[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt1
Bruce Mayer, PE Engineering-11: Engineering Design
Bruce Mayer, PELicensed Electrical & Mechanical Engineer
Engineering 11
Engineering
Design
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt2
Bruce Mayer, PE Engineering-11: Engineering Design
OutLine Engineering Design What is engineering design, really? Function to form Design process Phases of design Product Realization/Development Process Concurrent engineering Teamwork Summary
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt3
Bruce Mayer, PE Engineering-11: Engineering Design
Design vs. Ambiguity Design ≡ a “valid” or “acceptable” Solution
to an OPEN-ENDED Problem• e.g.; Design a Cell-Phone that OUTSELLS All Others
All design challenges are ambiguous. • Unlike answers to mathematical expressions there
are always several “right” answers to ANY design challenge.
The answer is always uncertain or ambiguous. Not all design solutions are equally good
however, and some are definitely wrong.
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt4
Bruce Mayer, PE Engineering-11: Engineering Design
Well-Defined vs. Open-Ended Design Problems Have NO “Correct” Solution;
• Have only: Successful and UNsucessful Solutions• Compare to Skills-Development (practice) problems
Skills Development (Textbook Type)• Well-defined, • Complete (correctly
stated, unique)• Correct answer exists• Money not involved• You know When You
Arrive at the Answer• Requires Application of
Very Specific Knowledge
Design Problems (Open Ended)• Poorly-defined• No Unique Solution;
Depends on Approach• Cost & Schedule are
Critical Factors• “Done Point” Very Hard
to Identify• Need MultiDisciplinary
Knowledge
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt5
Bruce Mayer, PE Engineering-11: Engineering Design
Analysis vs. Synthesis Analysis → Know What IS/OCCURS and
Then Try to EXPLAIN it• A separating or breaking up of a whole into its
parts, with an examination of these parts to reveal their nature, proportion, function, interrelationships, etc.
Synthesis → Know What IS NEEDED and Then Try to CREATE (Design) it • The putting together of parts or elements so as to
form a whole
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt6
Bruce Mayer, PE Engineering-11: Engineering Design
Example MechEngr Design Analysis
• Forces• Moments• Flow• Pressure• Machines• Mechanisms• Motion• Energy
Conversion
Synthesis & Testing• Sketch/
Draw• Predict
Behavior– Model or
Test• SubScale
Tests or Experiments
• Materials• Manufacturi
ng
Realization• Customer
needs• Company
Requirements• Manufacturing
Costs• Performance
– Analysis– Testing
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt7
Bruce Mayer, PE Engineering-11: Engineering Design
Design vs. Analysis Which of the following is design and
which is analysis?a) Given that the customer wishes to fasten
together two steel plates, select appropriate sizes & materials for the bolt, nut & washer
b) Given the cross-section geometry of a new airplane wing then determine the lift it produces using Fluid Mechanics principles
Form is the solution to a design problem• In this Case the Bolt SIZE & Material
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt8
Bruce Mayer, PE Engineering-11: Engineering Design
Form FOLLOWS Function Function “Directs” Form Form ≡ Shape, Size, Configuration,
Weight, Human InterFace Appearance, Materials of Construction, etc.
DESIGN connects Form (the OutPut) to the desired Function (the InPut) Thru a DECISION-MAKING PROCESS
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt9
Bruce Mayer, PE Engineering-11: Engineering Design
FunctionForm Graphically
Function
DESIGN
Form
Control, hold, move, protect, heat/cool, store, amplify, etc.
Decision-Making Process
Shape, configuration, size, materials, manufacturing processes, etc.
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt10
Bruce Mayer, PE Engineering-11: Engineering Design
Engr-Design as Decision-Making Design Definition Short Version
• Set of decision making processes and activities to determine the FORM of an object, given the customer’s desired FUNCTION
Design Definition Long Version• The process of devising a system, component,
or process to meet desired needs. It is a decision-making process (often iterative), in which basic-science, mathematics and the engineering-sciences are applied to optimally convert resources to meet a stated objective
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt11
Bruce Mayer, PE Engineering-11: Engineering Design
Decision-Making Design ProcessFormulating
Problem
GeneratingAlternatives
AnalyzingAlternatives
EvaluatingAlternatives
ReDesignIteration
Establish Functional Requirements
Determine Constraints Set Performance Goals
DESIGN Specs
CREATE Alternative Forms (Shape, Configuration, Size, Materials, Power-Sources, etc.)
