BarbeCube - a green energy project

GROUP
the green creatives
Annika Greven
Franziska Penning
Jan Weinsheimer
Jule Mohrdieck
Magnus de Witt
Martijn Bohnen
Max Borhof
Patrick Quandt
Ruud Kuypers
Sebastian Mellen
Tom Custers
Twan van Dijk
Time for a new barbecue generation

FOREWORD
In behalf of the whole group from the Fontys Minor 2013, we would like to say thank
you especially to Fontys Hogescholen Venlo, Mr. van Emmerik and Mr. Hepburn! We
really appreciate your help, your advices and the time you spent with us in order
to complete our project! Again we want to say thank you to Mr. van Emmerik for
lending al his material and tools we needed for our test models. Without your help
we wouldn’t be there where we are today.
Thank you very much!

CONTENT
I Introduction 001
II Orientation 003
III Analysis 031
IV Synthesis 081
V Evaluation 103

01
I INTRODUCTION

INTRODUCTION
During our minor IPD (Integrated Product Development) we had to choose a project. Therefore
we had to decide which of the following topics we wanted to work on:
- Green energy at home
- Street light project
- Electric vehicle project
Our choice was the “green energy at home” project. During this project we had to develop
a device which was saving water, energy or gas. It had to be developed in a way that it was
usable in or around the house. The project was not just a theoretical project. In the beginning
our goal was to hand in a 1:1 functional model. The group we were working in was defined by
12 students, Dutch and German students mixed. This required organization within the team
to insure that everybody was informed about the things each member of the group was doing.
This is the second report we made for our project. We are going to explain which steps we took
before we got to the final model. First we did some tests with a barbecue for our research so
we know how much heat a barbecue was able to produce. After that we started calculating how
much energy we could produce with our barbecue. We also did some color research and built
three paper models of our concepts to decide which concept we should choose. In the end we
actually built our final model out of metal.
To get some more information about what we did in order to get to the barbecue concept you
can take a look at our first report
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03
II ORIENTATION

CONTENT
Overall market research 05
Concept comparison 10
First ideas 11
Perceptual map with existing barbecues 13
Grilling method 15
Product-specific market research 17
List of requirements 21
Target group 23
Moodboards 27
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
OVERALL MARKETRESEARCH
To begin with we started an overall research
about our chosen project „Green Energy At
Home“. This research was the first helping tool
to get an idea of what the people are willing to
do for green energy at home and if they are
interested.
Problem Definition
Energy is getting more expensive and people
are looking for alternatives which are clean,
cheap and easy to handle
Objective
Gather information from the following
questions and find out peoples priorities
and put them in order.
People have to answer the questions and then
give numbers from 1 (low) to 5 (high)
regarding the priority of the answers:
Are people willing to pay to get clean/green
energy?
A –
B –
C –
D –
E –
How much are they willing to pay?
How much effort would they bring up to
install a new device?
How many years would they wait tops
before a profit is made?
How important is the design of the
systems/ the looks of the house?
Are they willing to invest time to keep
the system working/ for maintenance/
reparation?
Hypothesis
People only want clean/ green energy if it’s
cheap and doesn’t need much effort.
Research plan
Target group
People who own a house or are planning to
build or buy one/Technical freaks who like to
build stuff on their own/People who care about
the environment
Methods of research
Secondary:internet research, emails to
companies -> If we encounter problems
during the desk research, we will try to
solve them during our primary research/
Primary qualitative: expert opinions/Primary
quantitative: survey of approximately 50 to
100 people
Sample size
50 to 100 people
Method of analyzing the data
Leave out extremes (outstanding answers)
and concentrate on average thoughts.
Desk research
During our desk research we experienced
that it was hard to find the answers to our
questions because they were too specific for
05

our own project. We only found results from
other questionnaires which regard to green
energy in general. We think is it good that
we didn’t found a lot of information on the
internet, because otherwise we didn’t have to
do the research anymore.
Therefore it’s also very important that we do
our own survey.
We found out that there are a lot of different
meanings about clean/ green energy. There
are people who are not interested in the whole
clean/ green energy idea. On the other hand
there are people who want to pay extra for
clean/ green energy and are really interested
in this idea, and the third group of people also
want clean/ green energy but are not willing
to pay any more for it. Our survey will be very
important because we need to know if there is
a majority who wants to pay (more) for clean/
green energy, otherwise there are not a lot of
people who will be interested in our product.
Interview
We did an interview with our tutor Mr. van
Emmerik because he has a lot of knowledge
on the area of green/ clean energy. We ask him
our main questions and out of this interview
we made the questions for our survey.
A – Are people willing to pay to get clean/
green energy?
Yes, there are a lot of people willing to pay for
clean/ green energy.
B – How much effort would they bring up
to install a new device?
People don’t want to put a lot of effort into
installing an energy saving device. Also a lot
of people don’t have enough space to do this.
If it’s a small device which you will have to
install in your kitchen it would be okay. So to
make everything clear, people want standard
parts and no rebuilds.
C – How many years would they wait tops
before a profit is made?
If it’s around five years it’s okay, than a lot of
people will do it.
The functionality of the product has to be the
same or better than the normal one. So if the
energy saving device does not work as good
as a normal device than people won’t buy it.
Saving the environment is an extra and they
don’t want to pay for that if it’s not working
well.
If the price is not much higher than the price
of the standard. For instance if you have a
washing machine and it costs 300 euro and
you have an energy saving washing machine
that costs 400 euro than most people will
choose the energy saving washing machine.
D – How important is the design of the
systems/ the looks of the house?
The design of the device is very important, if
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
people leave it in their garden it may not rust.
Also people want a device that they can easily
store.
The function and ergonomics are more
important than the looks. Form follows
function!
It’s better when the device is ugly and works
perfect than have a nice looking device that
doesn’t function.
E – Are they willing to invest time to keep
the system working/ for maintenance/
reparation?
If it has a good functionality than people will
invest time to maintenance the system. It’s
the same with your car. You drive it every day
so if it’s dirty you wash it and if it’s broken
down you will repair it.
Survey and Analysis
We made seven simple questions for our survey
so we could compare the answers very quick.
We used the main questions from the briefing
but we changed them a little bit so they relate
to an energy saving product/ device, because
in the end we are making such a product. We
did the survey amongst 63 people. We made a
digital survey and asked every student of our
group to ask at least five people to fill it in.
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1. Average age: 26
2. Are you willing to pay for an energy saving device at home?
Yes 50 (79.37 %)
No 13 (20.63 %)
3. If so, how much are you willing to pay for an energy saving device?
0 - 500 euro 41 (67.21 %)
500 - 1,000 euro 14 (22.95 %)
1,000 - 10,000 euro 6 (9.84 %)
4. How many years would you wait before you get any profit out of the device?
0 - 1 year 20 (32.26 %)
1 - 5 years 38 (61.29 %)
5 - 10 years 4 (6.45 %)
5. Would you change the looks of your house because it’s needed to install an energy
saving device?
Yes 40 (64.52 %)
No 22 (35.48 %)
6. What is more important? The function of the device or the design of the device?
The function 56 (90.32 %)
The design 6 (9.68 %)
7. Are you willing to invest time to keep the device working?
Yes 35 (56.45 %)
No 27 (43.55 %)
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
Conclusion
Our hypothesis was that people only want
clean/ green energy if it’s cheap and doesn’t
need much effort. It partly is a correct
hypothesis, but we didn’t think a lot of
people would invest time to keep an energy
saving device working. When we looked at
the outcome of the survey we saw that more
people would invest time to keep the device
working than people who won’t. So it was
important that we did the survey.
The other part of our hypothesis was completely
correct. Because we already said that a lot of
people only want clean/ green energy if it’s
cheap. The outcome of our survey was that
the most people want to pay between 0 – 500
euro for an energy saving device.
We also didn’t expect that more people want
to change the looks of their house in order
to install an energy saving device, but when
you look at the outcome of the survey a lot of
people will change their house.
We will use the outcome of the survey to
develop a product for our project. We have
to look at the following results in order to
develop a good product:
- Our target group should be people between
20 and 40 years old.
-
-
-
The product should cost between 0–500
euro and the less it costs the better.
The function of the product is more important
than the design. Form follows function.
In the end we think that it was very important
that we did this survey related to our project
because there are a few outcomes that we
didn’t expect before we did the survey.
09

