Owners manual

Please read this guide carefully before using your DC11.
11323_DC11_USA_OWNER_MAN.qxd p1

9/23/04

2:43 PM

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Important safety instructions
IMPORTANT SAFETY INSTRUCTIONS
READ ALL INSTRUCTIONS BEFORE USING THIS VACUUM CLEANER When using an electrical appliance, basic precautions should always be followed, including the following:
Hold plug when rewinding onto cord reel. Do not allow plug to whip when rewinding. Do not handle the plug or machine with wet hands. Do not use the machine without the clear bin and the filters in place.

WARNING

TO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK OR INJURY: Do not leave plugged in. Unplug from electrical outlet when not in use and before servicing. Do not use outdoors or on wet surfaces or to vacuum water or other liquids electric shock and personal injury could occur. Do not allow to be used as a toy. Close attention is necessary when used by or near children. You are responsible for making sure that your vacuum cleaner is not used by anyone unable to operate it properly. Use only as described in this manual. Use only with Dyson recommended or approved attachments and accessories. Check to ensure your electricity supply corresponds to that shown on the rating plate, which can be found on the base of the machine between the wheels. The machine must only be used as rated. Do not use with a damaged cord or plug. If the machine is not functioning properly, has been dropped, damaged, left outdoors, or immersed in liquid, contact the Dyson Helpline on 1- 866 - 693 - 9766. Do not pull or carry by the cord, do not use the cord as a handle, do not close a door on the cord or pull the cord around sharp edges or corners. Do not run the machine over the cord. Keep the cord away from heated surfaces and open flames. Do not unplug by pulling on the cord. To unplug, grasp the plug, not the cord.
Do not put any objects into openings in the machine. Do not use with any opening blocked; keep free of dust, lint, hair and anything that may reduce air flow. Keep hair, loose clothing, fingers, and all parts of body away from openings in the machine and moving parts such as the brushbar. Do not use the machine to pick up sharp hard objects, small toys, pins, paper clips etc. They may damage the machine. The use of an extension cord is not recommended. Store the machine indoors. Put the machine away after use to prevent tripping accidents, with the cord coiled safely. Turn off all controls before unplugging. Take extra care when cleaning on stairs; always work with the machine at the bottom of the stairs. Do not put on chairs, tables etc, keep on the floor. Do not pick up anything that is burning or smoking, such as cigarettes, matches, or hot ashes. Do not use to pick up flammable or combustible liquids, such as gasoline, or use in areas where they may be present. When vacuuming, certain carpets may generate small static charges in the clear bin or wand. These are not associated with the electricity supply. To minimize any effect from this, do not put your hand or insert any object into the clear bin unless you have first emptied it and rinsed it out with cold water.
Use only identical replacement parts. Do not carry out any maintenance or repair work other than that shown in this manual or advised by the Helpline.

SAVE THESE INSTRUCTIONS

THIS APPLIANCE IS INTENDED FOR HOUSEHOLD USE ONLY
Dyson Helpline contact us on

1-866-693-9766

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Assembling your DC11

This machine was inspected and packaged carefully before being shipped from the factory. If you need assistance to assemble or operate it, please call the Dyson Helpline on 1- 866 - 693 - 9766. Clip the floor tool into the wand. Press catch 1 to release wand and extend it fully until the wand cuffs click. Clip the hose into the wand. 1 Align the cuff and pins. 2 Clip the hose into the machine. Click the tools onto the machine.

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Storing your DC11
Remove the floor tool from the wand. Compact the wand. To attach the wand to the machine, clip catch 1 between bins then press catch 2 to click it into place. Loop the hose around the machine. Clip the hose into sides 3 and 4. Slide the floor tool into the parking yoke. Please do not park the wand in an upright position, as its not designed for this.

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Using your DC11
WARNING To reduce the risk of electric shock and personal injury, this appliance has a polarized plug (one blade wider than the other). This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install the proper outlet. Do not force the plug into the outlet. Do not alter the plug in any way. CAUTION Keep hair, loose clothing, fingers, and all parts of the body away from openings and moving parts. Please note: The machine is intended for domestic use only. Fine dust such as plaster dust or flour should only be vacuumed in small amounts.

Extend the cable fully up to the red tape. Press the on/off button to start or stop the machine. To adjust the wand length, press catch 1 to slide the handle in or out. Extend wand fully before use. The floor tools fit into the end of the wand, the wand handle or the hose. Empty the clear bins as soon as either one reaches the max mark (see page 9).

