Embed Size (px)
Citation preview
APPLICATION OF AXIOMATIC DESIGN CONCEPT TO
IMPROVE THE PORTABLE CRANE DESIGN
Dayang Nur Rafiza Binti Awang Yusuf
Bachelor of Engineering with Honours
(Mechanical Engineering and Manufacturing System)
2006
Faculty of Engineering
APLLICATION OF AXIOMATIC DESIGN CONCEPT TO IMPROVE
THE PORTABLE CRANE DESIGN
DAYANG NUR RAFIZA BINTI AWANG YUSUF
This report is submitted to Faculty of Engineering University Malaysia Sarawak
(UNIMAS) as to fulfil the requirements of Bachelor Degree Program
Mechanical Engineering and Manufacturing System
Faculty of Engineering
UNIVERSITI MALAYSIA SARAWAK
2006
UNIVERSITY MALAYSIA SARAWAK
BORANG PENGESAHAN STATUS TESIS
Judul: APPLICATION OF AXIOMATIC DESIGN CONCEPT TO IMPROVE
THE PORTABLE CRANE DESIGN
SESI PENGAJIAN :2005/2006
Saya, DAYANG NUR RAFIZA BINTI AWANG YUSUF
(HURUF BESAR)
mengaku membenarkan tesis * ini disimpan di Pusat Khidmat Maklumat Akademik,
Universiti Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:
1. Tesis adalah hakmilik Universiti Malaysia Sarawak.
2. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat
salinan untuk tujuan pengajian sahaja.
3. Membuat pendigitan untuk membanguankan Pangkalan Data Kandungan Tempatan.
4. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat
salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.
5. ** Sila tandakan (√) di kotak yang berkenaan.
SULIT (Mengandungi maklumat yand berdarjah keselamatan atau kepentingan Malaysia
seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972).
TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan
di mana penyelidikan dijalankan).
TIDAK TERHAD
Disahkan oleh
___________________________ _________________________ (TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)
Alamat tetap: T15, QRTS LKTS. Puan Ervina Junaidi
Kpg Tunku Abdul Rahman, Nama Penyelia
P.O Box 661,
9800, Miri, Sarawak.
Tarikh: __________ Tarikh: __________
CATATAN * Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah, Sarjana dan Sarjana Muda
** Jika tesis ini SULIT dan TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi
berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai
SULIT dan TERHAD.
√
APPROVAL SHEET
This project report attached here to, entitle “Application of Axiomatic Design
Concept to Improve the Portable Crane Design” prepared and submitted by
DAYANG NUR RAFIZA BINTI AWANG YUSUF-8134 as a partial fulfilment of
the requirement for the Degree of Bachelor of Engineering with Honours in
Mechanical and Manufacturing System is hereby read and approve by:
_______________________ _________________
Puan Ervina Binti Junaidi Date
Supervisor
ii
ACKNOWLEDGEMENTS
Alhamdulillah, Thank God for all His blessing and permission I was able to
complete this Final Year Project. First of all, I would like to acknowledge and great
thank to my supervisor, Puan. Ervina Binti Junaidi for the excellent patience, careful
supervision and encouragement to me in preceding my final year project
successfully. Also special thanks goes to Encik Ghazali Thambi which never give up
to guide and advice me as well as gave me a fully support through the process to
complete this project. I am especially thankful for the advice given by both of you
when there were some bottlenecks in my project.
My next thanks are expressed to all the technicians of Mechanical and
Manufacturing System, especially Mr. Masri. They don’t hesitate in giving their
helping hands to help me solves problems and difficulties which I faced during the
period at the workshop and CNC lab.
Finally, I would like to thank my family and friends who always stand by me
giving me full supports mentally and financially, encouragement throughout the
project. You guys have helped me in finding precious information and data which
complete up my report.