CONCEPT COMPARISON
In an early state of our Green House Project
we did a lot of research to find a energy saving
technique that is innovative and interesting
to be developed. We found four different
techniques that made it into the short list:
Browns Gas, Silica Gel, TEG barbecue and
CO2 compensation/biofuel production via
special algae cultures. We discussed it in the
first report.
After an analysis with the Kesselring-Method
the Browns Gas and the TEG barbeque got
the most points and was ahead on our list. To
make our final choice we compared the two
techniques directly to each other and in the
end we have chosen the TEG babecue.
The reason was that we thought that this
technique will be accepted by more customers.
It is more of a lifestyle product that can easily
be integrated in peoples live. By using heat
energy which is normally wasted, the barbeque
is able to charge small electronic devices like
tablets or smartphones in an environment
where electrical power is hard to provide. This
is possible without any extra effort besides
the extra investment for the barbecue itself.
According to our research it is very important
that sustainable or “green” products provide
the same qualities as normal products or they
won’t be accepted by the potential customers.
The Browns Gas technique could be used to
store energy by using electrolysis. This gas is
basically the mixture of Oxygen and Hydrogen
that is produced by electrolyzing water. The
technique could make it possible to use solar
or wind energy for the electrolysis, to store
the browns gas and to burn it in a generator
when electrical power is needed. The big
problem is that the mixture of Hydrogen and
Oxygen is extremely explosive. It would not
be possible to store it at normal households.
Even dividing the two compounds would cause
problems. Hydrogen could only be stored in
very expensive tanks and Oxygen is also a
security risk. The storage is possible but it
would require a big investment.
Private customers probably won’t accept
this potential risk and the very high costs to
manage it.
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
FIRST IDEAS
At first the whole group visited some building
centers. To analyze other barbeques and the
existing market.
For capturing our first ideas we created a
mindmap with different topics. Therefore we
made a brainstorm meeting where everybody
should feel free to say what kind of thoughts
he had. The most important things were the
target group, the functionalities, the look and
the emotions our design should embody. This
mindmap helped us to get some new ideas in
a very short time and to collect the opinions
from every single team member.
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
PERCEPTUAL MAP WITH EXISTING BARBECUES
On this map you can see different barbecues
which helped us to place our barbecue in one
special segment of the four. The perceptiual
map gives an overview over already existing
products and relieves the designprocess of
the new product. After we chose the segment
we wanted to design for we‘ve got inspiration
from barbecues already placed in it. It also
helps not to lose the control of what you‘re
designing and to stay at the choosen special
segment you want to make a new product for.
It differs from cheap to expensive and from
simple to high end products.
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
GRILLING METHOD
We went for a charcoaled barbeque as our
grilling method and based our choice on
different facts.
Regarding to our area of application there
was from the start no use for an electro
powered barbeque. There are too little electric
energy sources and we wanted to be more
independent.
Another possible method was a gas driven
barbeque. In this case we didn‘t like the thought
to always take along a heavy gas cylinder
which is harder to transport. Nevertheless we
liked the idea to easy control the temperature
and prevent exhaust harmful gases which
a charcoaled barbeque most often does not
provide. On the other hand a barbeque which
is fired with charcoal can be very compact,
cheaper and simple. Furthermore you can use
other burning mediums like wood, as well.
Fortunately we found the principle of the
“Lotusgrill” which is based on a charcoalsystem
and connects a lot of advantages of
the two systems such as the control over the
temperature and the prevention of harmful
gases. You can read more about this system
later on in this report.
ELECTRO
PRO
very safe
no exhaust gases and ash
no ignition
no open flame
can be used indoor
easy to clean
CON
no BBQ aroma
need time to heat up and cool
down
bigger grills are expensive
high electricity consumption
need power connection
not very mobile
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GAS
PRO
automatic Ignition
no fire accelerants
safer than charcoal systems
easy to clean
easy to controll (Temperature)
few/clean exhaust gases
no fine dust
less smelly
CON
no BBQ taste
only with Woodchips (Pros
obsolete)
Gasbottle needed
Customers cant refill bottle by
themselves
often bigger and heavier
hard to transport
depending on the counstruction
hard to clean
technically complex
CHARCOAL
PRO
classic BBQ aroma/feeling
mobile and independent
can be very compact
can use wood
easy to construct
cheaper
CON
harder to ignite
products of combustion unhealthy
exhaust gases and ash
need to be cleaned often
controll of temperature is
complicated
smell
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
PRODUCT-SPECIFIC MARKETRESEARCH
Yet we are so far with our project that we
know we‘re going to develop an energy saving
barbecue. Our first market research was very
global and because of that we did a second
market research. This research was especially
designed for the barbecue.
We did the survey amongst 93 people
Introduction:
We are going to develop a BBQ combined with an energy saving system. We want to use the
heat of the BBQ to recharge things, for example a mobile phone. This can be very easy when
you’re camping or at a festival. We want to use your opinion to produce a very efficient and
good working BBQ.
Questions and results:
1. What is your age? (use two figures please, for example: 18)
Average age: 25,6
2. What is your gender?
Male 64 (68.82 %)
Female 29 (31.18 %)
3. What is your reason to buy this BBQ?
Gift 10 (10.99 %)
For yourself 75 (82.42 %)
Other reason 6 (6.59 %)
4. How often do you use a BBQ? (in the summer)
1 - 2 times a week 24 (25.81 %)
1 - 2 times a month 63 (67.74 %)
more often 6 (6.45 %)
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5. Where do you want to use the BBQ?
At Home 72 (78.26 %)
Camping 47 (51.09 %)
Festival 36 (39.13 %)
Public Area 27 (29.35 %)
Other 5 (5.43 %)
6. What would be handy to recharge with the BBQ?
Mobile phone 65 (70.65 %)
Laptop 31 (33.7 %)
Stereo 42 (45.65 %)
Small fridge 43 (46.74 %)
Light 32 (34.78 %)
Other 4 (4.35 %)
7. What do you prefer?
Gas 11 (11.96 %)
Charcoal 55 (59.78 %)
No preferation 26 (28.26 %)
8. How big does the BBQ have to be?
20 x 20 cm 1 (1.08 %)
25 x 25 cm 10 (10.75 %)
35 x 35 cm 24 (25.81 %)
40 x 40 cm 28 (30.11 %)
Diameter: 25 cm 3 (3.23 %)
Diameter: 35 cm 10 (10.75 %)
Diameter: 40 cm 17 (18.28 %)
9. What are you willing to pay for such a BBQ?
0 - 25 euro 7 (7.61 %)
25 - 50 euro 48 (52.17 %)
50 - 100 euro 33 (35.87 %)
>100 euro 4 (4.35 %)
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
Conclusion:
We used the outcome of the survey to develop
the barbecue. We had to look at the following
results in order to develop a good barbecue
for our target group:
Most people don’t buy a barbecue as a gift
but for themselves. It also shows that the
barbecue is mostly used one or two times
a month. Which is not very often. The most
common place to use the barbecue is at home.
Most people think it’s very handy if there‘s
a possibility to recharge a mobile phone or
a small fridge with the barbecue. Further
the most people like a barbecue which size
is about 40cm x 40cm big which should cost
between 25 and 50 euro.
Someone said as a remark to the survey that
it already would be handy if you can recharge
something with the barbecue even if it’s
something you don’t use around the barbecue.
That’s a nice thought because it doesn’t
really matter what you can recharge with the
barbecue. The most important thing is that
not every heat/ energy from the barbecue is
wasted.
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
LIST OF REQUIREMENTS
1
1.1
2 Design offer
2.1 Reason: development, Energy saving, environmentally friendly, portable electricity for
light, mobile phone
and more
2.2 Description of product family: BBQ, generator
2.3 Replacement of product: Connection of existing product (BBQ and generator)
3 Market
3.1 Market segment: international, middle
3.2 Requirements
3.3 Competition: only in small version, different target group
3.4 Market situation: new kind of product, growing market
4
4.1
4.2
4.3
4.4
Product
Product name: Green USB BBQ: Barbecube
Use
Range of application
private: family, young people, Camping; nature, beach, festival, adventure,
Target group
gender: unisex
age: 18-40
Ergonomic aspect: easy to transport and to use
Expectation of user: funcion (barbecue + electric; usb), comfort, coal transportation
mobility, tough, innovative,
reliable, easy, save, easy to clean, heatadjustment
4.5 Emotions: environmental awareness, intuitional, independent, community spirit, fun,
modern, free
4.6 Physical conditions: outdoor, for every weather condition, heat resistant
4.7 season: spring, summer, autumn
4.8 Situation of not use: small, modular system and folding legs
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5
5.1
5.2
5.3
6
6.1
6.2
6.3
6.4
7
7.1
7.2
8
8.1
8.2
9
9.1
9.2
Design
Form and Style: modern, functional, minimalistic, clear line, simple, basic, compact
Semantic of product: basic, cool, calm, rounded down, friendly, lifestyle, community
spirit
Colour and texture: smooth and bright surface, steal, metallic and colored
Sale
Sale organisation: hardware store, supermarket, specialised trade, internet store
Purchasing address: external purchaser and experts
Communication with costumer:bill board, flyer, portfolio, website, advert
Kind of communication with costumer:
Production
Manufacturing: efficient production, few waste, wood not from threatened trees
Standard parts: production on one place
Service and Recycling
Maintenance
Care: cleaning after use
Composition
Instruction: construction manual, directions for use
Tool and equipment
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
TARGETGROUP
For our BBQ we chose two different target
groups. Therefore we created two Personas
which should embody the target group at first
sight.
The first target group consist of people in the
middle- age and families. These people live
in the social ecological “Sinus environment”
and appear to present certain characteristics.
They‘re idealistic and critical of consumption.
Furthermore they have a distinct social and
ecological conscience. They‘re sceptical about
the globalisation and try to live as concious as
possible. Family, friends and social activities
have high value for them. They mostly live in
houses together with their family.
Take a look at our persona to complete your
impression:
Name: Chris Basche
Age: 32
Family status: married; 2 kids
Job: teacher
Interests: hiking, mountain-biking and
tinkering
Life Conditions: row house with a small
garden
Sinus Milieus: socio-ecological milieu
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
The second target group consist of young,
open minded people. Target group two lives in
the “Movers and Shakers Sinus Milieu”. They
distinguish themselves by their constantly
look-out for boundaries and changes.
Creativity, mental and geographical mobility
are further characteristics this target group.
They‘re affected by individuality and the digital
avantgarde. Due to the lack of money they
predominantly live in small living communities
together with friends. Mostly they‘re in the
middle of their studies. They place great
emphasis on meeting friends, visiting festivals
and travelling.
Name: Katja Kipping
Age: 22
Family status: single
Job: sport student
Interests: jogging, music, cooking, festivals
Life Conditions: living community
Sinus Milieus: movers and shakers milieus
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
MOODBOARD I
Form Function Emotion
This moodboard was created to help us giving
the barbecue a proper shape and to see on first
glance which was necessary for us. Therefore
we created three different main topics like
function, emotion and form. The barbeque
should be multifunctional and offer the
possibility to handle different operations like
recharging your mobile phone, listen to music
or open up your beer bottle. In the emotion
field, in the lower left corner, the colors like
blue and green play a dominant role. They
embody nature, freshness and comfort. On
the right side it‘s all about the form. We used
the different shapes as inspiration for our
design. As you can see the main colors used in
our moodboard are silver, white and black and
green. A cool, minimalistic mix which presents
the functions and shapes in a clean way.
That‘s our first moodboard, there‘re more to
come, where we will deepen the insight in our
design process.
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
MOODBOARD II
FEELING
The main area where our barbecue will be
used is at outdoor places like festival grounds,
camping sites, public parks and beaches.
This certainly means it may be necessary
to carry the barbecue around over longer
distances while walking on uneven ground.
Therefore the transport should be as
comfortable as possible considering that most
people will very likely be carrying additional
baggage that is for example needed for
camping.
This also means that it will be unlikely to find
a power supply system nearby or at least not
one that can be used for free. Considering the
battery service time of modern smartphones,
it will probably be necessary to recharge it at
least once on a weekend camping trip or a
multi-day music festival.
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31
III ANALYSIS

