Zephyr, an accessible helmet lock on the bike
Challenge
Urban cyclists often prioritize convenience over safety, leaving their helmets behind because they’re bulky and a hassle to carry around. This behavior highlights a critical tradeoff: convenience versus protection.
Impact
Zephyr is an attachment that is put on a bike to hold a helmet without it obstructing the mobility and convenience of the user. Our project was lauded for the detailed technical development that led to further iteration.
Tools
Sawtooth, Ansys Granta, Creo, Sketchup, Autocad, Miro, Qualtrics, Google Suite
Team
Minyu Li, Patrick Burden, Saumya Sharma, and
Shruti Chhajed
Duration
Sept - Dec 2022
Role
Product Designer
Process
Problem
Krystal, a common commuter says,
"It's a pain to bring the helmet around when I'm on the go, and I just don't know where to put it. Sometimes I prefer not to wear it even when I am concerned about my safety" .
Krystal is a busy grad student and urban professional, often relies on her bike to manage her classes, part-time job, and errands. While many commuters forget their helmets, most cite these reasons for neglecting helmet safety:
INEFFICIENT
Helmets can feel like a hassle during travel as bikers need to secure them alongside their bikes at racks or stands, which can be time-consuming and complex.
TAG IT ALONG
Current helmet lock solutions require riders to carry an extra responsibility, adding to their transit burden.
UNRELIABLE
Current lock solutions often leave helmets unstable and not securely fixed in place, leading many bikers to opt for carrying their helmets instead.
INCONSISTENT
Current solutions lack compatibility with a variety of helmets, as they can't securely attach to helmets of different shapes and sizes.
10 Guerilla and 5 Long form Interviews
Everyday commuters are constantly on the move, sometimes neglecting essentials like hydration, umbrellas, or helmets. They seek convenience without compromising safety.
82 Survey Results
70% of bike riders prioritize safety, but 30% don't always wear helmets due to issues like bulkiness, unavailability, or difficulty in carrying them.
Competitors and Benchmarking
The market is fragmented, with existing helmet lock solutions often falling short in addressing comfort, convenience, and portability issues.
Over 872,000 people in the US commute by bike everyday
Only 18% of bike riders wear a helmet
About 1 out of every 3 non-fatal bike injuries were head injuries
Quality Functional Deployment (QFD)
We conducted a comparative analysis, assigning weights to stakeholder requirements and aligning them with functional specifications. This benchmarking process aided in translating requirements into actionable plans.
For every stakeholder requirement across every functional specification we have given a weight with scale ranging from 1,3 and 9 (1 shows weak relation and 9 implies strong relation and 3 lies in between). An empty cell in the matrix implies that there is no relationship between the customer need and technical requirements.
Product Positioning Chart
This map reveals that most of these product manufacturers have a nascent presence in the market.
How might we
make the helmet more accessible for bike riders by giving riders the ability to keep their helmet with the bike?
Problem Analysis
Our target customer segment comprises urban professionals and students aged 18-35. To guide our design process, we prioritized six key attributes. These criteria were put in QFD and Pugh Chart analyses to rate to prioritize our solutions and informed the design drivers for our prototypes.
Portability
Enables bikers to carry their helmet effortlessly, wherever they go
Security
Stationary and reliably attached to bike in a way that is not susceptible to theft
Ease of Use
Quick, efficient, and manageable to setup with little time or hassle
Compactness
Light weight, smaller in size, and not a hassle to carry around
Feasibility of Production
Manageable to build and test within a short period of time and limited materials
Protection of Free Will
Does not obstruct a bikers choice to ride with or without a helmet
Ideation
Down Selection
During our conceptualization, we employed systematic and structured methods to filter, prioritize, and advance ideas. We assessed pros and cons, selecting the top 10 ideas, and then used a Pugh Chart, based on prioritized attributes from our QFD, to further refine them. This process ultimately led us to our top 5 ideas.
Pugh Chart
It specifically ranks 15 attributes that we found important to our solution, weighted against each other and ranked in descending order. We then scored each concept through a ++/-- system, where concepts could receive a 1 or 2 depending on the extend they met a criteria, a -1 or -2 if the solution performs negatively against the criteria, or a 0 if our evaluation on that criteria was neutral or not applicable.
Top Concepts
In helmet pop lock band - A pop lock within helmet with elastic/flexible lock band that extends and retracts.