v
TABLE OF CONTENT
CONTENT PAGES
ACKNOWLEDGEMENT
ABSTRACT
LIST OF TABLES
LIST OF FIGURES
ii
iii
ix
x
CHAPTER ONE : INTRODUCTION
1.1 Background 1
1.2 Introduction of Portable Crane 3
1.2.1 Problem Statement 4
1.3 Aim and Objectives
6
CHAPTER TWO : LITERATURE REVIEW
2.1 Axiomatic Design 7
2.1.1 Domain 10
2.1.2 Hierarchies 11
2.1.3 Zigzagging 11
2.1.4 Design Axioms 12
2.2 Ultimate Goal of Axiomatic Design
vi
2.2.1 The Scientific of the Field Design 13
2.2.2 Enhance Creativity Through Axiomatic Design 15
2.2.3 Relation of Axiomatic Design to Other Fields 16
2.3 Application of Axiomatic Design to Mechanical Design 17
2.3.1 Steam Engine 17
2.3.2 Refrigerator Design
2.4 Quality Function Deployment
19
22
CHAPTER THREE : METHODOLOGY
3.1 Introduction 26
3.2 The Design Process 26
3.2.1 Identify Needs 29
3.2.2 Plan for The Design Process 29
3.2.2.1 Types of Design Projects 29
3.2.2.2 Planning for Deliverables 30
3.2.2.3 The Three Steps in Planning 30
3.2.3 Develop Engineering Specifications 30
3.2.4 Concept Development 31
3.2.4.1 Concept Generation 31
3.2.4.2 Concept Evaluation 32
3.2.5 Product Development 32
3.2.5.1 Material, Component and Process Selection 33
3.2.5.2. Product Architecture and Design Configuration 33
vii
CHAPTER FOUR : RESULTS AND DISCUSSIONS
4.1 Introduction 34
4.2 Results
4.2.1 Identify Needs 35
4.2.2 Plan for the Design Process
4.2.2.1 Types of Design Projects 36
4.2.2.2 Planning for Deliverables 36
4.2.2.3 The Three Steps in Planning
4.2.2.3.1 Identify the tasks
4.2.2.3.2 State the objective for each task
4.2.2.3.3 Develop sequence for the tasks
37
38
38
4.2.3 Develop Engineering Specifications 39
4.2.4 Concept Development
4.2.4.1 Drawing of an improved portable crane
44
4.2.4.2 Concept Generation 46
4.2.4.3 Concept Evaluation
4.2.4.3.1 Axiomatic evaluation of an existing
design of portable crane
4.2.4.3.2 Axiomatic evaluation of an improved
design of portable crane
48
50
viii
4.2.5 Product Development
4.2.5.1 Material selection
4.2.5.2 Caster and wheel selection
4.2.5.3 Process Selection
55
58
60
4.2.5.4 Product Architecture and Design Configuration 61
4.2.5.5 Specification 63
4.3 Discussion
64
CHAPTER FIVE : CONCLUSION AND RECOMMENDATION
5.1 Conclusion and Recommendation
66
REFERENCES
68
APPENDICES
Appendix A : The Mechanical Design Process Diagram 71
Appendix B : Questionnaire 72
Appendix C : General Properties of Steel
74
Appendix D : Classification of Welding Processes 75
Appendix E : New Part by Part Features 76
Appendix F : Photo of the New Portable Crane 78
ix
LIST OF TABLES
TABLE
PAGES
2.4 Descriptions of Quality of House 24
4.2.2 The Project Design Schedule 39
4.2.3 Preliminary List of Customers’ Requirements for The
Portable Crane
40
4.2.4.1 Detail drawing of an improved portable crane 44
4.2.5.1 The Compositions of Carbon 56
4.2.5.2 Typical Applications for Plain Steels 57
4.2.5.3 Basic Type of Caster 59
4.2.5.5 Specification of New Portable Crane 63
x
LIST OF FIGURES
FIGURE
PAGES
1.2
2.1
The Existing Portable Crane
The Fundamental Concept of Axiomatic Design
5
11
2.2 Hierarchical Decomposition of a Design Problem and Zigzagging
between Design Domain
12
2.4 House of Quality 23
3.2 The Design Process of Portable Crane 28
4.2.3
4.2.4.1
House of Quality for the Portable Crane
Assembly drawing of an improved portable crane
43
45
4.2.4.2 Hierarchy of Functional Requirements for a New Portable Crane 46
4.2.4.3 Decomposition of an Existing Portable Crane into Sub-assemblies
and Components
47
4.2.4.4 Hierarchy of Design Parameters for a New Portable Crane 47
iii
ABSTRACT
A portable crane is designed for a whole range shop floor lifting job. It is
transportable and requires no external power. The application of portable crane is
widely used in the Mechanical Engineering field. This device is assisting any lifting job
and considered as one of the material handling system device. The axiomatic design
approach is applied to the design of the portable crane. An existing design is analyzed
based on the Independence Axiom, but the existing design is discovered to violate this
axiom. A new design is proposed to satisfy Independence Axiom. The design also
examined to determine whether any corollaries were followed. Investigation also done
whether the design contradicted any of the axioms or corollaries; this was done by
comparing the axiomatic evaluation of the design alternative with an intuitive one.
