Engineering 11 Configuration Design Bruce Mayer, PE Licensed Electrical & Mechanical Engineer BMayer@Chabot. College. edu Engineering-11: Engineering Design 1 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Out. Line 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) Engineering-11: Engineering Design 2 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Over. View – 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 Engineering-11: Engineering Design 3 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
What is Configuration Design? § Example Design Problem Reduce Rotational Speed § Design Concept Gear Pair Physical principle: Power. In = Power. Out Engineering-11: Engineering Design 4 geometry & material Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Possible Gear. Pair Configurations § Alternative configuration 1 § ARRANGE Part Differently Engineering-11: Engineering Design 5 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Possible Gear. Pair Configurations § Alternative configuration 2 Spur Gears Helical gears § Use different FEATURES or PARTS Engineering-11: Engineering Design 6 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Possible Gear. Pair Configurations § Alternative configurations 3 & 4 Wide Gear Face Similar Diameters § Use different RELATIVE DIMENSIONS Engineering-11: Engineering Design 7 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
What is Configuration Design? § Example Design Problem Support Vertical Load § Design Concept Wall Bracket Physical principle: Force Equilibrium Engineering-11: Engineering Design 8 geometry & material Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Wall Bracket Configurations Different Features Engineering-11: Engineering Design 9 Abstract Embodiment Different Arrangements Different Dimensions Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Configuration Decisions § To Create Different Configs Change one or more of these Engineering-11: Engineering Design 10 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Select the BEST Configuration Formulating Problem § Use the General Design Process as DESIGN Specs Generating a Model for Alternatives Choosing Between ALL Re. Design Configuration Alternatives Iteration Alternatives Analyzing Alternatives FEASIBLE Alternatives Evaluating Alternatives BEST Alternative MANUFACTURING Specs Engineering-11: Engineering Design 11 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Best concept(s) Configuration Design Iterate Configure Product architecture Integral / modular Standard / special purpose Configure Part(s) Re-examine EDS Research sources Configuration requirements sketch Analyze and Refine Design for Function Design for Assembly Design for Manufacture Evaluate Pugh’s Method Weighted Rating Method Best configuration(s) Engineering-11: Engineering Design 12 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Product Architecture § Analogous to Building Architecture Style COLONIAL RANCH Scheme 1 st Floor Rms: dining, living 2 nd Floor Rms: Bedroom, Office 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. ” Engineering-11: Engineering Design 13 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Example Product Architecture § This “System Architecture” Shows the Major Sub. Systems (the “rooms”), and their Physical Locations relative to each other (the “Floor Plan”) Engineering-11: Engineering Design 14 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Example Product Architecture March 1992 Engineering-11: Engineering Design 15 Jun 1994 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Re. Call Product De. Composition Product Standard Special purpose Part Shows Subassembly B Special purpose part § Subassembly A Special purpose part Standard part a) type, number, arrangement of components b) standard or special purpose (make or buy) Engineering-11: Engineering Design 16 Subassembly B 1 Standard part Special purpose part Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Product 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” Engineering-11: Engineering Design 17 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Modular Architecture Product examples Flashlight Refrigerator Automobile Personal computer Modular components Batteries, bulbs Motors, compressor, switches Tires, radios, seats, brakes, engines Drives, keyboards, mice, modems § “Chunks” implement one or a few functions § Interactions between chunks are well defined (standard interfaces and/or connections) Engineering-11: Engineering Design 18 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Integral Architecture Product examples BMW Motorcycle engine Printer case Shaft Beverage cup Modular components engine/frame integral snap-fasteners machined bearing race integrated handle § a single chunk implements many functions § Interaction is ill defined § Physical element “shares” functions Engineering-11: Engineering Design 19 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Developing 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 Engineering-11: Engineering Design 20 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Example Design Printer § Identify • Sub. Functions • Inter. Actions Engineering-11: Engineering Design 21 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Example Design Printer § Cluster Elements into Logical “Chunks” Engineering-11: Engineering Design 22 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Example Design Printer § Sketch rough geometric “layout” Engineering-11: Engineering Design 23 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
a REFINED Lay. Out Engineering-11: Engineering Design 24 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Example Design Printer § Sketch the Interaction Diagram Engineering-11: Engineering Design 25 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Best concept(s) Part Configuration Design Iterate Configure Product architecture Integral / modular Standard / special purpose Configure Part(s) Re-examine EDS Research sources Configuration requirements sketch Analyze and Refine Design for Function Design for Assembly Design for Manufacture Evaluate Pugh’s Method Weighted Rating Method Best configuration(s) Engineering-11: Engineering Design 26 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Part Configuration Design Configuration Problem Required Decisions Special Purpose Part Geometric Features Feature Arrangement Relative Dimensions Design Variable List § Many Issues Associated with Each Decision • Consider just Geometric Features walls rounds cubes ribs bosses spheres chamfers projections cylinders holes fillets Engineering-11: Engineering Design 27 tubes notches grooves slots Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Generating Alternatives § Recall Bracket Configurations Different Features Engineering-11: Engineering Design 28 Abstract Embodiment Different Arrangements Different Dimensions Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Example