ALLAlternatives
FEASIBLE Alternatives
BEST AlternativeMANUFACTURING Specs
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt12
Bruce Mayer, PE Engineering-11: Engineering Design
“Phases” of Engineering Design How do design decisions change over
time? Is there a logical grouping of decisions? Illustrate with an Example: Design a
Brake for stopping a Spinning Shaft.• Requirements for Brake
– 8” Diameter, Horizontal shaft– 4330 Ni/Cr/Mo Alloy-Steel shaft material– 1000 Pound shaft weight– 3600 rpm maximum rotational speed
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt13
Bruce Mayer, PE Engineering-11: Engineering Design
FORMULATION Phase - Brake Early in the design process, we decide
upon the nature of the Functional Requirements, and Inputs for the Design
Decide upon a satisfactory rate of deceleration
Determine the length of the shaft
Determine where it is supported
Determine what actuating energy is available
Decide to Learn From existing similar products
Choose to research brakes in the library
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt14
Bruce Mayer, PE Engineering-11: Engineering Design
CONCEPT Design Phase - Brake Decide PHYSICAL PRINCIPLES that
will perform the braking function1. surface friction (e.g. drum brake,
disk/caliper)2. opposing magnetic fields (e.g., inverse
motor)3. air friction (e.g. fan blades)
Assume we DECIDE on surface friction
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt15
Bruce Mayer, PE Engineering-11: Engineering Design
CONFIGURATION Dsgn Phase Decide upon PRODUCT components
& how they are arranged/configured Product configuration:
• disk/caliper, or drum, or band brake• location on shaft (right, left, middle)
Assume we decide on a disk/caliper brake
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt16
Bruce Mayer, PE Engineering-11: Engineering Design
CONFIGURATION Dsgn Phase Decide upon PART features & how
they are arranged/configured Part configuration:
• relative size of hubto disk
• relative size of rotor thickness to diameter
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt17
Bruce Mayer, PE Engineering-11: Engineering Design
PARAMETRIC Design Phase Decide upon SPECIFIC VALUES for
design variables/parameters1. rotor diameter (outer)2. rotor thickness3. brake pad area4. pad material5. hydraulic pressure
on piston
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt18
Bruce Mayer, PE Engineering-11: Engineering Design
DETAIL Design Phase Decide upon the remaining
MANUFACTURING specifications• Machined rotor tolerances• Pad bonding resin cure
time & temperature• Assembly procedure• Testing procedure
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt19
Bruce Mayer, PE Engineering-11: Engineering Design
Final FORM is the Design Solution FUNCTION stop a spinning shaft FORM
• rotor: 10 inch diameter, Cast Iron, 3/8-inch thick, cooling passages
• Forged 4140 steel caliper/housing • brake pads, 2 opposing, 4 sq. in., metal
particles in epoxy matrix• Stainless steel 304 piston,1.25-inch
diameter, with elastomeric seals• 105 psi hydraulic piston pressure
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt20
Bruce Mayer, PE Engineering-11: Engineering Design
DesignPhase
Summary
Configuration Design
Problem Formulation
Concept Design
ParaMetric Design
Detail Design
Preliminary
Design Embodiment
Design
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt21
Bruce Mayer, PE Engineering-11: Engineering Design
Alternative Design-Phases Another, more Detailed, Description of the
Stages/Phases of Design1. ID Problem or Needed-Fcn2. Define the Goals/Performance3. Research & Gather-Data4. BrainStorm/Creative-Solutions5. Analyze Potential Solutions6. Develop & Test Models7. Make the Decision8. Communicate & Specify9. Implement & Commercialize
ConceptualDesign
PreliminaryDesign
Critical Design Review
FinalDesign
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt22
Bruce Mayer, PE Engineering-11: Engineering Design
Product Realization Process Also Known as the Product LIFE CYCLE
• Design Occurs during PRODUCT DEVELOPMENT Process
Industrial Design
Engineering DesignProduction Design
Manufacturing(Production)
DistributionService
Disposal
Customer Need
FullyRealizedProduct
Sales & Marketing
Product Development Process
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt23
Bruce Mayer, PE Engineering-11: Engineering Design
The Product Life Cycle
Manufacture
Design
Use
Retire
establish function, determine form
fabricate, purchase, assemble, test, ship/distribute
set up, operate & maintain, repair
TearDown/disassemble, recycle/dispose
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt24
Bruce Mayer, PE Engineering-11: Engineering Design
Product Life Cycle - Graphically
Definition Freeze
Product Development
Break Even timeOpportunity
Investigation
Innovation Cycle time
ProfitZoneRelease
Obsolescence
Product Development “Kicks Off” the Product Life Cycle
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt25
Bruce Mayer, PE Engineering-11: Engineering Design
