[email protected] engr-11_lec-04_chp7_configuration_design.ppt 1 bruce mayer, pe...

[email protected] • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt1

Bruce Mayer, PE Engineering-11: Engineering Design

Bruce Mayer, PELicensed Electrical & Mechanical Engineer

[email protected]

Engineering 11

ConfiguratiConfigurationon

DesignDesign



OutLine OutLine Configuration Design Configuration Design

What is a product configuration? What is a part configuration? Product architecture design Part configuration design Evaluating Configurations Computer Aided Design (CAD) Computer Aided Engineering (CAE)



OverView – Config DesignOverView – Config Design

The Configuration Design moves the Design-Concept from the diagram phase to the one where specific components are now identified so that we can proceed to manufacture.• Start to Develop Specific Sizes, Shapes,

and Orientations

• Begin to Apply Highly Quantitative Science and Mathematics



What is Configuration Design?What is Configuration Design?

Example Design Problem Reduce Rotational Speed

Design Concept Gear Pair

geometry & material

Physical principle:PowerIn = PowerOut

2211 TT



Possible GearPair ConfigurationsPossible GearPair Configurations

Alternative configuration 1

ARRANGE Part Differently




Alternative configuration 2

Use different FEATURES or PARTS

SpurGears

Helical gears




Alternative configurations 3 & 4

Use different RELATIVE DIMENSIONS

Wide Gear Face Similar Diameters



What is Configuration Design?What is Configuration Design?

Example Design Problem Support Vertical Load

Design Concept Wall Bracket

geometry & material

Physical principle:Force Equilibrium

0F



Wall Bracket Wall Bracket ConfigurationsConfigurations Abstract

Embodiment

DifferentFeatures

DifferentArrangement

s

DifferentDimensions



Configuration Decisions Configuration Decisions

To Create Different Configs Change one or more of these



Select the BEST ConfigurationSelect the BEST Configuration

Use the General Design Process as a Model for Choosing Between Configuration Alternatives

FormulatingProblem

GeneratingAlternatives

AnalyzingAlternatives

EvaluatingAlternatives

ReDesignIteration

DESIGN Specs

ALLAlternatives

FEASIBLE Alternatives

BEST AlternativeMANUFACTURING Specs



ConfigurationConfigurationDesignDesign

ConfigurePart(s)

Configure Product

Analyzeand

Refine

Iterate

Re-examine EDS Research sourcesConfiguration requirements sketch

Best concept(s)

Design for FunctionDesign for AssemblyDesign for Manufacture

Bestconfiguration(s)

Pugh’s MethodWeighted Rating MethodEvaluate

Product architecture Integral / modular Standard / special purpose



Product ArchitectureProduct Architecture

Analogous to Building Architecture

Architecture Style Scheme

COLONIAL1st Floor Rms: dining, living

2nd Floor Rms: Bedroom, Office

RANCH all rooms on ground floor

Rooms arranged Using a logical “scheme.”• Before the details of the house are designed

we determine the general layout or “architecture.”



Example Example Product Architecture Product Architecture This “System

Architecture” Shows the Major SubSystems (the “rooms”), and their Physical Locations relative to each other (the “Floor Plan”)



Example Example Product Architecture Product Architecture

March 1992 Jun 1994



ReCall Product DeCompositionReCall Product DeComposition

Product

Subassembly AStandardPart

Standard part

Special purpose part

Special purposePart

Subassembly B


Subassembly B1

Standard part


Showsa) type, number, arrangement of

components

b) standard or special purpose (make or buy)



Product ArchitectureProduct Architecture

PRODUCT ARCHITECTURE is the scheme/plan by which the functional elements of a product are arranged into physical building blocks (components, subsystems or subassemblies) that interact with each other to perform the overall function of the product

Product architectures can be “modular” or “integral”



Modular ArchitectureModular Architecture

Product examplesFlashlight

RefrigeratorAutomobile

Personal computer

Modular components Batteries, bulbsMotors, compressor, switchesTires, radios, seats, brakes, enginesDrives, keyboards, mice, modems “Chunks” implement one or a few functions

Interactions between chunks are well defined (standard interfaces and/or connections)



