Mechanical Engineering Department Andalas University TMS 306

ENGINEERING DESIGN
2 cr.

Adjar Pratoto 2010

Quotes
If you fail to plan, you plan to fail. (Varanasi, 2006) The mere formulation of a problem is far more often essential than its solution, which may be merely a matter of mathematical or experimental skill. (Albert Einstein) If you dont know where youre going, youll probably end up somewhere else. (Yogi Berra)

Learning Objectives
After completing the course, the students should be able to:      differentiate the analytical approach and the design approach describe different design process models explain design phases communicate effectively work in team

References:
1. 2. 3. Cross, N., Engineering Design Methods, 2nd Ed., John Wiley & Sons, Chichester, 1994 Eggert, R.J., Engineering Design, Pearson Prentice Hall, Upper Saddle River, N.J., 2005 Dieter, G.E., Engineering Design, 3rd Ed., McGraw-Hill Intl. Ed., Singapore, 2000

Engineering Undertaking
New idea Define need or opportunity Specify criteria for success Determine probability of success Low probability - drop

High probability Market analysis Product or system design and cost estimate Feasibility study Refine and revise Feasible Not feasible - drop

Research and development

Stoecker, 1980

Implement construct or manufacture

Product Realization Process

Product Realization Process

Realized product Product development

Product design Engineering design Industrial design Sales/marketing

Disposal Service Distribution Manufacturing (Production)

Customer need

Ref.: 2

 A customer need for a new or improved product can originate from almost anywhere in the firm, but the majority ideas usually originate from the sales or marketing group Industrial design activities focus on how the new or revised product idea is compatible with the customers anatomical limitations and/or aesthetic trends in the marketplace Engineering design activities result in recommended manufacturing specifications that satisfy the customers functional performance requirements and manufacturing constraints Production design activities involve the design, fabrication, and installation of production equipment, such as jigs, fixtures, quality control instrumentation, and material handling equipment. In some cases, it might involve the construction of a new factory.
Ref.: 2

 Manufacturing activities relate to fabrication, assembly, and testing. They also include training, scheduling, and supervising production employees. Significant coordination between engineering design, production planning, and manufacturing is necessary during ramp-up as bugs in the product design and manufacturing processes are worked out. Distribution activities involve shipping the product in wholesale-sized lots to distribution centers located around the country or world. Service activities for consumer products usually relate to repair or replacement at the factory. However, large appliance manufacturers will train repair persons for home service. Disposal activities involve the removal, elimination, and/or recycling of hazardous chemicals or scarce materials
Ref.: 2

The four stages in the life of a product

Design Establish function Determine form Fabricate Assemble Distribute Set up Operate Maintain Repair Take down Disassemble Recycle Dispose

Manufacture

Use

Retire

Ref.: 2

To satisfy the consumer We must consider all the phases in the life of a product

What is engineering design?

A goal directed problem solving activity (Archer) Decision making in the face of uncertainty with high penalties for error (Asimow) The use of scientific principles, technical information and imagination in the definition of a mechanical structure, machine or system to perform pre-specified functions with maximum economy and efficiency (Fielden) To device, subject to certain problem solving constraints, a component, system or process to accomplish a specified task optimally, subject to certain solution constraints (Dixon)

What is engineering design?

Establishes and defines solutions to and pertinent structures for problems not solved before, or new solutions to problems which have previously been solved in a different way (Blumrich) Process of devising a system, component, or process to meet desired needs (ABET, Inc.) Engineering design integrates mathematics, basic sciences, engineering sciences and complementary studies in developing elements, systems and processes to meet specific needs. It is a creative, iterative and often open-ended process subject to various constraints (CAB, Canada)

In the course of performing design work, evidence of the following should be present:
Iterative re-evaluation re-assessment and redevelopment of work plans, specification and constraints Ongoing communication with key stakeholders or their representatives Co-operative approaches (team work)

Scientific method vs Design method

Existing knowledge
Communication Acceptance

State of the art Identification of need Conceptualization Feasibility analysis Production Design Method

