EC180 Engineering Practice

Engineering Design

Chulantha Kulasekere
Department of Electronic and Telecommunication Engineering University of Moratuwa ekulasek@gmail.com

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Dierence Engineering Design and Engineering Science

Engineering Science Problem Problem statement is compact and well-posed Problem has a readily identiable closure Solution is unique and compact Problem uses specialized knowledge

Engineering Design Problem Problem statement is incomplete, ambiguous, and self-contradictory Problem does not have a readily identiable closure Solutions are neither unique nor compact Problem requires integration of knowledge from many elds

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A Typical Engineering Science Problem Statement

A simply supported steel beam with a 3 diameter circular cross-section is loaded as shown. Determine the maximum stress and deection.

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Another Engineering Science Problem Statement

How much current is owing through the circuit 0.1 sec after the switch is closed?

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A Typical Engineering Design Problem Statement

Design a system for lifting and moving loads of up to 5000 lb in a manufacturing facility . The facility has an unobstructed span of 50 ft. The lifting system should be inexpensive and satisfy all relevant safety standards.

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Summary

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ABET Denition of Design

Engineering design is the process of devising a system, component, or process to meet desired needs. It is a decision-making process (often iterative), in which the basic sciences and mathematics, and engineering sciences are applied to convert resources optimally to meet a stated objective. Among the fundamental elements of the design process are the establishment of objectives and criteria, synthesis, analysis, construction, testing, and evaluation. The engineering design component of a curriculum must include: development of student creativity, use of open-ended problems, development and use of modern design theory and methodology, formulation of design problem statements and specications, consideration of alternative solutions, feasibility considerations, production processes, concurrent engineering design, and detailed system descriptions. Further, it is essential to include a variety of realistic constraints, such as economic factors, safety, reliability, aesthetics, ethics, and social impact.
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The Designs
James Watts Steam Engine

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The Designs
Henry Fords Motor Car

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The Designs
Sony Walkman

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The Designs
Philips -CD Player

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The Designs
Tank Sorowwa (Maduru Oya where Old and the New Met)

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The Designs
Biso Kotuwa (A Sri Lankan Invention to reduce water pressure)

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The Designs
The Toilet (We were the rst and not the French)

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The Designs
For discussion

How does the anti lock braking system work? Explain the shape of an aircraft wing Why is a dierential needed? What is the use of the independent suspension system in a car? Explain the fabrication of the bullet proof vest Why do cement bricks have holes in the middle? How does a thermos ask work? How does a touch screen work? How do you take a picture with a camera?

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Our Design History in the Recent Past

Heavy dependence on foreign technology Heavy dependence on imported machinery Heavy dependence on imported consumer products No clear support from state

Why? Local inventors were not supported by Colonial Rulers No local development in-line with technological development took place during last 200 years No signicant contribution from the educated sector to improve the technology generation in Sri Lanka

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Characteristics of a Design Engineer

ability to identify problems ability to simplify problems creative skills sound technical knowledge sense of urgency analytical skills sound judgment decisiveness open mindedness ability to communicate negotiating skills supervisory skills.

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Characteristics of a Design Engineer

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Why Engineering Design is Important

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Thinking Outside the BOX

Connect the dots using 4 straight lines without lifting the pen

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Thinking Outside the BOX

Now connect the dots using 3 straight lines without lifting the pen

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Thinking Outside the BOX

4 lines

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Thinking Outside the BOX

3 lines

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Some Software Tools used in Engineering Design

Project management tools (eg. Planner, MS Project) Mind mapping tool (eg. Freemind, MindMeister, XMind) Circuit design EDA (eg. OrCAD, Altium Designer, Proteus) Solid Modeling (eg. SolidWorks, Medusa, FreeCAD, Pro Engineer)

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Ten Step Model of the Design Process

1. Recognizing the need 2. Dening the problem 3. Planning the project 4. Gathering information 5. Conceptualizing alternative approaches 6. Evaluating the alternatives 7. Selecting the preferred alternative 8. Communicating the design 9. Implementing the preferred design 10. Evaluating the design

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Step 1: Recognizing the Need

Communicate with the client (communication is the key) Identifying the client needs against wants (customer requirements matrix.pdf) A requirement is something the product should do/produce or a quality that it must have. A customer requirements matrix can be lled if necessary.

