I and another student designed a new driver environment for a slag hauler, a big industrial machine for smelters as our master thesis project. We designed and built a full scale realistic prototype of the new cabin. The project was commissioned by Kiruna Utility Vechiles (KUVAB), a company producing special vehicles for smelters. We worked in close cooperation with the company during the whole project.
The design process had strong user focus and we developed our own design process and methods with core in human centred design. Our mission was to enhance the ergonomics, safety and user experience with all stakeholders in mind. The new design was highly appreciated and the company are now further developing the concept for production and launch during 2017. The project result is a realistic prototype with high level of detail and possibilities for customers to evaluate and experience the new design.
The project was comprehensive and included everything from learning about slag haulers and their applications by field studies and interviews, to designing in CAD and producing the prototype. The prototype was built in full scale using production methods available at the company such as laser cutting, bending, welding and laser etching. Some components were also made with rapid prototyping.
The best part about this project was the strong connection to the production and the short paths from an idea to draft to a physical component. In the morning I was designing a part in CAD, and a few hours later I could go down to the workshop to receive my component from the laser cutter and see the benders form it to the right shape. We had assistance from professional welders, but we also got to try welding ourselves as we assembled the prototype. This gave an understanding for possibilities and limitations with metal production that I could not learn any other way!
The prototype that we built in the project, lifted with a loader to show the right perspective.
This is what the slag hauler looks like today with the old cabin.
Our design of the new interior in the front view. Slag haulers are special because they are operated in two directions, the driver sits forward when driving and backwards when operating the slag pot.
This is what the front looks like in the old cabin.
Back view of our design. This is the working direction when operating the slag pot.
Rear view of the old cabin.
We visited several steel plants to observe the drivers while working. This photo is from a visit to a smelter in northern Finland were we got to ride along with the drivers while handling the slag.
Interviews with stakeholders gave input and revealed issues with the existing design.
The voice of a slag hauler driver.
Involvement of stakeholders was crucial throughout the design process to achive a relevant result.
Service mechanics at the steel plants have a lot of experience of maintaining the slag haulers.
Manager of slag hauler drivers. We heard stories of slag haulers that were not used because the drivers disliked them.
Designers at KUVAB appreciated our contribution of approaching the design task from a different angle.
Ideas started as sketches..
and was later discussed with production workers for optimization.
The prototype in an early stage
Many hours were spent in the workshop building the prototype.
Cooler Support for LKAB
Failure and subsequent replacement of wheels in the existing cooler support system have led to significant costs and lost production for LKAB. Me and four other students from mechanical engineering at Luleå University of Technology was given the task to redesign the support system in a project of 23 weeks. The new solution had to carry the weight of the cooler with a capacity to cool over 500 tons of iron per hour. Accordingly, the solution had to be robust while at the same time adjustable and maintainable for varying cooler loads and the geometries of the four pelletizing plants in Kiruna and Svappavaara.
The new solution is easier to monitor and maintain than the previous design thanks to its flexibility. It is also designed to facilitate the installation and service of the system. A double wheel design distributes the weight of the cooler more efficiently and balances the wheel construction to make sure both wheels are in contact with the cooler.
Illustration of the pellet production flow. The cooler is the last and most critical part, subsequent failure lead to stops of the entire production.
The cooler weights up to 500 tons and rotates slowly, about two rounds per hour. The extreme conditions demanded a tailor made construction with high focus on robustness.
Custom shaft mounts enables varying angels of the wheels to fit the various coolers with different radius.
The idea of using wear surfaces came up during interviews with mechanics at the plant. Severe wear of the wheels was found to be a problem, causing loss of contact between wheels and cooler.
The project aim was to develop new door concepts for the door producer Corrotech AB, located in Haparanda. The idea was to create a standard door frame with unlimited design options. The door can easily be customized into different designs with changeable fronts.
I worked in this project with two other guys, one industrial designer and one architect. We created a collection of design doors inspired by the Art Deco era. We also created some doors with light design that gives a spectacular effect in the dark and cold winters of the north.
Robotic Vacuum Cleaner
Design of a robotic vacuum cleaner inspired by the design of GARDENA, manufacturer of gardening equipment.
The GARDENA brand design was analyzed and expressed in a style board. Shapes and styles of their gardening equipment was translated into the design of a robotic vacuum cleaner. The project aimed to build a realistic prototype in scale 1:1, using advanced modeling techniques. The pictures below shows some of the work steps while creating the prototype, including laser scanning and vacuum forming.
If you're interested in seeing the complete work book from the project click here.
A clay model was created to test and refine the shape of the vacuum.
Safety chamber for future deep mining
dMine was a design project with focus to develop a refuge chamber for the European mining industry. The project was a sub project to “Deep Mine Rescue” which is a part of the EU Project I2Mine. I worked on the project together with nine other students in the course Advanced Product Development at Luleå University of Technology.
The result is a conceptual solution of a refuge chamber with capacity to store enough necessities for trapped miners to survive two weeks without contact with surface. The chamber have a modular moving system which allows it to always be close to the working area and possibility to move the chamber during blasting.
The interior is designed to comfort the trapped miners and give a more home like atmosphere compared to existing refuge chambers on the market.
We made a broschure to explain the work process an result, see it here.
The project got some attention in the media, read the articles from the swedish paper Ny teknik here, and Swedish radiohere.
Transportation module with rubber tracks. Because of the bearing connection to the frame, it has the ability to turn in relation to the load.
Simple scale paper models were used to test the size of the chamber.
Conceptual design of an outdoor gym completely made of wood. I worked with the project together with another Industrial designer, Tommy Alatalo.
The customer asked for an unsupervised outdoor gym. We developed a gym with the main focus on using your own body weight while working out, thus minimising the need for moving parts such as bearings or axles. The gym is based on modular units offering balanced exercises.