CONTENT
Barbecue input & output 33
First temperature test 35
Concepts 37
Concept 1 39
Concept 2 43
Choice: concept 3 47
Design-process: lid 50
Result: no lid, but a bag 54
Ergonomics 56
Color Research 58
Coloar Choice 61
Technical Model 65
Electric Overview and components 69
TEG Test 75
Exploded View 77
Air Flow 79
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
BARBEQUE INPUT & OUTPUT
By looking on the energy content of 1 kg
charcoal, you get an impression of how
much of the energy is wasted and how
little is actually being used to barbeque the
food. A large percentage of the heat energy
is transferred into hot air that leaves the
barbecue without even heating the food.
Another large percentage of heat-energy is
simply radiated into the surrounding. Meat
consists 40% to 80% of water. So for example
the energy that is needed to boil a kilo of
water should be roughly comparable to the
energy that is needed to barbeque 1 kilo of
Meat. So it is easy to calculate how much of
the energy input is being used to barbeque
the food. By using a Thermoelectric generator,
(short TEG) a part of the heat that would
normally be wasted, can be transformed into
electricity. Tough our experiment has shown
that the charcoal produces sufficient heat
for about 1,5 hours of barbequing the TEG
needs far less heat to produce electricity and
therefore it can run between 3 to 4 hours on
1 Kilo charcoal. This means, that a small 40W
TEG could recover up to 160Wh electricity.
This means, the barbecues energyefficiency
in relation to its efficiency without
the TEG would increase at almost 20%.
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
Input:
1 Kg Charcoal= 8,6 kWh
(at 6h heatproduction)
Wasted:
7.88 kWh (91,6%) heatenergy
is wasted
Used:
Only around 720 Wh
(8,4% ) of the heat
are actually used to
barbeque 1 Kilo of
Food.
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
FIRST TEMPERATURE TEST
When we chose to make a barbecue that
produces electricity, we had to collect some
information. First we needed numbers about
the heat en radiation when you burn charcoal.
We made an overview and tried to make a
SolidWorks radiation calculation with the
simulation tool. When we tried to make a
calculation of the radiation we concluded that
this was too complicated. The next step that
we took was a test with a camping barbecue.
These are some pictures of the first test. We
did this test to investigate the temperature of
a charcoal barbecue. The technical model of
our barbecue was not finished at this moment
therefor we used a camping barbecue. We knew
that the burning temperature of charcoal was
above 500 °C. The thermo electric generator
that we are going to use is effective till 250
°C so we had to know what the temperature
was in different places on the barbecue. With
two different thermometers we measured the
temperature on four places: under, above, on
the side and under a heat-conductive stone.
Before we started with the test we compared
the thermometers and concluded that the
deviation was minimal and not important for
our test. The charcoal had a weight of 0,5 kg,
and we used firelighters to ignite the charcoal.
Every 2 minutes we measured the temperature
in and around the barbecue. After 50 minutes
the charcoal reaches the highest temperature
of 438 C° and than temperature started to
drop down.
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
CONCEPTS
This is a rendering of our three concepts which
we will describe now.
In the end we chose to develop the concept
on the left. One of the reasons we chose this
concept is because it is one solid barbecue.
The other two concept are made out of two
separate parts which you will have to turn
around to use the barbecue. Turning and
sliding mechanisms are not recommended
when you want to use your barbecue on the
ground at a festival or on the beach.
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
CONCEPT 1
Concept 1 is quite close to concept 2. By
turning around the base of the barbecue you
can use the standard of the barbecue as a
lid. The handle is fixed at the barbecue body
itself. To close the barbecue you have to take
the standard-part of the barbecue turn it and
rotate it about 90°. By putting it on top of
the barbecue body and turning the handle into
the right position you can carry it very easy.
Additionally the USB modules are protected,
if it‘s closed. The unique feature from this
concept is the fact that you can serve the
barbecue by yourself. You don‘t need “three
hands”, this was the idea behind this concept.
When the barbecue is opened and ready for
use it has the shape of a cube.
39

