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Project «PROJECTOR» SUBMITTED TO THE SANYO Electric Co. Ltd. PRESENTED BY Institute of Innovative Design Terms: Beginning:January 2003 Completion:March.

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Presentation on theme: "Project «PROJECTOR» SUBMITTED TO THE SANYO Electric Co. Ltd. PRESENTED BY Institute of Innovative Design Terms: Beginning:January 2003 Completion:March."— Presentation transcript:

1 Project «PROJECTOR» SUBMITTED TO THE SANYO Electric Co. Ltd. PRESENTED BY Institute of Innovative Design Terms: Beginning:January 2003 Completion:March 2003 FINAL PRESENTATION

2 Object of Analysis DLP Projector

3 Main Function To receive modulated on brightness and color light

4 Main Goal Noise level from projector must be less then 22 dB(A) Project Goals

5 Restrictions Changing Lamp and DLP unit are impossible now. Size must be be same (or little larger is acceptable). Changing Lamp and DLP unit are impossible now. Size must be be same (or little larger is acceptable).

6 Innovative Technology of Design Supporting Information Gathering Supporting information Analysis of the Object Functional and Flow models, Evolution Trends, Key Disadvantages, Contradictions Problem Solution Engineering Solutions Data Gathering Background information Function Based Information Gathering Function oriented information CONCEPTUAL STAGE INFORMATION STAGE ANALYTICAL STAGE Concept substantiation Concepts, Ideas for Further Development Problem Statement Trimming problems, Feature transfer problems, Key problems

7 INFORMATION STAGE

8 Processing Information Information reply Information request Legend: Conceptual stage Information stage Info 2 Scientific (basic) information Info 1 Source information Info 3 Functional information Info 4 Support information Analytical stage Key problems Concepts

9 Information Search Types of Information Used INFORMATION Info 4 SUPPORTING INFORMATION Info 3 FUNCTIONAL INFORMATION Info 1 INFORMATION SOURCE  INFORMATION ON SPECIFIC CONCEPTS  SCIENTIFIC BASIS, CALCULATIONS  REFERENCES   LEADING AREAS OF ENGINEERING  ENGINEERING DEVELOPMENTS AND THEIR COMPONENTS (EQUIPMENT, MATERIALS, ETC. I.E. DATA FOR FORMULATION OF FUNCTIONS)  RESOURCES FOR STATED KEY PROBLEMS SOLVING  BASIC SCIENTIFIC PRINCIPLES OF OBJECT ACTION (PHYSICAL, CHEMICAL, GEOMETRICAL, BIOLOGICAL)  OBJECT EVOLUTION  PARAMETERS CHARACTE- RIZING THE OBJECT AND ITS COMPONENTS  INITIAL INFORMATION FROM CUSTOMER (DIAGRAMS, SAMPLES, ETC.)  DATA OF COMPETITORS PRODUCTION SCIENTIFIC (BASIC) INFORMATION Info 2

10 Table of Information Search Fragment Search directionLeading filds of sience and technology Principle, method, devicePossible application to the project 1. Engineering function To create airflow  Generalized engineering function: To move substance 1.1. Problem:Fan generate noise at creation of airflow. 1.1.2. Exinguishing of sound by antisound Electronic engineeringSystem of active noise control (electronic cirquit) To applay active noise control system in order to reduce noise. 1.1.3. Noise reduction of fans Aerodynamics Aircraft construction PCs Screw-propeller engine CPU Fans To change amount of impellers. To make impellers of special shape 1.1.4. Decrease of turbulence of stream Wings of airplanes Stabilizer of missiles Aircraft construction Lattice wingsTo 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 engineTo 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.

11 Analytical Stage

12 Analytical Stage Structure

13 Component Structural Analysis DLP Projector Projector case Intake vents Exhaust vents DLP Block DLP case DMD Chip Micromirror Memory cell Condenser lens Color wheel Motor of color wheel Light absorber Electronic circuit Chassis Power supply of projector Lamp power supply Screen Electric current Electric current User Desk (selling) Desk (selling) Ambient air Ambient air Video signal Video signal Lamp case Lamp house Air duct Centrifugal fan Axial fan Power supplyOptical system Lamp unit Lamp Cooling system Centrifugal fan case Centrifugal fan rotor Rotor blades DC motor Fan case Fan rotor Impellers DC motor Control unit Power cord Super system elements

14 ElementFunctionRank 7. Intake vents7.1 To direct ambient airA1 7.2 To decelerate ambient airH 8. Exhaust vents8.1 To decelerate airflowH 8.2 To pass out luminous lightH 8.3 To output airflowA3 9. DLP case9.1 To hold condencer lensA2 9.2 To decelerate airflowH 9.3 To hold light absorberA2 9.4 Not emit out luminous lightA1 9.5 To hold memory cellA2 9.6 To absorb infrared and ultraviolet of luminous lightH 10. Micromirror10.1 To produce modulated lightB 10.2 To absorb luminous lightH 10.3 To modulate luminous lightB 10.4 To heat memory cellA1 11. Memory cell11.1 To decelerate airflowH 11.2 To heat DLP caseH Function Analysis Fragment of function table

15 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

16 Diagnostic Analysis Element for trimmingTrimming problems Rotor blades1. How to create airflow by centrifugal fan rotor without rotor blades? Impellers2. How to create airflow by axial fan rotor without impellers ? DC motor of axial fan 3. How to create airflow by electric current without fans? DC motor of centrifugal fan Air flow4. How to cool the elements of DLP projector by projector case without air flow?

