Bruce Mayer, PE Licensed Electrical & Mechanical Engineer [email protected]

[email protected] • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt1

Bruce Mayer, PE Engineering-11: Engineering Design

Bruce Mayer, PELicensed Electrical & Mechanical Engineer

[email protected]

Engineering 11

Configuration

Design



OutLine Configuration Design What is a product configuration? What is a part configuration? Product architecture design Part configuration design Evaluating Configurations Computer Aided Design (CAD) Computer Aided Engineering (CAE)



OverView – Config Design The Configuration Design moves the

Design-Concept from the diagram phase to the one where specific components are now identified so that we can proceed to manufacture.• Start to Develop Specific Sizes, Shapes,

and Orientations• Begin to Apply Highly Quantitative

Science and Mathematics



What is Configuration Design? Example Design Problem

Reduce Rotational Speed Design Concept Gear Pair

geometry & material

Physical principle:PowerIn = PowerOut

2211 TT



Possible GearPair Configurations Alternative configuration 1

ARRANGE Part Differently



Possible GearPair Configurations Alternative configuration 2

Use different FEATURES or PARTS

SpurGears

Helical gears



Possible GearPair Configurations Alternative configurations 3 & 4

Use different RELATIVE DIMENSIONS

Wide Gear Face Similar Diameters



What is Configuration Design? Example Design Problem

Support Vertical Load Design Concept Wall Bracket

geometry & material

Physical principle:Force Equilibrium

0F



Wall Bracket Configurations Abstract

Embodiment

DifferentFeatures

DifferentArrangement

s

DifferentDimensions



Configuration Decisions Configuration Problem Required Decisions Product Types of component

Number of components Arrangements / connectivity Relative dimensions

Special purpose part Geometric features Arrangements of features Relative dimensions Design variable / Parameter list

Standard part, or Standard subassembly

Type of component Relative dimensions Design variable / Parameter list

To Create Different Configs Change one or more of these



Select the BEST Configuration Use the General

Design Process as a Model for Choosing Between Configuration Alternatives

FormulatingProblem

GeneratingAlternatives

AnalyzingAlternatives

EvaluatingAlternatives

ReDesignIteration

DESIGN Specs

ALLAlternatives

FEASIBLE Alternatives

BEST AlternativeMANUFACTURING Specs



ConfigurationDesign

ConfigurePart(s)

Configure Product

Analyzeand

Refine

Itera

te

Re-examine EDS Research sourcesConfiguration requirements sketch

Best concept(s)

Design for FunctionDesign for AssemblyDesign for Manufacture

Bestconfiguration(s)

Pugh’s MethodWeighted Rating MethodEvaluate

Product architecture Integral / modular Standard / special purpose



Product Architecture Analogous to Building Architecture

Architecture Style Scheme

COLONIAL1st Floor Rms: dining, living2nd Floor Rms: Bedroom, Office

RANCH all rooms on ground floor

Rooms arranged Using a logical “scheme.”• Before the details of the house are designed

we determine the general layout or “architecture.”



Example Product Architecture This “System

Architecture” Shows the Major SubSystems (the “rooms”), and their Physical Locations relative to each other (the “Floor Plan”)



Example Product Architecture

March 1992 Jun 1994



ReCall Product DeCompositionProduct

Subassembly AStandardPart

Standard part

Special purpose part

Special purposePart

Subassembly B


Subassembly B1

Standard part


Showsa) type, number, arrangement of

componentsb) standard or special purpose

(buy vs. make)



Product Architecture PRODUCT ARCHITECTURE is the

scheme/plan by which the functional elements of a product are arranged into physical building blocks (components, subsystems or subassemblies) that interact with each other to perform the overall function of the product

Product architectures can be “modular” or “integral”



Modular ArchitectureProduct

examplesFlashlight

RefrigeratorAutomobile

Personal computer

Modular components Batteries, bulbsMotors, compressor, switchesTires, radios, seats, brakes, enginesDrives, keyboards, mice, Displays “Chunks” implement one or a few

functions Interactions between chunks are well

defined (standard interfaces and/or connections)



