Mobile Truck Lab
The Navy wanted an off-grid mobile workspace to support on-site maintenance of equipment.
This custom design and production project involved outfitting 3 trucks with advanced off-grid capabilities and a fully equipped mobile lab to support a maintenance crew of four. The design features a robust power input system, including solar panels, generators, and battery storage, ensuring reliable power supply in remote locations. The aim was to create a versatile, self-sustaining vehicle that excels in providing on-site support and maintenance services, showcasing a blend of innovation, efficiency, and user-centered design.
Our Human-Centered Design Process
Our research and planning process embraced human-centered design philosophies to ensure the final product truly meets user needs. We constructed a full-scale cardboard model of the interior, incorporating various swappable furniture and tools, allowing the service technicians to interact with the space and provide invaluable feedback. Additionally, we built the lab in virtual reality (VR), enabling technicians to explore the space with greater fidelity. This collaborative method ensured that the design met the practical needs of the users, accounting for constraints we might not have otherwise considered. This project exemplifies how we work alongside clients to realize the perfect solution for their needs.
Interior Design
Comfort and efficiency were key considerations for the lab's interior. Heating and cooling are managed by a heat pump mini-split system, supplemented by an electric heater for freezing conditions. A vent fan provides both light fume extraction and humidity control, essential in enclosed spaces. Generous mounting options are available throughout the lab to accommodate various packing strategies, including ratcheting straps for securing equipment. All work surfaces feature butcher block countertops, and wooden open-top storage bins are provided for miscellaneous items and cables, keeping the lab organized.
Tool and Equipment Integration
The lab is equipped with essential tools to support the maintenance crew effectively. This includes a small shop vac, an abrasive saw, bench-mounted vises, and a portable air compressor. A drill press is also included, ensuring the crew has everything they need to perform their tasks efficiently. The lab features robust power outlets, including some with USB-A and USB-C sockets, ensuring all equipment can be powered efficiently. Exterior lights have been added for late-night work, ensuring the crew can operate effectively at any time.
Box Lab Configuration
The box lab was designed for maximum usability and storage. Flip-down stairs provide convenient access to the lab. The driver-side storage bay includes slide-out drawers for easy generator maintenance and refilling, while the passenger-side storage bay offers flexible storage options. Inside, a 4’x6’ whiteboard is mounted near the rolling door for planning and notes. The lab’s walls and ceiling are insulated to maintain a comfortable temperature, ensuring a pleasant working environment.
Safety and Comfort
Safety and comfort are integral to the lab's design. Emergency power cutoffs (e-stops) are installed at each egress point to cut power in case of an emergency, along with fire extinguishers and first aid kits. For added comfort, a Bluetooth speaker allows the crew to enjoy music or other audio while working. A magnetic mosquito net for the rear door enhances usability in various conditions, making the lab a pleasant workspace. These features ensure the crew can work efficiently and comfortably, even in remote locations.
Power System
The truck's power system is designed for unparalleled reliability and flexibility. It includes 1200W solar panels on the roof, a 10kWh battery storage system, and two generators with a total output of 6000W. Each component of the power system is designed with redundancy and workarounds, ensuring the system can continue to operate even if individual parts fail. The generators can provide power directly to the batteries or the lab itself, while a shore power hookup offers another layer of versatility. A touch screen display allows users to monitor and configure the system in real time, providing comprehensive control over energy management.
Truck Modifications
Truck modifications focused on enhancing functionality, safety, and comfort. A bridge camera was installed to prevent clearance issues, an essential feature given the box truck's height of 14 feet. A solar battery tender ensures the vehicle battery stays charged, so the truck is always ready to start. An anti-corrosion finish was applied to the truck's underside for durability in various environments.