Innovative product design conceptualization with oil · PDF fileINNOVATIVE PRODUCT DESIGN ......
Transcript of Innovative product design conceptualization with oil · PDF fileINNOVATIVE PRODUCT DESIGN ......
University of Technology, Sydney
Faculty of Engineering
INNOVATIVE PRODUCT DESIGN
CONCEPTUALIZATION WITH OIL-LESS
TWO-STROKE ENGINE AS A CASE STUDY
by
Holger Roser
A thesis submitted for the degree of
Master of Engineering (by Thesis)C03017
Sydney
August, 2003
I wish to dedicate this to my parents,
Manfred and Ellen Roser,
whose kindness, support, and care I am forever grateful.
CERTIFICATE OF ORIGINALITY
I certify that the work in this thesis has not previously been submitted for a degree nor
has it been submitted as part of requirements for a degree except as fully acknowledged
within the text.
1 also certify that the thesis has been written by me. Any help that I have received in my
research work and the preparation of the thesis itself has been acknowledged. In
addition, I certify that all information sources and literature used are indicated in the
thesis.
Signature of Candidate
1
ACKNOWLEDGMENT
First and foremost, I would like to express my grateful appreciation to both the people
and organisations involved in this project, for their support and contribution in
completing this project. I pay my sincere gratitude to my supervisors, namely
Mr. John Dartnall (Principal Supervisor)
Mr. Chris Tyree (Industry Supervisor and Sponsor)
Dr. Fred Sticher (Co-Supervisor and Lecturer)
for their inspiration, enthusiasm, guidance, and encouragement, which made this
research successful. Special thanks go to Mr. Chris Tyree of TyTeam Pty Ltd and the
Tyree Group for providing the funding without which this research would not have been
possible.
I also owe thanks to Robert Cleary, Dylan Buckley, and Robert Smith, all
undergraduate project students, for their invaluable assistance and contribution to both
construction and testing of the research engine.
Additionally, I wish to thank all the workshop and technical personnel at UTS for their
highly valued assistance, in particular
Mr. Chris Chapman
Mr. Charles Evans
Mr. Bill Firth
Mr. Scott Graham
Mr. Matthew Low
Mr. Harold Myers
Mr. Richard Turnell
(Scientific Officer)
(Technical Manager)
(Technical Officer)
(Technical Officer)
(Engineer Mechanical Laboratories)
(Technical Officer)
(Technical Officer)
Appreciation is also given to the UTS Faculty of Engineering for providing the
opportunity, facilities, and resources for this project. Special reference is made to the
assistance provided by Rosie Hamilton for her constant willingness to help with
administrative issues, and Professor Stephen Johnston for his invaluable support and
advice.
Finally, acknowledgements are due to my family and friends without their
encouragement and emotional support I would not have tackled this project.
TABLE OF CONTENTS
Certificate of Originality.................................................................................................... i
Acknowledgment.............................................................................................................. ii
List of Figures................................................................................................................. vii
List of Tables................................................................................................................... ix
Glossary and Notations..................................................................................................... x
Symbols..........................................................................................................................xiii
Abstract........................................................................................................................... xv
Chapter 1: Introduction.......................................................................................................1
1.1. Background and Motivation............................................................................ 1
1.2. Problem Formulation....................................................................................... 2
1.3. Research Objectives......................................................................... ...A1.4. Research Scope and Procedure........................................................................ 5
1.5. Thesis Outline................................................................................................. 8Chapter 2: Innovative Product Development - An Overview......................................... 10
2.1. Introduction....................................................................................................102.2. Definitions......................................................................................................12
2.3. Product Development Approaches................................................................ 13
2.3.1. A Fundamental Product Development Process.................................... 13
2.3.2. Strategies of Product Development...................................................... 18
2.3.3. Classification of Design....................................................................... 21
2.3.4. Sequential Product Development Process............................................ 22
2.3.5. Parallel Product Development Process................................................ 24
2.4. Product Design Management........................................................................ 27
2.4.1. Project Planning and Control............................................................... 27
2.4.2. Organisational Structure and Climate.................................................. 29
2.4.3. Cross-Functional Teams...................................................................... 31
2.4.4. Supplier and Customer Integration.......................................................... 32 .
2.4.5. Communication.................................................................................... 33
2.4.6. Information Management and Infrastructure....................................... 35
2.4.7. Continuous Design Documentation..................................................... 36
2.5. Chapter Review............................................................................................. 36
Section Page
Chapter 3: Conceptual Design Approaches - A Summation...........................
