABS and PP plastics, the zapper have high endurance even when it falls to the ground. Using an adapter as power source, the zapper can lasts for 4 hours in use without overheating. When the zapper is in operation, the amount of noise is reduced compare to other bug zapper.


Reliability

The Bug Zapper offers a good after sales service, a 1-year warranty was provided for this product and the damage done within those period are claimable. Featuring a bright LED UV bulb that attract mosquito then make contact with an extremely powerful high voltage electrically charged metal grid, instantly killing them.


Conformance

Electric Bug Zapper committed to comply with the standards imposed by the Restriction of Hazardous Substances Directive, which restricts the use of certain hazardous substances in electrical equipment. It is also complies with the standards imposed by the Conformance European (CE), a division of the Interfek group.


Aesthetics

The Electric Bug Zapper is equipped with a trapper that is designed to keep dead mosquitoes and other insects collected inside the unit, which can then be easily removed for cleaning and bug disposal by gently shaking them. Available in the colour black, the bug zapper appears to look modern and simple and is easy to carry and use. Just clamp the device onto any table and it’s good to go. The effective coverage is about 20 square meters.


Perceived Quality

Electric Bug Zapper is powerful but quiet with PCB design which proves that the product eco-friendly. There is no harmful radiation, non-toxic quiet and safe to humans and pets. The product is recommended for outdoor use, particularly at restaurants that have outdoor dining tables. It also have low power consumption when it is in active-off mode. Due to electric shock danger, the users were advised not to touch the high voltage grids when in use and keep it away from children.


Product Warranties of Electrical Bug Zapper





Future Recommendations and Improvements

For the designed Electric Bug Zapper, there are still a few improvements that can be made for future uses. One is to install a larger trapper for the biting insects to be kept. By increasing the size of the trapper, this will reduce the frequency on how many times it takes for user to empty the trapper. Another idea for future improvement is to add a fan to aid the dead biting insects to fall down into the trapper. The added fan will suck down the dead insects that were stuck on the wire grid. By adding a fan to the design, there will be less dead biting insects stuck on the wire grid, thus increasing the efficiency of killing them.

    Apart from that, the current design for the Electric Bug Zapper are not foldable. This can become an idea for an improvement. By making the zapper become foldable, it will not consume much space in the suitcase when carrying them around during travel. When changing the zapper to be able to fold, it must come with a customized case to keep the parts safe when packing them in the suitcase, thus making the use of the zapper a lot easier for users.

    Another improvement that can implemented for future design is to make the design of Electric Bug Zapper easy to assemble and disassemble. This idea can be done by adding more snap-fits into the design itself. For example, the casing and the trapper can be assemble and disassemble easily when snap-fit is used to bind them together.


Conclusion

Bug zapper, those sizzling glowing fixtures in many restaurants, kill billions of insect every year, but still biting insects are lingering around us to some point that it became annoying. Based on a research done by Dr Douglas W. Tallamy, an entomologist in Newark, out of 13,789 dead bugs caught by the zapper, only 31 were biting flies. Nearly all the neighborhoods’ biting flies remained on the wing to torment the zapper’s owners. By redesigning the bug zapper, the number of biting flies can be increased by simply placing the zapper near the user. In order to design a more efficient bug zapper compared to the ones in the market, many procedures were done. Some of them were problem identification, concept generation and selection of the new design, design modelling and FMEA.

    Based on the findings, a few ideas were found. As the current design consumed space when placed on the table, the new designed zapper’s position were a crucial point, and as a result, the new designed bug zapper will be placed beside a table, clamped. By doing this, the zapper can kill more biting flies in the hidden areas such as under the table. An addition to that, the bug zapper also implemented a mosquito attractant that mimics the human breathe to increase the number of dead biting insects. Apart from that, a filter that prevent the trapped insects in the zapper from coming out again was also added in the new design bug zapper.

    While the current bug zapper do work, it was not nearly well enough to make them worthwhile if the number of dead biting insects were still significant. By improving the design and its function, the number of dead biting insects might increases, thus making the user felt free without having to worry about these annoying insects biting them while enjoying their meal.

Subscribe to: Posts (Atom)