Scientific curiosity Hypothesis Logical analysis Proof Scientific Method

The Four Cs of Design

Creativity
Requires creation of something that has not existed before or not existed in the designers mind before

Complexity
Requires decisions on many variables and parameters

Choice
Requires making choices between many possible solutions at all levels, from basic concepts to smallest detail of shape

Compromise
Requires balancing multiple and sometimes conflicting requirements
Ref.: 3

Types of design
Original design Variant design Adaptive design Selection design Redesign Artistic design Tinkering

Ref.: 2

Variant design seeks to modify the performance of an existing product by varying some of its design variable values or product parameters, such as size, or specific material, or manufacturing processes. Note, however, that the fundamental working principle or concept is usually maintained. Adaptive design is when we adapt a known solution to accomplish a new task. Original design refers to conceiving and embodying an original, innovative concept for a given task. It develops a new component, assembly, or process that had not existed before.

In selection design, we match the desired functional requirements of a component with the actual performance of standard components listed in vendors catalogs. Redesign. Much of our working career will be devoted to the improvement of existing products. To obtain the improvements we usually modify parts, or subassemblies, or combinations thereof, by changing their shapes, sizes, configurations, materials, and manufacturing processes. Since design is determining form, whenever we improve an aspect of form, we are essentially redesigning

Design projects commonly fall into one of five types:

Variation of an existing product Improvement of an existing product Development of a new product for a lowvolume production run Development of a new product for mass production One-of-a-kind design

Ref.: 3

Design Process

 Anybody can design products! The design engineer has specific skills: - He can use analytical tools

Structured Design Methodologies Get Results!

Notable design cycle time reductions: Xerox (design cycle)
70s 1990 1995 3 yr. < 2 yr. 30 wk. 50 mo. 20 mo.

Caterpillar
1980 1993

Steps in the Engineering Design Process

Design Phases
Formulation

Concept

Preliminary Design

Configuration Embodiment Design Parametric

Detail

Work breakdown structure

Widget Design

Problem Formulation

Concept Design

Configuration Design

Parametric Design

Detail Design

site visit QFD/HoQ Eng. Characteristics Constraints Saisfaction curves Select strategy Develop plan Design review meeting

Generate alternative concepts Analyze alternatives Evaluate alternative Refine Design review meeting

Develop architecture Generate configurations Analyze

Parametric problem formulation Generate alternatives Analyze alternatives

DFA DFM Evaluate Refine Desin review meeting

FMEA Fault trees Fishbone diagrams Evaluate alternatives Optimization Multi-attribute opt. Design review meeting

Detail drawings Assembly drawings Illustrations Project Report Prototype test reports Oral presentations Design review meeting

Need Identification - Clarifying objectives

When a client, sponsor or company manager first approaches a designer with a product need, it is unlikely that the need will be expressed very clearly The starting point for a design is therefore very often an ill-defined problem Customer requirements (Maslow, 1943):
Ref.: 1, 3

Physiological needs Safety and security needs Social needs Psychological needs Self-fulfillment needs

Stage 1: Clarifying objectives

Gathering Information from customers:

Interviews with customers Focus group discussion Customer surveys (external and internal) Customer complaints Constructing a survey instrument: Determine the survey purpose Determine the type of data-collection method Identify what specific information is needed Design the questions Arrange the order of questions Pretest the survey Administer the survey

Ref.: 3

Stage 1: Clarifying objectives

The Objectives Tree Method

Prepare a list of design objectives Order the list into sets of higher-level and lower-level objectives

Draw a diagrammatic tree of objectives, showing hierarchical relationship and interconnections

The branches (or roots) in the tree represent relationship which suggest means of achieving objectives Ref.: 1

Ref.: ECE 404 Scott Umbaugh

Establishing functions

The Function Analysis Method

Express the overall function for the design in terms of the conversion of inputs into outputs The overall , black box function should be broad widening the system boundary. Break down the overall function into a set of essential sub-functions The sub-functions comprise all the tasks that have to be performed inside the black box. Draw a block diagram showing the interactions between sub-functions The black box is made transparent, so that the sub-functions and their interconnections are clarified. Draw the system boundary The system boundary defines the functional limits for the product or device to be designed.

