1. Engineering Design Curriculum

2. Course Objectives Apply the engineering design process
Define a problem (need) and develop alternatives for solving
Build, test, evaluate prototypes
Create and use engineering drawings
Demonstrate drafting techniques
See CA Engineering and technology pathway standards for unit objectives
D5.0 Students understand the design process and how to solve analysis and design problems:
D5.1 Understand the steps in the design process.
D5.2 Determine what information and principles are relevant to a problem and its analysis.
D5.3 Choose between alternate solutions in solving a problem and be able to justify the choices made in determining a solution.
D5.4 Translate word problems into mathematical statements when appropriate.
D5.5 Understand the process of developing multiple details into a single solution.
D5.6 Build a prototype from plans and test it.
D5.7 Evaluate and redesign a prototype on the basis of collected test data.
1.1 Identify and explain the steps of the engineering design process, i.e., identify the problem, research the problem, develop possible solutions, select the best possible solution(s), construct a prototype, test and evaluate, communicate the solution(s), and redesign.
1.2 Demonstrate knowledge of pictorial and multi-view drawings (e.g. orthographic projection, isometric, oblique, perspective) using proper techniques.
1.3 Demonstrate the use of drafting techniques with paper and pencil or computer-aided design (CAD) systems when available.

3. Engineering design is…
the process of devising a system, component or process to meet needs
a decision-making process in which science and mathematics are applied to convert resources to meet objectives
establishing objectives & criteria, synthesis, analysis, construction, testing, and evaluation
From Richard Chung and ABETrev
Engineering design is the process of devising a system, component, or process to meet desired needs. It is a decision-making process (often iterative), in which the basic sciences and mathematics, and engineering sciences are applied to convert resources optimally to meet a stated objective. Among the fundamental elements of the design process are the establishment of objectives and criteria, synthesis, analysis, construction, testing, and evaluation.

4. Problem Characteristics
Engineering Problem
Problem statement incomplete, ambiguous( more then one solution)
No readily identifiable closure
Solutions neither unique nor compact
Solution needs integration of many specialties
Science Problem
Succinct problem statement  (expressed in few words; concise)
Identifiable closure
Unique solution
Problem defined and solved with specialized knowledge
From Chung, SJSU,

5. Typical Design Problems
“Design a system for lifting and moving loads of up to 5000 lb in a manufacturing facility. The facility has an unobstructed span of 50 ft. The lifting system should be inexpensive and satisfy all relevant safety standards.”
From Chung, SJSU
Have Students research and find other examples of design problem statements.
As a classroom exercise, divide the students into design teams and have a quick design contest to come up with alternative solutions to this or other simlple design problem statements. Use imagination and be fanciful

6. Studying Engineering Design
Develop student creativity
Use open-ended problems
Use design theory and methods
Formulate design problem statements and specifications
Consider alternative solutions
Consider feasibility
Chung
ABET Definition of Design (cont.)
The engineering design component of a curriculum must include most of the
following features:
– development of student creativity,
– use of open-ended problems,
– development and use of modern design theory and methodology,
– formulation of design problem statements and specifications,
– consideration of alternative solutions,
– feasibility considerations,
– production processes,
– concurrent engineering design, and
– detailed system descriptions.
Further, it is essential to include a variety of realistic constraints, such as
economic factors, safety, reliability, aesthetics, ethics, and social impact.

7. Studying Engineering Design
Know and apply production processes
Understand concurrent engineering design
Create detailed system descriptions
Include realistic constraints such as…
Economic factors, safety, reliability
aesthetics, ethics, social impacts
Chung
ABET Definition of Design (cont.)
The engineering design component of a curriculum must include most of the
following features:
– development of student creativity,
– use of open-ended problems,
– development and use of modern design theory and methodology,
– formulation of design problem statements and specifications,
– consideration of alternative solutions,
– feasibility considerations,
– production processes,
– concurrent engineering design, and
– detailed system descriptions.
Further, it is essential to include a variety of realistic constraints, such as
economic factors, safety, reliability, aesthetics, ethics, and social impact.

