Licensed Electrical & Mechanical Engineer BMayer@ChabotCollege.edu Engineering 11 Configuration Design Bruce Mayer, PE Licensed Electrical & Mechanical Engineer BMayer@ChabotCollege.edu

OutLine  Configuration Design What is a product configuration? What is a part configuration? Product architecture design Part configuration design Evaluating Configurations Computer Aided Design (CAD) Computer Aided Engineering (CAE)

OverView – Config Design The Configuration Design moves the Design-Concept from the diagram phase to the one where specific components are now identified so that we can proceed to manufacture. Start to Develop Specific Sizes, Shapes, and Orientations Begin to Apply Highly Quantitative Science and Mathematics

What is Configuration Design? Example Design Problem  Reduce Rotational Speed Design Concept  Gear Pair Physical principle: PowerIn = PowerOut geometry & material embodiment

Possible GearPair Configurations Alternative configuration 1 ARRANGE Part Differently

Possible GearPair Configurations Alternative configuration 2 Helical gears Spur Gears Use different FEATURES or PARTS

Possible GearPair Configurations Alternative configurations 3 & 4 Wide Gear Face Similar Diameters Use different RELATIVE DIMENSIONS

What is Configuration Design? Example Design Problem  Support Vertical Load Design Concept  Wall Bracket Physical principle: Force Equilibrium geometry & material embodiment

Wall Bracket Configurations Abstract Embodiment Different Features Different Arrangements Different Dimensions

Configuration Decisions To Create Different Configs Change one or more of these

Select the BEST Configuration Formulating Problem Use the General Design Process as a Model for Choosing Between Configuration Alternatives DESIGN Specs Generating Alternatives ReDesign Iteration ALL Alternatives Analyzing Alternatives FEASIBLE Alternatives Evaluating Alternatives BEST Alternative MANUFACTURING Specs

Configuration Design Generate Best concept(s) Product architecture Integral / modular Standard / special purpose Configure Product Generate Re-examine EDS Research sources Configuration requirements sketch Configure Part(s) Iterate Design for Function Design for Assembly Design for Manufacture Analyze and Refine EDS = Engineering Design Specification Pugh’s Method Weighted Rating Method Evaluate Best configuration(s)

Product Architecture Analogous to Building Architecture Architecture Style Scheme COLONIAL 1st Floor Rms: dining, living 2nd Floor Rms: Bedroom, Office RANCH all rooms on ground floor Rooms arranged Using a logical “scheme.” Before the details of the house are designed we determine the general layout or “architecture.”

Example  Product Architecture This “System Architecture” Shows the Major SubSystems (the “rooms”), and their Physical Locations relative to each other (the “Floor Plan”)

Example  Product Architecture March 1992 Jun 1994

ReCall Product DeComposition Subassembly A Standard Part Standard part Special purpose part Special purpose Subassembly B Subassembly B1 Shows type, number, arrangement of components standard or special purpose (make or buy)

Product Architecture PRODUCT ARCHITECTURE is the scheme/plan by which the functional elements of a product are arranged into physical building blocks (components, subsystems or subassemblies) that interact with each other to perform the overall function of the product Product architectures can be “modular” or “integral”

Modular Architecture “Chunks” implement one or a few functions Product examples Flashlight Refrigerator Automobile Personal computer Modular components Batteries, bulbs Motors, compressor, switches Tires, radios, seats, brakes, engines Drives, keyboards, mice, modems “Chunks” implement one or a few functions Interactions between chunks are well defined (standard interfaces and/or connections)

Integral Architecture Product examples BMW Motorcycle engine Printer case Shaft Beverage cup Modular components engine/frame integral snap-fasteners machined bearing race integrated handle a single chunk implements many functions Interaction is ill defined Physical element “shares” functions

Developing Architectures Create a schematic of functional and physical elements cluster elements into logical chunks to: exploit standard components to exploit standard interfaces (e.g. 115 VAC, USB) fully utilize manufacturing process(es), or suppliers provide for maintenance sketch a rough geometric layout identify interactions between elements refine layout

