Engineering Design: BITS Pilani

Engineering Design
Module 6: Embodiment Design
BITS Pilani
Pilani | Dubai | Goa | Hyderabad
Dr. Nitin Kotkunde
In tr o duction
ETZC 413 – E N G IN E ERIN G D E S IG N 2 BITS-Pilani

C o n tent : Em b o diment D e si gn
• Introduction
• Product architecture
• Configuration design
• Best practices for configuration design
• Parametric design
• Dimensions and tolerances
• Industrial design
• Human factors design
• Design for environment
• Prototyping and testing
• Design for ‘X’

Pr o d uct Ar c h i tecture

Pr o d uct Ar c h i tecture
• Product architecture is the arrangement of the physical elements of a product to

carry out its required functions.
– Mapping from product function to the product form
– Layout and architecture of the product their interfaces (Best possible architecture
selection).
– Rough sketches of concepts
– Proof-of-concept model
– Key decisions on how the product will physically operate
– Key milestone for any class of products

Ar c h i tecture T y p e s
Architecture
Types
Integral Modular
Slot Bus Sectional Mix

In te gr al Ar c h i tec ture
 Only one or few modules

 No individual isolated components
 Components perform multiple
functions
 Complex interactions
 Changes made to any component in a
integral architecture tend to propagate
to many
 High-volume products
 Product architecture has strong
implications for manufacturing costs.

M o d ular Ar c h i tecture
• Overall function through the combination of distinct building

blocks or modules.
• A modular architecture makes it easier to evolve a design

over time.
• Difficulties may be faced in initial stages because compatibility

of the modules in first product needs to be established with
those in the subsequent products.
• The product can be adapted to the needs of different

customers by adding or deleting modules.

• It helps to develop a product family.
• Modular products make economic sense
• They offer easier assembly and disassembly, modification and reassembly
• Standardization of components
• Re-configurability of devices

M o d ular vs . In te grated a r chi tecture
Pros Cons
• Improve device reconfigurability • May make devices look
• Increases the device variety and similar
speed of introduction for new • Reduces device
Modular devices performance
• Improves maintainability and • More expensive
Serviceability
• Decuples development and
manufacturing tasks
• Harder for competitor to copy the • Hinders changes of
design design in production
Integral • Tighter coupling of teams with • Reduce the varity of
less interface problems devices that can be
• Possible reduction in system cost produced.
C o n si derations a t p r o duct a r ch itecturi ng
• How will it affect the ability to offer product variety?
• How will it affect the product cost?
• How will it affect the design lead time?
• How will it affect the development process management?

Modular
Architecture
Manufacturing
based Function based
modularity modularity
Original
Assembly Equipment
Conceptual
modules Manufacturin Sizable Bus
g (OEM) modules modules Slot Sectional Mix
modules

F u n c ti on b a s ed m o dul arity

F u n c ti on b a s ed m o dul arity

F u n c ti on b a s ed m o dul arity: Exa m p l e
Modular trailer architecture exhibiting a one-to-one

Function structure of a trailer mapping from functional element to physical component
Karl Ulrich, The role of product architecture in the manufacturing firm, Research Policy 24 (1995) 419-441)
Integral trailer architecture exhibiting a one-to-one mapping from functional element to physical component
F a ctor s a ffe c ting a r ch itecture m o d ulari ty
• Product changes
Upgrade
• Product variety
• Component standardization
• Product performance Add-ons Re-use
• Manufacturability
• Product development management
Flexibility
Adaptation
in use

Ar c h i tecture D e s i gn Pr o cess
Create a schematic of the product
Cluster the elements of the schematic
Create a rough geometric layout
Identify the fundamental and incidental interactions

• Creating a product schematic: DeskJet Printer Schematic

• Cluster the elements of the schematic: DeskJet Printer Schematic

• Create a rough geometric layout: DeskJet Printer Schematic

• Identify the fundamental and incidental interactions: DeskJet Printer Schematic

Laser-fusing rapid prototyping machine



F u n damental D e c i si ons
• Integral vs. modular architecture?
• What type of modularity?
• How to assign functions to chunks?
• How to assign chunks to teams?
• Which chunks to outsource?

C o n figuration D e s i gn
Four possible configurations of features for a right-angle bracket. (a) Bent from a flat plate.(b) Machined from
a solid block. (c) Bracket welded from three pieces. (d) Cast bracket.

