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

2. 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)

3. 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

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

5. Possible GearPair Configurations
Alternative configuration 1
ARRANGE Part Differently

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

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

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

9. Wall Bracket Configurations
Abstract Embodiment
Different Features
Different Arrangements
Different Dimensions

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

11. 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

12. 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)

13. 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.”

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

15. Example  Product Architecture
March 1992
Jun 1994

16. 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)

17. 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”

18. 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)

19. 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

20. 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

21. Example  Design Printer
Identify
SubFunctions
InterActions

22. Example  Design Printer
Cluster Elements into Logical “Chunks”

23. Example  Design Printer
Sketch rough geometric “layout”

24. a REFINED LayOut

25. Example  Design Printer
Sketch the Interaction Diagram

26. 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)

27. 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

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

29. Example  Sponge Holder
Prepare configuration requirements sketch
Sponge Holder

30. Example  Sponge Holder
Prepare NON-Contiguous configuration requirements sketch

31. Example  Sponge Holder
Prepare alternative CONTIGUOUS configuration sketches

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

33. 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)

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

35. 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

36. 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.

37. 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

38. 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

39. 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

40. 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

41. 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)

42. 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.”

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

44. 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

45. Eval Sponge Holder ConFigs

46. 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)

47. 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”

48. 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

49. Sketches for Patent Doc.

50. USA Patent App

51. 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”

52. LayOut For FC CCA Enclosure

53. LayOut for 800mm Glass Coater

54. Elect Pwr & Control Schematic

55. 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.

56. Computation Fluid Dynamics

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

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

59. WJ-1000 Product

60. 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 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.