Integral ArchitectureProduct examples

Car Body/ChassisPrinter case

ShaftBeverage cup

Integral components One-Piece Welded Structureintegral snap-fastenersmachined bearing race integrated handle

a single chunk implements many functions

Interaction is ill defined Physical element “shares” functions



Developing Architectures1. Create a schematic of functional and physical

elements2. cluster elements into logical chunks to:

exploit standard components to exploit standard interfaces (e.g. 115 VAC, USB) fully utilize manufacturing process(es), or suppliers provide for maintenance

3. sketch a rough geometric layout4. identify interactions between elements5. refine layout



Example Design Printer Identify

• SubFunctions• InterActions



Example Design Printer Cluster

Elements into Logical “Chunks”



Example Design

Printer

Sketch rough geometric “layout”



a REFINEDLayOut



Example Design Printer

Sketch the Interaction Diagram



Part ConfigurationDesign

ConfigurePart(s)

Configure Product

Analyzeand

Refine

Itera

te


Best concept(s)




Product architecture Integral / modular Standard / special purpose



Part Configuration DesignConfiguration Problem Required Decisions

Special Purpose Part Geometric FeaturesFeature ArrangementRelative DimensionsDesign Variable List

Many Issues Associated with Each Decision• Consider just Geometric Features

walls rounds cubes notchesribs bosses sphere

schamfers

projections

cylinders

holes grooves

fillets tubes slots



Generating Alternatives Recall

BracketConfigurations

AbstractEmbodimen

t

DifferentFeatures

DifferentArrangement

s

DifferentDimensions



Example Sponge Holder1. Prepare configuration requirements

sketch

Sponge

Holder



Example Sponge Holder2. Prepare NON-Contiguous

configuration requirements sketch



Example Sponge Holder3. Prepare alternative CONTIGUOUS

configuration sketches



Example Sponge Holder4. Refine

Configs

hole in back wall hole in offset wall



ConfigurationAnalysis

ConfigurePart(s)

Configure Product

Analyzeand

Refine

Itera

te


Best concept(s)




Product architecture Integral / modularStandard / special purpose



Analysis Queries Will the Configuration Perform the

Desired FUNCTION? Can all the Parts be MADE

(manufactured)? Can the

Configuration be ASSEMBLED?



Design for Function (DFF) Functional Considerations List

Strong Stiff or flexible Buckling Thermal expansion Vibrate Quiet / Noise Heat transfer Fluid(s) transport

and/or storage Energy efficient Stable

Reliable Human

factors/ergonomics Safe Easy to use Maintain Repairable Durable (wear,

corrosion) Life-cycle costs Styling/aesthetics



Design for Assembly (DFA) Assembly ≡ a process of handling

components to bring them together (inserting) and then fastening them.

Design for Assembly ≡ a set of design practices which reduce the manpower time required to handle, insert and fasten components of a product.



DFA Reduce Handling Handling GMOP: Grasping, Moving,

Orienting, Placing. Design parts or products to reduce the

influence on handling Size Thickness Weight Nesting Tangling

Fragility, Flexibility, Slipperiness, Stickiness

need for: 2 hands, tools, optical magnification, mechanical assistance, etc



DFA Reduce Insert & Fasten Insertion & Fastening Mating a part to

another part or sub-assembly. Design parts or products to reduce the effort

associated with inserting & fastening Accessability Resistance (force) to

Insertion Visibility Ease of Alignment &

Positioning

Depth of insertion Separate operation

required Fastener used



DFA GuideLines from the SME minimize part count minimize levels of assembly (number of assemblies) encourage modular assembly use standard parts stack sub-assemblies from the bottom up (use gravity) design parts with self-fastening features (snap-fits,

press-fits) facilitate parts handling (grasp, orient, move) design parts with self-locating features (e.g. chamfers,

aligning recesses/dimples) eliminate reorientation (i.e. insertion from 2 or more

directions) eliminate (electrical) cables



PROs & CONs of DFA Design Guidelines

• pros: fast, easy, non-coupled• cons: non-quantitative; no metric to

compare alterative designs Assembly Efficiency

• pros: systematic, comparative • cons: takes time to code & calculate

TimeAssy ActualTimeAssy Minimum lTheoretica

ma



ConfigurationEvalualtion

ConfigurePart(s)

Configure Product

Analyzeand

Refine

Itera

te


Best concept(s)



Pugh’s MethodWeighted Rating Method

Evaluate




Evaluation Methods Once the design concepts are generated and

evaluated for feasibility, the surviving design concepts need to be evaluated to determine which one is “BEST.”

