squidlabsradical innovation

Lightweight devices for harnessing human power

Objectives

Prototypes

Innovations / Risk abatement

Power Data

Production Approach

Team

Presentation Overviewsquidlabs

squidlabs Objectives

people power

20 W, < $10

Bio-mechanically efficient - not a lot of energy to waste.

Low Noise - workplace, classroom and home use scenarios.

Small - should be smaller and lighter than devices to be powered.

Integrated package - components should pack small, stay together.

Robust, Field Repairable - Minimize non-user servicing. Replaceable

cord.

Multi-modal operation - provide biomechanical and situation options.

Range of harsh conditions.Varying environmental “plug ins” to support modes of use.

squidlabs

target consumers

World Demographics

squidlabs Power in humans.

From: “Human Powered Vehicles”,

Abbott, & Wilson

squidlabs Power in humans.

Muscles are most efficient and develop maximum power when they contract quickly against a small resistance - a good impedance match.

Limited studies suggest 165mm as optimal hand crank length for adults.

Maximal power output for arms is 30-50% of that of legs, largely due to difference in muscle mass in each location.

As an “engine” the human body is 15-25% efficient at conversion of fuel to net mechanical work. The rest is typically dissipated as heat.

From: “Human Powered Vehicles”,

Abbott, & Wilson

Rapid iteration and testing.

squidlabs Approach

Version 1 Version 3 Version 2

Multimodal use enabled by device design.

Different muscle groups can be employed to avoid fatigue.

Different users can find their own optimum depending on disability etc.

squidlabs User Scenarios

Zip Pull See-Saw

Rowing Erg Treadle / Pedal

Why we use logic instead of mechanisms:

Eliminate gear stagesEliminate clutchesEliminate return springs

Optimize power outputLoad controlLoad conditioning

Right for every user

squidlabs Lower Complexity by logical control

squidlabs Advantages of logical control

Device dynamically adjusts loading condition to optimize for every user

Rope TestingRope ChoiceFairlead Re-design

squidlabs Risks Rope lifetime testing.

QuickTime™ and aH.264 decompressor

are needed to see this picture.

Optimal Rope:

16 head Polyester Overbraid, - Low friction, High temperature tolerance.

Dyneema / Spectra Core - High strength, minimizes overall diameter.

Expected Rope lifetime:

2-3 years at 30 minutes per day use rate.

Rope TestingFairlead Re-design

squidlabs Risks Resulting solution.

Traditional fairlead Optimized fairlead

Elliptical fairlead design minimizes wear for random/changing input angles.

OPTIMAL FAIRLEAD:

Eliptical Delrin

squidlabs Prototype Final

squidlabs User interface: Handles and clamps

Design details to be determined

Cost

Cleanliness

Multimodal

Integration with package

squidlabs Power Specs Estimates

Qualitative Data:

Hand crank based solutions, fixed to ground can achieve 20W peaks, but for prolonged use, 5W for 2.5 minutes looks a

reasonable limit for a healthy 60kg subject.

A sustained 20W for 5 minutes is possible for strong healthy subjects using a see saw method in hand operation mode.

Using feet 20W can be produced for similar or longer times.

.Subjects reported lower fatigue for see saw and zip pull operations. Cranks were particularly hard on hands and wrists.

Quantitative Data:

Our preliminary data would suggest twice the efficiency in our see-saw models compared to crank models in terms of calories

consumed to power produced.

squidlabs Cost Estimates

4.06 Electronics & PCB

1.14 Motor (0.88)

0.39 Gears & Pulleys

0.16 Bearings & Shafts

0.70 Handles & Cord

0.76 Enclosure (2 shells)

0.30 Power Cord

0.40 Assembly

0.20 Packaging

8.16 Total

PCH

Cousins (custom rope)

Ultimate Target Cost:

