Senior Design Senior Design Fall 2005, Week 3 Fall 2005, Week 3 Notes are based on Engineering Notes are based on Engineering Design and Design for Manufacturing Design and Design for Manufacturing A Structured Approachby John R. A Structured Approachby John R. Dixon and Corrado Poli Dixon and Corrado Poli
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Group 1 (Energy 1Group 1 (Energy 1 project presented by Dr.project presented by Dr.Fl
etcher)Fletcher) Richelle AtienzaRichelle Atienza Holman ChuaHolman Chua Jason GarnerJason Garner Jason HarringtonJason Harrington Joshua SeveranceJoshua Severance
Group 2 (ASME 1)Group 2 (ASME 1) William BerryWilliam Berry Nicholas FonderNicholas Fonder Jason KardosJason Kardos James MartiniJames Martini
Group 3 (Energy 2Group 3 (Energy 2 project to be discussedproject to be discussed
wi
th Dr. Fletcher)with Dr. Fletcher) Sean MochockiSean Mochocki Evan McNayEvan McNay Lince PhilipLince Philip Richard ThompsonRichard Thompson Stephen ThompsonStephen Thompson
Group 4 (ASME 2)Group 4 (ASME 2) Justin CaudleJustin Caudle Luke DelaneyLuke Delaney Joshua IsaacsonJoshua Isaacson Peter VergenzPeter Vergenz
Group 5 (ExtruderGroup 5 (Extruder Project presented by Dr.Project presented by Dr. Ad
ewale or a modification to the project) Adewale or a modification to the project) Anthony Barletta Anthony Barletta Daniel JonesDaniel Jones Parineeta NayyarParineeta Nayyar Spencer SchwabSpencer Schwab
Determine the physical concept of the designed object Determine the physical concept of the designed object Information about the physical principles by which the object Information about the physical principles by which the object
will achieve its principal functionswill achieve its principal functions An abstract physical description of the object called the An abstract physical description of the object called the
embodiment embodiment Embodiment: Abstract physical description with few detailsEmbodiment: Abstract physical description with few details
providedprovided
Beam is long and slender member of uniform cross sectionBeam is long and slender member of uniform cross sectionbut we dont know the exact cross sectional shape orbut we dont know the exact cross sectional shape ordimensionsdimensions
The process of decompositionThe process of decomposition
decompositiondecomposition It is necessary to decompose the design intoIt is necessary to decompose the design into
more manageable submore manageable sub--assemblies/components.assemblies/components.
Helps in finding creative solutions and ultimatelyHelps in finding creative solutions and ultimatelygenerating a superior designgenerating a superior design
Two primary approaches of conceptualTwo primary approaches of conceptualdecomposition are useddecomposition are used Direct decompositionDirect decomposition
FunctionFunction--First decompositionFirst decomposition Will need to include the couplings betweenWill need to include the couplings between
subsystemssubsystems How are forces transferred? Energy transfer?How are forces transferred? Energy transfer?
A product is composed of the subsidiary A product is composed of the subsidiarycomponents (the design is not reallycomponents (the design is not reallydecomposed)decomposed)
Ex: An automobile is decomposed into itsEx: An automobile is decomposed into itsengine, drive train, body, suspensionengine, drive train, body, suspensionsystem, steering system.system, steering system.
Then you work on each of the decomposedThen you work on each of the decomposed
systems and find the best design for each.systems and find the best design for each. This decomposition method minimizesThis decomposition method minimizes
Overview of Guided IterationOverview of Guided Iteration Applied to Engineering Applied to Engineering
Conceptual DesignConceptual Design Formulating the Engineering Conceptual Deisgn Problem: The Engineering DesignFormulating the Engineering Conceptual Deisgn Problem: The Engineering Design
SpecificationSpecification The Engineering Design Specification is used during the conceptual design stage and through theThe Engineering Design Specification is used during the conceptual design stage and through the
rest of the design stages.rest of the design stages. Should be a written document Should be a written document Convert the vague, qualitative, and incomplete information that is generally available at theConvert the vague, qualitative, and incomplete information that is generally available at the
beginning of the conceptual design stage into a set of specific, quantitative, completebeginning of the conceptual design stage into a set of specific, quantitative, completeperformance requirementsperformance requirements
Will use Quality Function Deployment (more to come)Will use Quality Function Deployment (more to come) Ex: Should be easy to carryEx: Should be easy to carry the weight should be less than 20lbthe weight should be less than 20lb
Generating Alternatives in Engineering Conceptual Design ProblemsGenerating Alternatives in Engineering Conceptual Design Problems The selection of the best possible conceptual design is crucial in obtaining the best possible finalThe selection of the best possible conceptual design is crucial in obtaining the best possible final
design solution.design solution. Mistakes at the conceptual design stage are extremely costly if you must backtrack when in theMistakes at the conceptual design stage are extremely costly if you must backtrack when in the
configuration, parametric, and detailed design stages.configuration, parametric, and detailed design stages.