Sponge Holder 1. Prepare configuration requirements sketch ge on er Sp old H Engineering-11: Engineering Design 29 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Example Sponge Holder 2. Prepare NON-Contiguous configuration requirements sketch Engineering-11: Engineering Design 30 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Example Sponge Holder 3. Prepare alternative CONTIGUOUS configuration sketches Engineering-11: Engineering Design 31 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Example Sponge Holder 4. Refine Configs hole in back wall Engineering-11: Engineering Design 32 hole in offset wall Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Best concept(s) Iterate Configure Product Configure Part(s) Configuration Analysis Product architecture Integral / modular Standard / special purpose Re-examine EDS Research sources Configuration requirements sketch Analyze and Refine Design for Function Design for Assembly Design for Manufacture Evaluate Pugh’s Method Weighted Rating Method Best configuration(s) Engineering-11: Engineering Design 33 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Analysis Queries § Will the Configuration Perform the Desired FUNCTION? § Can all the Parts be MADE (manufactured)? § Can the Configuration be ASSEMBLED? Engineering-11: Engineering Design 34 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
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 Engineering-11: Engineering Design 35 § Reliable § Human factors/ergonomics § Safe § Easy to use § Maintain § Repairable § Durable (wear, corrosion) § Life-cycle costs § Styling/aesthetics Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
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. Engineering-11: Engineering Design 36 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
DFA 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 Engineering-11: Engineering Design 37 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
DFA 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 Engineering-11: Engineering Design 38 § Depth of insertion § Separate operation required § Fastener used Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
DFA Guide. Lines 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 Engineering-11: Engineering Design 39 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
PROs & CONs of DFA § Design Guidelines • pros: fast, easy, non-coupled • cons: non-quantitative; no metric to compare alterative designs § Assembly Efficiency • pros: systematic, comparative • cons: takes time to code & calculate Engineering-11: Engineering Design 40 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Best concept(s) Iterate Configure Product Configure Part(s) Configuration Evalualtion Product architecture Integral / modular Standard / special purpose Re-examine EDS Research sources Configuration requirements sketch Analyze and Refine Design for Function Design for Assembly Design for Manufacture Evaluate Pugh’s Method Weighted Rating Method Best configuration(s) Engineering-11: Engineering Design 41 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Evaluation 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. ” Engineering-11: Engineering Design 42 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Evaluate Sponge Holder Con. Figs hole in back wall Engineering-11: Engineering Design 43 hole in offset wall Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Eval 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 Engineering-11: Engineering Design 44 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Eval Sponge Holder Con. Figs Engineering-11: Engineering Design 45 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Best concept(s) Config Design Summary Iterate Configure Product architecture Integral / modular Standard / special purpose Configure Part(s) Re-examine EDS Research sources Configuration requirements sketch Analyze and Refine Design for Function Design for Assembly Design for Manufacture Evaluate Pugh’s Method Weighted Rating Method Best configuration(s) Engineering-11: Engineering Design 46 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Using Sketches in Con. Fig 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” Engineering-11: Engineering Design 47 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Creative Visualization § Sketching Stimulates Creativity And Helps Visualization • Sketching Ideas That Are Partially Developed Often Aids The Design Process Ø Do Not Wait Until You Have A Clear Picture Before You Start Sketching Ø Allow Yourself The Freedom To Make Mistakes § Visualization Of The Entire Design Is Essential But Often IMPOSSIBLE Without the Aid Of Sketches Engineering-11: Engineering Design 48 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Sketches for Patent Doc. Engineering-11: Engineering Design 49 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
USA Patent App. 20030113451 Engineering-11: Engineering Design 50 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
CAD DWGs for Con. Fig Design § Typically used to Produce “Lay. Outs” § Lay. Out 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 Inter. Connections – Check for Proper Control of Fluid, Electrical, Optical, Magnetic, or Information “Flow” Engineering-11: Engineering Design 51 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Lay. Out For FC CCA Enclosure Engineering-11: Engineering Design 52 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Lay. Out for 800 mm Glass Coater Engineering-11: Engineering Design 53 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Elect Pwr & Control Schematic Engineering-11: Engineering Design 54 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Uses of Accurate Lay. Outs § Lay. Outs 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 Proto. Typing Engineering-11: Engineering Design 55 § Electro. Magnetics § SPICE (Analog Electrical Circuit) § Wire/Pipe Routing Software § Kinematics Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Computation Fluid Dynamics Engineering-11: Engineering Design 56 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
All Done for Today Lay. Outs Transistor Plumbing § Transistor Lay. Out by MAGIC Software Engineering-11: Engineering Design 57 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Engineering 11 Appendix Bruce Mayer, PE Registered Electrical & Mechanical Engineer BMayer@Chabot. College. edu Engineering-11: Engineering Design 58 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
W J -1 0 0 0 P r o d u c t Engineering-11: Engineering Design 59 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
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. Engineering-11: Engineering Design 60 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
Engineering-11: Engineering Design 61 Bruce Mayer, PE BMayer@Chabot. College. edu • ENGR-11_Lec-04_Chp 7_Configuration_Design. ppt
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