17 Cause-and-Effect Chains Analysis Friction of airflow with surfaces of projector components and exhaust vents Voltaic arc in mercury vapor Modulation of light by selective reflection Method of creation of monochrome light Method of transformation of electric energy into mechanical Action of electric current emit Joule heat Radiation of IR and UV rays Heating of projector components Absorption of visible light by colour filter Cooling of projector components by airflow Acceleration of airflow Inhomogeneity of airflow Aerodynamic noise Rigid junction of fan with projector case Transmission of vibration through projector components Mechanical noise Rotation of DC motor rotor NOISE Discrete noise Internal friction of airflow (viscosity) Deceleration of airflow Rotation of rotor blades (impellers) in air Absorption of visible light Absorption IR and UV rays Physical properties of substances

18 Statement of Key Problems Key problem Amount of key problems Direction 1. The noise reduction with the minimum changes in system3 Direction 2. The noise reduction of discrete noise in fans2 Direction 3. The change of method of airflow creation1 Direction 4. The change of method of cooling of projector’s components 2 Direction 5. The reduction of heating of projector’s components1 Direction 6. The change of a physical operation principle of projector5

19 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

20 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?9, 10 4.2. How to cool the elements of DLP projector by case of projector without airflow? 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

21 Conceptual Stage

22 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

23 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. 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.

24 Concept 1. FASTENING OF THE FAN TO THE CASE OF THE PROJECTOR BY MAGNETIC SUPPORTS 3. Annular const magnet N S N S N S N S 1. Fan case 2. Conical const magnet 4. Clips

25 Concept 2. THE FAN BEARINGS WITH AIR LUBRICATION 1. Axle of fan rotor2.Teflon porous bushing3 4. Piezoelectric ceramic vibration generator 6. Electrodes 5. Fan case

26 Concept 3. COOLING OF INTAKE AIR BY THERMOELEMENTS WITH PELTIER EFFECT Top view Side 1 view

27 Concept 4. COOLING OF INTAKE AIR BY ADSORPTION REFRIGERATOR BY USING HEAT OF LAMP 1. Condenser- reboiler 2 AB 3. Pipe 4 5. Adsorber- generator 6 7. Capillary- porous substance + CaCl 2 8. Flat condenser part 9 10.Heat Pipe 11 14. Flexible heat pipe 12. Flat condenser part 13 17. Heat insulator 15.Fan 16

28 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. 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.

29 Concept 5. THE SCREW DISK-SHAPED FAN 1. Fan case 2. Fan rotor 3. Screw disk

30 Concept 6. THE CONIC SPIRAL FAN 1. Fan rotor 2. Spiral cone 3. Fan case 4. DC motor FCFC FNFN FAFA

31 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. 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.

32 Concept 7. THE IONIC NOISELESS FAN Operating mode Storage mode 1. Negative grid electrode 2. Needles 3. The movlees part of a case 4. The positive grid electrode 5. The movable part of a case

33 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. 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.

34 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

35 Concept 9. HEAT REMOVAL FROM PROJECTOR BY FLEXIBLE HEAT PIPE INTEGRATED WITH POWER CORD 1. Case 2. Contacts 3. Wires 4. Flexible heat pipe 5. Evaporator part 6. Condencer part 7. Capillary-porous canal 8. Condencer part

36 Concept 10. COOLING OF PROJECTOR ELEMENTS BY THERMOIONIC SEMICONDUCTOR ELEMENTS 1. Heat pipe 2 3 4. Condencer part 5 6 7. Air canal 7.7. 8.Projector case 9. Thermoionic element 10 11 12. Element with Peltier’s effect 13 14 15. Radiator enclosure

37 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. 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.

38 1. IR transparent window 2. Projector case 3. Lamp unit IR rays Concept 11. CASE OF PROJECTOR MADE OF MATERIALS TRANSPARENT FOR IR BEAMS

39 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. 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.

40 Concept 12. LASER PROJECTOR 1. Red semiconductor laser 2 3 4. Mirror 8. Chip 5. Micromotor 6 7

41 Concept 12. LASER PROJECTOR WITH MATRICES OF SEMICONDUCTORS MICROLASERS 1. Control chip 2 3 4. Semiconductor micro lasers 5 6 7. Mixing prism


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