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Bruce Mayer, PE Engineering-11: Engineering Design

Bruce Mayer, PELicensed Electrical & Mechanical Engineer

[email protected]

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



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.



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



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



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



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



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



FunctionForm Graphically

Function

DESIGN

Form

Control, hold, move, protect, heat/cool, store, amplify, etc.

Decision-Making Process

Shape, configuration, size, materials, manufacturing processes, etc.



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



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



“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



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



CONCEPT Design Phase - Brake

Decide PHYSICAL PRINCIPLES that will perform the braking function

1. 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



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



CONFIGURATION Dsgn Phase

Decide upon PART features & how they are arranged/configured

Part configuration:• relative size of hub

to disk• relative size of

rotor thickness to diameter



PARAMETRIC Design Phase

Decide upon SPECIFIC VALUES for design variables/parameters

1. rotor diameter (outer)

2. rotor thickness

3. brake pad area

4. pad material

5. hydraulic pressure on piston



DETAIL Design Phase

Decide upon the remaining MANUFACTURING specifications• Machined rotor tolerances• Pad bonding resin cure

time & temperature• Assembly procedure• Testing procedure



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



DesignPhase

Summary

Configuration Design

Problem Formulation

Concept Design

ParaMetric Design

Detail Design

Preliminary

Design Embodiment

Design



Alternative Design-Phases Another, more Detailed, Description of the

Stages/Phases of Design1. ID Problem or Needed-Fcn

2. Define the Goals/Performance

3. Research & Gather-Data

4. BrainStorm/Creative-Solutions

5. Analyze Potential Solutions

6. Develop & Test Models

7. Make the Decision

8. Communicate & Specify

9. Implement & Commercialize

ConceptualDesign

PreliminaryDesign

Critical Design Review

FinalDesign



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



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



Product Life Cycle - Graphically

Definition Freeze

Product Development

Break Even timeOpportunity

Investigation

Innovation Cycle time

Profit

ZoneRelease

Obsolescence

Product Development “Kicks Off” the Product Life Cycle



ConCurrent Engineering

Also Known as Simultaneous Engineering, this Method Reduces the time spent in Product Development



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



WJ-2000 Concurrent Engineering

FSMenagh L. Harla

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B. Mayer

AKPlumley

AKMcGrogan

CEE

rickson

R. Reghitto

MSWalton

MSW

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DMDobkinZ. Yuan

B. Mayer

By Assignment• Sales Engineer• Safety Engineer• Manufacturing Engineer• Reliability Engineer• Service Engineer

SysEn

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ME

SWE

ME

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Proce

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Engr

EE

ME

ME IE

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Physic

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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)



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



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



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



All Done for Today

DilbertDesign



Bruce Mayer, PERegistered Electrical & Mechanical Engineer

[email protected]

Engineering 11

Appendix

Engineering Rolls



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



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



The HYPE Cycle



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

http://starwars.wikia.com/wiki/File:ATAT-CHRON.jpg

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