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December 8, 2015 3:22 pm DownloadInventor James Dyson faces challenge to clean up EU vacuum tests You have viewed your allowance of free articles. If you wish to view more, click the button below.Couple of weeks ago, Volkswagen admitted it had cheated US tests to make its diesel cars seem more green than they actually were. Later, ZME Science reported companies like Renault, Nissan, Hyundai, Citroen, Fiat or Volvo could be also cheating. Independent lab tests showed  some Samsung TVs were rigged to use less energy during official testing conditions than they do during real-world use. Now, famous British inventor James Dyson is accusing German companies Bosch and Siemens of doing the same thing – gaming energy ratings for their vacuum cleaners.“Bosch has installed control electronics into some of its machines to wrongfully increase energy consumption when in use — to cheat the EU energy label,” said Dyson. “It seems that industry is rife with manufacturers engineering to find their way around tests, rather than engineering better, more efficient technology.

This behavior is seriously misleading customers.”James Dyson is the founder of Dyson, a company that sells vacuum cleaners, bladeless fans, hand dryers and other products in this range. Dyson says the German companies’ vacuum cleaners are actually using twice as much energy as they claim, based on independent testing. At home, these vacuum cleaners apparently use  1,600W of power, instead of the rated 750W. Well, Dyson says that all of these tests are made with the dust bag empty. Sensors inside send a signal to the motor once more dust gathers to turn up the power and make the vacuum cleaner actually useful. In this case, a rating of AAAA in test conditions could drop to an E or F in the home.For Dyson, this kind of cheating also means a lot of lost business. Most of Dyson’s vacuum cleaners are below 1400W, but the best selling models use half as much energy – or so they’re labeled. Dyson says consumers choose these vacuum cleaners, not because they believe they’re better than Dyson models, but because they think they’ll save money on electricity bills.“

It seems that industry is rife with manufacturers engineering to find their way around tests, rather than engineering better, more efficient technology. This behaviour is seriously misleading customers,” Dyson said who also launched legal action against the two companies.nilfisk vacuum cleanerBSH Home Appliances, on behalf of Bosch and Siemens, rejects these accusations. best lightweight upright vacuum cleaners“All Bosch and Siemens vacuum cleaners are measured in compliance with European energy regulations. henry type vacuum cleanersAppliance performance at home is consistent with laboratory performance – and any suggestion to the contrary is grossly misleading.“The purpose of energy labelling is to give consumers a clear and independently-validated indication of energy consumption and broader performance criteria.

We have a long and proud tradition of stringent testing.“We are committed to providing full disclosure on the energy ratings and broader performance of our vacuum cleaners so that consumers can make an informed decision. For reasons we fail to understand, this is not something that Dyson choose to do.“European commission regulations and energy labelling on vacuum cleaners provide a valuable and reassuring guide that benefits the consumer. We believe that clear, accurate and independent performance information should be available to all consumers – and we are proud to share this.”Dyson is far from convinced. In fact, the British inventor is quite fed up with the way EU runs its tests.“[There are] fridges tested with no food, vacuum cleaners tested with no dust, and washing machines tested at inaccurate temperatures,” he claimed. “The regulators clearly live in a place that looks nothing like the real world and manufacturers are taking advantage,” Dyson said speaking for The Telegraph.If this is true, then Dyson is right: the EU energy ratings are useless and should be overhauled.

How many companies are actually cheating these energy ratings? Next year we might be in for some surprises as more and more tests show up.Like ZME Science on facebook:Dyson uses digital product development in its R&D projects, such as the D15 vacuum cleaner, while maintaining fast development cycles.Led by its charismatic founder, James Dyson, Dyson is an innovation success story. In 1993 the company introduced the Dyson DCO1 Dual Cyclone, the first vacuum cleaner with constant suction. Over the following decade, Dyson has grown to become the top-selling vacuum cleaner manufacturer in Western Europe and the leading vendor of upright vacuums in the USA. It now employs 1,400 people in the UK and sells machines in 38 countries.Dyson’s most recent vacuum cleaner innovation is the Dyson DC15, launched in 2005. The DC15 incorporates the revolutionary Ball technology, which replaces the traditional, rigid wheels of a vacuum cleaner with a ball. This configuration allows the user to guide the cleaner around furniture and other obstacles.

The Ball successfully eliminates the struggle of maneuvering a vacuum around a room, allowing the user to control the movement – not the other way around.One of the issues facing Dyson is how to create increasingly sophisticated machines such as the DC15, which has more components, while ensuring that design and development cycle times do not become overly extended.Since 1998 Dyson has been a committed user of the NX™ next-generation digital product development software system. Dyson originally bought five seats of NX. Over the years this has increased to 88 licenses, with the software now being used by more than 100 in the Dyson R&D team: design engineers who are part of the New Product Development team, which generates ideas and concepts; scientists involved in testing and developing ideas and technologies; and the engineers responsible for the actual detail design of the machines.As the early ideas and concepts for the DC15 began to come together in cardboard and foam, design engineers used NX to produce detailed 3D models that helped them clarify their thinking and refine the ball mechanism.

“Our conceptual designs are produced in 3D, which has fantastic benefits,” explains John Myers, CAD systems manager at Dyson. “Rather than just producing views of the product, you design the real thing. This reduces ambiguity and often makes it easier to understand complex assemblies. You get a lot of feedback, seeing it coming together before your very eyes.”The modeling features within NX enabled Dyson’s design engineers to work extremely quickly. “With the 2D CAD software that had been used before, a design engineer could spend weeks on the design of a complex part. With NX we can produce a 3D model in a fraction of the time,” Myers says.The next phase in the DC15’s development involved the creation of physical prototypes to help the design team better evaluate the new concept. Designs created in NX were used directly for rapid prototyping, supporting the swift creation of physical models for testing and evaluation. NX geometry was converted into STL files that were then used by Dyson’s in-house prototyping modeler, which creates prototypes from successive layers of powdered nylon.

Fast prototyping of metal components was made possible by NX’s integrated NC machining functionality, part of NX’s computer aided manufacturing (CAM) portfolio. NX Machining leveraged the 3D design geometry to drive milling and cutting tools. One of the advantages of using NX Machining was that refinements made to the design were automatically incorporated into the CNC programs, without the need for reprogramming. This avoided potentially costly delays to the creation of successive prototypes.Dyson generated a variety of prototypes as the design engineers and scientists considered alternative designs. The speed at which NX could help deliver prototypes was a major benefit. “With a complex project such as the DC15 that required us to evaluate a number of alternative models, NX’s ability to support rapid prototyping was an important factor in helping us to keep the development time in check,” Myers adds.To improve accuracy and eliminate errors in the design – and ultimately speed the overall development cycle – Dyson used a number of NX digital simulation and testing capabilities.

For example, NX’s assembly modeling functionality allowed Dyson to ensure that the many parts within the product, which were created by different design engineers, would fit together correctly.NX mechanism analysis allowed the design engineers to view a nimated sequences simulating the precise motion of the moving parts. This ensured that parts did not interfere with each other as they moved. And to help engineers understand the stresses on the different parts within the DC15, 3D design data was also used for finite element analysis (FEA) within NX.When the major design and testing phase was completed, it was time for the tooling manufacturers to get involved. Dyson partners with several specialist toolmakers. The toolmakers fashion the machine tools used in the manufacturing, which takes place on Dyson’s purpose built assembly lines in Malaysia.It was important to provide the toolmakers with the information they need quickly and accurately to avoid delays. The high quality of NX data, due to the rigorous simulation and prototyping it had undergone, was able to support this fast turnaround.