Excellence In Design Spring 2023
Orcaron Angle Grinder
Angle grinders are powerful tools meant for jobs ranging from cutting through tough materials to working with fine detail sanding, having a device designed for the range of functions with settings to match each function perfectly will lead to higher levels or efficiency and user satisfaction.
About The Orcaron
The Orcaron is designed to tackle drawbacks and gaps in the leading designs for angle grinders readily available in the market. With a large focus on safety and extended usability, the Orcaron combines ideal components and new approaches to control and safety attachments to give the user maximum control while reducing chances of injury.
Research
Mapping
Primary and secondary Research surrounding the Orcaron consisted of several categories;
- Market Research
- Hands-on teardown of existing product
- Initial User Interviews & Task Analysis
Benchmarking was done between top-rated brands and products and included lower-rated designs. Insights from user reviews, videos, and first-hand experience were taken into account, compared, and used to finalize design decisions surrounding features and interactions such as handles, guards, motors, etc.
A Journey Map and Respondent plan was crafted and 3 initial interviews planned on top of a self-assessment with given products.
Over the course of the design process additional interviews would be conducted with more people regarding aspects such as features and more.
Handling, Safety
Common themes surrounding the usage of angle grinders almost always boiled down to levels of control and safety. Its no secret that users take a risk when they run a metal or ceramic blade at hundred or even thousands of revolutions per minute.
Thankfully, modern designs include both a pin-handle for the user to hold to gain stability and a blade shield to catch sparks and debris, particularly from the blade (angle grinder blades tend to shatter at the end of their lifespan).
However, through interviews and research I found that it was quite common for users to forgo usage of one or even both of these components due to them giving the opposite of the desired effect.
Pictured on the right is one way many users held their devices, ignoring the handle and placing their hands on the head of the device, much closer to their grind surface and the blade. Shield usage varied, most users remained in favor of the shield but some would still decline to utilize this component as well.
Desired Features
When looking at reviews and interview notes, I compiled a list of favorable features and organized them from most to least.
Among the most favorable were the quick release guard and a trigger-safety device, and a power lever/paddle.
Other favored features included a trigger-lock mechanism for extended usage, a speed controller, and a spin-lock for attaching the blades.
Items lower on the list included attachments to spindle components and soft-start mechanisms.
Electrical & More
On top of components that the user directly interacts with there is also major importance surrounding what goes into the device, two major areas for this include topics such as the type of motor (brushed vs brushless, etc.) and power source (chorded vs battery).
Many factors go into the motor, such as power output, power usage, heating up, wearing down the user, maintenance, and more. Chorded vs Battery power was also a major debate. Chorded benefits included a much longer usage period and consistent power supply at the cost of mobility. Battery power gave you mobility but also creates a usage time limit.
*MOVEMENT*
A trend among designs and improvement has been with integrating options with moving parts, such as dimensions, changes (shortening, extending) and feature adjustments. What areas can we explore with angle grinders to bring moving parts to a design in a useful way?
Personas (Simplified)
Tyler Apodaca
Age: 24
Occupation: Home Depot Associate
Hobbies: Woodworking, Metal Crafts, Sells custom art pieces as a side gig
Tool Usage: Uses Angle grinders and similar power tools 3 - 4 times a week for an hour or two at a time. Works on wood carving and sanding, metal cutting, finishing, and slight scale removal.
Needs: A device that gives reliable control for high-detail levels of work and easy to setup and use.
How can we design a device to maximize comfort and control on different levels of detail?
John Crouch
Age: 49
Occupation: Bike Repair Technician
Hobbies: Motorcycling, Camping, Working and maintaining their bike
Tool Usage: Uses heavy tools and precise tools 5 - 6 days a week for managing repairs and slight custom work on the side. Sometimes runs heavy power tools for over 8 hours a day during and after work.
Needs: A device that can function for hours at a time while wearing out the user as little as possible.
How can we develop an ergonomic and non-damaging device for prolonged usage?
Jamie Scherer
Age: 27
Occupation: Graduate Student
Hobbies: Robotics and mechanical work, arts and crafts, media programming and light effects
Tool Usage: Rarely uses heavy tools unless doing hands-on work and prototyping with metals and robotics, or helping her parents with maintenance around the house.
Needs: A device that is easy to setup and gives control to smaller and infrequent users.
How can we develop an ergonomic and non-damaging device for prolonged usage?
