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Contents

1 Introduction 11.1 Th e En ginee ring Design er 11.1.1 Tasks an d Ac tivities 1

1.1.2 Position of th e Design Processwithin a Com pany 61.1.3 Trends 61.2 Necessity for System atic Design 91.2.1 Re quirem ents and the Needfor System atic Design 91.2.2 H istor ical Backgro und 101.2.3 C urren t M ethods 141.2.4 Aims an d Objectives of this Book 19

2 Fundamentals 272.1 Fu nda m entals of Technical Systems 272.1.1 Systems, Plant, Equ ipmen t, M achines,Assemblies and Com ponen ts 272.1.2 Co nversion ofEnergy,M aterial an d Signals 292.1.3 Functional Interrelationship 312.1.4 W orking Interrelations hip 382.1.5 Co nstructional Interrelationship 422.1.6 System Inter relatio nsh ip 422.1.7 System atic Gu ideline 432.2 Fu ndam entals of the Systematic Ap proach 452.2.1 Problem Solving Process 452.2.2 Ch aracteristics of Good Prob lem Solvers 492.2.3 Problem Solving as Information Processing . . . . 512.2.4 General W orking M ethodology 532.2.5 Generally Applicable M etho ds 582.2.6 Role of C om pute r Sup port 62

3 Product Planning S olution Finding and Evaluation 633.1 Produc t Plann ing 633.1.1 Degree of Novelty ofaProd uct 64

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i Contents3.1.2 Prod uc t Life Cycle 643.1.3 Co m pan y Goals an d Th eir Effect 653.1.4 Pro duc t Plann ing 66

3.2 Solution Finding M ethods 773.2.1 Con ventional M ethod s 783.2.2 Intuitive M ethods 823.2.3 Discursive M etho ds 893.2.4 M ethods for Co m bining Solutions 1033.3 Selection an d Evaluation M etho ds 1063.3.1 Selecting Solution Variants 1063.3.2 Eva luating Solution Variants 109

Product Development Process 1254.1 General Problem Solving Process 1254.2 Flow of W ork Du ring the Process of Designing 1284.2.1 Activity Plann ing 1284.2.2 Tim ing and Scheduling 1344.2.3 Plan ning Project an d Pro duc t Costs 1364.3 Effective Org anisa tion Stru ctu res 1384.3.1 Interdisciplinary Co ope ration 1384.3.2 Leadership an d Team Behaviour 141

Task Clarification 1455.1 Im po rtan ce of Task Clarification 1455.2 Setting Up a Require ments List Design Specification) 1465.2.1 Conten ts 1465.2.2 Fo rm at 1475.2.3 Identifying the Re qu irem ents 1495.2.4 Refining and Ex tend ing the Requirem ents 1515.2.5 Compiling the Re quire m ents List 1525.2.6 Exam ples 1535.3 Using Re quirements Lists 1535.3.1 Updating 1535.3.2 Partia l Re quirem ents Lists 1565.3.3 Fur ther Uses 1575.4 Prac tical Application of Re quirem ents Lists 157Conceptual Design 1596.1 Steps of Co ncep tual Design 1596.2 Abstracting to Identify the Essen tial Problem s 1616.2.1 Aim of Abstrac tion 1616.2.2 Broaden ing the Problem Form ulation 1626.2.3 Identifying the Essen tial Prob lemsfrom the Requirem ents List 1646.3 Establishing Function Stru ctur es 169

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Contents xix6.3.1 Overall Fu nctio n 1696.3.2 Breaking a Fun ction Down into Subfunctions . . 1706.3.3 Practical Applications of Fu nction Struc tures . . 1786.4 Developing W orking Structu res 1816.4.1 Searching for W orking Principles 1816.4.2 Com bining W orking Principles 1846.4.3 Selecting W orking Struc tures 1866.4.4 Practical Application of W orking Structu res 1866.5 Developing Co ncep ts 1906.5.1 Firming Up into Principle Solution V a ri a n ts .. .. 1906.5.2 Evaluating Principle Solution Varian ts 1926.5.3 Prac tical Application of Developing Concepts . . 1986.6 Exam ples of Co ncep tual Design 1996.6.1 On e-H and ed Hou sehold W ater Mixing Tap 1996.6.2 Im pulse -Loading Test Rig 210