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Step 1: Recognizing the Need

Dierent Perspectives on Requirements

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Step 1: Recognizing the Need

A typical example1

Sandra: Jane, we need you to design a stronger bumper for our new passenger car. Jane: Why do we need a stronger bumper? Sandra: Well, our current bumper gets easily damaged in low-speed collisions, such as those that occur in parking lots. Jane: Well, a stronger bumper may be the way to go, but there may be better approaches. For example, what about a more exible bumper that absorbs the impact but then returns to its original shape? Sandra: I never thought of that. I guess I was jumping to conclusions. Lets restate the need as there is too much damage to bumpers in low-speed collisions. That should give you more exibility in exploring alternative design approaches.
1

Tapping rubber, Writing on the Moon

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Step 2: Dening the Problem

Goal Objective Constraints Use of design Notebooks Use of Mind Map tools to dene the problem Describe the problem by writing a problem statement. Your problem statement must answer three questions:
What is the problem or need? Who has the problem or need? Why is it important to solve?

You can elaborate these ideas and gather information later

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Design Notebooks
Part of Leonardo daVincis notebook

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Design Notebooks
Part of Thomas Edisions notebook

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Design Notebooks

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Step 3: Planning the Project

Using a tool to develop a Gantt Chart Identifying the milestones and the costs involved.

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Step 4: Gathering Information

Information sources to do a background research Verify the accuracy Organize and categorize the collected information To make a background research plan, a road map of the research questions you need to answer:
Identify questions to ask about your target user or customer. Identify questions to ask about the products that already exist to solve the problem you dened or a problem that is very similar. Plan to research how your product will work and how to make it. Use this Background Research Plan Worksheet to help you develop your own plan.

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Step 5: Conceptualizing Alternative Approaches

Create design options (deal with objectives and constraints) Concurrent engineering: which is sometimes called Simultaneous Engineering or Integrated Product Development (IPD), is a work methodology based on the parallelization of tasks (i.e. performing tasks concurrently). It refers to an approach used in product development in which functions of design engineering, manufacturing engineering and other functions are integrated to reduce the elapsed time required to bring a new product to the market. Totally dierent approaches should be analyzed and pruned (eg. AnalyzeaPhysicalProduct.pdf) The alternatives can be based on new ideas, examining existing solutions to come up with better designs or based on creating and using analogies (applying design methods applied to other artifacts). All of these will enrich the creative process.
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Brainstorming as a Tool for Idea Generation

Composition:
Small team (5 to 10 members allowing individual ideas not to be hidden) Diverse team: Select team members from dierent backgrounds. people with little and more experience

Logistics
Short meetings: brainstorming should be less than an hour Record meetings: Identify a person to record the ideas on a board etc

Meeting protocol:
Group members should be considered equal: no hierarchy Nonjudgmental: nothing is stupid Quantity over quality Build ideas: create new ideas by combining and building other ideas

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Methods for Generating New Ideas

Checklist: Is a tabulation of ways that an objective can be achieved. Attribute Listing: table of attributes of the device considered and the possible values or solutions for each attribute. Attribute values can be combined in dierent ways to generate new ideas as well. Morphological analysis: All the permutations of the attribute listing is called a morphological analysis. Ideation This creative process of developing multiple ideas to solve a single problem is called ideation.

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Example of Generating Alternatives via New Idea Generation (1)

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Example of Generating Alternatives via New Idea Generation (2)

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Step 6/7: Evaluating/Selecting the Alternatives

Determine the eects and impact of each alternative Use an objective evaluation methods (using formula, probability, or science principle) The Universal Design Criteria can also be used: Elegance, Robustness, Aesthetics, Cost, Resources, Time, Skill required, Safety. Note that alternatives should be compared across a common set of criteria Collect critiques via a decision matrix eg. DecisionMatrix.pdf The answer to the above lies on the dierent feasibilities learned before: Technical, Economic, Fiscal, Social/political/environmental.