Why focus on safety?
In the year 2008, Dessert Diamon Industries reported a global total of almost
25,000 Injuries
occurring during usage of angle grinders. The RoSPA even lists angle grinders as the 3rd most dangerous tool, reporting over 5,000 yearly accident cases in the United Kingdom alone.
OSHA statistics studied the injuries related to grinder and saw blade kickback and reported a
20% Fatality Rate
along with the remaining percent of cases leading to hospital visits. Kickback incidents usually result from operator fatigue but can be attributed to incorrect tools and missuse.
Needs Hierarchy
Safety
Most users noted safety as a top priority, specifically surrounding debris such as sparks, sawdust, and broken grinder blades. Certain approaches to increasing safety include utilizing components such as speed controls, light and durable guards, and improved handling.
Comfort
Comfort goes adjacent to safety and control, being able to handle a device for hours at a time without wearing down the user is ideal. Focusing on features such as kick-back control, heat control, and even chord management are ideal for maximizing comfort.
Control
Maximizing control is another favorable aspect. Many users find themselves using devices angle grinders for extended periods of time. Being able to maintain control using ergonomic parts and control over individual features such as speed are ideal for designs.
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Safety
Control,
Comfort
Durable for heavy workloads
Easy setup, teardown, and storage
Aesthetically pleasing,
attractive features
Sketch Exploration
Features and Functions
Sleek and powerful
Designs for the device should display forward attributes such as power and sharpness. A sleek device could show a potential for controlled, in-line movement, and chiseled features could show durability and strength for all types of usage. Showing power and control embodied in a power tool was the approach taken for sketching ideation.
Holding & Handles
When looking at preffered options and disregarded features, details surrounding the handles and ergonomics of angle grinders are under constant contention. What innovations and designs can we explore to maximize safety and control in a way that is not disregarded and is favored by users?
Specialized features
In order to stand out as a superior device, what types of features can be included and how would they interact with the body of the device and the device as a whole? Where would they go? What would they look like once integrated? Exploring what features are part of the design and all the interactions that would follow are explored.
Viable Movement
To create a meaningful design insight that utilizes movement in the body of an angle grinder, what places would give the user a meaningful benefit in performance from an adjustment? A repeated insight from interviews stated adjusted approached in angled from the head could be beneficial.
Opening New Angles
The approach that an adjustable head angle can give users more control in more specific situations and use types was a major focus in my sketches when looking for innovations, alongside the exploration of new and improved handles. In the journey to explore how these features would physically interact, I spent time researching and testing ways to make these features a reality, including looking up mechanical details and creating movement tests with materials around me. In addition to working on the gears and inner mechanisms I also explored several foam explorations for the body, head, and especially the handles.
3D Explorations
CAD Modeling
The final model would be completely through Onshape, with certain components such as the universal gear, brushless motor, and bevel gears being sourced through McMaster-Carr and other sites for realistic sizing and specifications
Performance for any project
Made to match your needs of the job without compormising safety.
Adjustable speed means users can use proper and safe settings to cut and sand materials ranging from softer woods to hard stones and even the toughest of metals.
An adjustable angle means users can find more ergonomic approaches and fit into more unusual spaces.
Features & Controls
Bringing together the best features for any job
- Trigger Safety to avoid accidents & misfires
- Trigger lock to ease strain on extended usage
- Speed controller to meet different job needs
- Quick Release Guard
- Textured comfort grip
- Multiple hold configurations
Using a press-release system to adjust the head, the user is given 3 options to adjust their grinder to for their task, 0 degrees (Straight), 22.5 degrees, and 45 degrees.
Pins lock the head into place in order to ensure no unwanted movement.
Traditional and Ergonomic Handles
Trigger Safety
Trigger Safety & Trigger Lock features for extended and safe usage and easily accessible.
Comfort & Feel
Textured Silicone and ribbed speed tiel for a more comfortable and tactile feel.
Speedy Switches
Quick release guard set for 4.5 inch blades. Quick adjustment to access different angle settings.
Power Type
Chorded power to a brushless motor for longer jobs and less maintenence
Full Parts Performance
Component inclusion and full assembly, from bevel gears and mounting screws.
The body and head were designed with ventilation in mind without compromising this by changing the head angle.
Assembly/disassembly was kept in mind for maintaining the device through repair and replacement of parts such as the motor or universal gear.
