ENGR-11_Lec-01_Intro_Engr_Design.ppt 1 Bruce Mayer, PE Engineering-11: Engineering Design Bruce Mayer, PE Licensed Electrical & Mechanical Engineer Engineering 11 Engineering Design

ENGR-11_Lec-01_Intro_Engr_Design.ppt 2 Bruce Mayer, PE Engineering-11: Engineering Design OutLine  Engineering Design  What is engineering design, really?  Function to form  Design process  Phases of design  Product Realization/Development Process  Concurrent engineering  Teamwork  Summary

ENGR-11_Lec-01_Intro_Engr_Design.ppt 3 Bruce Mayer, PE Engineering-11: Engineering Design Design vs. Ambiguity  Design ≡ a “valid” or “acceptable” Solution to an OPEN-ENDED Problem e.g.; Design a Cell-Phone that OUTSELLS All Others  All design challenges are ambiguous. Unlike answers to mathematical expressions there are always several “right” answers to ANY design challenge.  The answer is always uncertain or ambiguous.  Not all design solutions are equally good however, and some are definitely wrong.

ENGR-11_Lec-01_Intro_Engr_Design.ppt 4 Bruce Mayer, PE Engineering-11: Engineering Design Well-Defined vs. Open-Ended  Design Problems Have NO “Correct” Solution; Have only: Successful and UNsucessful Solutions Compare to Skills-Development (practice) problems  Skills Development (Textbook Type) Well-defined, Complete (correctly stated, unique) Correct answer exists Money not involved You know When You Arrive at the Answer Requires Application of Very Specific Knowledge  Design Problems (Open Ended) Poorly-defined No Unique Solution; Depends on Approach Cost & Schedule are Critical Factors “Done Point” Very Hard to Identify Need MultiDisciplinary Knowledge

ENGR-11_Lec-01_Intro_Engr_Design.ppt 5 Bruce Mayer, PE Engineering-11: Engineering Design Analysis vs. Synthesis  Analysis → Know What IS/OCCURS and Then Try to EXPLAIN it A separating or breaking up of a whole into its parts, with an examination of these parts to reveal their nature, proportion, function, interrelationships, etc.  Synthesis → Know What IS NEEDED and Then Try to CREATE (Design) it The putting together of parts or elements so as to form a whole

ENGR-11_Lec-01_Intro_Engr_Design.ppt 6 Bruce Mayer, PE Engineering-11: Engineering Design Example  MechEngr Design  Analysis Forces Moments Flow Pressure Machines Mechanisms Motion Energy Conversion  Synthesis & Testing Sketch/Draw Predict Behavior –Model or Test SubScale Tests or Experiments Materials Manufacturing  Realization Customer needs Company Requirements Manufacturing Costs Performance –Analysis –Testing

ENGR-11_Lec-01_Intro_Engr_Design.ppt 7 Bruce Mayer, PE Engineering-11: Engineering Design Design vs. Analysis  Which of the following is design and which is analysis? a)Given that the customer wishes to fasten together two steel plates, select appropriate sizes & materials for the bolt, nut & washer b)Given the cross-section geometry of a new airplane wing then determine the lift it produces using Fluid Mechanics principles  Form is the solution to a design problem In this Case the Bolt SIZE & Material

ENGR-11_Lec-01_Intro_Engr_Design.ppt 8 Bruce Mayer, PE Engineering-11: Engineering Design Form FOLLOWS Function  Function “Directs” Form  Form ≡ Shape, Size, Configuration, Weight, Human InterFace Appearance, Materials of Construction, etc.  DESIGN connects Form (the OutPut) to the desired Function (the InPut) Thru a DECISION-MAKING PROCESS

ENGR-11_Lec-01_Intro_Engr_Design.ppt 9 Bruce Mayer, PE Engineering-11: Engineering Design Function  Form Graphically Function DESIGN Form  Control, hold, move, protect, heat/cool, store, amplify, etc.  Decision-Making Process  Shape, configuration, size, materials, manufacturing processes, etc.

ENGR-11_Lec-01_Intro_Engr_Design.ppt 10 Bruce Mayer, PE Engineering-11: Engineering Design Engr-Design as Decision-Making  Design Definition  Short Version Set of decision making processes and activities to determine the FORM of an object, given the customer’s desired FUNCTION  Design Definition  Long Version The process of devising a system, component, or process to meet desired needs. It is a decision-making process (often iterative), in which basic-science, mathematics and the engineering-sciences are applied to optimally convert resources to meet a stated objective

ENGR-11_Lec-01_Intro_Engr_Design.ppt 11 Bruce Mayer, PE Engineering-11: Engineering Design Decision-Making  Design Process Formulating Problem Generating Alternatives Analyzing Alternatives Evaluating Alternatives ReDesign Iteration  Establish Functional Requirements  Determine Constraints  Set Performance Goals DESIGN Specs  CREATE Alternative Forms (Shape, Configuration, Size, Materials, Power-Sources, etc.) ALL Alternatives FEASIBLE Alternatives BEST Alternative MANUFACTURING Specs