Example  Design Printer Identify SubFunctions InterActions

Example  Design Printer Cluster Elements into Logical “Chunks”

Example  Design Printer Sketch rough geometric “layout”

a REFINED LayOut

Example  Design Printer Sketch the Interaction Diagram

Part Configuration Design Best concept(s) Part Configuration Design Product architecture Integral / modular Standard / special purpose Configure Product Re-examine EDS Research sources Configuration requirements sketch Configure Part(s) Iterate Design for Function Design for Assembly Design for Manufacture Analyze and Refine Pugh’s Method Weighted Rating Method Evaluate Best configuration(s)

Part Configuration Design Configuration Problem Required Decisions Special Purpose Part Geometric Features Feature Arrangement Relative Dimensions Design Variable List Many Issues Associated with Each Decision Consider just Geometric Features walls rounds cubes notches ribs bosses spheres chamfers projections cylinders holes grooves fillets tubes slots

Generating Alternatives Recall Bracket Configurations Abstract Embodiment Different Features Different Arrangements Different Dimensions

Example  Sponge Holder Prepare configuration requirements sketch Sponge Holder

Example  Sponge Holder Prepare NON-Contiguous configuration requirements sketch

Example  Sponge Holder Prepare alternative CONTIGUOUS configuration sketches

Example  Sponge Holder Refine Configs hole in back wall hole in offset wall

Configuration Analysis Best concept(s) Configuration Analysis Product architecture Integral / modular Standard / special purpose Configure Product Re-examine EDS Research sources Configuration requirements sketch Configure Part(s) Iterate Design for Function Design for Assembly Design for Manufacture Analyze and Refine Pugh’s Method Weighted Rating Method Evaluate Best configuration(s)

Analysis Queries Will the Configuration Perform the Desired FUNCTION? Can all the Parts be MADE (manufactured)? Can the Configuration be ASSEMBLED?

Design for Function (DFF) Functional Considerations List Strong Stiff or flexible Buckling Thermal expansion Vibrate Quiet / Noise Heat transfer Fluid(s) transport and/or storage Energy efficient Stable Reliable Human factors/ergonomics Safe Easy to use Maintain Repairable Durable (wear, corrosion) Life-cycle costs Styling/aesthetics

Design for Assembly (DFA) Assembly ≡ a process of handling components to bring them together (inserting) and then fastening them. Design for Assembly ≡ a set of design practices which reduce the manpower time required to handle, insert and fasten components of a product.

DFA  Reduce Handling Handling  GMOP: Grasping, Moving, Orienting, Placing. Design parts or products to reduce the influence on handling Size Thickness Weight Nesting Tangling Fragility, Flexibility, Slipperiness, Stickiness need for: 2 hands, tools, optical magnification, mechanical assistance, etc

DFA  Reduce Insert & Fasten Insertion & Fastening  Mating a part to another part or sub-assembly. Design parts or products to reduce the effort associated with inserting & fastening Accessability Resistance (force) to Insertion Visibility Ease of Alignment & Positioning Depth of insertion Separate operation required Fastener used

DFA GuideLines from the SME minimize part count minimize levels of assembly (number of assemblies) encourage modular assembly use standard parts stack sub-assemblies from the bottom up design parts with self-fastening features (snap-fits, press-fits) facilitate parts handling (grasp, orient, move) design parts with self-locating features (e.g. chamfers, aligning recesses/dimples) eliminate reorientation (i.e. insertion from 2 or more directions) eliminate (electric) cables

PROs & CONs of DFA Design Guidelines Assembly Efficiency pros: fast, easy, non-coupled cons: non-quantitative; no metric to compare alterative designs Assembly Efficiency Assembly Efficiency (Boothroyd & Dewhurst) pros: systematic, comparative cons: takes time to code & calculate

