STEM Marin

Septe
mber
TOASTER
Engineering
19,

Tak Maga
Colin
McGarty
Nitin Mamidi
Tyler
Nettlemen
Table of Contents
Table of Contents 1

Overview 2

Assemblies 2

Slider Assembly 3

Overview 3

Bill of Materials - Slider Assembly 3

Improvements 4

Timer Assembly 5

Overview 5

Bill of Materials - Timer Assembly 5

Improvements 6

Heating Assembly 7

Overview 7

Bill of Materials - Heating Assembly 7

Improvements 8

Toasting Assembly 9

Overview 9

Bill of Materials - Toasting Assembly 9

Improvements 10

Procedure 10

Wrap Up 10

Sketches 11

1
Overview
The purpose of the electric toaster is to improve the quality of life for the
consumer, through the toasting of bread items in a simple, safe, and easy to
use manner.

How can we improve on it?

2
3
Assemblies

4
 The toaster is split up into four distinct but intertwined assemblies. The slider
assembly takes the input from the user, or the pressing down of the lever, and
converts that into actions that start the rest of the assemblies. It starts the flow of
electricity to the heating assembly, which heats a set of wires to toast the bread
item. The actual food itself is contained by the toasting mechanism, which is a pair
of metal grates that encases the bread item until such time that it is released. That
action is taken by the timer apparatus, which takes the human input of the
potentiometer and converts that into a delayed electromagnet activation, sending
the slider back to neutral position and stopping the heating.

Slider Assembly
Overview
The slider assembly is the mechanism by which the input from the user, or
the pressing of the lever to activate the machine, is taken and activates several
components. The lever pushes the assembly (1) down on a pair of slider columns
(3), pulling on a spring to close the toasting assembly. The plastic notch on the
other side of the lever pushes the prongs of the heating assembly together,
completing the circuit and starting the flow of electricity. Finally, the latch (4)
present gets caught in the timer assembly, until such time it is released and the
assembly moves back up by way of a spring (toasting mechanism). This moves the
circuit back into its resting state, stopping the toasting and flinging the toast into
the air.

Bill of Materials - Slider Assembly

1. Slider Assembly (1)

See attached for exact dimensions.

Moves on sliders in relation to human input on lever. Pushes prongs on

5
 heating assembly to start toasting. Held in place by timing assembly
through latch. Closes toasting assembly through springs. Stops toasting
when released by timer.

Steel, $1.96 per 100 grams

aqua-calc.com/calculate/materials-price/substance/steel

2. Pin, (1)

See attached for exact dimensions.

Held by slider assembly, allows the latch to rotate 85 degrees around.

Steel, $1.96 per 100 grams

aqua-calc.com/calculate/materials-price/substance/steel

3. Slider Column (2)

See attached for exact dimensions.

Fixed items upon which the slider part studio slides. The pair go through
holes on either side of the slider. This allows for the slider to travel linearly.

Stainless Steel, $1.55 per pound

4. Latch (1)

See attached for exact dimensions.

The latch is attached to the slider assembly by means of the pin. In its
natural state, the latch is parallel to the slider, but moves outward and is
contained by the timing mechanism. The magnet on the timing mechanism
releases the latch, allowing the slider assembly to move upwards.

Nickel, $7.85 per pound

dailymetalprice.com/metalpricecharts.php?c=ni&u=oz&d=5

Improvements
A possible improvement to the slider assembly would be the inclusion of
stronger springs. While in our depiction this aspect is included in the heating
assembly, including a stronger spring would allow for the toast, upon completion,
to obtain a higher altitude. This would improve the impression of the toaster to one
of high quality, as well as amuse the user.

6
 However, the use of the toaster in an enclosed space may lead to the contact
of the toast on surfaces not intended. Another drawback is the lever may be harder
to press down, and may put increased pressure on the latch.

Timer Assembly
Overview
The timing assembly is used to control the level of toasting that is received by
the toast, through the limitation of the time that the toast is inside the toaster.
There are several parts. The potentiometer is the human input, controlling the
resistance, that combined with a circuit with capacitors and resistors, activates an
electromagnet. This magnet pulls the latch of the slider mechanism out of position,
allowing the assembly to travel upwards. This stops the flow of electricity, as well as
popping the toast up. By altering the level of resistance in the potentiometer, the
operator can change the amount of time the bread is inside the toaster.

Bill of Materials - Timer Assembly

1. Linear Rotary Potentiometer (10k ohms) (1)

See attached for exact dimensions.

Offers varying resistance, which depends on the position that the rotating column
is placed. This is operated by the human directly, and is connected to the timing
circuit board.

Assorted, $0.16

electroncomponents.com/10k-potentiometer-variable-resistor-controller

2. 24v Electromagnet, (1)

See attached for exact dimensions.

The electromagnet makes use of holding solenoids, activating and changing to a

charged state when a current passes through it. In this assembly, the magnet is
positioned so that when activated by the timing circuit, it will pull the latch of the
sliding assembly out of its holder, allowing the slider to return upwards. The
magnet then becomes neutral as power is lost.

7
 Assorted, $10.09

Note - Most likely above manufacturing cost, due to unknown specifications

and price reduction due to bulk purchase not publicly available.

apwelectromagnets.com/round-electromagnet

3. Circuit Board (1)

See attached for exact dimensions.