How does one define “BEST”? One common method is to use the criteria for

the design and weight the relative importance of these facotor to determine the “BEST” OverAll Design• Note: the designers must be careful not to rig the

weighting to make a favorite come out “best.”



Evaluate Sponge Holder ConFigs

hole in back wall hole in offset wall



Eval by Weighted Rating Method1. List evaluation criteria (in a column).2. Determine importance weights (in an

adjacent column)3. List alternatives (along the top row)4. Rate each alternative on each criterion5. Compute the weighted rating for each

criterion6. Sum the ratings to produce the

Overall Weighted Rating



Eval Sponge Holder ConFigsSponge Holder Configuration Ratings

With hole With bracket Criteria

Importance

Weight Rating Wt. Rating Rating Wt. Rating Function drains well 15 3 0.45 3 0.45 dries quickly 10 3 0.30 3 0.30 stays clean 10 2 0.10 3 0.15 sponge inserts easily 15 2 0.40 4 0.80 Manufacture material usage 10 3 0.30 2 0.20 tooling costs 15 3 0.45 2 0.30 processing costs 5 3 0.15 3 0.15 Assembly handling 5 3 0.15 3 0.15 insertion 5 3 0.15 3 0.15 number of parts 10 3 0.30 3 0.30 100%

Weighted rating 2.75 2.95



Config DesignSummary

ConfigurePart(s)

Configure Product

Analyzeand

Refine

Itera

te


Best concept(s)



Pugh’s MethodWeighted Rating Method

Evaluate




Using Sketches in ConFig Dsgn Sketches are used often in

configuration design Sketches assist creativity Sketches are not

typically used to “document” the “design”• But CAN be used to

Document“IDEAS”



Creative Visualization Sketching Stimulates Creativity And

Helps Visualization• Sketching Ideas That Are Partially

Developed Often Aids The Design ProcessDo Not Wait Until You Have A Clear Picture Before

You Start SketchingAllow Yourself The Freedom To Make Mistakes

Visualization Of The Entire Design Is Essential But Often IMPOSSIBLE Without the Aid Of Sketches



Sketches for Patent Doc.



USA Patent App. 20030113451



CAD DWGs for ConFig Design Typically used to Produce “LayOuts” LayOut Characteristics

• If Physical Object, then drawn PRECISELY to Scale showing ALL Parts– Check for Form and Fit

• If Schematic, the shows precisely ALL Components and InterConnections– Check for Proper Control of Fluid, Electrical,

Optical, Magnetic, or Information “Flow”



LayOut For FC CCA Enclosure



LayOut for 800mm Glass Coater



Elect Pwr & Control Schematic



Uses of Accurate LayOuts LayOuts often serve as Input to CAE

Software which aids Feasibility Checks Partial List of CAE tools

Structural Mechanics (FEA)

Computational Fluid Dynamics (CFD)

Coupled Physics Rapid ProtoTyping

ElectroMagnetics SPICE (Analog

Electrical Circuit) Wire/Pipe Routing

Software Kinematics



Computational Fluid Dynamics



All Done for Today

LayOuts: TransistorPlumbing

Transistor LayOut byMAGIC Software



Bruce Mayer, PERegistered Electrical & Mechanical Engineer

[email protected]

Engineering 11

Appendix



WJ-1000 Product



Method 6-3-5 (Brain-Writing) The traditional brainstorming relies on verbal

communications.• Idea generation may be dominated by a small

number of aggressive members. Guidelines for 6-3-5 method Team members are arranged around a

circular table to provide continuity. Six (6) members are ideal.

Each member sketches three (3) ideas for the product configuration or functions. Sketches should be the focus of this activity. The top five product functionswith respect to the customer needs are considered.

Bruce Mayer, PE Licensed Electrical & Mechanical Engineer [email protected]

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