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The tools clean upholstery, curtains and stairs.
The tools fit the wand, wand handle and hose.
Hold the cable rewind button down to rewind the cable. CAUTION Hold plug when rewinding onto cord reel. Do not allow plug to whip when rewinding.

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Using your tools

clean air turbine head

bare floor tool

mini turbine head

Clean air turbine head When you start the machine the Turbine head is already in carpet mode. For bare floors, press in the button to turn the brushbar off. To return to carpet mode, pull out the button or turn the machine off. Optional Bare floor tool Cleans bare floors gently. Optional Mini turbine head Cleans hair from confined spaces such as the car. 1 Attach the enclosed adapter to the Mini turbine head. 2 Attach the complete tool to the end of the wand.

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Carrying your DC11
Crevice tool Reaches into nooks and crannies. For loose fabrics pull the trigger and hold it to reduce suction. For your safety do not press the cyclone release catch when carrying your machine. CAUTION Do not shake the machine when carrying. Ensure the cyclone pack and wand handle are firmly secured to the base. Ensure the hose has clicked into place on both sides.

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Emptying your DC11
CAUTION Disconnect the machine from the electrical outlet before emptying the bin. Failure to do so could result in electric shock or personal injury. Do not use the machine without the clear bins in place.
Press the red catch 1 to release the cyclone pack.
Press catch 2 to empty the bins. Close the bin base securely. To re-assemble the bin bases, squeeze the hinges at the back.
Replace the cyclone pack firmly onto the machine.
Empty the clear bins as soon as either one reaches the max mark.

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When necessary

Optional

Press catch 3 to remove the bins.
CAUTION Do not rinse the cyclones in water. Brush the fine dust off the shroud.
Bins must be completely dry before refitting them. CAUTION Do not use detergents, polishes or freshening products. Do not immerse any other part of the machine in water.
Recommended for allergy sufferers.

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Cleaning the lifetime filter
. CAUTION Disconnect the machine from the electrical outlet before removing the filter. Failure to do so could result in electric shock or personal injury. Wash filter at least every 6 months. When vacuuming fine dust, the filter may require more frequent washing. Press catch 1 to release cyclone pack. Lift the plastic filter case out of the machine. Separate the foam layer and filter case and shake both over the dustbin. Wash the filter and case in cold water only. CAUTION Rinse in cold water only. Do not use detergent. Do not put in a washing machine or dishwasher.

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Wash the filter until the water runs clear and squeeze it to remove excess water.
Wash the case until the water runs clear and tap it dry to remove excess water.
Dry the filter and case for at least 12 hours. CAUTION Do not dry in an oven or microwave. Do not dry in a clothes dryer. Do not dry near an open flame.
The filter and case must be completely dry before refitting. CAUTION Do not use the machine without the filter in place.

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Blockages
CAUTION Disconnect the machine from the electrical outlet before starting to look for blockages. Please note: Should any part of the machine become blocked, the motor may overheat and stop due to the thermal cut-off being triggered. Disconnect from the electrical outlet and let the machine cool down for at least 30 minutes before clearing the blockage. Clearing blockages is not covered by your machines limited warranty.
Check A and B to ensure nothing is obstructing the ducts. CAUTION Dont use sharp objects when clearing blockages. Check the accessory tools. Check C where the hose joins the machine. CAUTION Make sure all parts have been replaced securely before using your machine.

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Clean air turbine head Press catch 1 to release cyclone pack. Check whether the filter and case need washing. Check the air inlets. 1 Release the catches. 2 Remove the soleplate. 3 Remove the brushbar and clear away thread and hair. 4 Check the duct for blockages. 5 To re-assemble, align the arrows on each brushbar in the same direction, click and fasten the soleplate into place.
Mini turbine head 1 Release the catches. 2 Remove the soleplate. 3 Remove the brushbar and clear away thread and hair. 4 Check the duct for blockages. 5 To re-assemble, align the arrows on each brushbar in the same direction, click and fasten the soleplate into place.

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1 Do not pull the cable. 2 Do not use near open flames. 3 Do not leave near heat sources. 4 Do not run over the cable. 5 Do not pick up water or liquids. 6 Do not pick up burning objects. 7 Do not put your hands near the brushbar in use. CAUTION 8 To avoid personal injury and to prevent the machine from falling when cleaning stairs, always place it at the bottom of the stairs.