$6.50

squidlabs Cost Estimates - electronics

dual nfet 60v 2.6a smt 2V threshold Infineon BSO615N 3 $0.35 $1.05schottky 40V 3A .45v drop SMA On Semi mbra340t3 8 $0.12 $0.96dual pfet 55v 3.3a smt 2V threshold IRF IRF7342 2 $0.40 $0.80AT Tiny MCU 10MHz AVR attiny2313v-10mi 1 $0.74 $0.74Hall Effect Sensor Melexis US2881EUA 1 $0.32 $0.32Voltage Regulator, 30V, 100mA Linear LM2931M-5.0 1 $0.25 $0.25nfet, 100v 17A, smt 2V threshold IRF irlr3410 1 $0.25 $0.25Resistor 0603 10K Digikey 311-10KGRCT-ND 7 $0.01 $0.07100uF Electrolytic Cap Panasonic ECE-A1AKS101 1 $0.04 $0.0420v 500mw smt zener diode Diodes, Inc BZT52C20-7-F 1 $0.02 $0.02 PCBA totalResistor 0603 100K Digikey 311-100KGRCT-ND 2 $0.01 $0.02 $4.77

vol.disc. $4.06

squidlabs 3 Device OptionsZip Pull

$7.61

See-Saw

$6.91

Multimodal

$8.16

squidlabs Future Developments

Generation 2:

Specific motor - Eliminate remaining gear.

Higher output device based on stair master

- ruggedized - 40-50W expected.

squidlabs Production Approach Timeline

2mo Phase 2 / Development

4mo Phase 3 / Production

4mo Phase 4 / Delivery

11 months

squidlabs

Phase 2 / Development :

Engineering Refinements

RobustnessTesting

Manufacturing Sourcing (offshore)

Revised Prototypes (10 units)

User Testing

Engineering Finalization

Release design to manufacturing

Production Approach Timeline

squidlabs

Phase 3 / Production :

Tooling

First Article Approvals

Tooling Modifications

Pre-production TBDs

Quality Control

Production Approach Timeline

squidlabs

Phase 4 / Delivery

100k units month 1

200k units month 2

300k units month 3

400k units month 4

1M units total

Production Approach Timeline

People Power Teamsquidlabs

Technology Strategists

Mechanical Engineers

Electrical Engineers

Materials Scientists

Software Engineers

Industrial Designers

Manufacturing Engineers

Colin Bulthaup - Squid Labs, Partner

Saul Griffith - Squid Labs, Partner

Corwin Hardham - Squid Labs, Partner

Geo Homsy - Squid Labs, Partner

Brian Warshawsky - Apple iPod Operations Product Manager since 2002, Launched iPod Mini.

Don Montague - Naish / Quality Control / Manufacturing / Rope consultant

Ken Gilliam - ID Management

Jonathan Brill - ID Management

squidlabs Conclusion

questions ?

Power output: 20W is achievable in a very small package.

The issue is about fatigue and how long that can be

sustained. Data suggests strong healthy individuals can

sustain 20W outputs for 5 minutes or more during “see-

saw” operations.

Size: Similar to a computer mouse or AC adapter.

Weight: 300gms or 3/4lb.

Manufactured Cost: Sub $10 is achievable, $8 realistic,

$6-7 not impossible longer term.

Risks and life time issues resolved, electronic load and

motor control is possible, rope and fairlead design can get

long lifetimes.

Future developments include new motor design and

complete elimination of gears resulting in simplification of

device. Function specific chips will further eliminate

electronics complexity and cost and size.

Potential Design Directionssquidlabs

Potential Design Directionssquidlabs

Our Capabilities

Mechanical

Mechanical Systems

Nanotechnology

Robotics

Vibration Isolation

Unmanned Aerial Vehicles

Physiological Simulations

Hydraulic Actuators

Thermal Analysis

Electrical

Embedded Systems

MEMS

Accelerometer Devices

GPS and GIS Sys

Solar Power

PCB Development

High Speed Digital Signal Processing

RF Integration

Software

Firmware Development

Driver Applications

Industrial Design

Ergonomics

Graphic User Interface

Consumer Research

Product Design

Rapid Prototyping

Short Run Production

Usability Testing

Appearance Models

squidlabs

Materials

Shape Memory Alloys

Nanowires

Carbon Fiber

Aeroelastics

Thermo-Reactive Textiles

Optics

Opto-Mechanics

Deformation Analysis

High Precision Testing

Manufacturing System

cross disciplinary

thank you

Squid Labs 1467 Park Ave.Emeryville, CA 94608510.653.1643www.squid-labs.com

squidlabsradical innovation

squidlabs Electronics Schematics of smart control unit.

Power Generation

Motor Driving

Micro Controller

squidlabs Parts list