3.1. Introduction.....................................................................................
3.2. Definitions.......................................................................................
3.3. Design Methodologies....................................................................
3.3.1. Axiomatic Design by Suh......................................................
3.3.2. Systematic Engineering Design by Pahl & Beitz..................
3.3.3. Total Design by Pugh.............................................................
3.3.4. Theory of Inventive Problem Solving (TRIZ)......................
3.3.5. Contradiction Oriented Innovation Strategy (WOIS)...........
3.3.6. Computer Aided Design Tools and Artificial Intelligence....
3.4. Design for X....................................................................................
3.4.1. Design for Manufacturing and Assembly.............................
3.4.2. Design for Reliability and Durability....................................3.4.3. Design for Serviceability and Maintenance..........................
3.4.4. Design for Disassembly and Recycling................................
3.5. Chapter Review.......................................... ....................................
Chapter 4: Innovative Conceptual Product Design - An Enhanced Approach
4.1. Introduction.....................................................................................
4.2. The Importance of the “Fuzzy Front End”.....................................4.3. Environment for Innovative Engineering Design..........................
4.4. The ICD Framework.......................................................................
4.5. Identification of Need.....................................................................
4.5.1. Market Analysis.....................................................................
4.5.2. Identification of Customer Needs.........................................
4.5.3. Technology Analysis..............................................................
4.5.4. Case Study..............................................................................
4.6. Product Definition...........................................................................4.6.1. Functional Decomposition.....................................................
4.6.2. Objectives Tree Method.........................................................
4.6.3. Quality Function Deployment...............................................
4.7. Determination of Product Attributes..............................................
4.7.1. Function Analysis..................................................................
4.7.2. Setting of Specification Requirements..................................
4.7.3. Determination of Critical Design Issues...............................
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IV
4.8. Concept Generation....................................................................................... 90
4.8.1. Creativity and Ideation......................................................................... 91
4.8.2. Morphological Analysis....................................................................... 92
4.8.3. Early Empirical Design........................................................................ 94
4.9. Concept Evaluation....................................................................................... 97
4.9.1. Weighted Objectives Method...............................................................98
4.9.2. Pugh Method.......................................................................................101
4.10. Concept Decision.........................................................................................102
4.11. Concept Classification and Evaluation Scheme - A Combined Matrix....104
4.12. Iteration and Refinements............................................................................109
4.13. Chapter Review.... ....................................................................................... 109
Chapter 5: Design in the Spotlight of TICS - Four Pillars of Design............ ........... 111
5.1. Introduction..................................................................................................Ill
5.2. Accelerated Product Design - The Time Focus.......................................... 1135.2.1. Benefits of Accelerated Product Design............................................ 114
5.2.2. Product Development Accelerators...................................................116
5.2.3. Risks and Implications........................................................................119
5.2.4. The Bottom Line.................................................................................121
5.3. Design for Originality - The Innovation Focus.......................................... 122
5.3.1. Technology Identification, Analysis, and Evaluation (TIAE)........... 1235.3.2. Innovation Risk and Technological Uncertainties............................. 126
5.3.3. The Bottom Line.................................................................................1285.4. Design for Affordability- The Cost Focus................................................. 129
5.4.1. Product Cost Management..................................................................130
5.4.2. Value Engineering.............................................................................. 131
5.4.3. The Bottom Line.................................................................................133
5.5. Reducing Design Complexity - The Simplicity Focus.............................. 134
5.5.1. Keep it Simple.....................................................................................135
5.5.2. Function Sharing................................................................................ 136
5.5.3. The Bottom Line.................................................................................138
5.6. Chapter Review....................................... 139