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Warranty and customer care
Household 2 year limited warranty Domestic use
Your Dyson vacuum cleaner is warranted against original defects in material and workmanship for a period of two years from date of purchase, when used only for private household purposes and in accordance with the Owners Manual. This warranty provides, at no cost to you, all labor and parts to place your vacuum cleaner in proper operating condition during the warranty period. For further details of the warranty including limitations and exclusions, and to register your purchase, please refer to the product registration form found in your instruction pack.

Dyson customer care

If you have a question about your Dyson vacuum cleaner, call the Dyson Helpline on 1- 866 - 693 - 9766 with your serial number and details of where/when you bought the cleaner. The serial number can be found on the base of your machine between the wheels. Most queries can be solved over the phone by one of our Helpline staff. If your cleaner needs service, call the Dyson Helpline we will discuss with you the options available for service. If your machine is under warranty, your machine will be repaired at no cost to yourself. To reach the Dyson Helpline call on 1- 866 - 693 - 9766, or visit Dyson online at www.dyson.com.
This product is protected by the following intellectual property rights: Patent/Patent Application numbers: PCT/GB02/00320; PCT/GB02/00298; PCT/GB03/003659; PCT/GB03/003658; WO 02/067742; WO 02/067753; WO 02/067752; WO 02/067746; WO 02/067757; WO 02/067755; WO 02/067713; US 5,078,761; US 10/468,304; US 10/239,426; US 10/467,671; US 10/468,870.
Please note: Small details may vary from those shown.

2.1.1the DESIGN BRIEF A design brief explains the challenge that must be answered by a product and the parameters in which an engineer or designer must work. For example, the product might need to be a certain size or perform a particular function. The brief that design engineers start with is very broad. Space is an issue in many modern homes and the new machine had to fit into a small storage space, so the brief for the DC22 team was to make a new vacuum cleaner that was very compact. But the engineers didnt want to compromise on its ability to pick up dust. In fact, they wanted to make it as efficient as possible when it came to filtering dirt out of the air.
CODE NAMES When engineers work on a new design, they give it a code name so they can talk about it without giving away their secrets. This name begins with an X and is followed by a project number. X71 was the code name for the DC22 machine the 71st project that Dysons engineers have worked on. All the development is carried out in secret until the design is registered and protected with intellectual property offices.
Find out more about the design process at www.jamesdysonfoundation.com

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This is the really technical one the engineering specification lists all the technical performance details.
2.2.2The DESIGN Specification A specification is the measuring stick for a design. Imagine you need a new pair of shoes. Before you go shopping, you think about what sort of shoes you want according to when youll wear them. If theyre school shoes they need to be black, smart and hardwearing. If theyre for sport, lightweight and supportive. This is how a design specification is set. A list of requirements is compiled, relating to how the product will be used and how it will look. At Dyson, engineers start by creating a vision specification. This is a basic diagram of what the machine will look like and what features it will have. The vision specification for DC22 is shown above. Its called a vision specification because the engineers imagine what the new machine might look like and the best way to do this is to draw it. The next step for the engineers is to develop a much more detailed engineering specification. This sets the limits the machine must work within, like size, weight, power and noise. It is referred to throughout the design process.

Engineering specif ication Air Watts Pick up Hard Floo r Pick up Crevice Motion Force Noise Normal Noise Whisper Bin Volume Weight Size Pick up Wilton Car pet
200 74% 99% 104% 10/8 Neutons forward s/backwards 89 Average
78 dB(A) 1.21 Litres 4.81 Kilograms 292/255/397 Millimetres
The engineering specification doesnt stop at size, weight, air watts and bin volume either. We go right down to specifying the force needed to press each button and catch. Jon, Principal Engineer

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2.1.3Research and Idea Development So-called eureka moments are rare. Instead, ideas come from experimentation and sketching, from analysing problems with existing products and carrying out research into new technologies. This is all part of research, design and development, or RDD. Design engineers work in teams, sketching out and discussing their ideas. Sketching is an important communication tool. Drawings tend to be rough and ready but theyre an important bridge between the engineers concept and the next vital step creating basic 3D models.
2.1.4Creative Thinking Dyson engineers need to think creatively all the time. The most obvious example of where they use creative thinking is in these early stages of the design process when sketching new ideas, or developing a design brief. But creative thinking is just as important when problem solving later on in the development of a new product.
When desig n at Dyson b engineers ra ideas, they instorm new always sta r with the p roblem. Th t en they take a piece of paper and fold it into 16 squ ares, thinking c reatively t of every squa re with a p ill o solution. Try it your ssible self and see what y ou come u p with.
Use this tech nique as you think about th suggested in e problems section 2.1.8
Another technique is called negative brainstorming. Think about everything that could go wrong with a product. How could you design it better so that it doesnt go wrong?