Concept 1
40

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
Prototype is made out of carton:
41

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
CONCEPT 2
The unique feature of Concept 2 is that the
barbecue is made out of two different parts
which are attached together. The advantage
of this concept is that you can‘t lose anything.
That‘s a big plus factor, especially while
ha¬ving holidays or being at a festival it‘s
good not to have any small extra parts which
can be lost easily.
When you close the barbecue, the user
disco¬vers the handle of the barbecue. The
USB-lid gets covered by the bottom part of
the barbecue and protects it against dust and
dirt.
The bottom part had two functions. The first
function is that it as a standard for the barbecue
and the second function is that it is the cover
and the handle of the BBQ. You can switch
between lid and base easily by un¬twisting
the adjusting knob and twisting the bottom
part, afterwards you just have to twist the
adjusting knobs again and it stays tight at it
adjusted height. To create a save and clean
place for the technical advices the metal is
folded. That makes sure that the electric parts
don‘t stay at the same level as the ground.
The closed barbecue has the shape of a cube.
43

Concept 2
44

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
Prototype is made out of carton:
45

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
CHOICE: CONCEPT 3
Concept 3 has it‘s focus on being as minimalistic
as possible. It‘s a clean and light-weight design
which still catches ones eye. The USB bar is
placed at the front with a big adjusting knob
on top of it. It comes with an ergonomic bag
it‘s design concerted to the design of the BBQ.
You can put the bag on top of your shoulder
and place the grill via adjusting the tie on top
of your hips. It disposes of a cushion filled with
tiny polystyrene balls for a comfortable seat.
Moreover it has a plate out of metal sewed
inside the fabric which serves as lid for the
BBQ.
Concept 3 comes in the shape of a bbq but
to make the shape more interesting and
eye catching it‘s not totally square-cut. Via
the front view it‘s clear to see that it has
juvenescent edges.
We made several sketches with different
design focuses of the barbecue. Some of them
had the focus on the base of the barbecue,
some at the USB-lid and some were really
focused on the shape of the barbecue itself.
We discussed the sketches with the hole group
and after that we made a selection between
our favorite concepts. In the end we only had
three different concepts left. The three final
concepts have some commonalities but every
concept has it own unique feature. This is
why we chose these three concepts instead
of the other concepts. To get a better look
of the different concepts we made a paper
model from them. Now we were able to see
the different concepts in real and on the right
scale. This was the point when we chose the
final concept.
On this render you can see our three concepts.
In the end we chose to develop the concept
on the left. One of the reasons we chose this
concept is because it is one solid barbecue.
The other two concept are made out of two
separate parts which you will have to turn
around when you want to use the barbecue.
Turning and sliding mechanisms are not
recommended when you want to use your
barbecue on the ground. It will get dirty
and sand and dirt will stuck between these
mechanism. Our barbecue should be used
on the ground on a festival for example and
this is also a reason why we didn’t chose the
concepts on the right.
This is the concept which we eventually chose.
47

Concept 3
38

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
Prototype is made out of carton:
49

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
DESIGN-PROCESS: LID
Concept 1
Sketches for the lid
Scetches for a lid
This is the selected concept of our barbecue and different systems for a lid. We wanted to
integrate a lid in a nice and simple way without using handles. With the help of a lid the coal
can This is be the transported first concept of inside our barbecue. the barbeque We wanted easily. to integrate It would the lid also in a nice be nice and simple if the way lid had a second
function without using and handles. therefore It would our also idea be was nice to if the make lid had a surface a second out function of it and to therefor lay your our telephone idea on while
recharging
was to make a
or
surface
to lay
out
on
of
meat
it to lay
for
your
the
telephone
barbecue.
on while recharging or to lay on meat for the
barbecue.
50