Chapter 6: Conceptual Design of an Oil-less Two-Stroke Engine - A Case Study... 140
6.1. Introduction.................................................................................................. 140
6.2. Case Study Background...............................................................................143
6.3. Engine Development Goals and Objectives................................................ 145
6.4. Engine Fundamentals and Definitions......................................................... 146
6.4.1. The Internal Combustion Engine........................................................ 147
6.4.2. The Two-Stroke Cycle........................................................................ 149
6.4.3. Scavenging.......................................................................................... 150
6.4.4. Engine Parameters.......................... 153
6.5. Preliminary Research and Determination! of Critical Design Issues........... 158
6.5.1. Stratified Charging.............................................................................. 160
6.5.2. Direct Fuel Injection........................................................................... 161
6.5.3. Oil-Less Operation.............................................................................. 164
6.5.4. Alternative Fuels................................................................................. 166
6.5.5. Homogeneous Charge Compression Ignition.................................... 167
6.6. Early Empirical Design................................................................................ 1696.6.1. Overall Engine Design........................................................................ 170
6.6.2. Kinematic Design................................................................................ 1716.6.3. Cylinder Head, Cylinder, and Scavenging Chamber Design.............. 174
6.6.4. Piston and Seal Design........................................................................ 178
6.6.5. Fuel Supply System............................................................................ 180
6.6.6. Engine Testing.................................................................................... 1816.7. Concept Iteration and Refinements....... ..................................................... 185
6.8. Chapter Review............................................................................................ 186
Chapter 7: Conclusions................................................................................................... 189
7.1. Research Review and Summary....................................................................189
7.2. Results and Contributions............................................................................ 192
7.3. Recommendations and Further Work.......................................................... 194
7.4. A Personal Note........................................................................................... 196
References....................................................................................................................... 197
Bibliography....................................................................................................................208
Appendices......................................................................................................................209
LIST OF FIGURES
Figure 1.1: Project Timeline..............................................................................................7
Figure 2.1: Product Development Process.......................................................................14
Figure 2.2: Uncertainty Matrix........................................................................................19
Figure 2.3: Taxonomy of Product Strategies.................................................................. 20
Figure 2.4: Stage-Gate Process....................................................................................... 22
Figure 2.5: Overlapping Stage-Gate Process.................................................................. 25
Figure 2.6: Functional Interactions of Concurrent Engineering.....................................26
Figure 2.7: Typical PERT Chart..................................................................................... 28
Figure 2.8: Organisational Structure............................................................................... 29
Figure 2.9: Modes of Communication............................................................................ 33
Figure 3.1: Committed & Incurred Cost During Design................................................ 39
Figure 3.2: Framework of Axiomatic Design....................................................... 42
Figure 3.3: Model of Systematic Design........................................................................ 45
Figure 3.4: Pugh’s Total Design Activity Model............................................................ 47
Figure 3.5: TRIZ Problem Solving Model...................................................................... 49
Figure 3.6: WOIS - Overcoming the Spiral of Evolution.............................................. 51
Figure 4.1: A Model of the Fuzzy Front End.................................................................. 62
Figure 4.2: The Design Paradox..................................................................................... 63
Figure 4.3: Environment for Creativity........................................................................... 64
Figure 4.4: Innovative Conceptual Design Framework.................................................. 68
Figure 4.5: Technology Identification, Analysis, & Evaluation Chart........................... 73
Figure 4.6: The Black Box Model...................................................................................77
Figure 4.7: Functional Decomposition of the Oil-Less Two-Stroke Engine Problem.... 78
Figure 4.8: Objectives Tree for the Oil-Less Two-Stroke Engine.................................. 80
