2.1 product modeling 2.2 virtual prototyping ent 452: rapid engineering ruslizam daud product...
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2 .1 P RODUCT M ODELING2 .2 V IRT UA L P ROTOT YPING
ENT 452 : RA P ID ENG IN EERIN GRUSLIZA M DA UD
Product Modeling and Virtual Prototyping
2.1 Product Modeling
This section will help to answer the following questions:
Is there any systematic way to
model a product or prototype?
How to organize all aspects of the model
design phase?
How to choose which model type to use, formal or informal
models?
2.1 Product Modeling
1. Product Model is a model of a product metric that is representation, simplification or estimation of a product’s realization to aid in making product decisions.
2. To establish a model, a wealth of data needs to be collected to develop analytical models, including customer needs, PDS, the house of quality, chosen product concepts, etc.
2.1 Product Modeling
Model Preparation: To map and relate the customer need/weight to the
product function
Model Prioritization: To identify the functions that relate most strongly to
the customer needs
Model Quantification: To choose the metrics or engineering characteristic that may
be used to quantify the material, energy or signal flows for these functions. To identify
target values for these metrics based on benchmarking.
House of Quality (QFD)
House of Quality (QFD)
House of Quality (QFD)
2.1 Product Modeling
Informal model
•A designer’s interpretation of description of customer needs, engineering characteristics, manufacturing requirement, etc.
Formal model
•It constructs a computable or analytical model of the design problem. The goal is to find the optimal design variables to satisfy design requirement.
2.1 Product Modeling INFORMAL MODEL
What is the problem really about?
What implicit expectations and desires are involved?Are the customer’s needs,
requirements, and constraints truly appropriated?
What characteristic or properties must the product have/must the product not
have?What are technical conflicts inherent in the design task?What aspects of the design task should be quantified
now?Are there any other features
of the product?
2.1 Product Modeling (example: Retractable earphone)
What is the problem really about?
What implicit expectations and desires are involved?
Are the customer’s needs, requirements, and constraints
truly appropriated?What characteristic or properties must the product have/must the
product not have?
What are technical conflicts inherent in the design task?
What aspects of the design task should be quantified now?
Are there any other features of the product?
When removed, always get caught and tangled
Usability, comfort, portability, quality, cord length
Small and light
Comfortable, easy to operate/bulky, awkward
A coil of spring to wind/unwinding the cord, the spool diameter must be
largeTotal length of the cord, retracting device length and acceptable
tension.
Aesthetic
2.1 Product Modeling (example: Binder clip)
1. Interview
2. Present cost scenario
3. Cost breakups
4. Technical questioning
5. Mission statement
6. Technical evaluation
7. Material selection
8. Manufacturing technique used
1.together papers, official, 50-100 pieces, easy, compact, average
2.Not many binder can hold more than 150 pieces, available cost about RM 3.50 each,
plastic and Al spring3.Assembly, transportation, design costs,
material cost, packaging, advertising, profit
4.Basic use, customer needs, company aim, product operation/usage
5.Hold 150 pieces, easy to use, not too stylish, formal, use metal to increase
product life cycle
6. thickness, mouth open, material high spring constant, torque compression.
7. Longevity, steel with powder coating
8. Forging, bending, powder coating
2.1 Product Modeling FORMAL MODEL
•Identify a material, energy, or information flow associated with each effect of the product concept.•The flow is the possible interaction of the product with its usage environment.
Step 1:Identify a flow
•Identify a balance relationship for the flow to find the equilibrium equation to model the system.
Step 2:Identify a balance
relationship
•Recognize the boundary conditions of the product concepts. How its is loaded, how does it interact as a system in environment including human interface. What are the input and outputs across the boundary, and its limit ranges.
Step 3: Identify a boundary for the
balance relationship
2.1 Product Modeling FORMAL MODEL
•Convert the balance relationship to a mathematical form by assigning geometric variables, material property constants to formulate a set a equations. Applied m mathematics and science are required. •A number of assumptions and simplifications are needed.
Step 4:Formulate an
equation for the balance relationship
•Use the model to explore design configuration options
Step 5:Design
exploration
2.1 Product Modeling FORMAL MODEL: PRODUCT MODEL FOR JAR OPENER
Step 1:Identify a flow
Step 2:Identify a balance
relationship
Step 3: Identify a boundary for the
balance relationship
Customer need Flow
Easy to store Kitchen
Easy to hold Handle
Receive the torque Force
Increase the torque Force
Grasp the jar tops Jar tops
2.1 Product Modeling FORMAL MODEL
•F1=F sin θ•F2=F cos θ•Ff=F1µ=F sin 赕Ff·L1=F2·L2
Step 4:Formulate an
equation for the balance relationship
•With this model, the working principles of this kind of opener is known and this product can be improved.•The length of L2 needs to be optimized in order to get the best effect of increasing torque and facility to be operated.
Step 5:Design
exploration
L2
L1
FfF2
θ F
F1
2.1 Product Modeling
Solid model
Surface model
Wire frame
2.1 Product Modeling
CAD data
2.1 Product Modeling
FEA
Inertia
Fatique
Mass prop.
dynamicLinear and non linear
Heat transfer
Mold flow
2.2 Virtual Prototyping
Virtual prototyping is combining the virtual environment with engineering design to mallow designer or engineer to play an active role in the design sensitivity and optimization process.
Virtual reality is a system that provides a non-real environment but gives the feeling of real sense.
2.2 Virtual Prototyping
Robotic part handling
Parts in fixture
Parts on conveyor
Components interaction
2.2 Virtual Prototyping
Observe
Parts going jammed in
transfer line
Robot can successfully pick
part in right orientation
Modular fixture can firmly
clamped for machining
Redesign consideration for cost
down purpose and quality /functional
improvement
2.2 Virtual Prototyping
Clearance
Friction
Chamfers
Parts Feasibility
2.2 Virtual Prototyping
1. Observe a visual representation of the
virtual parts and equipment involved
2. Can interactively manipulate a virtual part or equipment through haptic
interface devices according to the force and motion
3. Can feel the objects and hear the sounds
from virtual work cell
Tutorial and Quiz
T1•Prepare the Customer Attributes CAs according to Primary, Secondary and Tertiary level. Case study product: Manual Inflator (11-12/8/08)
Q1•Develop a product model (informal or formal model) for mechanical pencil (12/8/08)