iv
ABSTRAK
Kren mudah alih dicipta khas untuk melakukan semua kerja yang berkaitan dengan
mengangkut barang. Ia mudah diangkut dan tidak memerlukan kuasa dari luar untuk
menggerakkannya. Penggunaan kren mudah alih diguna dengan luasnya dalam
lapangan Kejuruteraan Mekanikal. Alat ini membantu dan memudahkan semua kerja
mengangkut dan juga dikategorikan sebagai salah satu daripada alat dalam sistem
mengendalikan bahan. Kaedah “Axiomatic Design” diaplikasikan untuk merekabentuk
kren mudah alih yang baru. Reka bentuk yang lama dianalisa berdasarkan
“Independence Axiom” didapati bercanggahan dengan “Axiom”. Reka bentuk baru
dicadangkan untuk mematuhi “Independence Axiom”. Rekabentuk diuji untuk
memastikan penggunaan “corollaries”. Penyelidikan juga dilakukan untuk memastikan
rekabentuk tidak bercanggahan dengan “axiom” atau “corollary”. Penyelidikan
dilakukan dengan menilai perbezaan di antara rekabetuk baru dan lama.
1
CHAPTER 1
INTRODUCTION
1.1 Background
Human have been designing mechanical objects for a long term. Each of the
objects is the end result of a long and often difficult design process. There are
certain techniques that can be used during the design process to help ensure
successful results. In the design process there are divided into two stages of design.
The first stage is conceptual stage and the second stage is embodiment stage. During
the conceptual design stage, there are several tools can be applied to enhance the
creativity and provide framework so the process will be more organize.
Design involves a continuous interplay between what we want to achieve and
how we want to achieve it. The objective of design is always stated in the functional
domain, whereas the physical solution is always generated in the physical domain.
The design procedure involves interlinking these two domains at every hierarchical
2
level of the design process. These two domains are inherently independently of each
other.
Design may be formally defined as the creation of synthesized solution in the
form of products, processes or system that satisfy perceived needs through the
mapping between the functional domain and the physical domain, through the
proper selection of design parameters that satisfy functional requirements. The
design axiom provides the principles that the mapping techniques must satisfy to
produce a good design, and offer a basis for comparing and selecting designs. The
design axioms apply to all synthesis processes: the design of manufacturing process,
machines, products, and even organizations. Since we are surrounded by products, it
easy to pick one of the products and analyzed its design from the axiomatic point of
view.
3
1.2 Introduction of Portable Crane
The portable crane is a product selected into the application of design axiom
for this project. Portable crane is a small crane that can be broken down into several
parts for easy transportation. It must be assembled and bolted into place to be used
effectively. Portable crane designed for a whole range of floor lifting job. They are
transportable and require no external power. They can be used where no overhead
lift is available and relatively short lift required. It also increase efficiency and
productivity while decreasing operator bending and risk of back injury. The portable
crane is widely used in the Mechanical engineering field for assist any heavy duty
job. There are various types of a portable crane that available in the market with a
various function and features.
4
1.2.1 Problem statement
Based on the Mechanical Engineering Laboratory’s (UNIMAS) environment, there
arise several limitations for existing portable crane that available the laboratory. The
limitations were classified in term of functionality and ergonomically.
In term of functionality, the existing portable crane is difficult to steer because of
the roller used to move the crane. Besides, the roller also limit the mobility of crane
when require to go up the steps and it is difficult to cross the crane over the drain.
The problem also encounter at in term of it is ergonomically. The application of
ergonomics should be result in products that are safer or easier to use. For existing
portable crane in the mechanical laboratory, the location of manual hydraulic hand
pump that used to raised and lowered the boom are not suitable for the average height of
the user in mechanical laboratory. So it cause of the uncomfortable during the adjusting
the boom.
The existing portable crane is a heavy-duty steel construction. It is makes the
portable crane heavy and causes the limitation of crane’s mobility. A part from that, bas
the load is increases, the more difficult it is to steer.
5
Figure 1.2 shown the existing portable crane in Mechanical Laboratory of
UNIMAS and the causes of limitations of existing portable crane as discussed above is
designated in the yellow circle
Figure 1.2 The Existing Portable Crane
6
1.3 Aim and Objectives
The aim of this project is to improve the performance of the system which does not
necessarily mean improve the performance of each component. The capability of
creating a new design becomes more important than ever before because of the
engineering environment is rapidly changing. Accordingly, a change to one portion of
the design can negatively impact other portions unintentionally, because no framework
was used to trace the impact of the design choices between the task decisions. It is
generally no feasible to restart the design process from scratch, so new modified
functional requirements (FRs) and constraints (Cs) must be incorporated into the
existing design as the change occur.