ENGR-11_Lec-01_Intro_Engr_Design.ppt 12 Bruce Mayer, PE Engineering-11: Engineering Design “Phases” of Engineering Design  How do design decisions change over time?  Is there a logical grouping of decisions?  Illustrate with an Example: Design a Brake for stopping a Spinning Shaft. Requirements for Brake –8” Diameter, Horizontal shaft –4330 Ni/Cr/Mo Alloy-Steel shaft material –1000 Pound shaft weight –3600 rpm maximum rotational speed

ENGR-11_Lec-01_Intro_Engr_Design.ppt 13 Bruce Mayer, PE Engineering-11: Engineering Design FORMULATION Phase - Brake  Early in the design process, we decide upon the nature of the Functional Requirements, and Inputs for the Design  Decide upon a satisfactory rate of deceleration  Determine the length of the shaft  Determine where it is supported  Determine what actuating energy is available  Decide to Learn From existing similar products  Choose to research brakes in the library

ENGR-11_Lec-01_Intro_Engr_Design.ppt 14 Bruce Mayer, PE Engineering-11: Engineering Design CONCEPT Design Phase - Brake  Decide PHYSICAL PRINCIPLES that will perform the braking function 1.surface friction (e.g. drum brake, disk/caliper) 2.opposing magnetic fields (e.g., inverse motor) 3.air friction (e.g. fan blades)  Assume we DECIDE on surface friction

ENGR-11_Lec-01_Intro_Engr_Design.ppt 15 Bruce Mayer, PE Engineering-11: Engineering Design CONFIGURATION Dsgn Phase  Decide upon PRODUCT components & how they are arranged/configured  Product configuration: disk/caliper, or drum, or band brake location on shaft (right, left, middle)  Assume we decide on a disk/caliper brake

ENGR-11_Lec-01_Intro_Engr_Design.ppt 16 Bruce Mayer, PE Engineering-11: Engineering Design CONFIGURATION Dsgn Phase  Decide upon PART features & how they are arranged/configured  Part configuration: relative size of hub to disk relative size of rotor thickness to diameter

ENGR-11_Lec-01_Intro_Engr_Design.ppt 17 Bruce Mayer, PE Engineering-11: Engineering Design PARAMETRIC Design Phase  Decide upon SPECIFIC VALUES for design variables/parameters 1.rotor diameter (outer) 2.rotor thickness 3.brake pad area 4.pad material 5.hydraulic pressure on piston

ENGR-11_Lec-01_Intro_Engr_Design.ppt 18 Bruce Mayer, PE Engineering-11: Engineering Design DETAIL Design Phase  Decide upon the remaining MANUFACTURING specifications Machined rotor tolerances Pad bonding resin cure time & temperature Assembly procedure Testing procedure

ENGR-11_Lec-01_Intro_Engr_Design.ppt 19 Bruce Mayer, PE Engineering-11: Engineering Design Final FORM is the Design Solution  FUNCTION  stop a spinning shaft  FORM  rotor: 10 inch diameter, Cast Iron, 3/8-inch thick, cooling passages Forged 4140 steel caliper/housing brake pads, 2 opposing, 4 sq. in., metal particles in epoxy matrix Stainless steel 304 piston,1.25-inch diameter, with elastomeric seals 105 psi hydraulic piston pressure

ENGR-11_Lec-01_Intro_Engr_Design.ppt 20 Bruce Mayer, PE Engineering-11: Engineering Design Design Phase Summary Configuration Design Problem Formulation Concept Design ParaMetric Design Detail Design Preliminary Design Embodiment Design

ENGR-11_Lec-01_Intro_Engr_Design.ppt 21 Bruce Mayer, PE Engineering-11: Engineering Design Alternative Design-Phases  Another, more Detailed, Description of the Stages/Phases of Design 1.ID Problem or Needed-Fcn 2.Define the Goals/Performance 3.Research & Gather-Data 4.BrainStorm/Creative-Solutions 5.Analyze Potential Solutions 6.Develop & Test Models 7.Make the Decision 8.Communicate & Specify 9.Implement & Commercialize Conceptual Design Preliminary Design Critical Design Review Final Design

ENGR-11_Lec-01_Intro_Engr_Design.ppt 22 Bruce Mayer, PE Engineering-11: Engineering Design Product Realization Process  Also Known as the Product LIFE CYCLE Design Occurs during PRODUCT DEVELOPMENT Process Industrial Design Engineering Design Production Design Manufacturing (Production) Distribution Service Disposal Customer Need Fully Realized Product Sales & Marketing Product Development Process

