Final Project

Adonis Pimienta-Penalver
3270-5895

11/12/2009
MAE 377
University at Buffalo
1 Contents
2 Introduction..........................................................................................................3
3 Problem Statement..............................................................................................3
4 Design Goals........................................................................................................4
5 Market Survey/Product Descriptions....................................................................4
6 Project Management............................................................................................6
6.1 Gantt chart.....................................................................................................6
6.2 Alternative Designs (Hand Sketches).............................................................7
6.3 Analysis of Alternative Designs....................................................................10
6.4 Decision Making...........................................................................................11
7 CAD Models........................................................................................................14
7.1 Parts.............................................................................................................14
7.2 Assembly.....................................................................................................17
7.3 Rendering....................................................................................................20
7.4 Animations...................................................................................................28
8 Manufacturing Analysis......................................................................................29
8.1 BOM/Drawings.............................................................................................29
8.2 Cost Analysis................................................................................................36
9 Service Analysis.................................................................................................38
9.1 Product Manual............................................................................................38
9.2 Product Life Analysis....................................................................................41
10 Conclusion.......................................................................................................41
11 References......................................................................................................43
References

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2 Introduction
The product I will inspect for the final design project of our MAE 377 class is
the gamepad/joystick device. This device is used as an advanced controller with
several input buttons to provide better controlling capabilities for certain games or
simulators. The success of my work will be measured by if I can design a new
product with the ability to provide users with greater controlling capabilities and
more versatility in terms of being adaptable to different types of games. I will
accomplish this task by researching different present models and their respective
customer satisfaction, pros and cons; to be able to obtain an idea of what the
market is asking for, and supply a solution to the general demand. The design will
feature a more functionality-based approach because while many companies have
products that excel at their respective domains, there are only a few that are
directed to provide the gamer with a complete package to fit every type of game. I
will show the prototype model to my peers in order to get feedback on its user
friendliness and market appeal. The worth of my project will be determined by how
much I am able to adapt the design to the needs of the users.

3 Problem Statement
Gaming in today’s world isn’t simply a matter of having a console and a few
game cartridges; as time has passed, users have grown more demanding of
increased control and user-friendliness of these interfaces; sometimes, until the
point of turning gaming into something else but a hobby anymore.

This presentation is the result of extensive survey and understanding of the

needs of consumers in the current gaming world in terms of user friendliness and
aesthetical appeal of the interfaces used to input commands into the games they
play.

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4 Design Goals
My objective is to create a new product, to address the needs of gamers in
terms of user-friendliness and overall ergonomic design.

I will focus on several parameters to complete my design, these will be crucial in

guaranteeing the overall value of my final product in the hypothetical case it
becomes available in the market. These parameters are, primarily: Versatility
(ability to adapt to different gaming experiences), user friendliness, durability, cost
and appearance.

5 Market Survey/Product Descriptions

Product Picture Price Pros/Cons

Logitech Attack 31 $19.35 -User friendliness

-Availability

-Low price

-Ease of
connectivity

-Placement of
buttons is
uncomfortable

-Not many buttons

Saitek PS41 $38.99 -Connectivity

2
Aviator
-Versatility

-Compatible with
many consoles
and PCs.

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 -Average price

-Lacks in
programmable
buttons

CH products $100.67 -Compatible with

fighterstick USB3 many operating
systems

-Very wide range

of programmable
buttons

-Realistic flight
control

-Steep price

Microsoft $85.95 -Plug and play

Sidewinder force easy
4
feedback joystick
-lack of
programmable
buttons

-High price

Table 1: Market survey featuring four popular joystick controllers

In the process of choosing the best design possible for the new controller it is
important to know what features are being looked for and which will enhance the
functionality or general characteristics of the product. The Logitech Attack 3
joystick5, for example, combine the easiness of use and the ease of connectivity
that is looked for in a joystick by any regular or casual gamer; it is important to
have a device which can be utilized easily without any cumbersome method of
connection. It is also important to look for the highest amount of programmable
buttons as possible, this allows the user to gain more control in the game being
played, while shortening the time it takes for him or her to perform a specific task.