Concept 1
Lid Sketches idea 2for the lid
The The idea idea behind behind this this sketch sketch was was to make to make a lid a which lid which exist exist out of out two of parts two parts combined combined together together with
a hinge. with a The hinge. lid would The lid be would attached be attached to the barbecue to the barbecue also with a also hinge. with At a one hinge. side At of one the lid side are of two the
pins lid which are two you pins can which stick in you the can holes stick at the in the side holes of the at barbecue. the side of the barbecue.
51

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
Concept 1
Sketches Lid DESIGN idea for 3 the PROCESS
lid
This solution is very simple as you can see on the sketch. The lid is again made from two different
parts but these parts are not attached to each other. At both sides of the lid there are two small
folded edges and on the inside of the barbecue are two holders where you can hang in these
folded edges.
This solution is very simple as you can see on the sketch. The lid is again made from two
different parts but these parts are not attached to each other. At both sides of the lid there are
two small folded edges and on the inside of the barbecue are two holders where you can hang
in these folded edges.
52

Concept 1
Lid idea 4
Sketches for the lid
In this solution the lid is also made out of two different parts. These two separate parts are connected
In this to the solution barbecue the on lid the is side also by made using out a hinge. of two The different metal plate parts. wouldn’t These be two very separate stable and parts are
probably connected going to the bend. barbecue We thought on to the make side these by using triangle a formed hinge. ribs The on metal it to make plate it wouldn’t more be very
stable. stable and probably going to bend. We thought to make these triangle formed ribs on it to
make it more stable.
53

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
RESULT: NO LID, BUT A BAG
For our final concept we chose to don’t use a
cover for the barbecue anymore. Instead of the
cover we used a bag with a curt attached to it
so you can easily pack and carry the barbecue
with you. The lid is sewn into the bag. So the
bag has two functions. The first function is
carrying the barbecue of course and close the
barbecue. On that account you‘re protected
against the dirt. The second function is to use
is as a pillow to sit on or as a “table” to lay
your handy or meat on. The bag has a soft
and a hard side. The soft side is to sit on and
this is the side which is against your hip when
you carry the barbeque. The hard side, with
the lid inside could be used as a “table”. When
you look at the sketches you can get a better
look of the functions.
54

used as a table
hard
sit on it
55

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
ERGONOMICS
To test our final prototype we asked different
people of different length and weight to carry
our BBQ-bag.
Our collage demonstrates the testing. Most of
the testers have been persuaded of our bag.
They liked the cushion and the possibility to
wear the bag over the shoulder.
During this phase we noticed also that the
belt needed to be modified. One of the tested
persons said that it is not clear how to wear
the bag. In his opinion the manner of carrying
the bag should be more obvious: Should I
carry the bag sideways or should I drape it
over my shoulders?
We resolved that the “draped around” position
is the safest to prevent the BBQ from dropping
on the floor. In this case our belt needed to be
formed in a more ergonomic way.
Therefore we watched out for another
possibility for a belt.
During our experiments for a barbeque based
on ergonomic aspects we noticed that there
are a lot of things we need to consider. We
turned our main attention to a portable
system because we think that this is the most
important part for the chosen surroundings
and our target group.
In the end we were proud to have a final
prototype of a bag which fitted precisely
around the barbeque we made for our main
project. It was not only a fictional product but
a fully functional testing part. We liked the fact
to connect the two projects together and to
interlink the different aspects with each other.
Moreover this project also demonstrated us
advantages in the disposal. We developed
an extra unmated product which can be seen
as an “additional must-have feature” for our
barbeque.
In this case every consumer of our BBQ is also
a potential customer for our bag.
To sum it up, we all share the opinion that we
found a reasonable market gap that needs to
be bridged.
In the appendix of this report you can find the
whole ergonomic report and more sketches and
photos to get a better idea of our ergonomic
research.
56

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
COLOR RESEARCH
One of our last decisions we had to make was
the color choice for our barbeque.
We came to the agreement that the barbecue
should be available in three different colors
to reach as much customers as possible. We
split the color choice in three different groups,
one of them was for our first target group, the
second one for the second target group and
the third one should be a „classic“- version.
The classic version should suit everybody and
we decided to give it a light-weight, simplistic
coloring with maybe an eye catcher on it. Of
course the three color-concept should fit to
each other and complement each other. To
get a series of barbecues which consorts with
each other.
Therefore we made a trend research and
took a closer look to the color trends of the
lifestyle products 2013. Consequently one of
the available colors should follow this trend
to make sure that we provide a color variant
that is up-to-date and more individual/
unconventional/funky. For the current year
the color of the year is called “Pantone 17-
5641 Emerald”. This color is a green tone and
reminds, as its title suggests, of an emerald.
58

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
COLOR CHOICE
As we explained earlier our choice was based
on our two main target groups. For the first
target group, for Chris Basche, we chose a
dark color which associates robustness and
strongness. We consciously didn’t give it an
obtrusive coloring. A matt black fits perfect
as it looks stylish and at the same time highquality.
As eye catcher and to highlight our
“special” feature we gave the USB-port a
flashy green color.
This flashy green also fits perfectly to our
second target group, for Katja Kipping. It’s
eye-catching, individual and modern. These
values are important for the second target
group and it also suits our green-energy-topic.
The classic-version comes with a lightweight
color, which suits everybody. It’s not
to dominant but still has a friendly, trustable
character. The warm grey and the catchy green
complete each other very well and round the
series off.
On the right side you can see some other
variation which we had discussed.
61

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
During our color research we decided to make
the USB lid green from the inside to represent
the idea of green energy which is coming out
of the USB ports. You will only see the green
color when the barbecue is opened and in use.
When the lid is closed it has the same color as
the barbecue itself.
63

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
TECHNICAL MODEL
Because of the time schedule and the many
things that were not certain of in this stage
of our product, we decided to make two
different models: one for the design and one
for the technical tests. Because we thought
about the changes we had to make on this
design during the testing period, we made
most of the connections easy to detach. In the
annexes the technical drawings of this model
are attached.
In this stage of the design we also looked at the
electronically part of the barbeque. Here we
chose our TEG and thought about the energy
storage. The cooling of our TEG was a part
that was really important. We decided to use a
CPU cooler from a PC. To get a chimney effect,
we made a bin on the bottom of the barbecue
where our electrical parts were installed.
We installed two fans on the bottom that blow
fresh air inside this bin and through the cooling
elements. On the upper side the air comes out
of the bin. The airflow could be controlled with
a valve.
65