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2.1.5 Designing with your user in mind who will use your design and how? Design engineers must never lose sight of the person wholl use the product theyre designing. Its important to consider that they may not always use it in the correct way. The catch The design engineers designing the DC22 thought a lot about how people use their vacuum cleaners, including how they carry them up stairs. On the DC22 you have to remove the clear bin from the chassis in order to empty it. The engineers studied how people replaced the bin on the chassis and noticed that many people attach the bin properly at the top, but not the bottom. Because the bin wasnt securely fixed, it meant that the chassis could become detached when the vacuum was picked up possibly causing damage or injury. The solution was an interlocking handle mechanism and a protruding tooth on the base of the bin. The tooth slots into a notch on the chassis and if this doesnt happen, the catch on the handle will not engage. This prevents the bin from being replaced on the chassis incorrectly. This is an example of poka yoke design. This is a Japanese phrase which means fail-safing or fool-proofing. The engineers were also worried that the bin might become detached accidently. So they also designed a locking mechanism on the handle of the bin itself so that the bin release button cannot be pressed when youre carrying the machine by the handle.

2.1.6 Designing for different markets THE DC22 MACHINE AND JAPAN Dyson machines are sold in countries all around the world, each with a different culture that influences how people use and relate to them. This must be considered when composing the design brief. For the DC22 vacuum cleaner, the design engineers used information gathered through Japanese user trials to inform their brief. A user trial involves putting test vacuums in the hands of a cross-section of the public (sworn to secrecy). It gives Dyson engineers a chance to get important feedback on a design. User trials in Japan revealed that people didnt want to use their feet to step on the power switch to turn the machine on and off. In Japan, using your feet like this is considered dirty and rude. The engineers had to design an on / off switch that fits on the wand handle. This switches the motor on and off using radio-frequency signals.
If you have the Education Box, youll notice that the UK version of the DC22 has a switch on the body of the machine which you can turn on and off by stepping on it or by pressing with a finger. In the UK and Europe, people dont mind using their feet to switch the machine on and off in fact they often prefer to do this rather than bending over.
If you have the Education Box, take a look at the DC22 bin mechanisms. Pick up the product. Is it easy to carry? Can you see where the bin attaches? Try removing it and replacing it. Lift up the DC22 by the handle and try to press the bin release button. Youll find you cant. Have a look at the design of this lock: With the bin attached to the chassis, look at the side of the clear handle below the grey bin release button. Youll see a transparent tooth on the inside of the handle theres one on each side. Notice the notch in the side of the bin release button. Now lift the handle up and youll see it flexes before the vacuum is lifted up. As the handle flexes, the tooth on the handle slides into the notch on the button, preventing the release button from being pressed.

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2.1.7 design and the environment Its important to think seriously about the impact your design will have on the environment. Its not just the amount of raw materials thats important its the whole lifetime of a product.
Todays big challenge is to reconcile peoples love of stuff with the pressures upon us to be more sustainable. Dyson Engineer, Caroline, designed an environmentally friendly product for her final year project at university
Manufacturers have to be responsible with the raw materials and resources they use. This has to be considered throughout the design process.
D isposable nappies produce waste which fills up landfills. Caroline designed a reusable nappy that is as convenient as disposable nappies but kinder to the planet since it doesnt produce any waste (except, of course, for the waste from the babys bottom!) She looked at sports and medical equipment to find high tech textiles which would be suitable.
rolines Samples of Ca d inspiration research an Sac. for her Nap
USE AND DISPOSAL Dyson engineers are challenged to design the best performing technology with the fewest parts using complementary materials. By choosing materials which can be recycled, a designer can help prevent unnecessary landfill. In the European Community there is a directive called Waste Electrical and Electronic Equipment Directive or WEEE. Dyson products are collected at the end of their lifetimes and disposed of responsibly. Lifetime Ensuring a long lifetime for your product reduces its environmental impact. At Dyson, all vacuum cleaners come with a five year guarantee. Engineers have tested the machine to destruction, and redesigned it to withstand those tests. Theyre confident that it will last. If your product has a long life then your user wont need to replace it as often, which saves both waste and resources. FUNCTION If a product is well designed, it will do its job efficiently, without wasting energy. Cyclone technology means that Dyson vacuum cleaners are more efficient so they can afford to have a less powerful motor, but still do their job as well.
TECHNOLOGY AND ECOLOGY The technology that powers a product can make a real difference to its environmental impact. Solar cells can power electric cars and charge your mobile, and you can get a wind turbine that powers your TV. Dyson engineers worked for 10 years on a small, high efficiency motor, the Dyson digital motor. This is used in the Dyson Airblade hand dryer, which as a consequence uses up to 80 per cent less energy to dry hands than warm air hand dryers.