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6 Project Management

6.1 Gantt chart

D
a
y
s 1 1 1 1 1 1 1 1 1 1
Pe R 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
D rc D e 1 1 1 1 / / / / / / / / / / 2
ur en ay m / / / / 1 1 1 1 1 2 2 2 2 2 /
at t s a 3 5 7 9 1 3 5 7 9 1 3 5 7 9 1
io Co Co i / / / / / / / / / / / / / / /
n m m n 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
(D pl pl i 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
ay et et n 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Tasks Start End s) e e g 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9
Propos 10
al 11/3 11/5 2 0 2 0
Introduc 10
tion 11/3 11/5 2 0 2 0
Product
Descript 10
ion 11/3 11/5 2 0 2 0
10
Phase 1 11/5 11/12 8 0 8 0
10
Outline 11/5 11/12 7 0 7 0
Problem
Stateme 10
nt 11/5 11/12 7 0 7 0
Design 10
Goals 11/5 11/10 5 0 5 0
Market 10
Survey 11/6 11/10 4 0 4 0
Gantt 10
Chart 11/10 11/12 2 0 2 0
10
Phase 2 11/12 11/24 12 0 12 0
Project
Managem 10
ent 11/12 11/24 12 0 12 0
Desig
n
Sketche 10
s 11/12 11/19 6 0 6 0
Analyz
e
Sketche 10
s 11/19 11/21 2 0 2 0
Decisi
on- 10
making 11/21 11/24 3 0 3 0
Phase 3 11/24 12/01 7 0 0 7
CAD
Models 11/25 12/01 6 0 0 6
Drawing
s 11/27 12/01 4 0 0 4

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User
Manual 11/27 12/01 4 0 0 4
Animati
ons/Pict
ures 11/29 12/01 2 0 0 2
Presentati
on 11/29 12/01 2 0 0 2
Website
Complet
ion 11/29 12/01 2 0 0 2
Cost
Analysis 11/27 12/01 4 0 0 4
Product
Life
Analysis 11/25 12/01 6 0 0 6
Table 2: Gantt chart with expected completion dates for individual tasks.

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6.2 Alternative Designs (Hand Sketches)

Figure 1: First proposed design.

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Figure 2: Second proposed design.

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6.3 Analysis of Alternative Designs
Design 1 (figure 1) Design 2 (figure 2) Design 3 (figure 3)

Pros Cons Pros Cons Pros Cons

Features May be No true Responsive Some Combines Not many

used as joystick. joystick. games classical programmable
joystick and Several cannot be joystick with buttons for
gamepad programma played with popular joystick
at user’s ble buttons. joysticks. gamepad. feature.
discretion.

Ergonom Small, Needs the Buttons are Not The gamepad Very small
friendly to base to be easy to portable. serves as joystick could
ics
the user’s used as reach. base when be a nuisance
hand. joystick or Designed user is when user is in
wheel. May symmetrica utilizing the “gamepad
be heavy. lly. joystick. mode”. It may
break easily as
well.

Appeara Streamline Streamline Awkward

d; usual d, small but appearance.
nce
controller sturdy base
shape. area.

Versatilit Innovative Programma Can only be May be used Joystick not

joystick ble buttons used for with games very
y
design may be games that that utilize responsive due
allows very useful require joystick or to its small
acting as and joysticks. gamepad. size. Games
joystick and configured that require

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 wheel at for every rapid joystick
the same game. handling
time. May (driving
also be simulators),
used as require sturdier
regular joystick design.
gamepad

Size Folding Slightly Regular Designed to Slightly larger

handles bigger than joystick minimize than usual.
reduce its average. size. size.
size.

Table 3: Analysis of pros and cons of the previously-listed designs based on several
constraints.