When we finished the prototype, we started
to test our TEG elements. First we tried some
peltier elements that are almost the same
components as TEG but than a lot cheaper.
We used these because we didn’t know what
the temperature will do with the TEG when we
heated up the barbeque. In the attachments
the numbers of our test are projected in a
table. The alignment that we used is projected
in a schematic overview on the side.
First we tried with a blower to blow hot air
against the peltier and TEG elements. This
was to know what the hot and what the cold
side was and how the elements react on this
kind of heat difference.
Then we build a peltier element with cooler
and ventilation bin under the barbeque. We
tried how much heat the peltier could have
and how much energy we could gather out of
the element. Because of the big heat directly
on the surface of the element the part was
broken when we were done with this test.
By these tests we used the following alignment.
66

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
The plates between the TEG and the cooling
element/heat conductor are to measure
the temperature over the whole surface of
the TEG. First we tried to get the needed
temperature difference between the hot and
cold side with just a cooling element. When
we concluded that this wasn’t going to work,
we tried with isolation to stop the heating of
the element. The isolation we used is a rock
wool of basalt. This is a rock formed from
the rapid cooling of basaltic lava exposed at
or very near the surface. Only this kind of
isolation was suitable for our purpose because
of the high temperatures.
67

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
ELECTRIC OVERVIEW AND COMPONENTS
To charge a mobile phone or tablet with our
barbeque, we needed an electrical diagram.
In this chapter all the components and the
whole diagram will be explained.
In the picture below you see the electrical
diagram of the barbeque. The components
and the function of them will be explained
further in this chapter.
69

Components:
To get a better overview of our electrical
circuit, we discus all the individual parts that
we used in our barbeque.
TEG element:
A TEG element (thermo electron generator)
can generate electrical power. In the picture
you see such an element. The element has a
hot and a cold side. This means that one side
has to be heathen up and the other side has
to be cool down. When there is a temperature
difference, there will be power generated.
The TEG element that we used in our barbeque
has the following properties:
- The element has a maximum temperature
of 230 °C
- Delivers a voltage off 0-16V
- Delivers a current off 0-10V
- The dimensions are 40x40x3.1
- The optimal temperature difference is 230
°C on the hot side and 30 °C
The highest voltage that is given by the TEG is
too high so we concluded that these numbers
are of a unencumbered element. When the
TEG is used the voltage will drop down. Our
prediction is that the voltage we get is 6 to 8
Volt.
70

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
Step up converter:
Because of the low voltage that we get of the
TEG element,
we need to increase it. This will be done by a
step up converter.
In the picture you see these elements.
The converter has the following properties:
• Input 3 - 30 Volt
• Output 4 - 35 Volt
• Maximum input 3 Ampère
• Output is adjustable
Because the output is adjustable we can
decide what this value is. As you see in the
diagram we use two of these converters. This
is because our current probably will be more
than 3 Ampère. With a circuit with two of these
converters parallel we will be able to convert
up to 6 Ampère.
Diode:
The next component is a diode. In the picture
you see the one we used. A diode has the
property to let current float in only one
direction. In our circuit this is an important
part because the TEG element can be used
as a heating element too. When the element
get power, one side will be hot and the other
side will get cold. In our circuit we use two
elements that will be linked parallel. When the
both elements don’t deliver the same current,
the other one will use the power to heat up.
With two of these simple parts we exclude
this.
71

Protection board:
The protection board switches the cells on and
off when the voltage is getting too high or too
low.
The cells can’t resist a voltage that is higher
than 4 Volt or lower than 2.5 Volt. When this
happens the cells will be damaged or burn.
USB connection:
From the 5 Volt output we control a USB
connection. This has the advantage that the
power we use isn’t harmful for the user and
the connection is universal. In the picture you
see the connector.
Li-Po accu:
After we convert our voltage, the Li-Po battery
can be charged. Li-Po stands for Lithium
Polymer en has big advantages comparing a
Ni-Cd en Ni-Mh. The weight is lower and the
capacity of the cells is bigger. One cell of Li-
Po has a nominal voltage of 3.7 Volt. We use
a battery with four cells. This tells us that we
have a collected voltage of 4x3.7=14.8 Volt.
A disadvantage of Li-Po is that every cell has
to be charged under control. This is done by a
input output protection board.
72

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
Step down converter:
From the battery we get two different voltages,
12 Volt and 5 Volt. The 5 Volt is used to charge
a tablet or phone. The 12 Volt is used for the
cooling fans. The step down converter has the
following properties:
- Input voltage: max 20 Volt
- Dual way output: 1-16 Volt
- Output 1 max 6 Ampère, output 2 max 5,5
Ampère
Fan:
From the 12 Volt output we control a cooling
fan. This fan blows cool air too the cooling
block that is mounted on the cold side of the
TEG. The cooling block takes over the heat of
the TEG. The cooling block is cooled by the
cold air that the fan blows. In the picture you
see a fan that we used in our first tests.
One output can be set on 12 Volt and the other
one on 5 Volt. In the picture you see the step
down converter.
73

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
TEG TEST
The test of the parallel connection shows that
it is not possible to get a voltage over 3V for
a long period. The step-up converter needs a
input Voltage between 3V and 30V. It is possible
to work with 3V from the parallel connection
but it is not good to work at the lower limit. If
the consumer load requests a higher amperage
the voltage drops immediately. Than is the
voltage for the Step up converter to low and
the supply of 12V will breaking off.
That is the reason why a higher voltage is
needed!
A solution could be a series connection. These
connection adds the voltage of the two. A
problem which have to be clarified is: That the
first TEG is producing electricity and supplied
this electricity to the second TEG. The second
TEG uses this electricity for the heat production
instead of electricity production:
After a test of the TEG series connection the
result shows that the first TEG is producing
2,29V and the second TEG 1,41V. The big
different between TEG one and two is the
result of the heat measuring component. The
measuring of the total voltage indicate a value
of 3,65V
Voltage
5
4,5
4
3,5
3
2,5
2
1,5
1
0,5
0
Series Connection
00:00 00:20 00:40 01:00 01:20 01:40 02:00 02:20 02:40 03:00 03:20 03:40 04:00
The last simulation which have to be done is
to test with the TEG’s in series connection and
with the step up converter. The connection is
constructed as the electronic schema shows.
Time
75

The step up converter starts to work if the
TEG’s supplied a voltage of 3V. During the
period with a voltage under 3V the electricity
can flow through the step up converter without
losses. After the 3V are reached the voltage
climbs fast to the output level of 12V as the
following graph shows.
14,00
Series connection with Step up converter
12,00
10,00
8,00
Voltage
6,00
4,00
2,00
0,00
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85
Time in sec.
76

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
EXPLODED VIEW
The “barbecube” is a very energy efficient
barbecue. It is based on the technology of
the existing “Lotusgrill”. The “Lotusgrill” has
an integrated, battery powered fan which is
firing the charcoal. To lite up the charcoal you
need burning gel. As a result it is instantly
ready for operation and has an on/off switch
to control the heat stepwise.
Advantages
-
-
Low smoke development -> no fat dropping
on the hot charcoal
Heat control -> No burning of the foot or
development of harmful substances like
Hydrocarbons, Nitrosamines, Benzopyrene
or Acrylamide
-
-
-
Fast ready to use
Less charcoal
Easy to clean
77