Evaluating Alternatives in Engineering Conceptual DesignEvaluating Alternatives in Engineering Conceptual Design Alternatives are rated and compared Alternatives are rated and compared
Guided RedesignGuided Redesign Illuminate the specific characteristics of proposed alternatives that are weak and strong.Illuminate the specific characteristics of proposed alternatives that are weak and strong. Is the design goodIs the design good--enough?enough?
Formulating the Problem: TheFormulating the Problem: The
Engineering Design SpecificationEngineering Design Specification Includes statementsIncludes statements
InIn--use purposes, anduse purposes, and
Functional requirementsFunctional requirements
Some information may be available from marketingSome information may be available from marketingand industrial design stageand industrial design stage
Most information available at this stage is typicallyMost information available at this stage is typicallyqualitative, incomplete, and/or approximatequalitative, incomplete, and/or approximate
The Engineering Design Specification will be used inThe Engineering Design Specification will be used infuture design stages so care should be put intofuture design stages so care should be put intomaking it as detailed and complete as possible.making it as detailed and complete as possible.
Environmental and other conditionsEnvironmental and other conditions Economic issuesEconomic issues Physical attributesPhysical attributes Process technologiesProcess technologies Aesthetics Aesthetics Product development time and cost Product development time and cost
Before developing the Specs it is best to understand the customer needs.Before developing the Specs it is best to understand the customer needs. House of QualityHouse of Quality
Quality FunctionQuality FunctionDeployment (QFD) and theDeployment (QFD) and theHouse of Quality (HoQ)House of Quality (HoQ) QFD: term used to describe a strategyQFD: term used to describe a strategy
for focusing engineering designfor focusing engineering design
attention on quality issues asattention on quality issues asperceived by customersperceived by customers
HoQ: A technique used for structuringHoQ: A technique used for structuring
information commonly used toinformation commonly used toimplement QFD.implement QFD.
Matrix that relates the customers wants (Customer Attributes)Matrix that relates the customers wants (Customer Attributes)to the technical product characteristics (Engineeringto the technical product characteristics (EngineeringCharacteristics)Characteristics)
Customer Attributes (CA)Customer Attributes (CA) Generally qualitativeGenerally qualitative
Fast, smooth, easyFast, smooth, easy
The Customer Attributes are listed to the left of the rows (alsoThe Customer Attributes are listed to the left of the rows (alsogroupedgrouped functions, features)functions, features)
QualitativeQualitative Weight in poundsWeight in pounds
The Engineering Characteristics are listed at the top of theThe Engineering Characteristics are listed at the top of thecolumns (grouped by categories)columns (grouped by categories)
HoQ is also used for competitive benchmarkingHoQ is also used for competitive benchmarking
Goodness of coffee (in measurable quantities)Goodness of coffee (in measurable quantities) Functional requirementsFunctional requirements
TemperatureTemperature Flow rate of waterFlow rate of water Time the water takes to flow through the groundsTime the water takes to flow through the grounds Temperature when poured into the cupTemperature when poured into the cup
EC will include requirements such as the electrical resistance to the heater, theEC will include requirements such as the electrical resistance to the heater, thesize of the tube supplying the hot water to the coffee grounds, and othersize of the tube supplying the hot water to the coffee grounds, and otherfactors having to do with geometry and materials.factors having to do with geometry and materials.
Since there are yet no proposed designs there are no engineeringSince there are yet no proposed designs there are no engineeringcharacteristics yet.characteristics yet.