6.4 Decision Making

Based on the design goals set forth in section 4, one preliminary design or a
combination of any of them must be chosen as the design model to pursue during
this project. The first prototype offers very good versatility, innovation and
ergonomic characteristics; it is a viable design that could be very successful in
attracting PC gamers to make use of its features. While the second design offers a
more traditional approach to its functions and the third design attempts to unite two
features to capture both the simulation and gaming market; I believe that based on
the constraints set forth for innovation, ergonomic design, versatility and user-
friendliness, the first model is the one fit to base this project upon. The feature that
sets this model apart from the others is its ability to combine a gamepad and a
joystick/wheel into one part; the latter is a prime example of innovation, as it
mimics the design of a commercial airplane’s handle, which can be folded back into
the device so as to maintain its convenient size while usage in “gamepad mode”.
Below, I have produced a table to compare the three preliminary designs based on
a 1-10 scale.

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Candidate User Versatili Appeara Featur Total
Friendliness ty nce es

8 9 7 9 33

9 5 8 7 29

5 8 5 7 25

Table 4: Final asessment of preliminary designs. Based on a 1 to 10 scale.

As we have seen above, the design that best fits the requirements and
constraints laid out in previous sections of this report is design number 1. It
combines adequate versatility, user friendliness and several features to make the

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gaming experience complete. In the next page is a preliminary sketch of the final
chosen prototype to work on during the course of this project.

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Figure 4: Final prototype choice with rough preliminary dimensions.

7 CAD Models
The process of creating parts to recreate the chosen design was mostly about
being able to keep track of meaningful dimensions and provide with as much
realism and detail as possible in order to present the work to my peers and to any
other who reviews my work.

As it will be seen in subsequent sections, I created the circuit boards of the

device paying close attention to actual circuit boards of devices in the market. I
have created a rumble motor to give the gamer feedback response; a detailed
assembly of the control stick devices, highlighting the mechanisms of springs and
damping along with the potentiometers. I have also created a battery compartment,
which will allow the controller to be played wirelessly without the need to connect it
to the power source; this battery compartment adds to the versatility and the user
friendliness of my product, hence satisfying some of the constrains laid out above.

I have also attached a USB cord to the assembly of the base, in order for the
user to be able to connect it to a computer if he/she desires so. This feature is also
complimented by a USB adaptor slot in the bottom of the controller which also
allows the user to connect to a computer and interact via USB connection.

The base assembly was designed to provide the gamer with the most
ergonomically adaptive features that will allow him/her to experience better
interaction with whichever game is being played. For those who prefer flight
simulation or racing games, a throttle has been added to the front cover assembly
in order to provide the user with a way to increase or decrease velocity in certain
games.

Please be sure to refer to the sections that specify pertinent dimensions to be

able to see that this assembly has been created to actual, real world dimensions (in
mm).

7.1 Parts
Here are some pictures of some of the more challenging individual parts.

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(A)

(B)

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(C)

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 (D)

(E)
Figure 5: Above are pictures of, (A) the front cover of the assembly, (B) the Directional
button pad, (C) the back cover, (D) the upper circuit board and lastly (E) the lower circuit
board.

7.2 Assembly
In order to create the assembly, I set the back cover (figure 5c), as the ground
reference for the process. This allowed me to base my subsequent additions to the
device on the dimensions already placed in the back cover. To accurately create the
holes and extrusions of the cover, I used feature cutouts in order to obtain the exact
dimensions of the cut and paid close attention to the dimensions that I created
before.

The process of assembly was particularly difficult at times, since some of the
parts in my device are not linear and thus are very hard to constrain to adjacent
objects or planes; in order to solve this issue I created several datum planes to
specify certain positions or conditions to align my new incoming parts. Below are
pictures of my different subassemblies.

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(A) Back Subassembly (B) Back Subassembly

(C) Back Subassembly (D) Control Stick Subassembly

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(E) Control Stick Subassembly (F) Control Stick Subassembly

(G) Base Subassembly (H) Base Subassembly

(I) Base Subassembly (J) Front Subassembly

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 (K) Front Subassembly (L) Front Subassembly
Figure 6: Different exploded and assembled views of several subassemblies.

7.3 Rendering
Below are several rendered images of my assembly in a pertinent setting;
please note the semitransparent plastic utilized for the front and back covers. This
adds appeal to the product and increases its value in the market.