Integral ArchitectureIntegral Architecture

Product examplesBMW Motorcycle

enginePrinter case

ShaftBeverage cup

Modular components engine/frameintegral snap-fastenersmachined bearing race integrated handle

a single chunk implements many functions Interaction is ill defined Physical element “shares” functions



Developing ArchitecturesDeveloping Architectures

1. Create a schematic of functional and physical elements

2. cluster elements into logical chunks to: exploit standard components to exploit standard interfaces (e.g. 115 VAC, USB) fully utilize manufacturing process(es), or suppliers provide for maintenance

3. sketch a rough geometric layout

4. identify interactions between elements

5. refine layout



Example Example Design Printer Design Printer Identify

• SubFunctions

• InterActions



Example Example Design Printer Design Printer Cluster

Elements into Logical “Chunks”



Example Example Design Design

PrinterPrinter

Sketch rough geometric “layout”



a REFINEDa REFINEDLayOutLayOut



Example Example Design Printer Design Printer

Sketch the Interaction Diagram



Part ConfigurationPart ConfigurationDesignDesign

ConfigurePart(s)

Configure Product

Analyzeand

Refine

Iterate


Best concept(s)




Product architecture Integral / modular Standard / special purpose



Part Configuration DesignPart Configuration DesignConfiguration Problem Required Decisions

Special Purpose Part Geometric FeaturesFeature ArrangementRelative DimensionsDesign Variable List

Many Issues Associated with Each Decision• Consider just Geometric Features

walls rounds cubes notches

ribs bosses spheres chamfers

projections cylinders holes grooves

fillets tubes slots



Generating AlternativesGenerating Alternatives

RecallBracketConfigurations

AbstractEmbodimen

t

DifferentFeatures

DifferentArrangement

s

DifferentDimensions



Example Example Sponge Holder Sponge Holder

1. Prepare configuration requirements sketch

Spong

e

Holder




2. Prepare NON-Contiguous configuration requirements sketch




3. Prepare alternative CONTIGUOUS configuration sketches




4. RefineConfigs

hole in back wall hole in offset wall



ConfigurationConfigurationAnalysisAnalysis

ConfigurePart(s)

Configure Product

Analyzeand

Refine

Iterate


Best concept(s)




Product architecture Integral / modularStandard / special purpose



Analysis QueriesAnalysis Queries

Will the Configuration Perform the Desired FUNCTION?

Can all the Parts be MADE (manufactured)?

Can the Configuration be ASSEMBLED?



Design for Function (DFF)Design for Function (DFF) Functional Considerations List

Strong Stiff or flexible Buckling Thermal expansion Vibrate Quiet / Noise Heat transfer Fluid(s) transport

and/or storage Energy efficient Stable

Reliable Human

factors/ergonomics Safe Easy to use Maintain Repairable Durable (wear, corrosion) Life-cycle costs Styling/aesthetics



Design for Assembly (DFA)Design for Assembly (DFA)

Assembly ≡ a process of handling components to bring them together (inserting) and then fastening them.

Design for Assembly ≡ a set of design practices which reduce the manpower time required to handle, insert and fasten components of a product.



DFA DFA Reduce Handling Reduce Handling Handling GMOP: Grasping, Moving,

Orienting, Placing. Design parts or products to reduce the

influence on handling Size Thickness Weight Nesting Tangling

Fragility, Flexibility, Slipperiness, Stickiness

need for: 2 hands, tools, optical magnification, mechanical assistance, etc



DFA DFA Reduce Insert & Fasten Reduce Insert & Fasten Insertion & Fastening Mating a part to

another part or sub-assembly. Design parts or products to reduce the effort

associated with inserting & fastening Accessability Resistance (force) to

Insertion Visibility Ease of Alignment &

Positioning

Depth of insertion Separate operation

required Fastener used



DFA GuideLines from the SMEDFA GuideLines from the SME minimize part count minimize levels of assembly (number of assemblies) encourage modular assembly use standard parts stack sub-assemblies from the bottom up design parts with self-fastening features (snap-fits,

press-fits) facilitate parts handling (grasp, orient, move) design parts with self-locating features (e.g.

chamfers, aligning recesses/dimples) eliminate reorientation (i.e. insertion from 2 or more

directions) eliminate (electric) cables



PROs & CONs of DFAPROs & CONs of DFA

Design Guidelines• pros: fast, easy, non-coupled

• cons: non-quantitative; no metric to compare alterative designs

Assembly Efficiency

Time Assembly Actual

Time Assembly Min. lTheoreticama

• pros: systematic, comparative

• cons: takes time to code & calculate



ConfigurationConfigurationEvalualtionEvalualtion

ConfigurePart(s)

Configure Product

Analyzeand

Refine

Iterate


Best concept(s)



Pugh’s MethodWeighted Rating Method

Evaluate




Evaluation MethodsEvaluation Methods Once the design concepts are generated and

evaluated for feasibility, the surviving design concepts need to be evaluated to determine which one is “best.”