Embodiment Design 2277.1 Steps of Em bod ime nt Design 2277.2 Checklist for Em bo dim ent Design 2337.3 Basic Rules of Em bod im ent Design 2347.3.1 Clarity 2357.3.2 Sim plicity 2427.3.3 Safety 2477.4 Principles of Em bo dim ent Design 2687.4.1 Princ iples of orceTransm ission 2697.4.2 Princ iple of the Division ofTasks 2817.4.3 Pr inciple of Self-Help 2907.4.4 Princ iples of Stability an d Bi-Stability 3017.4.5 Principle s for Fault-Free Des ign 3057.5 Guidelines for Em bod ime nt Design 308

7.5.1 General Co nsid eratio ns 3087.5.2 Design to Allow for Ex pansion 3097.5.3 Design to Allow for Creep and Relaxation 3217.5.4 Design Against Co rros ion 3287.5.5 Design to M inim ise W ear 3407.5.6 Design for Ergono mics 3417.5.7 Design for Aesthetics 3487.5.8 Design for Product ion 3557.5.9 Design for Assembly 3757 5 1 Design for M aintenance 3857 5 11 Des ign for Recycling 3887 5 12 Design for M inimu m Risk 4027 5 13 Design to Stan dards 4107.6 Evaluating Em bod im ent Designs 4167.7 Example of Em bod im ent Design 4177.8 Detail Design 436

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xx Contents8 Mechanical Connections Mechatronicsand Adaptronics 4398.1 M echanical C onn ection s 439

8.1.1 Gen eric Fun ctions and General Beh aviour 4408.1.2 M aterial Co nne ction s 4408.1.3 Form Co nnec tions 4418.1.4 Force C onn ection s 4438.1.5 Ap plications 4478.2 M echatronics 4488.2.1 Gen eral Arc hitecture and Term inology 4488.2.2 Goals and Lim itations 4508.2.3 Developm ent of M echatronic Solution s 4508.2.4 Exam ples 4518.3 Ad aptron ics 4588.3.1 Fund am entals and Terminology 4588.3.2 Goals and Lim itations 4598.3.3 Developm ent of A dap tron ic Solutions 4608.3.4 Exam ples 461

9 Size Ranges and Modular Products 4659.1 Size Ranges 4659.1.1 Sim ilarity Laws 4669.1.2 Decimal-Geom etric Preferred Nu m ber Series . . 4 6 99.1.3 Rep resentation an d Selection ofStepSizes 4729.1.4 Geom etrically Sim ilar Size Ranges 4769.1.5 Sem i-Similar Size Ran ges 4819.1.6 Development ofSizeRanges 493

9.2 M odular Prod ucts 4959.2.1 M odular Pro du ct Systematics 4969.2.2 M odular Pro du ct Developm ent 4999.2.3 Advantages and Limitations of M odu lar Systems 5089.2.4 Exam ples 5109.3 Recent Ration alisation App roaches 5149.3.1 M odularisation and Produ ct Architecture 5149.3.2 Platform C on stru ctio n 515

10 Design for Quality 51710.1 Applying a Systematic Ap proach 51710.2 Faults and Dis turbin g Factors 52110.3 Fault-Tree Analysis 52210.4 Failure M ode and Effect Analysis FMEA) 52910.5 Qu ality Fun ction Dep loym ent QFD) 531

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Contents xxi11 Design for Minimum Cost 53511.1 Cost Factors 53511.2 Fun dam entals of Cost Calculations 53711.3 M ethods for Estim ating Costs 539

11.3.1 Co m par ing with Relative Costs 53911.3.2 Es timating Using Share of M aterial Costs 54411.3.3 Es tim ating Using Regression Analysis 54511.3.4 Ex trapolatin g Using Sim ilarity Relations 54711.3.5 Cost Structu res 55811.4 Target Co sting 56011.5 Rules for M inim ising Costs 561

12 Summary 56312.1 The Systematic Approach 56312.2 Exp eriences of App lyingthe Systematic App roach in Practice 567References 571English Bibliography 603Index 609