The Dyso

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design brief Activity

The result? They could add an intermediary cyclone called a core separator between the outer cyclone/ shroud and the inner cyclones. This intermediary cyclone, the core separator, would reduce the dust load entering the inner cyclones, meaning no more blockages.
Another challenge that the engineers faced was how to make sure that the extra tools supplied with the machine dont go missing. How would you solve this challenge?
If you have the Education Box, take a look at the DC22. Have a look at how the engineers solved the problem of extra tools. They came up with a simple solution they developed a clip that Exploded view of handle. holds the tools and attaches to the wand DC22 They also designed a bracket to mount the floor tool on the back of the machine for storage.

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Computationa l Fluid Dynamics (CFD ) models the air flow through the cones of the cyclone
2.3.2Computational fluid dynamics Whilst the engineers were working on the cyclone, they needed to understand what was happening to the air in the inner cyclones. They used computer software called computational fluid dynamics (CFD), it enables the engineers to visualise the air as it moves around the machine and see if anything obstructs or hampers it. The airflow in a vacuum is like the water in a river. Any rocks, tree branches or bridges in the river influence the movement of the water, causing it to swirl, ripple and become disturbed. Protruding screws, rough edges and lumps and bumps in the airways of the vacuum affect the airflow in a similar manner. CFD simulates this, calculating how fast the air spins, how efficient the cyclone is at separating the dirt particles from the airflow and works out how much G-force is generated. The faster the air spins, the higher the Gforces and the more efficient the cyclone is at removing dirt from the air. This helps the engineers design a better cyclone more quickly so they can make fewer prototypes. The DC22 engineers used CFD to help them understand what the air was doing in the root cones.
Computational fluid dynamics is a very effective tool in ensuring that the air flows through the machine in the best way possible. Richard, Fluid Dynamics Engineer

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2.4 TEST TEST TEST
Testing is what literally makes or breaks a product. When you test your design you know it wont be right first time. But you see why it doesnt work and the whole process of problem solving starts all over again. You just keep redesigning and testing until you get it right. Jim, Design Engineer.

The DC22 design was constantly evaluated by teams of engineers. Prototypes were tested to destruction so that any potential weak points could be identified. Its essential to look at the design with a critical eye.
Testing and prototyping go hand in hand. Throughout the design process, engineers turn their ideas into 3D models, building slightly different versions until they get it right. These prototypes are then tested to make sure they work and fulfil the original brief. This testing isnt saved for the end of the design process its a crucial part of engineering a new product and goes on throughout.

Mechanical Testing

Sound Testing

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ays, r of d matte a ly ime in e High A lifet ers us ing (HALT). t engine s Dyson ated Life Te er Accel
2.4.1 Drop Test One of the easiest tests to carry out is the drop test. Engineers use this test to see if a design is strong enough to withstand being dropped on the floor. They use a special testing rig that drops a vacuum cleaner over 1,000 times in a row, but you can easily try it in your classroom. First you work out how great a drop your design should be able to survive. Once youve decided the height it should be able to survive, take a prototype and drop it from exactly that height (making sure its not your only copy of the design, in case it breaks). If your design survives, its passed the test. If it doesnt, you need to examine where it failed then redesign it to strengthen that part of the design. Test it again and again until it passes.
2.4.2Life Test The major challenge is to test a design so that it undergoes all the physical stresses its likely to receive during its lifetime and fitting it all into a matter of days or weeks. Dyson engineers use Highly Accelerated Life Testing (HALT) to do just that, compressing a lifetimes use into just a few days. For example, one testing rig pushes and pulls Dyson prototypes over a distance of 1,357 kilometres, at walking pace, night and day, for just over two weeks straight. Watch how Dyson test their machines at www.jamesdysonfoundation.com