ENGR-11_Lec-01_Intro_Engr_Design.ppt 23 Bruce Mayer, PE Engineering-11: Engineering Design The Product Life Cycle Manufacture Design Use Retire  establish function, determine form  fabricate, purchase, assemble, test, ship/distribute  set up, operate & maintain, repair  TearDown/disassemble, recycle/dispose

ENGR-11_Lec-01_Intro_Engr_Design.ppt 24 Bruce Mayer, PE Engineering-11: Engineering Design Product Life Cycle - Graphically Definition Freeze Product Development Break Even time Opportunity Investigation Innovation Cycle time ProfitZone Release Obsolescence  Product Development “Kicks Off” the Product Life Cycle

ENGR-11_Lec-01_Intro_Engr_Design.ppt 25 Bruce Mayer, PE Engineering-11: Engineering Design ConCurrent Engineering  Also Known as Simultaneous Engineering, this Method Reduces the time spent in Product Development

ENGR-11_Lec-01_Intro_Engr_Design.ppt 26 Bruce Mayer, PE Engineering-11: Engineering Design ConCurrent ENGR Elements  non-linear product design approach  all phases of product development operate at the same time – simultaneously Both product & process design run in parallel and occur in the same time frame  Product and Process are closely coordinated to achieve Optimum Results in a short amount of time  Decision making involves full team participation and involvement

ENGR-11_Lec-01_Intro_Engr_Design.ppt 27 Bruce Mayer, PE Engineering-11: Engineering Design WJ-2000 Concurrent Engineering FSMenagh L. Harlamoff HSPaek B. Mayer AKPlumley AKMcGrogan CEErickson R. Reghitto MSWalton RSMurphy DMDobkinZ. Yuan B. Mayer  By Assignment Sales Engineer Safety Engineer Manufacturing Engineer Reliability Engineer Service Engineer SysEngr ME SWE ME Process Engr EE ME IE Engr Physics ME

ENGR-11_Lec-01_Intro_Engr_Design.ppt 28 Bruce Mayer, PE Engineering-11: Engineering Design The Need for Engineering Teams  Increasing Technology Content Complex Engineered Systems Have Too Much Information Content for Any One Person to Address  Speed Time-To-Market Often Means the Difference Between Profits & Losses Teams Allow work to Be Done in PARALLEL (at the SAME TIME)

ENGR-11_Lec-01_Intro_Engr_Design.ppt 29 Bruce Mayer, PE Engineering-11: Engineering Design A Team  What is it?  A Team Is A Small Group Of People With Complementary Skills Who Are Committed To A Common Purpose, Performance Goals, and Approach For Which They Hold Themselves MUTUALLY ACCOUNTABLE

ENGR-11_Lec-01_Intro_Engr_Design.ppt 30 Bruce Mayer, PE Engineering-11: Engineering Design Team Attributes  Common Goal This Must Be Clearly Communicated to Generate a Feeling of Common Purpose  Leadership A Critical Function To Keep The Team Focused  Complementary Skills Resources are Limited; Each Team Member Should have a CLEARLY DEFINED and UNIQUE Role

ENGR-11_Lec-01_Intro_Engr_Design.ppt 31 Bruce Mayer, PE Engineering-11: Engineering Design Team Attributes cont.  Effective Communication A CRITICAL Leadership Function Honest & Productive Communication is Needed for Design/Solution Integration Greatest advantage Humans have over the rest of the Animal Kingdom is communication  Creativity A “Close Knit” & Motivated Team Generates Creative Energy Thru Goal-Oriented Interaction

ENGR-11_Lec-01_Intro_Engr_Design.ppt 32 Bruce Mayer, PE Engineering-11: Engineering Design All Done for Today Dilbert Design

ENGR-11_Lec-01_Intro_Engr_Design.ppt 33 Bruce Mayer, PE Engineering-11: Engineering Design Bruce Mayer, PE Registered Electrical & Mechanical Engineer Engineering 11 Appendix Engineering Rolls

ENGR-11_Lec-01_Intro_Engr_Design.ppt 34 Bruce Mayer, PE Engineering-11: Engineering Design LifeCyc Engineering Activities

ENGR-11_Lec-01_Intro_Engr_Design.ppt 35 Bruce Mayer, PE Engineering-11: Engineering Design LifeCyc Engineering Activities

ENGR-11_Lec-01_Intro_Engr_Design.ppt 36 Bruce Mayer, PE Engineering-11: Engineering Design The HYPE Cycle

ENGR-11_Lec-01_Intro_Engr_Design.ppt 37 Bruce Mayer, PE Engineering-11: Engineering Design Potato Sorting Machine  Optyx® WPS for whole potatoes achieves a three-way sort using a combination of air ejectors to remove foreign material (FM) and a unique deflector system to separate potatoes for rework from good potatoes. Maximizing the removal of foreign material and providing extremely gentle handling to avoid potato bruising, Optyx WPS improves product quality and protects downstream equipment while reducing labor costs and increasing yields.