prototyping teaching materials to accompany: product design and development chapter 12 karl t....
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Prototyping
Teaching materials to accompany:
Product Design and DevelopmentChapter 12
Karl T. Ulrich and Steven D. Eppinger2nd Edition, Irwin McGraw-Hill, 2000.
Product Design and DevelopmentKarl T. Ulrich and Steven D. Eppinger2nd edition, Irwin McGraw-Hill, 2000.
Chapter Table of Contents
1. Introduction2. Development Processes and Organizations3. Product Planning4. Identifying Customer Needs5. Product Specifications6. Concept Generation7. Concept Selection8. Concept Testing9. Product Architecture10. Industrial Design11. Design for Manufacturing12. Prototyping13. Product Development Economics 14. Managing Projects
PlanningPlanning
Product Development Process
ConceptDevelopment
ConceptDevelopment
System-LevelDesign
System-LevelDesign
DetailDesign
DetailDesign
Testing andRefinement
Testing andRefinement
ProductionRamp-Up
ProductionRamp-Up
Prototyping is done throughout the development process.
Concept Development Process
Perform Economic Analysis
Benchmark Competitive Products
Build and Test Models and Prototypes
IdentifyCustomer
Needs
EstablishTarget
Specifications
GenerateProduct
Concepts
SelectProduct
Concept(s)
Set Final
Specifications
PlanDownstreamDevelopment
MissionStatement Test
ProductConcept(s)
DevelopmentPlan
Four Uses of Prototypes• Learning
– answering questions about performance or feasibility– e.g., proof-of-concept model
• Communication– demonstration of product for feedback– e.g., 3D physical models of style or function
• Integration– combination of sub-systems into system model– e.g., alpha or beta test models
• Milestones– goal for development team’s schedule– e.g., first testable hardware
Types of Prototypes
ComprehensiveFocused
Physical
Analytical
finalproduct
betaprototype
alphaprototype
ballsupport
prototype
simulationof trackball
circuits
equationsmodeling ball
supports
trackball mechanismlinked to circuit
simulation
notgenerallyfeasible
Physical vs. Analytical PrototypesPhysical Prototypes
• Tangible approximation of the product.
• May exhibit unmodeled behavior.
• Some behavior may be an artifact of the approximation.
• Often best for communication.
Analytical Prototypes• Mathematical model of the
product.• Can only exhibit behavior
arising from explicitly modeled phenomena. (However, behavior is not always anticipated.
• Some behavior may be an artifact of the analytical method.
• Often allow more experimental freedom than physical models.
Focused vs. Comprehensive Prototypes
Focused Prototypes• Implement one or a few
attributes of the product.
• Answer specific questions about the product design.
• Generally several are required.
Comprehensive Prototypes• Implement many or all
attributes of the product.• Offer opportunities for
rigorous testing.• Often best for milestones
and integration.
Boeing 777 TestingBrakes Test• Minimum rotor thickness• Maximum takeoff weight• Maximum runway speed• Will the brakes ignite?
Wing Test• Maximum loading• When will it break?• Where will it break?
Comprehensive Prototypes
Cost of Comprehensive PrototypeHighLow
Tec
hn
ical
or
Mar
ket
Ris
k
Hig
hL
ow
One prototype may be used for verification.
Few or no comprehensiveprototypes are built.
Many comprehensiveprototypes are built.
Some comprehensiveprototypes build (and sold?).
Prototyping Strategy• Use prototypes to reduce uncertainty.• Make models with a defined purpose.• Consider multiple forms of prototypes.• Choose the timing of prototype cycles.
–Many early models are used to validate concepts.–Relatively few comprehensive models are
necessary to test integration.
• Plan time to learn from prototype cycles.–Avoid the “hardware swamp”.
Rapid Prototyping Methods
• Most of these methods are additive, rather than subtractive, processes.
• Build parts in layers based on CAD model.• SLA=Stereolithogrpahy Apparatus• SLS=Selective Laser Sintering• 3D Printing• LOM=Laminated Object Manufacturing• Others every year...
Virtual Prototyping
• 3D CAD models enable many kinds of analysis:– Fit and assembly– Manufacturability– Form and style– Kinematics– Finite element analysis (stress, thermal)– Crash testing– more every year...