Configuration Evalualtion Best concept(s) Configuration Evalualtion Product architecture Integral / modular Standard / special purpose Configure Product Re-examine EDS Research sources Configuration requirements sketch Configure Part(s) Iterate Design for Function Design for Assembly Design for Manufacture Analyze and Refine Pugh’s Method Weighted Rating Method Evaluate Best configuration(s)

Evaluation Methods Once the design concepts are generated and evaluated for feasibility, the surviving design concepts need to be evaluated to determine which one is “best.” How does one define “best”? One common method is to use the criteria for the design and weight the relative importance to determine “best.” Note: the designers must be careful not to rig the weighting to make a favorite come out “best.”

Evaluate Sponge Holder ConFigs hole in back wall hole in offset wall

Eval by Weighted Rating Method List evaluation criteria (in a column). Determine importance weights (in an adjacent column) List alternatives (along the top row) Rate each alternative on each criterion Compute the weighted rating for each criterion Sum the ratings to produce the Overall Weighted Rating

Eval Sponge Holder ConFigs

Config Design Summary Best concept(s) Product architecture Integral / modular Standard / special purpose Configure Product Re-examine EDS Research sources Configuration requirements sketch Configure Part(s) Iterate Design for Function Design for Assembly Design for Manufacture Analyze and Refine Pugh’s Method Weighted Rating Method Evaluate Best configuration(s)

Using Sketches in ConFig Dsgn Sketches are used often in configuration design Sketches assist creativity Sketches are not typically used to “document” the “design” But CAN be used to Document“IDEAS”

Creative Visualization Sketching Stimulates Creativity And Helps Visualization Sketching Ideas That Are Partially Developed Often Aids The Design Process Do Not Wait Until You Have A Clear Picture Before You Start Sketching Allow Yourself The Freedom To Make Mistakes Visualization Of The Entire Design Is Essential But Often IMPOSSIBLE Without the Aid Of Sketches

Sketches for Patent Doc.

USA Patent App. 20030113451

CAD DWGs for ConFig Design Typically used to Produce “LayOuts” LayOut Characteristics If Physical Object, then drawn PRECISELY to Scale showing ALL Parts Check for Form and Fit If Schematic, the shows precisely ALL Components and InterConnections Check for Proper Control of Fluid, Electrical, Optical, Magnetic, or Information “Flow”

LayOut For FC CCA Enclosure

LayOut for 800mm Glass Coater

Elect Pwr & Control Schematic

Uses of Accurate LayOuts LayOuts often serve as Input to CAE Software which aids Feasibility Checks Partial List of CAE tools Structural Mechanics (FEA) Computational Fluid Dynamics (CFD) Coupled Physics Rapid ProtoTyping ElectroMagnetics SPICE (Analog Electrical Circuit) Wire/Pipe Routing Software Kinematics Computer-aided Engineering the application of computers to the generation of the engineering specifications of a product. Computer-aided engineering fits into the production process between computer-aided design and computer-aided manufacturing. It is similar to CAD/CAM software, but with a focus on the engineering processes required for converting a design to a manufacturable product. The software package can include aspects of design, analysis, process planning, numerical control, mold and tool design, and quality control.

Computation Fluid Dynamics

LayOuts Transistor Plumbing All Done for Today LayOuts Transistor Plumbing Transistor LayOut by MAGIC Software

Registered Electrical & Mechanical Engineer BMayer@ChabotCollege.edu Engineering 11 Appendix Bruce Mayer, PE Registered Electrical & Mechanical Engineer BMayer@ChabotCollege.edu

WJ-1000 Product

Method 6-3-5 (Brain-Writing) The traditional brainstorming relies on verbal communications. Idea generation may be dominated by a small number of aggressive members. Guidelines for 6-3-5 method Team members are arranged around a circular table to provide continuity. Six (6) members are ideal. Each member sketches three (3) ideas for the product configuration or functions. Sketches should be the focus of this activity. The top five product functionswith respect to the customer needs are considered.