Introduction to Engineering

Design

Bo Hu

John Nieber

What is an engineer?

What is engineering design?

Difference between engineering analysis and engineering design

What is the difference between product and process design?

What is the context of the design process?

Engineering design vs. design in other academic disciplines?

Why design?

Foundational Questions

What is engineering? “…the purposive adaptation of means to reach a pre-conceived end…” E.T. Layton, Jr.

“Technological activity to solve problems”

Human creativity

The use of technology to make products and systems

for societal benefit.

Engineering as a “Thinking-Making” Activity

What role of engineers in history? Irrigation and farming equipment, dam projects, water and wind mills building construction,

the Pyramids, the Great Wall, Leonardo’s contraptions, the printing press, the Wright brothers’

aircraft, fermented beverages, nuclear power, the Space Shuttle, Tacoma Narrows Bridge,

electric appliances, petroleum products, pharmaceuticals.

When did the engineering disciplines begin? 3000 BC Civil

1000 BC Military

AD 1700 Mechanical

AD 1800 Materials

Agricultural

Electrical

AD 1900 Chemical

Aerospace

AD 1950 Computer, Nuclear, Biochemical

Biomedical

Historical Questions

[ Holtzapple, M. T., Reece, W. D. (2005) ]

Product Realization Process

(PRP) • Engineering design

• Industrial design

• Production planning

• Manufacturing

• Distribution

• Sales

• Marketing

• Service

• Disposal

• Environmental assessment

• Stakeholder involvement

• Engineering design

• Construction planning

• Construction

• Effectiveness monitoring,

control, and maintenance

Problem solution

Problem identification

Synthesis

Analysis

Application

Comprehension

Solution

Engineering as Problem Solving

[ Holtzapple, M. T., Reece, W. D. (2005) ]

Orderly stepwise approach

Qualitative/general

quantitative/detailed

Process of Engineering

Think

Sketch

Make

Show

Think

Sketch

Make

Show

Analysis

Physics

Chemistry

Biology

Economy

Environmental

Ethics

Use Use

Math

Law

Politics

Brainstorming

Rule : There are

no stupid ideas

in a brainstorm

Process of Engineering Need

Analysis of Problem

Statement of Problem

Conceptual Design

Selected Schemes

Embodiment of Schemes

Detailing

Working drawings, etc.. [ Ferguson, E. S. , (1992) ]

• What is a product or process? Object produced, substance, material, arrangement, service, step sequence,

manufactured good, transformation of something, system, organization.

Example 1 : Water bottle made of biodegradable plastic

Example 2 : Biorefinery for ethanol production from biomass

Example 3 : Bio-repellant coatings

Example 4 : Flood control structures

Example 5: Contaminant/pollutant removal systems

Example 6: Structures for wildlife migration

Examples in bio-based products

Materials and Chemicals

- Wood

- Wood-based

- Paper

- Biodiesel fuel

- Bio-based plastics

- Biodegradable plastics (e.g. drink bottles)

- Ethanol (bio-based)

-

-

Examples in bioprocessing

Utilization of living cells or their components to obtain

desired products

- Ethanol fermentation from corn

- Antibody production via fungal fermentation

- Anaerobic digestion to treat wastewater

- Biodegradable plastics (e.g. PLA) production from corn

- Enzymatic hydrolysis to produce sugar from cellulose

-

-

What is engineering design?

• Engineering design is the set of decision-making processes

and activities used determine the form of an object given the

functions desired by the customer. (Gov of MA)

• Engineering design is the process of devising a system,

component, or process to meet desired needs. It is a decision-

making process (often iterative), in which the basic science

and mathematics and engineering sciences are applied to

convert resources optimally to meet a stated objective. Among

the fundamental elements of the design process are the

establishment of objectives and criteria, synthesis, analysis,

construction, testing and evaluation. (ABET)

Context of Design Historical

Precedents

Ideal Society

Projections

Cosmological

Global

Regional

State

City

Ward

House

Person

Bodypart

Organ

Cell

Organelle

Molecular

Atomic

Government

Commercial

Industry

Military

Non-profit NGO’s

Biology

Chemistry

Physics

Mathematics Family

Product Design

• New products are critical for corporate

prosperity

• Approximately 33% of revenues come

from products that did not sell 5 years ago

• Successful new products are profitable – Median achieve 33% ROI or better

– Median have payback of 2 years or less

– Median achieve market share of 35%

• Significant R&D expenditures and

investment

Manufacturing of Chemical Products

Process Engineering Design

Environmental Design

• Changing human needs mean the need

for the design of new infrastructures

• Design with a focus on natural processes

• Designs should mimic nature – i.e., self-

adaptive, self-sustaining, and resilient

Engineering Design vs Engineering Analysis

• Engineering analysis: Predicted behavior is the solution

to an analysis problem

– Formulating

– Solving

– Checking

• Engineering design: – Formulating

– Generating

– Analyzing

– Evaluating

Design Step

Process of Engineering

[ SSL (2004) ]

Map

Process of Engineering (cont.)

