Project: Safety Dave Caravan Mover Design
CLIENT: Safety Dave
SCOPE: Concept to Production
Cyborg Autonomy was contracted by Safety Dave to develop a caravan mover product from concept through to production. The design was validated through AS/NZS 60335.1 safety testing to ensure safe consumer operation.
We identified a need for a significant number of custom parts to meet weight and per-unit cost requirements. FEA and DFM were utilised to achieve an optimal design for the customer’s expected manufacturing volume and margins.
We designed custom die-cast aluminium chassis and wheels with polyurethane overmoulding to reduce weight and control manufacturing costs.
High-quality electronics design enabled a first-time pass of AS/NZS CISPR 14.1 EMC testing, saving the significant time and rework costs often associated with EMC testing.
Die-case aluminium parts
Converting to die-casting resulted in a per-unit cost 5x lower than the original sheet metal design, with a lower defect rate.
Custom Electronics Design
Custom electronics enabled first-pass safety and EMC testing. CISPR 14.1 was passed with a 9.8dB margin in radiated emissions.
FEA (Finite Element Analysis)
FEA simulations were performed on all critical components to achieve optimal performance-to-weight while maintaining safety margins.
Custom Electronics Design
A holistic design approach resulted in an easy, clean assembly, with reduced assembly steps and minimal wiring.