• Review the product design specification and any specifications developed for the particular
subassembly to which the component belongs.
• Establish the spatial constraints that pertain to the product or the subassembly being
designed.

• Create and refine the interfaces or connections between components. Much design effort
occurs at the connections between components, because this is the location where
failure often occurs. Identify and give special attention to the interfaces that transfer the
most critical functions.
• Before spending much time on the design, answer the following questions:
– Can the part be eliminated or combined with another part?
– Can a standard part or subassembly be used?
• Generally, the best way to get started with configuration design is to just start sketching
alternative configurations of a part (Substituting, Combining, Decomposing, Magnifying,
Minifying, Rearranging).
An a l yz ing th e C o n fi guration D e si gn

Eva l u ati ng th e c o n figurati on d e si gn
• Performance
• Cost
• DFMA
• DFE
• Ergonomics and aesthetics

Be s t p r a cti ces fo r co n fi guration d e sign
• Clarity of function pertains to an unambiguous relationship.
• Simplicity refers to a design that is not complex and is easily understood and readily
produced.
• Safety should be guaranteed.
• Minimal impact on the environment
• Design guidelines:
– Force transmission
– Division of tasks
– Self-help
– Stability

Ad d i tional Design guidelines
• Tailor the shape to the stress or load distribution
• Avoid geometry that is prone to buckling
• Use triangular shapes and structures
• Don’t ignore strain considerations in design

In te r fac es a n d C o n nections
Adjustable
connection
Connections
Fixed, nonadjustable
connection
Separable connection
Hinged or pivoting
connection
Locator connection

C h e ck li st fo r C o n figuration D e si gn
• Identify the likely ways the part might fail in service:

• Excessive plastic deformation.
• Fatigue failure
• Stress concentrations
• Buckling
• Shock or impact loads
• Identify likely ways that part functionality might be compromised:

• Tolerances.
• Creep.
• Thermal deformation

• Materials and manufacturing issues:

• Is the material selected for the part the best one to prevent the likely failure modes in service?
• Is there a history of use for the material in this or similar applications?
• Can the form and features of the part be readily made on available production machines?
• Will material made to standard quality specifications be adequate for this part?
• Will the chosen material and manufacturing process meet the cost target for the part?

• Design knowledge base:
• Are there aspects of the part design where the designer or design team is working without adequate
knowledge?
• Have you considered every possible unfortunate, unlikely, or unlucky event that could jeopardize the
performance of the design? Have you used a formal method like FMEA to check for this?

Pa r a metric d e s ign
Formulate the parametric design problem
Generate alternative designs
Analyze the alternative designs
Evaluate the results of the analyses
Refine/Optimize

F a i l ure M o d es a n d Effe cts An a l ysis ( F M EA)
• FMEA is an analytical technique used to identify, define, and eliminate, to the extent possible,
known as potential failure modes of product system.
• FMEA Goals:
– Evaluation of design requirements and design alternatives.
– Initial design for manufacturing and assembly requirements.
– Increasing the probability that potential failure modes and their effects on system operation have been
considered in the design/development process.
– Providing additional information to aid in the planning of thorough and efficient design improvements
and development testing.
– Providing an open issue format for recommending and tracking risk reducing action.
– Providing future references to aid in analyzing field concerns, evaluating design changes, and
developing advanced designs.
F M EA b a s ic q u es tions
• What could fail or go wrong with each component of a product?
• To what extent might it fail, and what are the potential hazards produced by the
failures?
• What steps should be implemented to prevent the failures?
• These questions gives rise to three basic elements of FMEA: failure modes
(identification), failure effects (ramifications) and failure criticality (relative
importance of given failure states).