8. “Awesome” Engineers… Place ethics and morals above all else
Are team players
Follow a deterministic design process
Follow a schedule
Document their work
Never stop learning
From “Design is a passionate process”
Consider the design engineer.
A design engineer is an engineer whose job is to produce a detailed design from a conceptual design, thereby bringing the real from the abstract.
A design engineer’s product is usually a set of drawings and specifications that should produce a working product with very little final adjustment needed. If significant rework is required in the construction, startup, or manufacturing phase, the design engineer did not do an acceptable job. This ability to foresee potential problems is a key skill for a design engineer. Flaws in the conceptual design that go uncaught by the design engineer or others will not surface until production or construction. A design engineer would usually work on a newer and less proven design than a designer, since once the engineering principles are proven to be correct in a similar design, further engineering knowledge and skill is not generally needed to produce similar designs.
Combining design and engineering into a single discipline is perhaps a lost practice due to increasing division of work and specialization. However, current (1990s and on) trends in the engineering of complex systems are largely towards re-integration of work processes. For example, the notions of Integrated Product Teams and Concurrent Engineering place design firmly within the scope of a wider engineering activity.
Design engineer From Wikipedia, the free encyclopedia, wikipedia.com, August 2006

9. Module Organization: The Design Process
Identify a need, who is the “customer”
Establish design criteria and constraints
Evaluate alternatives (systems or components)
Build a prototype
Test/evaluate prototype against criteria
Analyze, “tweak” (), redesign (), retest
Document specifications, drawings to build
“The crux of the design process is creating a satisfactory solution to a need.
The need may be to improve an existing situation or to eliminate a problem.

10. Engineering Design Process Backup Chart
Identify a need
Establish design criteria and constraints
Evaluate alternatives
Build prototype
Test/evaluate against design criteria
Analyze, redesign, retest
Communicate the design
This is a simplified design process appropriate to introduce high school-ers to a problem solving method. It includes building something tangible and is exactly the process we created for the science fair association. We have this process in the science fair handbook, so hopefully many more students and teachers will be using it to improve fair exhibits. It recognizes the resource and time constraints in the classroom. These steps are not inconsistent with the ABET criteria. Some ABET steps, like “implement the design,” are beyond the scope of a six-week module.
ABET is the Accrediting Board for Engineering and Technology and they define processes for college programs. Richard knows

11. The Engineering Design Process

12. Design is an Iterative Process A process for calculating a desired result by means of a repeated cycle of operations, which comes closer and closer to the desired result
Begins with a recognition of need for a product, service, or system
During the idea phase encourage a wide variety of solutions through brainstorming, literature search, and talking to users
Best solutions are selected for further refinement
Models or prototypes are made and problems that arise may require new ideas to solve and a return to an earlier stage in the process
Finally drawings are released to manufacturing for production

13. Engineering Design Defined
The crux (an essential point requiring resolution) of the design process is creating a satisfactory solution to a need Harrisberger
“The crux of the design process is creating a satisfactory solution to a need.
The need may be to improve an existing situation or to eliminate a problem.
Or, the need may be to develop a use for a new discovery or concept. In any
case, it is what engineering is all about—using knowledge and know-how to
achieve a desired outcome. Designing is problem solving. It is creative
problem solving. A change has to be created. Something different will be
produced, and someone will have to decide what to do with the result.”
“Engineers are applications specialists. They apply the principles, discoveries,
experiences, techniques, and methods derived from ages of research,
experimentation, trial and error, and invention. It really takes some doing to
determine which elements of this vast storehouse of knowledge apply to the
situation at hand. Developing the best combination of principles and
procedures into a highly desirable plan and/or product is an engineer's business
and it's tough work. The design process is not just a matter of dreaming
up clever ideas and schemes. It is a long process of imaginative planning, detailed
analysis, computational prognostication, experimentation, detailed
sizing, specifications for every piece and part, development of tools and
manufacturing procedures, selection of materials, and detailed planning for
assembly, maintenance, repair, safety, durability, sales appeal, etc. And,
superimposed on all of this activity is the continuous and necessary attention
to cost. The design process is an integration of technical knowledge drawn
from the research laboratory and applied to the market place and customer
use. It converts information into decisions and ideas into useful hardware.”
from Lee Harrisberger, "Engineersmanship ... The Doing of Engineering
Design," 2nd Ed, Brooks/Cole Engineering Division, Monterey CA, 1982.
From: Lee Harrisberger, "Engineersmanship ... The Doing of Engineering Design," 2nd Ed,
Brooks/Cole Engineering Division, Monterey CA, 1982

14. Engineering Design Process
Customer Need
or Opportunity
Problem Definition/
Specifications
Data & Information
Collection
Development of
Alternative Designs
At the heart of engineering is the Engineering Design Process.
This is a step-by-step method with the objective of producing a device,
structure, or system that satisfies a need.
Evaluation of Designs/
Selection of Optimal Design 1.
Need established by customer
missile for launching satellite
Implementation of
Optimal Design
Opportunity identified by company
little pieces of paper which could stick onto almost anything
but could be removed easily without leaving any trace
Source: Accrediting Board For Engineering and Technology 2.
Need generally described by a set of specifications (specs)
performance specifications (e.g. Weight, size, speed,
safety, reliability)
economic specifications (e.g. Cost, profit)
scheduling specifications (e.g. Production & delivery
dates