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(A)

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(B)

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(C)

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(D)

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(E)

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(F)

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(G)

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 (H)
Figure 7: Rendered of the completed product at different views.

7.4 Animations
Below, you will find links to the animation created to present the features of my
design. Please feel free to browse my website
(www.sites.google.com/site/apimientapenalvercaddesign) in order to appreciate the
embedded animations that were created.

In order to see a non-rendered version of the animation please refer to:

To see a rendered version of the animation please refer to:

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8 Manufacturing Analysis
Below, you will find drawings of the different parts and assemblies that form
part of my device. Dimensions and names are specified. For a complete list of the
parts, please refer to the manual or my website
(www.sites.google.com/site/apimientapenalvercaddesign).

8.1 BOM/Drawings

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Figure 8: Dimensions and BOM detail drawings for the parts and subassemblies of the
device.

8.2 Cost Analysis

This section is dedicated to perform a cost analysis for the device I have
created. I will list parts, approximated cost and quantity, a rough wholesale
estimate of the cost of the final product will be given, along with its implications.
The estimated total cost of the product is $47.98. This was done by researching
prices of individual parts. For parts which I did not find prices for, I gave my best
estimate.

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 Quant
Part Name Material ity Cost Total
Back Cover Plastic 1 $1.00 $1.00
Thread Steel 4 $0.05 $0.20
Circuit Board 1 Copper/Resin/Teflon 1 $2.00 $2.00
Circuit Board 2 Copper/Resin/Teflon 1 $2.00 $2.00
Lid Plastic 1 $0.30 $0.30
Directional Buttons Plastic 1 $0.90 $0.90
Directional Pad Rubber 1 $0.50 $0.50
A_Button Plastic 1 $0.50 $0.50
Oval Button Plastic 3 $0.30 $0.90
Action Buttons Pad Rubber 1 $0.50 $0.50
Index Button Plastic 2 $0.30 $0.60
Index Pad Rubber 2 $0.50 $1.00
Control Stick Plastic 2 $0.70 $1.40
Control Stick $12.0
Potentiometer Aluminum/Copper 2 $6.00 0
Control Stick Fulcrum Plastic 2 $0.50 $1.00
Pin Steel 8 $0.01 $0.08
Spring Steel 8 $0.05 $0.40
Circuit Board Screw Steel 17 $0.10 $1.70
Circuit Board 3 Copper/Resin/Teflon 1 $0.70 $0.70
Center Button Plastic 3 $0.40 $1.20
Center Pad Rubber 3 $0.50 $1.50
Aluminum/Steel/Coppe
Rumble Motor r 1 $2.00 $2.00
Rumble Hammer Steel 1 $0.70 $0.70
Front Cover Plastic 1 $1.00 $1.00
Front Index Button Plastic 2 $0.30 $0.60
Front Index Pad Rubber 2 $0.50 $1.00
Thumb Button Plastic 2 $0.30 $0.60
Thumb Button Pad Rubber 2 $0.50 $1.00
Wheel Button Plastic 5 $0.30 $1.50
Wheel Axle/Holder Plastic 1 $2.00 $2.00
Shaft Plastic 1 $0.70 $0.70
Stand Plastic 1 $1.00 $1.00
Potentiometer Aluminum/Copper 1 $3.00 $3.00
Plastic/Rubber/Copper/
Base Steel 1 $1.00 $1.00
Base Circuit Board Copper/Resin/Teflon 1 $0.90 $0.90
Base Lid Plastic 1 $0.40 $0.40

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Throttle Lever Plastic 1 $0.20 $0.20
$47.9
Total 89 8

Table 5: Cost analysis with corresponding list of materials, cost of manufacture and total
cost.

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9 Service Analysis

9.1 Product Manual

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Figure 9: User manual for device

9.2 Product Life Analysis

The durability of this product depends on the wear and the stresses it is put
under by the customer. If used regularly (7 days a week), I estimate this product will
last nearly 2 to 4 years. If used in a more moderate way (2 or 3 days a week), this
product may last up to 5 years. This device needs no lubrication6.