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
AIR FLOW
-
-
-
-
The fans inside the barbecue suck air from
beneath the grill.
The sucked air from the 2 fans is blown
through an air tunnel to power the charcoal
with fresh oxygen.
Simultaneously another part of the cold
air is going through the cooling elements
to prevent an overheating of the thermoelectric-generators.
In the coal bucket the air becomes hot,
streams upwards and spreads out on the
grilling surface.
79

81
IV SYNTHESIS

CONTENT
Design prototype 83
Application 85
Logo choice 91
Single parts 93
Material use 98
Coating 99
Recycling 100
Production 101
Costs Calculation 102
82

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
DESIGN PROTOTYPE
For the eventual model we chose to make not only
a paper model but we also wanted to make a real
metal model. We wanted to prove to everybody that
we were able to make the model here on school
notwithstanding it has such a difficult conical form.
The model has also a function USB lid to show how
the mechanism exactly works.
All the electrical parts are installed in the technical
model so this model does not really work and it’s
only to show how the barbecue would look like when
it’s made out of metal.
83

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
APPLICATION
Here are some renderings of our barbecue
concept.
On the picture right you can see two barbecues.
One is in used and the other is not in use. The
USB-port is closed and the heat regulation
button is pushed in, if the barbeque isn’t in
use. The button has a push mechanism. By
pushing the button, it’s going to come out
and it’s ready to use. When you don’t want to
use it anymore you have to push it again and
it stays inside the barbecue. This function very
handy while carrying the barbeque around.
The picture below is a detailed render of the
push button and the USB lit. As you can see
the lit is open and you can use the USB port.
The USB lit has a built in turning mechanism
so when you don’t want to use it anymore you
will have to turn it 100 degrees and it’s closed.
This mechanism is very suitable. It defends
the port of sand and other dirt.
85

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
This is the movement of the USB lit. You
just have to push the lit and it will turn so
that you can use the USB ports. When the
lit is completely opened it’s stick out of the
barbecue with an angle from about 10 degrees
so you can easier reach to the USB ports.
87

On this rendering you can see that the lit is
placed under an angle of 10 degrees.
88

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
Push button mechanisme.
89

Around the push button there is a lighted
circle. The light can either be blue or green.
When you unpack your barbecue and turn it
on the light will be blue. This means that the
barbecue is cool.
When you lit up the charcoal and the grill
becomes warm, the light will turn green. This
means that it’s hot enough and ready to grill.
The green light also means that the barbecue
is generating “green” energy.
In the end when you don’t want to use the
barbecue anymore you will have to wait
till the light becomes blue again, than the
barbecue is ready to pack. The barbecue won’t
be completely cool but it will be save to pack
because the bag is made out of heat resisting
material on the inside.
90

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
LOGO CHOICE
We came up with multiple logo designs
because we wanted to try different styles.
We also tested different color combinations to
make the logo fit both our personas as well as
the overall product.
The shown design and color variations are the
ones that have been short-listed.
We wanted to use green since it represents
many things that match
our “barbecube” and he feelings it should
communicate:
We wanted to have a simple logo which can be
scaled down without losing details and which
can also be lasered or ingraved into the roast
of the barbecue itself.
The final logo we chose is a suggestion of the
outlines of a 3-dimensional cube with a green
organic form on top of it which could either
stand for a flame (grilling and green energy)
or a leaf (nature). It is also easy to scaledown,
to plot and to engrave.
- nature
- spring
- youth
- life
- health
91

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
SINGLE PARTS
To give you an idea about the sizes of the parts
from the barbecue we made some 2D drawings.
301,599
301,599
250
250
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
FINISH:
DEBUR AND
BREAK SHARP
EDGES
DO NOT SCALE DRAWING
REVISION
TOLERANCES:
LINEAR:
ANGULAR:
NAME
SIGNATURE
DATE
TITLE:
DRAWN
CHK'D
APPV'D
MFG
Q.A
MATERIAL:
DWG NO.
Baugruppe1
A4
WEIGHT:
SCALE:1:1
SHEET 1 OF 1
93
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
FINISH:
DEBUR AND
BREAK SHARP
EDGES
DO NOT SCALE DRAWING

UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
DRAWN
CHK'D
APPV'D
MFG
Q.A
NAME
FINISH:
SIGNATURE
DATE
MATERIAL:
WEIGHT:
DEBUR AND
BREAK SHARP
EDGES
TITLE:
DWG
SCAL
Body:
DETAIL A
TRUE R15
20,983
76
1164,706
22,558
A
220,006
20,958
156,223
22,078
88,424
1111,423
94

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
Mirrow:
This is the mirror which is placed under
the charcoal holder. We did this to make
sure that most of the heat from the
charcoal is guided to the grill.
81,183
81,183
240
240
8
367,041
367,041
A
A
122,469
122,469
103,520
103,520
182,02°
182,02°
15 15
8
DETAIL A
SCALE DETAIL 1 : A 2
SCALE 1 : 2
95

Roast:
This is a 2D drawing of our grill plate.
As you can see we placed our logo in
the middle of it to show that this is our
barbecue.
299,600
299,600
274,600
R29,800
R2,500
4,958
96

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
Push Button:
This is a 2D drawing of the push button
mechanism. With this button we can
regulate the air flow in the barbecue.
28
32
21
19
19,500
97

MATERIAL USE
The materials that we used in our barbeque are
heat conductive materials and heat inhibiting
materials. We used some isolation to prevent
the electronic parts from the heat that comes
of the charcoal.
Steel
The steel we use is normal sheet metal with a
thickness of 0.8 mm. Fabrication and bending
of this material is easy because of the high
Young’s module. The outside we produce
out of one piece. Other parts are produced
separately.
high temperatures. The material is made by
Basaltex in Belgium and it’s a very unique
product.
Protection layer
The barbeque is protected by a porcelain
enamel layer. This is sprayed on the steel
parts by a temperature of 860 °C. The layer
protects the steel against the weather and
reflects the radiation.
Electronic components
The electric components are made of composite
materials. Most of the PCB are made of FR4
because of the high fire retardancy. This is a
material that is made of glass fibre and an
epoxy resin. The circuit connections are etched
in the PCB. Other components are made of
plastics and electricity conductive materials.
Isolation
The isolation we used is a rock wool of
basalt. This is a rock formed from the rapid
cooling of basaltic lava exposed at or very
near the surface. Only this kind of isolation
was suitable for our purpose because of the
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
COATING
Most common methods:
• Powder coating
• Lacquer coating
• Anodizing
• Foil coating
Method of Choice:
We choose a special heat-proof lacquer coating
for the Barbecue which resists temperatures
up to 1200°C. The benefits of this method
are the relatively cheap price, the easy spray
application and it is available in every Color of
the RAL Color System.
Powder and foil coatings will not be able to
resist the high temperatures. The color tones
would change or the complete coating could
be damaged. Special powders that are able
to resist high temperatures are only available
in black and silver. Anodizing would also not
apply because this method does not work
with steel which is the main material of the
Barbecue
99