The objectives of this project are:
i. To apply Axiomatic Design methodology for improving existing design of
portable crane for the purpose of Mechanical Engineering Laboratory
(UNIMAS).
ii. To overcome the problem that encounter at existing portable crane.
iii. To develop prototype of an improved portable crane.
The important of this project is that the design axioms facilitate the evaluation of
existing designs and enable quick identification of poor designs. Once the problem is
identified based on the axioms, better designs can be developed.
7
CHAPTER 2
LITERATURE REVIEW
2.1 Axiomatic Design
Axiomatic Design is engineering theory that has been developed at Massachusetts
Institute of Technology (MIT). The basic idea for axiomatic design was advanced in the
mid 1970’s and it was later published in a book in 1990 [Suh, 1990]. Nam Suh’s
development of axiomatic design over the past 25 years or so, has been reported in a
series of theoretical papers, a research monograph, detailed solutions to practical
engineering designs, development of computational tools for rational designers and
most recently this text intended for graduate students and professional engineers. The
aim of this theory is to improve design activities by providing the designer with
theoretical foundation based on logical and rational through process and tool. A system
design technique based on Axiomatic Design theory is discussed as a tool that can be
used to improve communication between costumer and design engineer. Axiomatic
design defines as the creation of synthesized solution in the form of product, processes
or system that satisfy perceived needs through mapping between functional
requirements (FRs) and design parameters (DPs) [Almstrom, 1998]. Axiomatic design
8
is about how to think and used fundamental principles during synthesis or mapping
between the domains of the
design world [Suh, 1995]. Axiomatic design is conceptual because it is an abstraction of
the design process; it provides design tools because that is what theories do; and it has
been used successfully by many in industry and academia because the basic intent if
axiomatic design is to help current designers and future practitioners [Suh, 1995].
Whether the design solution is a tangible product, service, software, process or
something else, designers typically follow these steps [13]:
1. understand their customers’ needs
2. define the problem they must solve to satisfy these needs
3. create and select a solution
4. analyze an optimize the proposed solution
5. check the resulting design against the customers’ needs
The Axiomatic Design process guides designers through these same steps. They
can use all of their existing design tools and software and efficiently arrive at a
successful new design, or diagnose and correct an existing design. The main concepts of
Axiomatic Design are [Hinterstiener, 2000]:
9
1. Domains, which separate the functional and physical parts of the design.
2. Hierarchies, which categorized the progress of a design in the functional and
physical domains from the systemic level to more detail levels.
3. Zigzagging, which indicates that decisions made at one level of the hierarchy
affect the problem statements at lower levels; and
4. Design axioms, which dictate that the independence of the functional
requirements must be maintained, where FRs are defined as the minimum set of
independent requirements that characterized the design goals and the
information content (i.e., cost, complexity, ect.) must be minimized in order to
generate high quality designs.
Solution alternatives are created by mapping the requirements specified in one
domain to a set of characteristic parameters in an adjacent domain. The mapping
between the customer and functional domains is defined as concept design; the mapping
between functional and physical domains is product design; the mapping between the
physical and process domains corresponds to process design.
10
2.1.1 Domain
The world of design is made up of four domains; the customer domain, the
functional domain, the physical domain and the process domain.
Customer domain is characterized by needs that the customer is looking for in the
product or process or systems or materials.
In functional domain, the customer needs are specified in term of functional
requirements (FRs) and constraints domain (Cs).
To satisfy the specified FRs, design parameters (DPs) were conceived in the
physical domain.
Finally, to produce the product specified in term of DPs, a process that is
characterized was developed by process variables (PVs) in the process domain.
The domain on the left relative to the domain on the right represents “what we
want to achieve,” whereas the domain on the right represents deign solution of “how we
propose to satisfy the requirements specified in the left domain.” To ho from “what” to
“how” requires mapping. During this mapping process, the Independence Axiom must
be satisfied.
11
Figure 2.1 The Fundamental Concept of Axiomatic Design [16]
2.1.2 Hierarchies
According to Axiomatic principle, the essence of the design process lies in
hierarchies. The designers begin the design from comprehensive functional
requirements and a design can decompose functional requirements into many
hierarchies [Shin, et al, 2002].
2.1.3 Zigzagging
The zigzagging between functional requirements and design parameters is
necessary because the two sets of each level are connected and mutually dependent
[Shin, et al, 2002].
Mapping Mapping Mapping
{CA}
{FR}
{DP}
{PV}
Customer
Domain
Functional
Domain
Physical
Domain
Process
Domain
Concept design phase Product design phase Process design phase