Determine the Customer Attributes, then write the Specs and thenDetermine the Customer Attributes, then write the Specs and thenreturn to the Engineering Characteristicsreturn to the Engineering Characteristics
carrying casecarrying case Customer AttributesCustomer Attributes
Protects the discsProtects the discs Attractive Attractive InexpensiveInexpensive
Can identify the contentsCan identify the contents Stays closedStays closed Easy to openEasy to open Cant be used as a coaster forCant be used as a coaster for
coffee cupscoffee cups Holds at least 6 CDsHolds at least 6 CDs Doesnt pop open on its ownDoesnt pop open on its own
Wont break if droppedWont break if dropped Compact Compact
Eliminate redundanciesEliminate redundancies Organize the list hierarchicallyOrganize the list hierarchically
Protects the discsProtects the discs Stays closedStays closed
Wont break if droppedWont break if dropped Cant be used as a coaster forCant be used as a coaster for
coffee cupscoffee cups
Convenient to useConvenient to use Easy to OpenEasy to Open Ca identify the contentsCa identify the contents Compact Compact
Attractive Attractive
Holds at least six CDsHolds at least six CDs InexpensiveInexpensive
Often priorities are assigned toOften priorities are assigned tothe customer attributes that the customer attributes that total 100 unitstotal 100 units
Content of the EngineeringContent of the Engineering
Design SpecificationDesign Specification Develop the Specs after the CustomerDevelop the Specs after the Customer Attributes have been identified Attributes have been identified
Primary Intended Use By CustomersPrimary Intended Use By Customers ExamplesExamples
To make coffeeTo make coffee To convert electrical to rotating energyTo convert electrical to rotating energy
To aid in the catching of a baseball and to protect the hand when doing soTo aid in the catching of a baseball and to protect the hand when doing so Some products have multiple usesSome products have multiple uses Baseball glove exampleBaseball glove example Hammer: Drive and pull nailsHammer: Drive and pull nails
Predictable Unintended UsesPredictable Unintended Uses Wrenches are used as hammersWrenches are used as hammers Screw drivers as chiselsScrew drivers as chisels Shelves and chairs as step laddersShelves and chairs as step ladders People standing (and jumping) on top of the washing machinePeople standing (and jumping) on top of the washing machine People driving with the windshield sun protector???? Remove whenPeople driving with the windshield sun protector???? Remove when
driving. UNF parking tag.driving. UNF parking tag. NOT enough to use warnings.NOT enough to use warnings. Must design with unintended uses inMust design with unintended uses in
mind. Legal and common sense reasons.mind. Legal and common sense reasons. Design the wrench such that it is reasonable safe to use as a hammerDesign the wrench such that it is reasonable safe to use as a hammer
Features that enhance the product Features that enhance the product
Rechargeable electric shaver that can beRechargeable electric shaver that can bedirectly plugged into the outlet rather thandirectly plugged into the outlet rather thanhaving an inconvenient cord.having an inconvenient cord.
Redial button on your telephoneRedial button on your telephone
NoNo--drip tops on laundry detergentsdrip tops on laundry detergents
May rate the special purpose features asMay rate the special purpose features asessential, important, or desirableessential, important, or desirable
Capacity (energy or material flow rate, force, )Capacity (energy or material flow rate, force, ) Input and output conditions (temperature, energy, pressures, flows,Input and output conditions (temperature, energy, pressures, flows,
power, deflections, forces)power, deflections, forces) EfficiencyEfficiency Accuracy and sensitivity Accuracy and sensitivity
Complementary PerformanceComplementary Performance Useful lifeUseful life ReliabilityReliability RobustnessRobustness SafetySafety NoiseNoise Legal requirementsLegal requirements Maintenance requirementsMaintenance requirements Requirements on users (skills, speed, knowledge, )Requirements on users (skills, speed, knowledge, )
ContinuedContinued Environmental and other conditionsEnvironmental and other conditions
Temperature, humidity, corrosive elements, noise, dirt, vibration, electricTemperature, humidity, corrosive elements, noise, dirt, vibration, electricor magnetic field.or magnetic field.
Extremes of variationsExtremes of variations
How product will be disposed, how it will influence the environment,How product will be disposed, how it will influence the environment,design for disdesign for dis--assembly.assembly. Is pollution a problem?Is pollution a problem?
