Problem:
The original handle design featured a pulley on the connecting side that allowed it to shift along the cable to create another range of motion. This was decided to be unwanted for user experience, safety, and comfort reasons during use.
Solution:
I simplified the design by reducing the components in this area to three: a machined aluminum nest for the cable with a TPE cover and the connecting stud that threaded into the nest to capture the cable in place securely. I was able to evaluate the tolerance stack-up to design it so that the cable would not move when subjected to the forces it would see while preventing any gap under the stud.
Role:
Owner of redesign while supporting overall development, testing and quality of the product during ongoing production.
Timeline:
6 months
Handle Cross-Section
Threaded components with thread-locker allow center to rotate fully within end pieces
Trapped bearings for smooth rotation
Swaged end piece to lock in cables
EPDM grip and end cap
Skills Demonstrated
Tolerance analysis
Material selection
Supplier communication
Quality control
Project management
CAD - master modeling