Search for appropriate components for performing the sub-functions and their interactions. Many alternative components may be capable of performing the identified functions. Ref.: 1

Determining characteristics

Quality Function Deployment (QFD) House of Quality

QFD is a planning and problemsolving tool for translating customer requirements (CRs) into the engineering characteristics (ECs) Listen to the voice of customer

House of Quality

Customer Requirement Whats

House of quality

1. Identify the customers (internal and external): consumers, manufacturing, regulators, distribution, marketing, sales 2. List the customer needs (WHAT is to be done), they can be list as primary, secondary and tertiary 3. Determine the primary importance or priority of the customer needs (scale of 1-5 or 1-10) (use if possible pairwise comparison) 4. Translate customer needs into measurable engineering requirements (HOW to do it in term of measurements). Each customer need can correspond to multiple engineering requirements that can be expressed in quantifiable terms, 5. Determine relationship of engineering design requirements to customer needs

House of quality

6. Use customer to benchmark existing products and evaluate the perceived competitions ability to meet the needs (1-not satisfied need, 5-fully satisfied need) 7. Rank the technical difficulty for each engineering requirement (1-5 or 1-10) 8. Define interrelationship between technical requirements, 9. Set target values and ideal values for engineering requirements, 10.Define the most critical engineering requirements by analyzing the conjunction between customer needs, benchmarking, interactions and importance

Design Requirements Customer Requirements

QFD 1
Design Requirements

Part Requirements

Part Requirements

Design Requirements Target

QFD 2

Manufacturing Requirements

Manufacturing Requirements

Part Requirements Target

QFD 3

Production Requirements

Manufacturing Requirements Target

QFD 4

Production Requirements Target

Generating alternatives

Generating alternatives

Alternative concepts 1 Subfunctions Transmit Brake Steer Chain Disc Belt Drum Fly-bywire 2 3 Gearbox

Handlebar Control Stick

Generating alternatives

Feature Support Propulsion Power Transmission Steering Stopping Lifting Operator Wheels Driven wheels Electric Gears and shaft Turning wheels Brakes Hydraulic ram Seated at front Track Air thrust Petrol Belts Air thrust Reverse thrust Rack and pinion Seated at rear

Means Air cushion Moving cable Diesel Chains Rails Ratchet Screw Standing Chain or rope hoist Walking Remote control Slides Linear induction Bottled gas hydraulic Steam Flexible cable Pedipulators

Evaluating Alternatives
The screening criteria should focus on functionality and manufacturability:
Will the concept likely function? Will the concept likely meet the customers minimum performance requirements? Will the concept likely survive the operating environment? Will the concept likely satisfy other critically important customer requirements? Will the concept be manufacturable? Will the concept likely satisfy the financial and/or marketing requirements?

The evaluation method:

Weighted-rating Method Pughs Concept Selection Method

The weighted objectives method

List the design objectives Rank-order the list of objectives Assign relative weightings to the objectives Establish performance parameters or utility scores for each of the objective Calculate and compare the relative utility values of the alternative designs

The weighted objectives method

List the design objectives Rank-order the list of objectives Assign relative weightings to the objectives Establish performance parameters or utility scores for each of the objective Calculate and compare the relative utility values of the alternative designs

The objectives: technical and economic factors, user requirements, safety requirements, and so on. The objectives should be represented in such a way that could be assessed quantitatively

The weighted objectives method

List the design objectives Rank-order the list of objectives Assign relative weightings to the objectives Establish performance parameters or utility scores for each of the objective Calculate and compare the relative utility values of the alternative designs For a pair of objectives, determine which is more important (A and B, A and C, and so forth); assign 1 for more important and 0 for less. Form a matrix.

The order of importance: B C D A E

The weighted objectives method

List the design objectives Rank-order the list of objectives Assign relative weightings to the objectives Establish performance parameters or utility scores for each of the objective Calculate and compare the relative utility values of the alternative designs Assign a numerical value to each objective; use a scale of, say, 1 to 10 or 1 to 100 C. Alternatively, decide to share a certain number of points say 100.

