ENGR-11_Small_Volume_Design.pptx 1 Bruce Mayer, PE Engineering-11: Engineering Design Bruce Mayer, PE Licensed Electrical & Mechanical Engineer Engineering 11 Engineering Design for Small-Volume Electro- Mechanical Systems

ENGR-11_Small_Volume_Design.pptx 2 Bruce Mayer, PE Engineering-11: Engineering Design To Build a Designed Object  Say you were Asked to BUILD or CONSTRUCT something using basic hand tools  You would need (at a minimum) A list of Parts with P/N’s and Qtys Parts FABRICATED specially for this Object Parts PURCHASED from Catalogs for this Object (a.k.a. “Standard Parts”) Instructions on how ASSEMBLE the Object

ENGR-11_Small_Volume_Design.pptx 3 Bruce Mayer, PE Engineering-11: Engineering Design Small-Volume Object Design Raw-Material in Basic-Shapes (chosen by the Engineer) Parts Fabricated per Specialized designs (your BluePrints) Parts Purchased from Technical Catalogs (Selected by the Engineer) Assembly Documentation (Parts-List, BluePrints, Instructions, etc.) Written by the Engineer

ENGR-11_Small_Volume_Design.pptx 4 Bruce Mayer, PE Engineering-11: Engineering Design When Designing Something…  Think About CRITICAL Issues Will It WORK Will it Meet the SCHEDULE & BUDGET Can it be BUILT from MY Design Documentation? – Ask Yourself: “If I were Building this object What Info would I need?”

ENGR-11_Small_Volume_Design.pptx 5 Bruce Mayer, PE Engineering-11: Engineering Design Discussion Scope  We Examine what it takes to BUILD small quantities (dozens to hundreds per year) of Engineering-Designed ElectroMechanical Systems for Sale  This Discussion Does NOT Address the FUNCTIONAL PERFORMANCE of the design; only what it takes to actually BUILD IT, regardless of how Well it works

ENGR-11_Small_Volume_Design.pptx 6 Bruce Mayer, PE Engineering-11: Engineering Design BUILDING SomeThing is HARD  Designing on Paper is MUCH EASIER than Designing Something that must be BUILT and Ultimately Sold  The Build-Process exposes Incomplete Design Documents –Wrong Parts Purchased  Incorrect Order Number –Part-Purchase Delayed  Incorrect Supplier Phone Number –$-Costs much higher than estimated

ENGR-11_Small_Volume_Design.pptx 7 Bruce Mayer, PE Engineering-11: Engineering Design BUILDING SomeThing is HARD  The Build-Process exposes Incomplete Design Documents –Not Sufficient Information to Construct  BluePrints Missing/Incorrect Dimensions or Notes; e.g.,  Inconsistent Material CallOut  Missing/Confusing Lines  Missing Surface Finish  Schematics or Assembly Drawing Missing/Incorrect ID-Information; e.g.,  Missing Balloon CallOut for O-Ring, Bolt, Valve, etc.  Missing Value for Resistor or Capacitor

ENGR-11_Small_Volume_Design.pptx 8 Bruce Mayer, PE Engineering-11: Engineering Design BUILDING SomeThing is HARD  The Build-Process exposes Design Errors –Mechanical Elements do NOT FIT –Electrical Elements SHORT or do not PowerUp –Can Not be Fabricated or Assembled as Designed –Mechanical Structures are NonRigid  “Floppy” or “Doingy” or “Cheesy” of “Wobbly” –Electrical or Fluid Systems are UnderPowered or Noisy or Unstable  “Whimpy” or “Flakey” or “Glitchy”

ENGR-11_Small_Volume_Design.pptx 9 Bruce Mayer, PE Engineering-11: Engineering Design To BUILD an Engineered Design  CORRECT & COMPLETE information on PURCHASED-Parts Given to the “Purchasing Department” NAMES & PHONE-NUMBERS of ALL Suppliers Correct Part-Numbers for ALL Purchased Parts Correct Order-Quantities and Estimated $-Costs

ENGR-11_Small_Volume_Design.pptx 10 Bruce Mayer, PE Engineering-11: Engineering Design To BUILD an Engineered Design  Dot “i’s” & Cross “t’s” on All FABRICATION Drawings (the “BluePrints”) A single Missing-Dimension or Superfluous Line or Missing Feature-Callout Brings Production to a HALT OMISSIONS result in ReWork or Scrap; e.g.; –Forgetting a needed Removed-Feature (Hole or Slot or Notch or Groove) –Superfluous Removed-Feature (‘extra” hole)

ENGR-11_Small_Volume_Design.pptx 11 Bruce Mayer, PE Engineering-11: Engineering Design Designed Part (Piece Part)

ENGR-11_Small_Volume_Design.pptx 12 Bruce Mayer, PE Engineering-11: Engineering Design To BUILD an Engineered Design  COMPLETE Bill of Materials (“BoM”, also called the “Parts List”) EVERY Nut, Bolt, Washer, Wire- Connector, Plumbing-Fitting, etc., Listed on the BoM Table Complete CallOuts  ALL parts shown with “Balloons” containing part ID-number  Clearly UNDERSTOOD Assy Dwgs Don’t Confuse the Assemblers

ENGR-11_Small_Volume_Design.pptx 13 Bruce Mayer, PE Engineering-11: Engineering Design Typical Assembly Drawing On-Dwg BoM Balloon CallOut

ENGR-11_Small_Volume_Design.pptx 14 Bruce Mayer, PE Engineering-11: Engineering Design Tools at the Engineer’s Disposal  INGENUITY & CREATIVITY MOST Important  Knowledge of SCIENCE and MATHEMATICS  Technical CATALOGS  “BluePrint” Making Software  Standard Fabrication Methods Machining, Welding, Injection-Molding, etc.

ENGR-11_Small_Volume_Design.pptx 15 Bruce Mayer, PE Engineering-11: Engineering Design Summary: Design Docs Include  Purchased Part Information What Mfr-PN, Who Supplies, How Much $  Fabricated Parts Drawings (BluePrints) 100% Accurate; generate NO Questions from Fabricators  BoM or Parts List 100% Accurate as it is used to “Pull Parts from Stock” to Make an “Assembly Kit”  NonConfusing Assembly Drawings

ENGR-11_Small_Volume_Design.pptx 16 Bruce Mayer, PE Engineering-11: Engineering Design Small Volume Design FlowChart Supplier Contact Info Purchased Part Catalog No. Purchased Parts Physical Design to Scale (LayOut) Material Selection Fabrication Notes Formal “BluePrints” (Use Std TitleBlock) To Fabricator Machine Shop, etc. Fabricator contact Info Fabricated Piece-Parts Assy Parts List (Bill of Materials) Order & Receive Purchased Parts Assembly Drawing & Documentation Physical Assembly and/or Construction

ENGR-11_Small_Volume_Design.pptx 17 Bruce Mayer, PE Engineering-11: Engineering Design All Done for Today Engineering Design Pyramid

ENGR-11_Small_Volume_Design.pptx 18 Bruce Mayer, PE Engineering-11: Engineering Design Bruce Mayer, PE Registered Electrical & Mechanical Engineer Engineering 11 Appendix

ENGR-11_Small_Volume_Design.pptx 19 Bruce Mayer, PE Engineering-11: Engineering Design