15. Primary Design Features
Meets a need, has a “customer”
Design criteria and constraints
Evaluate alternatives (systems or components)
Build prototype (figuratively)
Test/evaluate against test plans (criteria)
Analyze, “tweak” (), redesign (), retest
Project book: record, analyses, decisions, specs

16. Step 1: Need Have a need, have a customer
External vs internal; Implied vs explicit
Often stated as functional requirement
Often stated as bigger, cheaper, faster, lighter
Boilerplate purpose: The design and construction of a (better____something)_____ for (kids, manufacturing, medicine) to do __________.
Step 1. Identify a need. Needs (also called the problem you are solving or the engineering goal) are frequently identified by customers--the users of the product. The customer could be a retail consumer or the next team in a product development. Customers may express needs by describing a product (I need a car) or as a functional requirement (I need a way to get to school). The need should be described in a simple statement that includes what you are designing (the product), who it is for (customer), what need does it satisfy (problem to solve), and how does it improve previous designs (easy to use, less expensive, more efficient, safer).
Need established by customer
missile for launching satellite
Opportunity identified by company
little pieces of paper which could stick onto almost anything
but could be removed easily without leaving any trace

17. Step 2: Criteria & Constraints
“Design criteria are requirements you specify for your design that will be used to make decisions about how to build the product”
Aesthetics
Geometry
Physical Features
Performance
Inputs-Outputs
Use Environment
Usability
Reliability
Step 2. Establish design criteria and constraints. Design criteria are requirements you specify that will be used to make decisions about how to build and evaluate the product. Criteria are derived from needs expressed by customers. Criteria define the product physical and functional characteristics. Some examples of criteria are shape, size, weight, speed, ruggedness, and ease of manufacture.
Constraints are factors that limit the engineer’s flexibility. Some typical constraints are cost, time, and knowledge; legal issues; natural factors such as topography, climate, raw materials; and where the product will be used. Good designs will meet important design criteria within the limits fixed by the constraints. Good designs are also economical to make and use because cost is always a design constraint!

18. Some Design Constraints
Cost
Time
Knowledge
Legal, ethical
Physical: size, weight, power, durability
Natural, topography, climate, resources
Company practices
From battle bots the five constraints are cost, time, knowledge, power, weight
Cost is always. Cost to design, produce, maintain, support, guarantee, be competitive
Time usually always an engineering constraint. Complex project schedules, delivery dates, down-stream process, time to market
Knowledge often a problem cannot be solved without discovery or new invention. Strength to weight ratios, E.g. turbine disks
Legal ethical, patents, intellectual property, product liability, safety requirements. All cars must have air bag
Physical. Driven by tradeoffs, other constraints, customer expectations, interfaces. Normally more weight requires more power, but more strength does not necessarily mean more weight. It may cost more, though. Aluminum, steel, titanium, graphite composites
Natural. 1 constraint is building is the obstacle. How far to span drives bridge configuration. Temperature extremes very important too
Company May have to use common parts, manufacturing processes
There are others all these may not apply, but the design team needs to be aware of all

19. Activity/Demonstration
Product index cards
Pair up as customer-designer
Variation on 20 questions
Identify some design criteria and constraints for sample products
Discuss
See handouts, card sized problem set and instructions.
Have pictures of simple items (have like items so focus on needs, what function perform, identify alternatives, use answer to questions to come with simple criteria and constraints)
Use 20 questions model to figure out what some do, then guess what they are.
Once guessed, item or function, choose one item to fully develop, teams internal brainstorm to develop more criteria and constraints until everyone is done
Items to evaluate
candle, flashlight, kerosene lamp, lantern
Shaver, razor, scissors, tweezers, hair wax
flashlight, Candle, oil lamp, flaming torch
Phone, walkie-talkie, cell phone, tin cans an a string, telegraph
Generator, battery, solar cell
Bicycle, scooter, roller blades, roller skates, tricycle

