ES1050 – Introductory Engineering Design and Innovation Studio

Models and Prototypes

Prof. Paul Kurowski

This is a group assignment, only one copy per team should be submitted

Where to submit?

To the studio locker in TEB on the second floor

Prototype definitions

A prototype is an original type, form, or instance of

something serving as a typical example, basis, or

standard for other things of the same category.

http://en.wikipedia.org/wiki/Prototype

Models and Prototypes

Abstractions and simplifications of final design as needed to demonstrate, test and refine a design

Physical prototypes are needed to demonstrate, test and refine a design

Prototype Goals

Types of Prototypes 1

Proof-of-Principle Prototype

Form Study Prototype

Visual Prototype

Functional Prototype

http://en.wikipedia.org/wiki/Prototype

Types of Prototypes 2

Virtual (CAE) CAD models Mathematical models Numerical models

Physical Proof-of-concept Industrial design Experimental Alpha Beta Pre-production

DESIGN

PROTOTYPING

TESTING

PRODUCTION

CAD

PROTOTYPING

TESTING

PRODUCTION

CAE

FEA

Windows OS

solid CAD

TRADITIONAL PRODUCT

DESIGN PROCESS

SIMULATION DRIVEN PRODUCT

DESIGN PROCESS

affordable computers

CAE tools are implemented to move design iterations from physical prototypes to virtual space of numerical (computer) models

Why CAE?

Mathematical model

Vibration of a single degree of freedom system

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Numerical model

Motion of a mechanism

Numerical model

Modes of vibration of a tuning fork

Numerical model

Modes of vibration of a pumpkin

Types of Prototypes

Virtual (CAE) CAD models Mathematical models Numerical models

Physical Proof-of-concept Industrial design Experimental Alpha Beta Pre-production

Proof-of-concept Prototypes

Demonstrate feasibility Simple construction Often only a part or

subsystem Usually not fully

functional! Not sufficient for design

validation!

http://me118.stanford.edu/pictures/Win01Projects/TooShort/images/2nd%20prototype.JPG

Industrial Design Prototype How will the product look and feel? Simple materials (foam, wood, etc.) Usually non-functional

http://www.linternaute.com/auto/mondial-automobile-concept-car/audi-rsq3.jpg

1962 Prototype of Lunar Module

Industrial Design Prototype

Experimental Prototype Intended for

physical experiments and testing

Often only a subsystem

Prototype of shock-absorbing casterTest results

Alpha Prototype Include most but not all functions of the final design Answer questions about overall layout of the design

http://drwho.virtadpt.net/pictures/memorial-day-2004/apple-prototype.jpg

Beta Prototype

Fully functional prototype Final product form Purpose is final testing Different manufacturing

processes used Machining rather than

injection molding Made by hand

Pre-Production Prototype

Made using final production processes and tooling

Identical to the final product

Used to fine-tune the production process

Pre-production Prototypehttp://www.dpreview.com/articles/canoneos5d/

Prototype Goals

Answer simple questions (e.g. will an idea work?) Obtain feedback from customers Aid in visualization Provide realistic models for marketing and advertising Study the “look and feel” of the product Functional testing and evaluation

Prototype Construction in ES1050

Inexpensive Easy No special

tools Quick

http://www.ben.com/LEGO/rcx/picoscout/breadboard.jpg

Common Prototyping Materials in ES1050 Wood Plastic

Plexiglass Cardboard and

paper Metal

http://www.riscx.com/pyramac/proto_pics/proto_3_600.jpg

Prototyping Tools in ES1050

Simple hand tools Scissors Screwdrivers Wrenches

Simple joining methods Glue Duct tape Screws

Construction kits you may want to use in ES1050 Lego Meccano Others

http://www.sentex.net/~mwandel/legos/legos.html

Lego Many mechanical

and electrical parts

Inexpensive and easy

No tools required

http://www.hamster.dk/~purple/robot/iBOT/lego_robot_prototype.jpg

http://www.cs.rhul.ac.uk/eca/micromouse/lego/shakey/images/parts.jpg

Meccano Uses metal parts Simple tools

www.meccano.com

http://webperso.easyconnect.fr/esteve.jeanmax/j.e.o/fotopi%E8ces/MarklinPiecP.jpg

Rapid Prototyping is available to ES1050

Creates a physical prototype directly from a CAD model

Can include color Uses low-strength

materials

www.zcorp.com

Rapid Prototyping

www.zcorp.com

Rapid Prototyping

Types of prototypes commonly used in ES1050

ES050 Prototypes in 2006/2007

when the main Design Project was to “Demonstrate a Scientific Principle”

Select the incorrect statement about a prototype

A Does not have to be in the natural size

B Does not have to convey the essential design idea

C Can be material or virtual

D Can be made using simplified manufacturing processes

E Does not have to look identical as the indented final design