Ste p s i n F M EA
List each sub-assembly and component number, along with

the basic functions or function chains of the component
Identify and list the potential failures for each product component
11 –– No
Almost
effect
certain
List the possible potential causes or mechanism of the failure
modes 22 –– Very
2/3 –High
Lowminor
(relatively
(only noticed
few failures)
by
List the potential effects of the failure, including impact on the discriminating customers)
environment, property and hazards to human users 3 – Moderate
4/5/6 – Moderate (occasional failures)
3 – Minor (affects very little on the
Rate the likelihood of occurrence (O) of the failure system;
7/8 – High
4/5/6 notice
– Moderateby –average
(repeated most customers)
failures)
customers are
annoyed
4/5/6 – Moderate (most customers are
Estimate the potential severity (S) of the failure and its effects 9/10 – Very high (failure is almost
annoyed)
7/8 – Low
inevitable)
• 1000 = Harmful or hazardous
List current or expected design controls/tests for detecting (D) the 7/8 – High (causes a loss of primary
•9/101 –= Very
Failure is highly
remote unlikely and
to absolute
failure before the product is released for production functions; customers are dissatisfied)
unimportant
uncertainty
Calculate the Risk Priority Number (RPN) •9/10100– very
= Need
high to
and
consider
hazardous (product
𝑅𝑃𝑁 = 𝑆 × 𝑂 × 𝐷 •become
30 = inoperative;
Safe failure may results
unsafe operations and possible injury)

L o g ic al r e l ati ons hip o f F M EA

F M EA T e m plate

F M EA Exa m p le: Ba l l p o i nt p e n

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Engineering Design

Module 6: Embodiment Design

ETZC 413 – E N G IN E ERIN G D E S IG N 2 BITS-Pilani

ETZC 413 – E N G IN E ERIN G D E S IG N 3 BITS-Pilani

ETZC 413 – E N G IN E ERIN G D E S IG N 4 BITS-Pilani

• Product architecture is the arrangement of the physical elements of a product to

– Mapping from product function to the product form

– Rough sketches of concepts

– Key decisions on how the product will physically operate

– Key milestone for any class of products

Slot Bus Sectional Mix

ETZC 413 – E N G IN E ERIN G D E S IG N 6 BITS-Pilani

 Only one or few modules

ETZC 413 – E N G IN E ERIN G D E S IG N 7 BITS-Pilani

• Overall function through the combination of distinct building

• A modular architecture makes it easier to evolve a design

• Difficulties may be faced in initial stages because compatibility

• The product can be adapted to the needs of different

ETZC 413 – E N G IN E ERIN G D E S IG N 8 BITS-Pilani

• It helps to develop a product family.

• Modular products make economic sense

• They offer easier assembly and disassembly, modification and reassembly

ETZC 413 – E N G IN E ERIN G D E S IG N 9 BITS-Pilani

• How will it affect the ability to offer product variety?

• How will it affect the product cost?

• How will it affect the design lead time?

• How will it affect the development process management?

ETZC 413 – E N G IN E ERIN G D E S IG N 11 BITS-Pilani

ETZC 413 – E N G IN E ERIN G D E S IG N 12 BITS-Pilani

ETZC 413 – E N G IN E ERIN G D E S IG N 13 BITS-Pilani

ETZC 413 – E N G IN E ERIN G D E S IG N 14 BITS-Pilani

Modular trailer architecture exhibiting a one-to-one

• Product performance Add-ons Re-use

• Product development management

ETZC 413 – E N G IN E ERIN G D E S IG N 20 BITS-Pilani

Create a schematic of the product

Cluster the elements of the schematic

Create a rough geometric layout

Identify the fundamental and incidental interactions

ETZC 413 – E N G IN E ERIN G D E S IG N 21 BITS-Pilani

ETZC 413 – E N G IN E ERIN G D E S IG N 22 BITS-Pilani

ETZC 413 – E N G IN E ERIN G D E S IG N 23 BITS-Pilani

ETZC 413 – E N G IN E ERIN G D E S IG N 24 BITS-Pilani

ETZC 413 – E N G IN E ERIN G D E S IG N 25 BITS-Pilani

ETZC 413 – E N G IN E ERIN G D E S IG N 26 BITS-Pilani

ETZC 413 – E N G IN E ERIN G D E S IG N 27 BITS-Pilani

ETZC 413 – E N G IN E ERIN G D E S IG N 28 BITS-Pilani

• Integral vs. modular architecture?

• What type of modularity?

• How to assign functions to chunks?

• How to assign chunks to teams?

• Which chunks to outsource?

ETZC 413 – E N G IN E ERIN G D E S IG N 29 BITS-Pilani

ETZC 413 – E N G IN E ERIN G D E S IG N 30 BITS-Pilani

ETZC 413 – E N G IN E ERIN G D E S IG N 31 BITS-Pilani

– Can a standard part or subassembly be used?

ETZC 413 – E N G IN E ERIN G D E S IG N 33 BITS-Pilani

• Ergonomics and aesthetics

ETZC 413 – E N G IN E ERIN G D E S IG N 34 BITS-Pilani