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2.5 mass product
When you need to manufacture a design on a large scale, this too has to be factored into the design process.
Inside the top half of the cone pack mould tool
Notice how much larger the injection mould tool is compared to the cyclone assembly it will make.
When the DC22 team finished their design they transferred it to Dyson engineers in Malaysia for manufacture. There were two initial short production runs engineering build 1 (EB01) and engineering build 2 (EB02). EB01 is the first time that the design is made using mass production techniques. The EB01 machines are advanced prototypes its a last chance for the engineers to fix any small problems, like rough edges in the moulded plastic components. Any necessary changes are made and then EB02 machines are produced to make sure. This is the last stage before the design goes into mass production and onto shop shelves all over the world. The Dyson DC22 has hundreds of components, from screws and springs to electrical wires, electronics, plastic mouldings and a motor. Dyson buys some of the components, like the motor and cable rewind mechanism, from specialist suppliers. Others are made especially for Dyson for example, the 110 plastic moulded parts.

2.5.1Plastic moulding Dyson engineers design complex plastic parts, which require very sophisticated tools to make them. Heres a picture of the inside of the DC22 cone pack tool, the most important part of the vacuum cleaner the cones that separate the dust from the air. A plastic moulding tool comes in 2 or more parts that fit together to form a space which is the shape of the finished component. On this cone pack, there are no less than 12 injector points to make sure the plastic flows around the mould evenly. This tool weighs 2283kg (an average car weighs about 1300kg). A tool like this will cost tens of thousands of pounds to make, but it will in turn make hundreds of thousands of components. After the hot plastic is squirted into the mould, it is left to set for a few seconds. Then the mould tool opens up and the parts are ejected by moving metal pins.
If you have the Education Box, look at some of the plastic moulded parts. Can you find the injector point or points and the marks made by the ejector pins?

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One of the Dyson production lines in Malaysia.
2.5.2Assembly When the components have been manufactured, they are brought to the assembly line to be put together. A modern assembly line is usually clean and brightly lit, particularly where there are electronic components involved (and of course, nowadays everything from cars to televisions and vacuum cleaners contain electronic components). The Dyson factory can make several thousand DC22 machines every day. In total, the Dyson factories make over four million vacuum cleaners every year. Its therefore vital that the machine is designed so that it goes together without mistakes. This is another example of where engineers use poka yoke design: the engineer will design components so that they will only fit together in one way so that on the assembly line, they cant be put together upside down or back to front.
Question: Assuming a total of 4 million vacuum cleaners annually, with the factories working 5 days a week, 12 hours per day, 48 weeks of the year, approximately how many vacuum cleaners an hour does Dyson make? Answer: 1389
If you have the Education Box, pay attention when taking the machine and tools apart to see if you can find examples of fail-safe designs.
e : iz dy es tu t bi e s s ca
The worlds first affordable motor car not only introduced many innovations in automotive design, the process by which it was built was revolutionary too. The Model T was built on an assembly line that brought the car to the men working on it, rather than workers moving from car to car. It not only saved time, it enabled workers to specialise by performing the same tasks over and over. This helped keep costs low. When the Model T debuted in October 1908, it cost $850 (around 10,000 in todays money). In later years Ford was able to sell them for as little as $260 (2,700 today).

Ford wasnt the first to embrace assembly lines, but it was the first to perfect it. By 1914 a Model T chassis (the car minus the interior, body and paint) could be built in just 93 minutes, and 15 million were made in total. Discover more inspirational designers at www.jamesdysonfoundation.com

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The rubber trampoline sea l is inside the bin of the DC22
2.5.3Choosing the right materials In design engineering, the tolerance of a material refers to the margin of error in the specification of a particular dimension. For example, if you design a part to be 5mm thick, the tolerance is the amount thicker or thinner it can be once manufactured, without detrimentally affecting performance. For instance, a seal might have been designed to be 1mm thick. When mass produced, some will be precisely that. But others might be 0.9mm thick or 1.1mm thick. A seal is any device that joins two systems or elements in such a way as to prevent a leak. There are many places on the DC22 where two different parts meet and these have to be completely airtight. The join between the hose and the bin is just one example. The seals keep the DC22 airtight, so the air travels through the machine without escaping and degrading performance. In some instances its possible to live with wide tolerances. But when a seal has to make a join between two components airtight, tolerances are narrow. During their experiments with foam seals, the engineers discovered that foams tolerances werent narrow enough the deviation either side of the specification was too great. The acceptable margin of error like this in a design is called the tolerance range. The engineers therefore chose to make the seal from rubber which can be manufactured with a tighter tolerance range than foam.
If you have the education box, take the bin off the DC22 and open it by pressing the red button on the handle. Youll see two seals on the inside of the base of the bin. The outer seal makes the joint between the base and the sides of the bin airtight. The thicker inner seal called a trampoline seal prevents air entering the core separator and inner cyclones without passing through the shroud first. The trampoline seal is made from rubber. When the engineers originally designed the DC22, a foam seal was considered, but they experienced problems with tolerance.

