1. Configuration Design Architecture Abstract embodiment
Special Purpose Parts:
Features
Arrangements
Relative dimensions
Attribute list (variables)
Standard Parts:
Type
Abstract embodiment
Physical principles
Material
Geometry
Architecture

2. Product or Part
Product configuration = “architecture”
Part configuration
Start with the big picture....
i.e. Product architecture

3. 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
Pugh’s Method
Weighted Rating Method
Evaluate
Best
configuration(s)

4. Product First… Use component decomposition diagrams
penlight
bulb
battery
body
spring
screw cap
glass lens
filament
base
anode
cathode
electrolyte
plastic cover
switch
case
elements are arranged into “physical building blocks”

5. Generalized component decomposition
Product
Subassembly A
Standard
Part
Standard part
Special purpose part
Special purpose
Subassembly B
Subassembly B1
a. type, number, arrangement of components
b. standard or special purpose (make or buy)

6. Product architecture …like house architecture
Architecture style
Scheme
colonial
dining, living rooms 1st floor
bedrooms on 2nd floor
ranch
all rooms on ground floor
Rooms are arranged according to a logical “scheme.”
Before the details of all the house are designed we determine the general layout or “architecture.”

7. Product Architecture (Ullrich & Eppinger)
def – the scheme 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”

8. Modular architecture Product examples Flashlight Refrigerator
Automobile
Personal computer
Modular components
Batteries, bulbs
Motors, compressor, switches
Tires, radios, seats, pumps engines
Drives, keyboards, mice, modems
chunks implement one or a few functions,
interactions between chunks are well defined
(standard interfaces / connections)

9. Integral Architecture
Product examples
BMW Motorcycle engine
Printer case
Shaft
Beverage cup
Integrating aspects
engine/frame
integral snap-fasteners
machined bearing race
integrated handle
a single chunk implements many functions
interaction is ill defined
physical element “shares” functions

10. Printer Example

11. Cluster elements into logical chunks

12. Sketch rough geometric layout

13. Sketch interaction diagram

14. 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)

15. What is a part configuration?
For example:
Design problem: support vertical load ---- Concept: wall bracket
Physical principle
geometry & material
embodiment
What are some possible “configurations” for a wall bracket?

16. Part configuration design
geometric features include:
walls
rounds
cubes
notches
ribs
bosses
spheres
chamfers
projections
cylinders
holes
grooves
fillets
tubes
slots

17. How can we “generate” alternative part configurations?
Abstract
embodiment
Recall bracket
configurations
different features
alternative
arrangements
different
relative dimensions

18. Configuration decisions
Change one or more of these…
memorize
Configuration decisions
How do we create different configurations?

19. Obtaining the “best” configuration
To choose the “best” alternative….
Implies that we have a number of feasible alternatives!
To be selective, we need a selection!

20. Configuration design - analysis
Best concept(s)
Configuration design - 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)
Continue on Tuesday

21. To analyze configurations, we ask…
Will it likely function?
Will it likely assemble?
Will it be likely manufacturable?

22. Design for function Will the part or product perform its function(s)?
1.  Strong
2.  Stiff or flexible
3.  Buckle
4.  Thermal expansion
5.  Vibrate
6.  Quiet / Noise
7.  Heat transfer
8.  Fluids transport / storage
9.  Energy efficient
10. Stable
11. Reliable
12. Human factors/ergonomics
13. Safe
14. Easy to use
15. Maintain
16. Repairable
17. Durable (wear, corrosion)
18. Life-cycle costs
19. Styling/aesthetics
Use knowledge from math, eng’g and sciences…

23. Will it assemble? What do we mean by assemble?
Assembly - a process of handling components
to bring them together (inserting) and then
fastening them.

24. DFA
Design for Assembly - a set of design practices which reduce the manpower time required to handle, insert and fasten components of a product.
1. Design Guidelines (written and graphical)
2. Cost estimating methods

25. DFA Graphical 1

26. Design for Assembly Guidelines from 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

27. DFM
Deign for Manufacture (manufacturability) - A set of practices that aim to improve the fabrication of individual parts
1. Design Guidelines (written and graphical)
2. Cost estimating methods

28. DFM – Injection molding / casting
avoid designing parts with thick walls or heavy sections
design parts without undercuts
choose polymer for minimum total part cost
(i.e. tooling, processing, material)
design external threads to lie on parting plane/surface
add ribs for stiffening

29. DFM – Sheet metalworking
avoid designing parts with narrow cutouts or projections
minimize manufactured scrap (cut-off versus blanking)
reduce number of bend planes
keep side-action features to a minimum or avoid completely

30. DFM – Machining employ standard features
(e.g. holes, slots, chamfers, fillets, rounds)
use raw material available in standard forms
(e.g. sheet, roll, bar, plate)
avoid sharp internal corners on turned parts
specify liberal tolerances and surface finishes

31. Configuration design - evaluation
Best concept(s)
Configuration design - evaluation
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)

32. Graphics during Configuration Design
Sketches are used a lot in configuration design
Sketches assist creativity
Sketches are not typically used to “document” the “design”
CAD Drawings need sizes (e.g. H, W, L, D)
CAD Takes time
But, some CAD may be useful

33. Configuration design summary
Best concept(s)
Configuration design summary
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)

34. Configuration Design Architecture Abstract embodiment
Special Purpose Parts:
Features
Arrangements
Relative dimensions
Attribute list (variables)
Standard Parts:
Type
Abstract embodiment
Physical principles
Material
Geometry
Architecture