The timer board incorporates a series of capacitors and resistors, in conjunction

with the variable resistor found in the potentiometer. This allows for the
electromagnet to be triggered after a time determined by the potentiometer.

pcbgogo.com/?
gclid=Cj0KCQjwiILsBRCGARIsAHKQWLPpAeDdOQknwaaHGhoqFQfD6t_jkkcDQjvP-
wygD7dveRZIsV2eADYaAgNoEALw_wcB

Improvements

A possible improvement would be the inclusion of pre-set buttons, that

would change the amount of time to one adequate for a standard item, say a bagel.
This would allow the user to have peace of mind that their bagel would not be
burnt, or only slightly toasted.

A secondary improvement would be the use of a string of LEDs to indicate

the time remaining in the toasting process. While a more complex circuit would be
required, the base functions and operations would remain the same.

8
Heating Assembly
Overview
To make our toaster function, electrical energy flows from a wire connected
to the domestic power supply into the toaster. The electric current flows through a
sequence of thin filaments that are wide enough apart to toast the entire surface of
the bread. The filaments are so thin that when the electricity flows through them,
they shine red with heat. The filaments fashion a string of tiny radiators that strike
heat toward the bread in the toaster. and The constant heat supply quickly cooks
the bread.

Bill of Materials - Heating Assembly

1. Nickel Chromium Resistance Wire, Chromel-A (1)

See attached for exact dimensions.

Nichrome wire is what is typically used as a heating element in most toasters. It

has two characteristics that make it an excellent heat producer. Once the slider is
pushed down, electrical current is passed through the wires, heating the
nichrome coils. The coils have enough resistance to get quite hot, even for a brief
duration. When heated, the nichrome alloy will not oxidize.

Assorted, $25.04

See note for Electromagnet.

amazon.com/Nickel-Chromium-Resistance-Wire-Chromel-A/dp/B003R5024Y

2. 4-piece Waveguide Cover nb

See attached for exact dimensions.

Two mica sheets wrapped in nichrome wire would be the simplest toaster,
and they would be spaced to form a slot about an inch (2.5 cm) wide. Mica is
resistant to high temperatures and a great insulator, hence it is used to hold the
toaster heating wires. It also assumes electrical charges when heating up and is
therefore used in condensers and other electronic components.

9
 Assorted, $7.99

amazon.com/Waveguide-Microwave-Repairing-Scissor-
Universal/dp/B07Q81M72Z/ref=sr_1_1?keywords=4-
piece+Waveguide+Cover&qid=1568862784&s=industrial&sr=8-1

3. Copper wiring (assorted)

See attached for exact dimensions

The copper wire allows for the smooth transfer of electricity through the
entire heating circuit. Copper has low resistance, so the majority of electricity gets
to the nichrome wires.

Copper, $2.00 per pound

umw.com/pricing

Improvements
We saw no obvious improvements to the heating assembly, as knowledge of
a more effective heating source appropriate to a home environment was
beyond the purview of our investigation.

10
Toasting Assembly
Overview
The toasting apparatus is perhaps the most simple of them all; just a pair of
metal grates to keep the piece of bread in place. This, when combined with a
system of springs, allows for the grate to open and close in relation to the slider
and when the toasting starts and finishes.

Bill of Materials - Toasting Assembly

1. Steel Grate (2)

See attached for exact dimensions.

The grate contains the toast by pressing on it from either side, moving
apart when released by the springs in relation to the slider assembly.

Steel, $1.96 per 100 grams

aqua-calc.com/calculate/materials-price/substance/steel

2. Metal support

See attached for exact dimensions.

The support is located on the bottom of the toaster, and moves up and
down to alter the height of the toast. This is the actual mechanism by which the
toast springs up upon the completion of the process as set by the timer assembly.
It relates to the slider mechanism, as it is controlled by springs connected to it.

Steel, $1.96 per 100 grams

aqua-calc.com/calculate/materials-price/substance/steel

3. Springs (4)

Assorted sizes, see attached for exact dimensions.

11
 The springs move the toasting assembly in relation to the slider, opening
and closing the grate and moving up and down the support structure.

Stainless Steel Compression Spring, $2.8

See note for electromagnet.

hespringstore.com/pc004-109-12000-sst-0160-c-n-in.html

Improvements
Several improvements could be made to this assembly. As discussed earlier,
the replacement of the relatively weak spring with a stronger one could result in a
springer completion of the process.

Procedure
To operate the toaster, one first inserts the item, usually a bread, into the
open slot at the top of the device. Taking into consideration the size and volume
of the item placed in the toaster, as well as a personal preference for the level of
toastiness that will result, the operator will then rotate the potentiometer to the
desired level, indicating the amount of time the item will be toasted. If the device
can obtain electricity from a wall or similar standard outlet, the operator will
then depress the main slider. The internal processes then toast the toast, and
upon completion, the slider will move back upwards in a rapid fashion,
indicating that the toast should be removed.

Wrap Up
Our project had some peaks. We made a functional analysis of a common
appliance, that was more complicated than we anticipated. We also explored the
use of CAD to model some aspects of our toaster.

However, there were multiple failures. Our hacking designs never progressed
beyond the theoretical stage. While we had several ideas, detailed in the report and
with sketches attached, on how to improve upon the toaster, we were unable to
actually test them in any experiment.

The issue then was a lack of time. While certainly if given more time to
complete the project we would have been more successful, that was not the
primary cause for concern. A lack of communication and attendance of some

12
members effectively cut our workforce in half, and at the last minute. This lead to
the other half of the team scrambling to complete the entirety of their work within
two days of the deadline.

If necessary to do this project again, it would be essential to investigate the

work of all members to ensure they are actually doing it. On the technical side,
more time would have allowed for a more in depth analysis and hacking
experimentation.

Sketches

See attached.

13