Figure 4.9: House of Quality............................................................................................81
Figure 4.10: Hierarchical Structure of Engine Functions.............................................. 85
Figure 4.11: Morphological Chart for the Oil-Less Two-Stroke Engine....................... 93
Figure 4.12: Evaluation Chart for the Oil-Less Two-Stroke Engine.............................98
Figure 4.13: Weighted Values Assigned to the Objectives Tree from Figure 4.8.........99
Figure 4.14: Pugh's Evaluation Matrix for the Oil-Less Two-Stroke Engine............. 101
Figure Page
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Figure 4.15: Factors Influencing the Decision-Making Process....................................103
Figure 4.16: Concept Classification & Evaluation Scheme...........................................105
Figure 5.1: TICS Focus Model...................................................................................... 112
Figure 5.2: Product Cost Management..........................................................................131
Figure 5.3: Example of Function Sharing......................................................................137
Figure 6.1: Typical Configuration of a Two-Stroke Engine..........................................148
Figure 6.2: P-V Diagram of the Two-Stroke Cycle.......................................................149
Figure 6.3: Scavenging Arrangements........................................................................... 150
Figure 6.4: Typical Sequence of Two-Stroke Cycle Events..........................................152
Figure 6.5: Test Engine Model.....................................................................................170
Figure 6.6: Real Test Engine.......................................................................................... 171
Figure 6.7: Exhaust Valve Actuation Mechanism.........................................................175
Figure 6.8: Cylinder Head (Outside View)....................................................................176
Figure 6.9: Cylinder Head (Internal View)....................................................................176
Figure 6.10: Cylinder..................................................................................................... 177
Figure 6.11: Scavenging Chamber with Air-Inlet. Reed Valve. & Seal Package........177
Figure 6.12: Cylinder Assembly....................................................................................178
Figure 6.13: Piston with Piston Rings, Guide Ring, Piston Rod, & Rod End.............. 179
Figure 6.14: Flywheel with Magnet & Hall-Effect Sensors for Injection & Ignition... 180
Figure 6.15: Control Board............................................................................................ 181
Figure 6.16: Dynamometer............................................................................................ 182
Figure 6.17: Leakage Test.............................................................................................. 183
Figure 6.18: Initial Piston Ring & Modified Ring Design.............................................184
Figure 6.19: ICD Framework Applied to Case Study....................................................187
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LIST OF TABLES
Table 2.1: Reasons for New Innovative Products............................................................10
Table 2.2 Strategies of Innovative Product Development.............................................. 20
Table 2.3: Classification of Design................................................................................. 21
Table 3.1: Corollaries of Axiomatic Design................................................................... 43
Table 4.1: Identification of Need.....................................................................................69
Table 4.2: Market Analysis Methods...............................................................................71
Table 4.3: Market & Technology Data for Engine Concept........................................... 75
Table 4.4: Product Definition...........................................................................................76
Table 4.5: Determination of Product Attributes.............................................................. 83
Table 4.6: Engine Attributes............................................................................................86
Table 4.7: Rating Values for Some Specific Design Problems........................................89
Table 4.8: Concept Generation............................................ 90
Table 4.9: Concept Evaluation.........................................................................................97
Table 4.10: Five Point Evaluation Scale........................................................................100
Table 4.11: Concept Decision.......................................................................................103
Table 4.12: Maturity Scale............................................................................................. 106
Table 5.1: Classification of Costs.................................................................................129
Table 5.2: Value Engineering Aspects (adapted from Best 2000).................................132
Table 6.1: Case Study Procedures.................................................................................. 142
Table 6.2: Direct Fuel Injection Options........................................................................162
Table 6.3: Engine Mechanism Comparison..................................................................172
Table Page
GLOSSARY AND NOTATIONS
ACE Active Combustion Engine
AI Artificial Intelligence
ATAC Active Thermo-Atmosphere Combustion
BDC Bottom Dead Centre
CA Customer Attributes
CAD Computer Aided Design
CAE Computer Aided Engineering
CAM Computer Aided Manufacturing