How does one define “best”? One common method is to use the criteria for

the design and weight the relative importance to determine “best.”• Note: the designers must be careful not to rig the

weighting to make a favorite come out “best.”



Evaluate Sponge Holder ConFigsEvaluate Sponge Holder ConFigs

hole in back wall hole in offset wall



Eval by Weighted Rating MethodEval by Weighted Rating Method

1. List evaluation criteria (in a column).

2. Determine importance weights (in an adjacent column)

3. List alternatives (along the top row)

4. Rate each alternative on each criterion

5. Compute the weighted rating for each criterion

6. Sum the ratings to produce the Overall Weighted Rating



Eval Sponge Holder ConFigsEval Sponge Holder ConFigs



Config DesignConfig DesignSummarySummary

ConfigurePart(s)

Configure Product

Analyzeand

Refine

Iterate


Best concept(s)



Pugh’s MethodWeighted Rating Method

Evaluate




Using Sketches in ConFig DsgnUsing Sketches in ConFig Dsgn

Sketches are used often in configuration design

Sketches assist creativity Sketches are not

typically used to “document” the “design”• But CAN be used to

Document“IDEAS”



Creative VisualizationCreative Visualization

Sketching Stimulates Creativity And Helps Visualization• Sketching Ideas That Are Partially

Developed Often Aids The Design ProcessDo Not Wait Until You Have A Clear Picture Before

You Start SketchingAllow Yourself The Freedom To Make Mistakes

Visualization Of The Entire Design Is Essential But Often IMPOSSIBLE Without the Aid Of Sketches



Sketches for Patent Doc.Sketches for Patent Doc.



USA Patent App. 20030113451USA Patent App. 20030113451



CAD DWGs for ConFig DesignCAD DWGs for ConFig Design

Typically used to Produce “LayOuts” LayOut Characteristics

• If Physical Object, then drawn PRECISELY to Scale showing ALL Parts– Check for Form and Fit

• If Schematic, the shows precisely ALL Components and InterConnections– Check for Proper Control of Fluid, Electrical,

Optical, Magnetic, or Information “Flow”



LayOut For FC CCA EnclosureLayOut For FC CCA Enclosure



LayOut for 800mm Glass CoaterLayOut for 800mm Glass Coater



Elect Pwr & Control SchematicElect Pwr & Control Schematic



Uses of Accurate LayOutsUses of Accurate LayOuts

LayOuts often serve as Input to CAE Software which aids Feasibility Checks

Partial List of CAE tools

Structural Mechanics (FEA)

Computational Fluid Dynamics (CFD)

Coupled Physics Rapid ProtoTyping

ElectroMagnetics SPICE (Analog

Electrical Circuit) Wire/Pipe Routing

Software Kinematics



Computation Fluid Dynamics Computation Fluid Dynamics



All Done for TodayAll Done for Today

LayOuts TransistorPlumbing

Transistor LayOut byMAGIC Software



Bruce Mayer, PERegistered Electrical & Mechanical Engineer

[email protected]

Engineering 11

AppendiAppendixx



WJ-1000 P

rod

uct

WJ-1000 P

rod

uct



Method 6-3-5 (Brain-Writing)Method 6-3-5 (Brain-Writing) The traditional brainstorming relies on verbal

communications.• Idea generation may be dominated by a small

number of aggressive members. Guidelines for 6-3-5 method Team members are arranged around a

circular table to provide continuity. Six (6) members are ideal.

Each member sketches three (3) ideas for the product configuration or functions. Sketches should be the focus of this activity. The top five product functionswith respect to the customer needs are considered.

[email protected] engr-11_lec-04_chp7_configuration_design.ppt 1 bruce mayer, pe...

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