ConCurrent Engineering Also Known as Simultaneous
Engineering, this Method Reduces the time spent in Product Development
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt26
Bruce Mayer, PE Engineering-11: Engineering Design
ConCurrent ENGR Elements non-linear product design approach all phases of product development
operate at the same time – simultaneously• Both product & process design run in parallel
and occur in the same time frame Product and Process are closely
coordinated to achieve Optimum Results in a short amount of time
Decision making involves full team participation and involvement
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt27
Bruce Mayer, PE Engineering-11: Engineering Design
WJ-2000 Concurrent Engineering
FSMenagh L. Harlamoff
HSPaek
B. Mayer
AKPlumley
AKMcGrogan
CEErickson
R. Reghitto
MSWalton
MSW
alton RSMurphy
DMDobkinZ. Yuan
B. Mayer
By Assignment• Sales Engineer• Safety Engineer• Manufacturing Engineer• Reliability Engineer• Service Engineer
SysEn
gr
ME
SWE
ME
ME
ME
Proces
sEngr
EE
ME
ME IE
Engr
Physic
s
ME
ME
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt28
Bruce Mayer, PE Engineering-11: Engineering Design
The Need for Engineering Teams Increasing Technology Content
• Complex Engineered Systems Have Too Much Information Content for Any One Person to Address
Speed• Time-To-Market Often Means the
Difference Between Profits & Losses• Teams Allow work to Be Done in
PARALLEL (at the SAME TIME)
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt29
Bruce Mayer, PE Engineering-11: Engineering Design
A Team What is it? A Team Is A Small Group Of People
With Complementary Skills Who Are Committed To A Common Purpose, Performance Goals, and Approach For Which They Hold Themselves MUTUALLY ACCOUNTABLE
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt30
Bruce Mayer, PE Engineering-11: Engineering Design
Team Attributes Common Goal
• This Must Be Clearly Communicated to Generate a Feeling of Common Purpose
Leadership• A Critical Function To Keep The
Team Focused Complementary Skills
• Resources are Limited; Each Team Member Should have a CLEARLY DEFINED and UNIQUE Role
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt31
Bruce Mayer, PE Engineering-11: Engineering Design
Team Attributes cont. Effective Communication
• A CRITICAL Leadership Function• Honest & Productive Communication is
Needed for Design/Solution Integration• Greatest advantage Humans have over the
rest of the Animal Kingdom is communication Creativity
• A “Close Knit” & Motivated Team Generates Creative Energy Thru Goal-Oriented Interaction
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt32
Bruce Mayer, PE Engineering-11: Engineering Design
All Done for Today
DilbertDesign
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt33
Bruce Mayer, PE Engineering-11: Engineering Design
Bruce Mayer, PERegistered Electrical & Mechanical Engineer
Engineering 11
Appendix
Engineering Rolls
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt34
Bruce Mayer, PE Engineering-11: Engineering Design
LifeCyc Engineering Activities Job Title Description Sales & Marketing
Sales Engineer Meets customers, determines needs, presents product offerings
Applications Engineer Assists sales & marketing solving technical issues with respect to the use of product
Field Service Engineer Installs, maintains and repairs equipment at customers’ sites
Research & Development
Industrial Designer Establishes essential product appearance, human factors
Design Engineer Decides part or product form including: shape, size, configuration, materials, and manufacturing processes
Materials Engineer Investigates and develops improved materials
Test Engineer Designs and conducts performance and safety tests
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt35
Bruce Mayer, PE Engineering-11: Engineering Design
LifeCyc Engineering ActivitiesManufacturing Industrial Engineer Designs fabrication,
assembly and warehousing systems
Manufacturing Engineer
Develops manufacturing tools and fixtures
Quality Control Engineer
Establishes and maintains raw materials and finished goods quality controls
Processing / Operations
Plant Engineer Designs and maintains processing plant facilities
Project Engineer Coordinates project work tasks, budgets and schedules
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt36
Bruce Mayer, PE Engineering-11: Engineering Design
The HYPE Cycle
[email protected] • ENGR-11_Lec-01_Intro_Engr_Design.ppt37
Bruce Mayer, PE Engineering-11: Engineering Design
Potato Sorting Machine Optyx® WPS for whole potatoes
achieves a three-way sort using a combination of air ejectors to remove foreign material (FM) and a unique deflector system to separate potatoes for rework from good potatoes. Maximizing the removal of foreign material and providing extremely gentle handling to avoid potato bruising, Optyx WPS improves product quality and protects downstream equipment while reducing labor costs and increasing yields.
http://www.key.net/products/optyx/optyx-wps-sorter/default.html