CAPP Computer Aided Process Planning
CBR Case Based Reasoning
CCES Concept Classification and Evaluation Scheme
CE Concurrent Engineering
CFD Computational Fluid Dynamics
Cl Compression Ignition
CIM Computer Integrated Manufacturing
CL Complexity Level
CNG Compressed Natural Gas
CO Carbon Monoxide
C02 Carbon Dioxide
CPM Critical Path Method
DBD Decision Based Design
DCDI Determination of Critical Design Issues
DFA Design for Assembly or Design for Affordability
DFC Design for Cost
DFD Design for Disassembly
DFM Design for Manufacturing or Design for Maintenance
DFR Design for Recycling
DFS Design for Serviceability or Design for Simplicity
DFX Design for X
DI Direct Injection
DoE Design of Experiments
DP Design Parameters
DR Delivery Ratio
ECU Engine Control Unit
EED Early Empirical Design
EGR Exhaust Gas Recirculation
EPA Environmental Protection Agency (US)
EU European Union
FEA Finite Element Analysis
FR Functional Requirements
FSI Fuel Stratified Injection
GA Generic Algorithm
GDI Gasoline Direct Injection
HC Hydrocarbons
HCCI Homogeneous Charge Compression Ignition
1C Internal Combustion
ICD Innovative Conceptual Design
IDI Indirect Injection
LPG Liquefied Petroleum Gas
MADM Multiple Attribute Decision Making
ML Maturity Level
MODM Multiple Objective Decision Making
MON Motor Octane Number
NOx Nitrogen Oxides
NPD New Product Development
OCP Orbital Combustion Process
PA Problem Analogy
PC Problem Complexity
PEEK Polyetheretherketone
PERT Program Evaluation and Review Technique
PF Problem Familiarity
PDS Product Design Specification
PM Particulate Matter
PR Purity Ratio
PTFE Polytetrafluoroethylene
PV Process Variables
QFD Quality Function Deployment
R&D Research and Development
RC Relative Cost
RL Risk Level
RON Research Octane Number
RSM Response Surface Methodology
SI Spark Ignition
SiC Silicon Carbon
S02 Sulphur Dioxide
TDC Top Dead Centre
TIAE Technology Identification, Analysis, and Evaluation
TRIZ Teoriya Resheniya Izobreatatelskikh Zadatch (Theory of Inventive Problem Solving)
US United States
UTS University of Technology, Sydney
VA Value Analysis
VE Value Engineering
VDI Verein Deutscher Ingenieure
WOIS Widerspruchsorientierte Innovationsstrategie (Contradiction Oriented Innovation Strategy)
WOT Wide Open Throttle
SYMBOLS
B Cylinder Bore
S Piston Stroke
Sec Effective Compression Stroke
See Effective Expansion Stroke
a Crank Offset
rSb Stroke-to-Bore Ratio
Vd Displacement Volume
Vdec Effective Compression Displacement Volume
Vdee Effective Expansion Displacement Volume
Vc Clearance Volume
V, Total Cylinder Volume
Ap Piston Crown Surface Area
Ah Cylinder Head Surface Area
At Total Cylinder Surface Area
rc Compression Ratio
rgc Geometric Compression Ratio
rec Effective Compression Ratio
ree Effective Expansion Ratio
cp Crank Angle
Nc Rotational Speed of Crank
(oc Angular Velocity of Crank
vpm Mean Piston Velocity
nr Number of Crank Revolutions per Cycle
Pet Cylinder Pressure at TDC
pcs Cylinder Pressure after Scavenging
A/F Air/Fuel Ratio
m*a Mass Flow Rate of Air
m*/ Mass Flow Rate of Air
Qhv/ Lower Heating Value
Qa Heat Addition
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Zq, Cumulative Heat Release Fraction
n Weibe Form Factor
a Weibe Efficiency Factor
P Power Output
T Torque or Temperature
mep Mean Effective Pressure
imep Indicated Mean Effective Pressure
bmep Brake Mean Effective Pressure
fmep Friction Mean Effective Pressure
sfc Specific Fuel Consumption
Y\th Thermal Efficiency
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ABSTRACT
Innovative Product Design Conceptualization
with Oil-Less Two-Stroke Engine as a Case Study
Innovative product design is a creative process, involving extensive skills and
knowledge, numerous stakeholders with often conflicting interests, and a variety of
trade-off decisions. The multitude of different variables to be considered together with
the complex nature of engineering design confronts designers with a difficult challenge.
The objective of this thesis is to establish a methodology that will help to formalise and
enhance innovative conceptual product design. To achieve this, an oil-less two-stroke
engine concept has been taken as a case study in order to elaborate, demonstrate, and
validate the proposed Innovative Conceptual Design framework. The methodology aims
to yield design process insight and transparency, and embodies two major phases: the
Pre-Development activities, including the identification of need and product definition,
and the Conceptualization Loop, which comprises the determination of attributes,
concept generation, concept evaluation, and concept decision.
In this present research, the Determination of Critical Design Issues together with Early
Empirical Design are identified as two essential aspects of successful conceptual
design. Early detection of potential design problems is vital for making intelligent and
rapid concept decisions before significant development resources are committed. This
approach also allows critical design issues to be tackled first in order to avoid going
down blind alleys, and helps to control risk and cost.
The thesis presents the author’s view of conceptual design as involving a continuous
focus on four major pillars of design, namely the Time Focus, the Innovation Focus, the
Cost Focus, and the Simplicity Focus, the “TICS Focuses”. On the basis of this
perception the discrete design activities during the entire design process aim to develop
an innovative, inexpensive, and simple product that is introduced to the marketplace in a
timely manner. This may require the designer to make a number of compromises, which
can be facilitated by the early detection of design problems by means of Early Empirical
Design.
In essence, the suggested conceptual design framework supports design engineers in
making issues and problems obvious in the early, least-costly phases of product
development. This is the key to accelerating the overall design process and avoiding
product failures.
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