Retractable Strap - A retractable attachment to the helmet straps with a number locking mechanism.
Winner - Dial Clamp Helmet Lock
How it works?
The alpha prototype works on the principle of spring lock mechanism. The D flaps expand out on the rotation of dial and grips the helmet from inside. The dial lock holds the
D-clamps in locked position by storing the energy in spring.
Technical Development
After testing our alpha prototype and receiving feedback from peers and instructors, we got some more ideas that led us to iterate on our earlier steps. These recommendations were then integrated into our next stages of product development. As we neared the final product realization, we conducted various technical analyses to refine our alpha prototype.
Design Optimization
Through Kansei and Conjoint analysis, we gained insights to optimize form, materials, pricing, and manufacturing processes while focusing on user-centric factors. Zephyr utilizes FE analysis for form optimization and Ansys Granta for material optimization. Pricing is refined using Conjoint analysis and competitor rates that align with user preferences.
Conjoint Analysis
To ensure alignment with user preferences and needs, we integrated stakeholder input throughout our design process. Surveys like Conjoint and Kansei informed key design choices:
Pricing: Users are price-sensitive, preferring a range of $25-$38, with $45 or more deterring purchases.
Locking mechanism: Users prioritize lock types, favoring combination locks over alternatives like key locks and dial combination locks.
Holding mechanism: Adjustable clamps, as in the alpha prototype, were the least preferred. Retractable wires lacked adequate helmet support, so we opted for metal straps with better surface contact and durability based on user feedback and empirical testing.
Ansys Granta eco audit report
We used Ansys Granta to compare materials for various mechanism parts, with a focus on recyclability and environmental safety. Here are our material selections:
Steel straps: Chosen for their superior security and durability, ensuring protection against theft or damage compared to alternatives like aluminum.
Base Plate: Aluminum was selected for its strength in securing the helmet and withstanding extreme weather conditions. It offers sturdiness, lightweight properties, and ease of shaping without sharp edges, surpassing other options like steel, carbon fiber, and plastic.
Empirical Testing
We ran low-fidelity tests on components and materials to identify failure points and constraints. By experimenting with materials, sizes, and assembly, we optimized functionality and ensured compatibility across bike types.
FE Analysis
CREO Parametric FEA Simulation software was utilized to simulate the performance of the frame, hinge, and steel strap under typical helmet weight loads, ensuring structural integrity and functionality.
CREO Parametric FEA Simulation software was utilized to simulate the performance of the frame, hinge, and steel strap under typical helmet weight loads, ensuring structural integrity and functionality.
Proof of Concept
How it works?
Using Zephyr, the user starts by unlocking the helmet securing straps and placing the helmet on the base plate. After positioning the helmet on the bike, the user wraps the securing straps over it and clicks the helmet strap lock buckle onto the base plate. This locks and secures the helmet. To access the helmet, the user simply enters their chosen combination to release the straps from the base plate, allowing them to lift the straps and remove the helmet easily.
Business Plan
Based on market analysis, product positioning map and conjoint analysis, we can now determine the market value of our product. This data will eventually help us in optimizing the costs and manufacturing processes with further development in the product.
Investment costs encompass plant, equipment, setup, and in-house manufacturing machines. Operating costs include startup salaries, marketing, rent, utilities, maintenance, warranty, R&D, and loan payments.
The approximate cost to produce one unit, including materials, fabrication, assembly, manufacturing, labor, packaging, and distribution, is $25.76. We plan to sell it at $35, determined through conjoint and competitor analysis.
The Profit equation is :
$35.00 * Z > $25.76 * Z + $158,765.41 (where Z is the number of Zephyr units)
[Selling Price] x [No of Units] > [Cost Price] x [No of Units] + [Fixed Operating Costs]
We'll need to sell a minimum of 17,185 units to cover all the fixed operating costs.
Break Even Analysis Output
We'll be able to breakeven and start recovering our initial investment near the end of Year 2 Q1 of operating, which will allow us to remain profitable so long as we consistently sell above our breakeven point.
Limitations
Zephyr has not undergone testing with a diverse range of individuals with varying body sizes.
It has not been tested against different weather conditions.
Learnings
This was my first project since I began my Masters at the University of Michigan. I enjoyed working in a team with diverse backgrounds that complemented each other's skill sets.
Design is very subjective so seeking as much feedback at an early stage is beneficial to get the general reaction of users.
One can get a creative block especially when they are working with deadlines.