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malaysia
2.5.4Logistics During production and at the end of the production line each vacuum cleaner will undergo rigorous quality checks before it is packed into a cardboard box. The boxes are loaded into sea containers ready for shipping around the world. A sea container is a huge metal box, usually between 5 and 13m long, which can be loaded on a truck or onto a cargo ship. You will probably have seen them on the back of trucks on the motorway. Question: What route do you think the containers take from our factory in Malaysia to the shops in the UK? Try drawing the route on the map above. Answer: the containers are fumigated to kill any stowaway creepy crawlies, and then they are loaded onto a ship at the port at Johor Baru at the southern tip of Malaysia. The ships sail across the Indian Ocean, through the Red Sea and then the Suez Canal into the Mediterranean Sea. They pass through the mouth of the Mediterranean Sea at Gibraltar; make their way around Portugal, Spain and France to dock at Southampton in the UK. Smaller boxes mean fewer containers and less environmental impact. They are then loaded onto trucks and driven to Dysons distribution centre in Gloucestershire before being delivered to shops.

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3.1 disassembling the dc22 turbine head
Note on safety: When working on this machine Dyson recommends protective clothing and eyewear. Please take care when disassembling and reassembling the machine as there may be sharp edges or corners that are not normally accessible. It is the schools/organisations responsibility to ensure that pupils/clients are supervised at all times when disassembling and reassembling the machine and that the schools/organisations safety regulations are carefully followed. Please follow the instructions with disassembling the DC22. To ensure electrical safety, do not disassemble the machine further than the instructions suggest.

ANSWERS

A) What its made of. Some of the problems that the design engineers solved. Is it easy to assemble? Is it easy to clean? Can it get blocked during use? How easy is it to clear blockages? B) Cyclone technology. C) Examples include: Tools and hoses can be removed from the machine to make it easier to clean if it gets blocked with debris. ilters need to be washed or F replaced. The machine is designed so that the filters are easily accessible.
Use of colour to draw the eye (you will see examples of this later when disassembling the product). D) The engineers usually use quarter-turn fasteners and clip fittings for parts that can be removed by the customer. They use TORX screws to secure areas of the machine that should only be accessed by trained Dyson service engineers. E) Brush bar PP (Polypropylene) Turbine cover PBT (Polybutylene Teraphthalate) Main body of turbine tool PC (Polycarbonate) Flexible Hose PU (Polyurethane) Wheels primarily PP Sole plate ABS (Acrylonitrile butadiene styrene) Metal screws
F) Electric motor Electronics G) The plastic parts are injection moulded and then assembled with the other components on a production line.

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ELEMENTS OF A DS22 TURBINE HEAD
Use this diagram to identify parts of the DC22 Turbine Head when disassembling or reassembling.
Turbine Tool Hose Assembly

Turbine Tool Assembly

Screw Duct cover
Axial Turbine Assembly End Cap Assembly

Screw Belt Cover Seal

Belt Cover Assembly

Flicker Strip

Brushbar Assembly

Soleplate Wheel Axle

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Step one: Start with the turbine head floor tool
Start by looking at the turbine head and how it fits onto the vacuum cleaner. Detach the turbine head from the chassis of the vacuum cleaner or wand by lifting upwards.
A) How have the engineers solved the problem of where to store the machines tools? B) What are the main components of the turbine head? What are the components made of? C) How does it fit on the machine? D) hy is the turbine head W detachable from the hose and wand? E) Compare it with the Mini Flat Out head and other tools what are they all for? F) Look at the hose. What material is it made of and why is it appropriate for the hose?
Step two: Remove the duct cover

TORX screw (short)