RECYCLING
The main material that we use in our barbeque
is steel. This material is very good for reuse
in the production of new steel. The rest of our
used materials are composites and plastics.
These materials can’t be reused as they
are and need to be separated by material
properties and colour. Then the plastics can
be reused but the composites are waste.
The packaging material is cardboard and can
be used in the process to make new cardboard
or paper.
100

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
PRODUCTION
To realize our barbeque, we need to use
some different operations. These fabrication
processes are different for every material. The
process is defined in the following order.
The electric components like the TEG elements,
converters, protectors and the batteries are
bought from a reseller. The housing of the
barbeque is made out of sheet metal that is
punched out in the correct form. When this is
done the sheet is bended and the end is spot
welded together. The other metal parts are
produced the same way. The more complex
forms are punched and then finished with
rolling and bending. The grid is mechanically
made by a welding robot that welds all the
parts together.
When all parts are produced, the assembly of
the barbeque can start. The electronic circuit
is assembled first and later in the process
it is fit in the rest of the design. During the
assembly some parts will be welded together
for a solid product.
When everything is assembled the barbeque
is packed and ready for selling in the store.
101

COSTS CALCULATION
Electro components 1 part 1000 parts
Teg element € 45,44 € 37,87
Step up converter € 4,24 € 3,53
Step down converter € 10,6 € 8,83
battery € 24,82 € 20,68
li-ion protection board € 10,54 € 8,78
fan € 9,- € 0,94
diode € 1,25 € 1,04
total electro € 107,02 € 89,17
steel parts
sheet metal 0,8 € 12,91 € 10,33
sheet metal 1,5 € 7,18 € 5,74
tube Ø15x1.5 € 1,5 € 1,20
rod Ø8 € 0,2 € 0,16
heatsink € 22,70 € 18,16
total metal € 44,49 € 35.59
total € 151,59 € 124.76
The price we calculated is for one barbecue
and when you buy all your parts at a supplier.
When you really want to produce the barbecue
the parts would be a lot cheaper and maybe
you can built some of the parts yourself. When
you buy from a supplier as a consumer you
will have to pay more compared to when you
have your own company and order a lot of
components. In the end the price will be a lot
less and we would try to sell the barbecue for
a price between 50 and 100 euros.
102

103
V EVALUATION

CONTENT
Evaluation 105
Final word 106
Impressions 107
References 109
104

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
EVALUATION
In the beginning of our BBQ Project we decided
to divide the group into two parts. One group
had to develop the design concept, the shape,
color and the marketing appearance of the
product. The other group focused on the
technique with the goal to build a working
prototype to show the potential of the idea.
The design group started with a lot of
research about BBQ designs, shapes and
colors. This research was used for a series of
design suggestions that were developed into
different concepts were we chose the best one
afterwards. The winner of this comparison
was developed further by building cardboard
prototypes and CAD models to improve the
design and avoid design failures. When we
were confident with the design concept, we
realized a sheet metal prototype to prove that
our design ideas could be realized. The design
prototype turned out good altogether and the
group is satisfied with their achievement.
The technic group also did a lot of research to
realize a working BBQ, which is able to provide
electrical energy. This model is based on the
function and doesn‘t set value on the design.
With the support of Mr. Emmerik we ordered
all technical components that were needed to
realize the technique.
The technical group had some difficulties.
Their prototype didn‘t work in the beginning
because there wasn‘t enough heat difference
between the hot and cold side of the TEG
elements. Moreover they discovered that
they needed more cooling and had to find a
solution for that. To find the right amount of
TEG elements was also a big topic and quite
a few break during the tests. After a series of
trial and error tests the tech group managed
to make a working prototype.
After all, we as a group are sure, that we
reached our goals to create an elaborate
design that could be used for mass production
and a functional prototype that shows the
big potential of the complete technique. We
think that it is possible to combine the design
concept with the given technique.
After 16 project weeks we can claim that we,
as a group, achieved a lot.
We‘re really hungry
and feel like starting the new barbecue
generation right now!
105

FINAL WORD
In closing, and on behalf of the entire Greenenergy-
group we want to tell you our future
plans and the next steps we‘re going to take.
First of all, we got in contact with a radio
station from Germany, which would like to
have an interview with us. They were really
interested in our idea and would like to get
more information about our barbecue as soon
as possible, as there many festivals going
on during the summer months. Moreover we
have the plan to send a PDF-data to different
companies and maybe even make some
presentations there, if we get an invitation.
Our goal is to find some suppliers, who are
interested in producing our concept. We think
it‘s a great opportunity for us, as we think we
have big potential in our concept.
But first we have to make sure that everything
works well as we had quite few difficulties
during the test-period. Before we get in
contact with potential companies we have to
make sure that our system is a trustable and
long lasting device which produces energy.
If we succeed to convince somebody with our
idea, a new barbeque generation will start and
we‘re happy to welcome everybody to it!
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INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
IMPRESSIONS
107

108

INTRODUCTION ORIENTATION ANALYSIS SYNTHESIS EVALUATION
REFERENCES
www.ebay.com/itm/HIGH-TEMP-POWER-GENERATION-TEG-THERMOELECTRIC-MODULE-
/310209561834?pt=LH_DefaultDomain_0&hash=item4839ee44ea
step up converter
www.ebay.com/itm/5-pcs-LM2577-DC-DC-Adjustable-Step-up-Power-Converter-Module-NEW-
/370782480659?pt=LH_DefaultDomain_0&hash=item56545ba913
li-ion protetion
www.ebay.com/itm/4S-Li-ion-Lithium-Battery-Input-Ouput-Protection-Board-PCB-14-4V-14-8V-16-8V-
5A-/221179238980?pt=LH_DefaultDomain_0&hash=item337f4f5a44
accu
www.hobbyking.com/hobbyking/store/__9270__turnigy_2200mah_4s1p_20c_lipo_pack.html
step down converter
www.ebay.com/itm/DC-DC-dual-double-output-7-16V-Step-down-BUCK-1-16V-MAX-6A-converterregulator-/151052990298?pt=LH_DefaultDomain_0&hash=item232b75b75
www.ebay.nl/itm/SUNON-DC-VENTILATOR-/140883997512?pt=LH_DefaultDomain_146&hash=item20
cd573348#ht_829wt_1004
usb aansluiting
www.ebay.com/itm/2-x-USB-Type-A-Female-Connector-Free-Shipping-/261092142839?pt=LH_Default
Domain_0&hash=item3cca4deef7
http://www.ulfalux.com/de/produktion/ulfalux-spezialprodukte-fuer-den-ofenbau/farbtonkarten-fuerden-hochitzebereich.html?start=1
www.pantone.de/pages/index.aspx?pg=21055
www.welt.de/lifestyle/article112333589/Gruen-gruen-gruen-sind-alle-neuen-Trends.html
www.colorschemedesigner.com/
hwww.sinus-institut.de/loesungen/
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