Map

[ SSL (2004) ]

Issues in design Utility and cost

Single and multi-functionality

Batch or mass production

Patents

Aesthetics

Integrity of product (wholeness)

Whole life-cycle planning

Health effects and safety

Recycling and disposal

End of product life and replacement issues

Failure modes

Effects on society

Ethical issues design

Philosophical and practical ethics

Codes of Ethics

- Health and welfare of humans and nature

- Informing client/employers of consequences

- Statements and information in truthful manner

- Treating people fairly (avoiding conflict of interest)

- Limits of professional competence

- Building professional reputations according to merits

- Continuing professional development

- Issues with intellectual property.

Issues

Life systems preservation

Maintenance of quality of life

Maintaining high standards of personal and professional conduct

Managing intra-professional customs, identifiers, habits, and limits.

[ SSL (2004) ]

Economic analysis

What is the relevance of economic analysis to design?

Economic assumption : Measure of value is “monetary”

Process cost in context of the company

Reporting costs, financial status, and transactions.

Value today, value tomorrow.

Material cost, labour cost, indirect cost

Manufacturing cost, storage cost, transport cost

Product cost scaling and correction factors

Statistical analysis

What relevance is statistics to design?

Statistical focus : “The one and the many”

Measures of central tendency

Measures of variation

Probability

Uncertainty analysis

Linear regression

Six sigma quality concept

Optimization and development of designs

Statistics in process control for quality

AspenTech HYSYS Modeling Code

• Menu driven, Mouse driven.

• Flowsheets, Modular units.

– Mixers, Reactors, Flash separators,

Distillation units, Heat exchangers.

• Reaction databases.

• Chemical property calculations.

• Species, Mass, Momentum, Heat Balances.

• Equipment Sizing.

• Economic calculations.

• Optimization.

CAD, MAPWindow/ArcGIS, WAM,

HEC-RAS

• CAD – develop engineering drawings

• MAPWindow/ArcGIS – work with mapping

systems for various geographical analyses

• WAM – one of many models for watershed

assessments

• HEC-RAS – a model for water flow in open

channels

Introduction to Engineering Design Notes of S. Takagaki, H. P. Huang, S. Ramaswamy 30

Minnesota context

Products from Minnesota

Sources : Inventing Tomorrow Magazine

Minnesota context

Environmental analysis and design;

• Assessment of impaired waters – water quality

• Wetland loss mitigation

• Stormwater control and mitigation

• Drainage of lands for food production and

development

• Liquid and solid waste treatment

References

deCamp, L. Sprague, (1963) The Ancient Engineers, Bantam books Ferguson, E. S. , (1992) Engineering and the Mind’s Eye, MIT Press, Cambridge. Cussler, E.L., Moggridge, G.D. (2001) Chemical Product Design, MIT Press, Cambridge Holtzapple, M. T., Reece, W. D. (2008) Concepts in Engineering, 2nd Edition, McGraw-Hill. also Holtzapple, M. T., Reece, W. D. (2005) Concepts in Engineering, McGraw-Hill. Kangas, P.C., Ecological Engineering, Principles and Practice, Lewis Publishers, 2004 Ogot, M. G. Okudan-Kremer, Engineering design: a practical guide, Togo Press, LLC. 2004, 544 pages. Seider, W. D., Seader, J. D., Lewin, D. R. (2004) Product and Process Design Principles, Second Edition, Wiley. Smith, R. (2005) Chemical Process, Wiley.

Assignment 1 – Bioproducts and bioprocessing students

1. Search through issues of “Inventing Tomorrow” for articles on product and process design. Read and make notes, especially those related to bio-based products and processes. List your favorite three examples and explain their design process, for example: what is the problem? What are the alternative solutions? Why they choose the one and how do they do that?

2. Find library resources related to chemical and physical properties. find the flash point of ethyl alcohol and propylene

- CRC Handbook of Chemistry and Physics - Perry’s Chemical Engineers’ Handbook. 3. Find (free) websites which catalog Material Safety Data

Sheets (MSDS) and find an entry for isopropyl alcohol and propylene. Also check other safety data archives esp. governmental.

Assignment 1 – EEE students 1. Search through issues of “Transactions of the American

Society of Agricultural and Biological Engineers” , “Applied Engineering in Agriculture” , and “Journal of Ecological Engineering” for articles on the design of systems for water quality improvement, flood control, etc. Read the abstracts for these articles and make notes. List your favorite three examples.

2. Find website resources related to chemical and physical properties of soils, geological materials, and water.

3. Go to the MnDNR website to find out about the waters of the state. Find out how many lakes and miles of rivers/streams we have in Minnesota. How much is the mean annual precipitation, and how much of the water flows out of the state? How many of the waters of the state are known to be impaired (see MPCA website, http://www.pca.state.mn.us/water/tmdl/index.html)