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Universal Design Criteria

Elegance. An elegant design solution is simple, clever, or ingenious. It might have fewer parts to wear out or fail. It might combine solutions from dierent areas in an inventive way not seen before. All good designers strive for elegance in their designs. Robustness. A robust design is unlikely to fail, even when used in conditions more severe than it was designed for. It is sturdy or resilient, perhaps bending, but not breaking in hard use. Aesthetics. If everything else is equal, people prefer a solution that is tasteful and pleasing to look at. Cost. What will it cost? Can the target user aord the solution? Do you have enough money to build your prototype? Resources. Do you have all the materials and equipment you need for your engineering project, or will you be able to obtain them quickly and at a very low cost? Time. Do you have enough time to complete your design and make it before the due date? Allow time for doing additional research and xing problems. It is very rare for everything to work correctly the rst time. Skill Required. Do you have the skills to build and implement your solution, or can you learn them in the time available? Safety. Is your solution safe to build, use, store, and dispose of?
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The Funnel

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Example Analysis
Design of a portable wheelchair ramp. Requirements: Meet the disable people act, The ramp must be adjustable to slopes between 1:20 and 1:12, have a minimum width of 36 inches., ramp must be inexpensive, should be wheelchair-transportable. Lets say the brainstorming activity yielded: an inatable ramp, a foldable stainless steel ramp, berglass ramp In a case such as this the analysis might consist of the following questions:
Can the ramp be made adjustable to slopes between the values given? Can the ramp be made with a width of at least 36 inches? Can the ramp with the above specications be wheelchair-transportable? What is the cost of the ramp with all of the above characteristics?

Use the techniques learned to suggest an analysis.

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Step 8: Communicating the Design

Use of language to bridge the gap between the design swamp to land of the client Documentation methods which have to be followed. Balance between the technical content and the marketing content to meet the needs of the client.

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What issues do you see with the lack of communication within the design groups?

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Design Innovation Strategies

Concurrent engineering: Concurrent engineering is a work methodology based on the parallelization of tasks (i.e. performing tasks concurrently). It refers to an approach used in product development in which functions of design engineering, manufacturing engineering and other functions are integrated to reduce the elapsed time required to bring a new product to the market. Re-engineering (redesign): refers to a fundamental rethinking and radical redesign of a system. Reverse Engineering: refers to the process of taking apart an object or system to see how it works and design based on your ndings. Failures are the pillars of success A glue that did not stick well enough was nearly abandoned after a lot of research but became the solution to 3M post-it notes which took the world by storm.
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Mode rened way of looking at Design Strategies

Top-Down

Also called functional decomposition implementation details considered only at the lowest level top-down design, is not so clean and linear in practice Often implementation-level commitments are made at high levels in the design process

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Mode rened way of looking at Design Strategies

Case Based

Research a specic, similar design case study Model your process on that

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Mode rened way of looking at Design Strategies

Incremental Redesign

Find an existing design and unravel the design from the bottom up Modify as required Detailed and least global aspects of the design are explored and redesigned, if necessary, rst

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Mode rened way of looking at Design Strategies

Incremental Redesign

An iterative top-down approach First a rough, approximate and general design is completed Then we do it ner, more exact and more specic This process continues iteratively until the complete detail design in done

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Mode rened way of looking at Design Strategies

Bottom-up Design

Opposite of top-down Start at the bottom with detail design To do this, you must have some idea of where you are going. So, often this becomes a Hybrid Design

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Mode rened way of looking at Design Strategies

Hybrid Design

Combines aspects of both top down and bottom up More practical design approach then pure top down Start with a top-down approach, but have feedback from the bottom

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Mode rened way of looking at Design Strategies

Explorer Method

Typically used for new design ideas or research It is useful in initial design and specication stages, and is often used when in unfamiliar territory

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Example Exercises

5E method of addressing the supermarket organizer Building a single heat element coee maker (http://www.engineerguy.com/videos/video-coee-maker.htm)

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