10 Conclusion
The successful completion of this project has helped me integrate some of the
most important aspects of being an effective worker in the engineering field. I have
learned to carry out a complete design process and present it effectively to my
peers or coworkers. I have been able to implement the skills I have learned
previously from all my previous Pro/E work and put them to work to create an
appealing, realistic model of my design. Thanks to this project and this class
altogether, I now feel more confident with the basic skills of solid modeling, report
writing and presentation. The skills I have learned and the confidence I have gained
from working in Pro/E in this and other projects allow me to say that I would like to
further my work on this device, in order to create a more complete package to go
with the main controller and base.

The more challenging parts of this project was the animation, due to virtual
memory capacity restraints placed by the computer I was working on, I was not able
to create a video that performed everything I wanted it to perform. For example, I
would have wanted it to go through every single piece individually and demonstrate
how they assembled into position into the main device. I overcame this problem by
creating an animation that was not long so as to not put too much strain on the
computer, but at the same time, allowed the viewer to explore every the assembly
by seeing pieces assemble in and out of the device, though not in a piece by piece
manner.

This project has been a success; I have been able to surpass or at least meet
the design goals set forth in previous sections. These are listed below.

• User Friendliness : The device would be distributed to users in two

parts; these consists of the main gamepad and the stand. In order to
assemble them together, the user simply needs to insert the clamps of
the axle into the back of the gamepad. The design of the handles is
ergonomic and users will find it easy to adapt to. The layout of the
buttons emulates the layout of popular gamepads being marketed today.

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 • Versatility : This device is in fact very versatile; for the reasons that it is
designed to be used both as gamepad for regular games or as a wheel for
driving games or simulators. The gamepad itself can be attached to a
stand so as to allow the gamer to have a more realistic experience of
driving or piloting.
• Durability : According to the service life analysis for this device, I
believe it can actually be very durable and offer a good gaming platform
in a consistent basis for at least half a decade.
• Cost : Due to the sheer amount of working parts and the detail that it
takes to manufacture them, this product will place mid-scale in terms of
price compared to other products in the market. If we inspect the
following table, we will find a comparison of price between the product
we have created, its expected retail price and the prices of other popular
controllers/joysticks in the market today.

Product Picture Price

Logitech Attack 37 $19.35

Logitech Cordless Rumblepad $33.88

Saitek PS41 Aviator8 $38.99

Gamepad (My Design) $47.98

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Microsoft Sidewinder force $85.95
9
feedback joystick

CH products fighterstick USB10 $100.67

Table 6: Final price comparison of the products.

• Appearance : This may be, unfortunately, the department where this

product lacks the most. However, I believe that despite this small
drawback, gamers looking for a versatile, reliable and easy to use
controller will choose substance over style.

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1 References

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1 Amazon.com. http://www.amazon.com/b?ie=UTF8&node=172489. Page visited 11/11/2009 at
11:00.

2 Amazon.com. http://www.amazon.com/b?ie=UTF8&node=172489. Page visited 11/11/2009 at

11:00.

3 Amazon.com. http://www.amazon.com/b?ie=UTF8&node=172489. Page visited 11/11/2009 at

11:00.

4 Amazon.com. http://www.amazon.com/b?ie=UTF8&node=172489. Page visited 11/11/2009 at

11:00.

5 Logitech.com. http://www.logitech.com/index.cfm/search/&cl=us,en?q=attack+3. Site visited

4:58 am 11/4/09.

6 Wikipedia.com. Product Life Cycle. http://en.wikipedia.org/wiki/Product_life_cycle_management.

Visited 12/13/09

7 Amazon.com. http://www.amazon.com/b?ie=UTF8&node=172489. Page visited 11/11/2009 at

11:00.

8 Amazon.com. http://www.amazon.com/b?ie=UTF8&node=172489. Page visited 11/11/2009 at

11:00.

9 Amazon.com. http://www.amazon.com/b?ie=UTF8&node=172489. Page visited 11/11/2009 at

11:00.

10 Amazon.com. http://www.amazon.com/b?ie=UTF8&node=172489. Page visited 11/11/2009 at

11:00.