The weighted objectives method

List the design objectives Rank-order the list of objectives Assign relative weightings to the objectives Establish performance parameters or utility scores for each of the objective Calculate and compare the relative utility values of the alternative designs

The weighted objectives method

List the design objectives Rank-order the list of objectives Assign relative weightings to the objectives Establish performance parameters or utility scores for each of the objective Calculate and compare the relative utility values of the alternative designs

Pughs Concept Selection Method

Criteria High efficiency High reliability Low maintenance Low cost Light weight 7+ 77S Concept alternatives Gears V-belts Chain + + + 3 2 0 D A T U M n.a. n.a. n.a. + + S 2 2 1

Modified Pughs Method

Importance

Concept alternatives Gears V-belts Chain + D + + + 75 22 0 A T U M n.a. n.a. n.a. + S 55 25 20

Criteria High efficiency High reliability Low maintenance Low cost Light weight 7+ 77S

Weight (%)

30 25 20 15 10 100

Concept alternatives Gears

Importance Criteria Weight (%) Rating Weighted Rating

V-belts
Rating Weighted Rating

Chain
Rating Weighted Rating

High efficiency High reliability Low maintenance Low cost Light weight

30 25 20 15 10 100 Rating Unsatisfactory Just tolerable Adequate Good Very good

4 4 4 2 2

1.20 1.00 0.80 0.30 0.20 3.50 Value 0 1 2 3 4

2 3 3 4 4

0.60 0.75 0.60 0.60 0.40 2.95

3 3 2 3 3

0.90 0.75 0.40 0.45 0.30 2.80

Engineering Design Selection

Fig. 1-2, Design of Machinery, by R. L. Norton, McGraw-Hill, 2001

 We have discussed phases in design However sometimes it helps to first reverse engineer and then design

what is reverse engineering?

Dissecting a product Understanding how it functions Learn basic principles Designing/building a new product with the knowledge from dissection

Initial Observation
Let us explore how a vacuum cleaner works First identify the vacuum cleaner: type, manufacturer, model#, and performance specifications Read the instruction manual Plug the vacuum cleaner and run it Listen to the sound Feel how it runs Record your observations

Dissection
Wear safety glasses Unplug the vacuum cleaner Disassemble it as far as possible Put all parts in a bin (with label of your group) Note each part and their purpose (e.g. belt and pulley mechanism, types of bearings/bushings, motor, etc.) Are there any other alternatives of these components?

Reassemble
Now reassemble your vacuum cleaner Suggest any design changes to make reassemble easier Once all parts are assembled, plug it in and run it (make sure you have your safety glasses) If it does not sound or feel like before or smoke comes out, unplug immediately and run (try to fix the problem later !)

Drill Dissection
Whats so interesting about a drill? Its got lots of good stuff in it - electric motors, gears, bearings, couplings, etc It is a good example of an electro-mechanical power transmission system, and it is also an example of a machine tool (it drills holes)

FISHBONE DIAGRAM FOR MECHANICAL DISSECTION

(Example: Small Kitchen Scale)

Kitchen Scale

PLATFORM
TOP PLATE

STEM

RIVETS

SPRING MECHANISM

SPRING NUT

THREADED PIN

FOUR-BAR MECHANISM & HOUSING (Example: Small Kitchen Scale)

LINK 2 LINK 3

LINK 1

BOTTOM COVER

READOUT

Pepper Grinder

original design

new design

Fabricated cost Original product Redesigned product Save money

Purchased cost

Assembly cost

Total cost

$3.27 $2.7475 $0.5225

$5.12 $0.30 $4.1525 $0.10 $0.9675 $0.20

$8.69 $7.00 $1.69

Source: Huang, Chen, & Chen (2004)

Material Selection Chart

Ashbys selection chart

Importance of manufacturability and communication

Second floor collapsed, 114 people died

No Job's Finished Until the Paperwork is Done

Contoh-contoh karya mahasiswa (di sana!)