Once youve removed the duct cover: A) The duct cover has rubber around the edges. What is this for?
Theres a silver knob on the side of the turbine head. Near to it, on top of the turbine head is a TORX screw (short), unscrew it. Lift the panel with rubber edging off the top of the turbine head. The part that comes off is the duct cover. Youll see a metal rod connected to the silver knob this is the choke that opens and closes the airway to the turbine. The turbine uses air sucked in through the side of the turbine head to spin the brush bar. If the duct is open, the brush bar spins. If its closed, it doesnt.
Step Three: Remove the brush bar
Turn your turbine head upside down. On the bottom of the sole plate the part that moves along the floor is a quarter-turn fastener. The clue is in the name. Using a coin or a slotted-head screwdriver, carefully turn it one quarter-turn anticlockwise and lift the brush bar out. student activity
A) hat do you think the brush bar W is for? B) Why are the brushes on the brush bar red? C) hy do you think that the brush W bar is secured with a quarter turn fastener rather than a screw?

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A) The turbine head clips onto the machine. The tools clip onto the hose. B) Brush bar PP (Polypropylene) Turbine cover PBT (Polybutylene Teraphthalate) Main body of turbine tool PC (Polycarbonate) Flexible Hose PU (Polyurethane) Wheels primarily PP Soleplate ABS (Acrylonitrile butadiene styrene) C) The turbine head fits on the machine in two ways: Slots onto bracket for storage; Clips to end of hose when in use.

Manifold Seal Pre-Filter Motor Base Cap Seal Pre-Filter Door Side Cap Seal Pre-Filter Door Assembly Wheel Assembly Wheel Hub Screw Upper Hose Wrap Stow
Cyclone Release Catch Spring On/Off Actuator Cable Rewind Actuator Spring Spring

Cable Collar

Pre-Filter Assembly
On/Off Switch Screw Wheel Assembly

Exhaust Vent Screw

Wheel Hub

Chassis

Cyclone Inlet Assembly
Post Filter Housing Screw Post Filter Assembly

Cyclone Inlet Grille

Castor Body Castor Wheel Axle Post Filter Cover Assembly Fastener

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Step one: Remove the bin and cyclone assembly
Push the bin release button and lift the bin and cyclone assembly off the chassis. By removing the bin and cyclone assembly youve revealed the red bin empty button press it to open the base of the bin. You can see the bin empty mechanism working if you look at the rear of the bin. The bin and cyclone assembly can be separated press the grey button on the rear of the bin and pull them apart.
On removing the bin and cyclone assembly: A) hy does the bin open from W the bottom? B) Why is the bin empty button red? C) Look at the rubber seal in the base of the bin. How does it seal the cyclone? D) Separate the bin and cyclone assembly and have a look at the cyclone assembly. Can you identify the three stages of separation?
Step two: Have a look at the telescopic wand
DC22 has a telescopic wand you can extend it and it snaps into place. If you havent already, unwrap the hose. Find the end of the hose where it enters the chassis, unclip the hose bracket and pull it out (it can be stiff).
A) hy do you think the engineers W made the wand collapsible? B) How did they stop it collapsing when in use? C) hy would you need to remove W the hose?
Step Three: Remove the floor tool storage bracket
Return to the chassis and pull up on the hose retainer mounted on the front. It will slide out. Next, undo the screw beneath the bin release catch and pull the upper hose guide off the chassis. Then turn to the rear of the chassis and locate the floor tool storage bracket. Look down the hole in the middle of it and youll see a TORX screw remove it. Rock the floor tool storage point up, then pull it down and out.

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A) The bin opens from the bottom so that it can be emptied directly into the rubbish. B) The bin empty button is red so that its easily identifiable. Your eyes are naturally drawn to the red rectangle that leads from the button to the base of the bin, highlighting its function. C) It seals across all the chambers of the cyclone, separating them from one another.
D) Shroud Core separator Cyclone Head
A) Its easier to store. B) Extend the wand and examine the way it clicks into place. Look at the button that releases the catch its red to draw the eye.
C) Sometimes the hose can get blocked for example if you suck up a sock. If you can remove the hose from the machine, you can clear the blockage from the hose by pushing a broom handle through the hose.

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NOW ITS

YOUR TURN!

We hope this education pack and box has given your students an insight into how creative, challenging, and ultimately satisfying design engineering is. Were constantly working on materials that will help you to convey this in your classroom. Use our resources and give us your feedback. Please get in touch at www.jamesdysonfoundation.com jamesdysonfoundation@dyson.com