As extremum goals, with or without limits As extremum goals, with or without limits Mass should be as low as possibleMass should be as low as possible
Mass should be as low as possible but no higher than 10Mass should be as low as possible but no higher than 10lblb
As target values with tolerance As target values with tolerance The power output of an engine should be 5 Hp +/The power output of an engine should be 5 Hp +/-- 0.250.25
HpHp
As ranges As ranges Length must be between 3.7 and 4.8 inchesLength must be between 3.7 and 4.8 inches
Completeness andCompleteness andInvariability of theInvariability of the
Engineering DesignEngineering Design The Specs should never be though of The Specs should never be though of
as complete or invariable at any stageas complete or invariable at any stage
in the design process.in the design process.
Specifications should beSpecifications should be as completeas completeas possibleas possible onon what the designedwhat the designed
object is to doobject is to do. They should. They should say assay aslittle as possiblelittle as possible about about how thehow therequirements are to be met.requirements are to be met.
Chill MeterChill Meter InIn--purpose usepurpose use
Primary Intended UsePrimary Intended Use
For skiers and winter hikers: to be able to determineFor skiers and winter hikers: to be able to determinethe sothe so--called wind chill factor easily and convenientlycalled wind chill factor easily and conveniently
Unintended Uses:Unintended Uses:
Non anticipatedNon anticipated
Special FeaturesSpecial Features
Indicate temperature, wind velocity seperately as wellIndicate temperature, wind velocity seperately as wellas the combined wind chillas the combined wind chill
Functional Performance requirementsFunctional Performance requirements Indicated reading should be accurate within one degreeIndicated reading should be accurate within one degreeusing U.S. Weather Bureau formula for the wind chillusing U.S. Weather Bureau formula for the wind chill
The meter should provide a reading after no more thanThe meter should provide a reading after no more than20 seconds for reaching equilibrium with the outdoor20 seconds for reaching equilibrium with the outdoorenvironment environment
The meter should perform with the above accuracy fromThe meter should perform with the above accuracy from32 F to 50 F, and from wind velocities from 10 mph to32 F to 50 F, and from wind velocities from 10 mph to60 mph. Accuracy should not be affected by mis60 mph. Accuracy should not be affected by mis--orientation with the wind direction up to 20 degreeorientation with the wind direction up to 20 degreeangleangle
The expected life in normal use should be at least 10The expected life in normal use should be at least 10yearsyears
The reliability should be such that no more than one inThe reliability should be such that no more than one in1000 sold will be returned for repairs or replacement 1000 sold will be returned for repairs or replacement during the 1during the 1st st year of use.year of use.
Must be able to withstand shocks and pressure without Must be able to withstand shocks and pressure without damage when carried in jacket pocketsdamage when carried in jacket pockets
Hiker or skier should not be cut by the device if (s)heHiker or skier should not be cut by the device if (s)hefalls.falls.
No maintenance should be required (except batteryNo maintenance should be required (except batteryreplacement replacement if used)if used)
Environmental conditionsEnvironmental conditions Use at previously mentioned conditionsUse at previously mentioned conditions Survive summer shipping storage up to 120 FSurvive summer shipping storage up to 120 F
and 80% humidityand 80% humidity Economic issuesEconomic issues
$10 (for a volume of 5000)$10 (for a volume of 5000)
Physical AttributesPhysical Attributes
To be carried in a ski or hiking jacket pocket To be carried in a ski or hiking jacket pocket No more than 16 ozNo more than 16 oz 3 x 5 x ¾ in3 x 5 x ¾ in33
Aesthetics Aesthetics Should look like a rugged, reliable, accurate deviceShould look like a rugged, reliable, accurate device
compatible with the quality equipment needed by skierscompatible with the quality equipment needed by skiersand hikersand hikers
Product development time and cost Product development time and cost The product should be designed and prototyped byThe product should be designed and prototyped by
<specific date>. Design and development cost, including<specific date>. Design and development cost, includingengineering , model shop, and laboratory should not engineering , model shop, and laboratory should not exceed <specified amount>exceed <specified amount>
Meet with your groupMeet with your group Define a project leaderDefine a project leader
Determine times when you will work on theDetermine times when you will work on theproject as a groups each weekproject as a groups each week At least 2 times (Beginning of the week discuss At least 2 times (Beginning of the week discuss
the tasks, split and work independently, regroup)the tasks, split and work independently, regroup)
Define the Customer Attributes withDefine the Customer Attributes withprioritiespriorities
Start discussing the SpecsStart discussing the Specs