20. Step 3: Evaluate Alternatives
Needs best stated as function, not form
Likely to find good alternatives for cheapest, fastest, lightest, and encourage discovery
Research should reveal what has been done
Improve on what has been done
Play alternatives off criteria and constraints
Brainstorming helps
Step 3. Evaluate alternative designs. Your research into possible solutions will reveal what has been done to satisfy similar needs. You’ll discover where knowledge and science limit your solutions, how previous solutions may be improved, and what different approaches may meet design objectives. You should to consider at least two-to-three alternative designs and consider using available technology, modifying current designs, or inventing new solutions. Superior work will demonstrate tradeoff analyses such as comparing the strength vs. cost of various bridge-building materials. It’s important to document in your project book how you chose and evaluated alternative designs.
Development of Alternative Designs
involves creativity and engineering tools
CADD & computer modeling
stress analysis
material science
manufacturing processes
constraints must be identified & met
availability of parts & materials
personnel
facilities

21. Simulation
Using a simulation to do science experiment, engineering analysis, select alternatives,
example, the effect of altitude on lift. How the higher the altitude, the less the lift for a constant angle of attack and at an altitude of 1000’
Design tool Example, how big should my wing be to lift 20,000 d
analysis. What’s the maximum lift I can get from various shapes, chamber
testing. What race car has the least drag?

22. A quality design meets customers expectations!
Best Design
Choose best design that meets criteria
Demonstrate tradeoff analyses (among criteria and constraints) are high quality
Cost (lifecycle) is always consideration
Resist overbuilding; drives complexity, cost, time, resources
A quality design meets customers expectations!

23. Step 4: Prototype
Prototype is implementation of chosen design alternative
It is a proof of design, production and suitability
Prototypes are often cost prohibitive: Models and simulations may suffice
Quality design does not include redesigning a lot of prototypes
Step 4. Build prototype of best design. Use your alternatives analyses to choose the design that best meets criteria considering the constraints, then build a prototype. A prototype is the “first full scale and usually functional form of a new type or design” (Webster’s Dictionary).
Expense may limit full-scale; often prototype components
Prototype 1. An original model upon which something is patterned (Webster)
2. A standard or typical example. 3. A first full scale and usually functional
form of a new type or design
By definition represents the chosen alternative

24. Prototype picture of 747 Prototype
Prototype 1. An original model upon which something is patterned (Webster)
2. A standard or typical example. 3. A first full scale and usually functional
form of a new type or design
By definition represents the chosen alternative
Expected in a science project.
Expense may limit full-scale; often prototype components

25. Step 5: Test it Well
Test and optimize design against constraints and customer expectations.
Create a test plan showing how to test
Test in the conditions of use
Good test plan shows what test, expected results how to test, and what analyses will be. It relates to specification requirements
e.g. test plan for light bulb (activity)
Step 5. Test and evaluate the prototype against important design criteria to show how well the product meets the need. You should develop a test plan describing what you will test, how you will test, and how you’ll perform analyses. You must test your prototype under actual or simulated operating conditions. Customers are usually involved in product testing so be sure you have their approval.

26. Activity: Light Bulb Test
Production assembly-time-demonstration
Robustness-vibration, temperature-test article
Life-hours-statistical sample
Duty cycle-count on/off-prototype
Class interaction
Pose question what should I test about a light build
What parameter (design criteria), what to measure, and how to conduct it. Test, analysis, evaluation, demonstration
Write on acetate that has picture of light bulb.
Compare this chart with student answers
Consider making light bulb one of design need exercise
Alternative, have students design a test plan for something in teams
Brightness-lumens-measure
Packaging-drop test-do last
Base fit-yes/no-first article demo

27. Step 6: Test and Redesign
Step 6. Analyze test results, make design changes and retest. Testing will disclose some deficiencies in your design. Sometimes the testing fails completely and sends the designer “back to the drawing board.” Make corrections and retest OR prepare an analysis of what went wrong and how you will fix it. As always, document your analyses, fixes, and retests in you project book.

28. Test Results
Successful Test: Satisfying
Test Failure: Priceless

29. Step 7: Documentation Project data book A complete record
All key decisions
Good drawings
Test plans
Results
Conclusions
Things learned
Step 7. Communicate the design. The designer’s real product is the description of a design from which others will build the product. You’ll use project book and the fair exhibits/posters to communicate the design to your customer and the judges. Your product description will be conveyed in drawings, photos, materials lists, assembly instructions, test plans and results. Consider listing lessons learned so future designers need not repeat any of your “frustrations.” You’ll have clear instructions on how to produce your design in quantities, along with production cost estimates.

30. Draw a Good Picture
Drawings for project notebook, application, display
Photos, sketches, CAD 2-D or 3-D
Show assembly, components, materials
Most important aspect of patent
types of designs
isometric
projection
cad tools
photograph
schematics
flow chart
process chart
Picture of satellite

31. Product Sketches

32. Other Drawings Circuit design Functional diagrams Configuration
Connections
Flow Charts