systematic design process

8/10/2019 Systematic Design Process

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Chiradeep Sen

PhD Student136 Fluor Daniel [email protected]

http://aid.ces.clemson.edu/Chiradeep_Senhttp://www.ces.clemson.edu/~gmocko/people/csen.html

Advisors:Dr. Joshua D. SummersDr. Gregory M. MockoDr. Georges M. Fadel

Systematic Design Process


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What is Design

Design is:

the systematic and creative application of scientific and mathematical principles to practicalends such as the design, manufacture, and operation of efficient and economical structures,machines, processes, and systems(www.doe.mass.edu/frameworks/scitech/2001/resources/glossary.html )

is the creative, iterative and often open-ended process of conceiving and developingcomponents, systems and processes. Design requires the integration of engineering, basic andmathematical sciences. A designer works under constraints, taking into account economic,health and safety, social and environmental factors, codes of practice and applicable laws.www.ee.wits.ac.za/~ecsa/gen/g-04.htm

Design is an activity:

Affects all areas of life Uses laws and insights

Builds on experience

Is a prereq for the realization of ideas into reality

Is a SOCIAL activity


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Engineering Design

To design is to imagine things that dont exist and bring them into the world

These things are tangible

Design is regarded as an art rather than science

Science: proceeds by laws (sometimes mathematical)

Art: proceeds by rules of thumb, intuition, feeling; but adheres to constraints and

laws of nature

Engineering design is a systematic intelligent generation and evaluation ofspecifications for artifacts whose form and function achieve stated objectivesand satisfy specified constraints (Dym and Little)


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Engineering Design

Bigger part of the product realization process

Includes sales, marketing, industrial design, manufacturing, etc

Must work together with other disciplines

Engineering design is the set of decision-making processes and activities usedto determine the form of an object given the functions desired by the customer

(Eggert)


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Engineering Analysis

Predict the behavior or function of an object using analytical equations or

experimental methods

Formulating

Understand and plan solution

Gathering information Rough plan on how to solve

Solving

Determine unknowns of the equations

Solve and label with units

Checking

Does it make sense

Essential, but not only component to design


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Problems with Understanding Design

Some common and dangerous thoughts

Design Cannot be taught

In order to design you must build stuff!

Design is easy to demonstrate and not easy to articulate

Mathematics provides a formal language to articulate behavior

Such mathematical models do not exist to describe design


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What we know about design

Open ended problems

Ill structured

There are several acceptable solutions

Design solutions cannot be simply found by using mathematical formulae and

algorithms


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Motivation to Understand Design

Decisions made during a products design phase generally establish the majority

of manufacturing costs

The National Research Council has determined that nearly 70% of a products

cost is determined in the first 5% of the design process


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Systematic Design: Some Requirements

Requirements for a systematic design methodology:

be applicable to every type of design activity

foster inventiveness and understanding

be compatible with other disciplines

not rely on chance

facilitate the application of known solutions

be compatible with electronic data processing

be easily taught and learned

reflect the findings of psychology and ergonomics

emphasize the objective evaluation of results

P&B: 10-11.


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My View of Design

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A controlled broadening and narrowing of scope to generate information aboutthe product


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ASME Design Theory and Methodology

Topics of interest include, but are not limited to:

Advances in Design Theory, Representations, Methods, and Formalisms

Creativity and Innovation in Design

Design Behavior Study and Cognitive Modeling

Validating and Verifying Design Theories and Methods

Making Better Decisions in Engineering Design Risk Based Design

Designing in Collaborative and Distributed Environments

Product Architecture Design Methods

Theory and Methods for Sustainable Product Development

Widely Applicable Techniques for Improving Design Practice in Industry

Advanced Design Education and Design Curricula

Artificial Intelligence in Engineering Design

The impact of design theory and methodology research in the last 20 years


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The P&B Systematic Approach

Concept

Preliminary Layout

Definitive Layout

Documentation

Specification

Product Planning

& Clarification of

Task

ConceptualDesign

Embodiment

Design

Detail Design

Phase 0 - Start

UpgradeandImprove

Solution

CustomerTask

Specification

Concept

Preliminary Layout

Definitive Layout

Documentation

Solution

Finalize detailsComplete detail drawings and production documentsCheck all documents

Clarify the taskElaborate the specification

Identify essential problemsEstablish function structuresSearch for solution principlesCombine and firm up into concept variantsEvaluate against technical and economic criteria

Develop preliminary layouts and form designsSelect best preliminary layoutsRefine and evaluate against techincal and economic

criteria

Optimize and complete form designsCheck for errors and cost effectivenessPrepare the preliminary parts list and production

documents

Figure 3.3.P&B: 66.


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Phase 1 Product Planning

Developing and formulating a promising

product idea

Product Planning

Clarifying the Task

Analyze market / company

Find and select product ideas

Formulate a product proposal

Task

Specification

Clarify the task

Elaborate a requirements list

Product Proposal

Phase

1

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Overview of Product Planning

Successful product planning takes into account market, company, and economy

Market

technical and economic position of product

changes in market requirements

suggestions and complaints of customers

technical and economic superiority of other products

Other sources

economic and political changes oil prices regulations limitations culture

new technologies

environmental and recycling issues

Within the company

company R&D

product evolution new functions to satisfy new market needs

process evolution new ways of doing / making things

rationalization of product line

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Activities in Product Planning

Analyze the situation Analyze the situation of the company and products using knowledge of market and other

sourcesSituation Analysis

Formulate search strategies Take into account the goals, strengths and weaknesses of the company, market niches and

needsSearch fields

Find product ideas Search for new functions, working principles or geometries based on existing or extended

energy, material signal flowsProducts Ideas

Select product ideas Using selection procedure that takes into account goals, strengths, and market A Product

Idea

Define products Elaborate and evaluate product ideas. Results in a Product Proposal

Technology push vs. customer pull:Do you think that customers wanted to watch videos on

their IPODS?

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Case Study

Kittyhawk drive

HP introduced in 1992

1.3" Kittyhawk microdrive

20 and 40 megabytes of storage

Tiny motion sensor that would

park the heads if it detected the

device being dropped.

How not to bring a technology tomarket

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Phase 1 - Clarification of Task

Define the goals

Clarify boundary conditions

Dispel prejudice

Make decisions

What objectives must the intended solution satisfy?What properties must it have?

What properties must it not have?

Fixed solution ideas or concrete indications implicit in the taskformulation often have an adverse effect on the final outcome. PB:p130.

P&B: Chapter 5.

Specification

Clarify the task

Elaborate a requirements list

Product Proposal

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Clarifying the Task

What is the essence or crux of the problem?

What implicit wishes and expectations are involved?

Do the specified constraints actually exist?

What paths are open for development?

What are the objectives? What are essential properties?

Avoid:

fixed solution ideas / solution-specific considerations

fictional constraints and concrete implications

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Requirements List

The requirements list is a document that contains:

Problem Statement Summary of the the crux of the problem

Project ID / Issue Date ... the project identifier (e.g., project number and name) and the date the requirements list

was generated

Demands / Wishes ... an indication of requirements that must be satisfied versus those that are less critical

Group or Individual Responsible the name of the group(s) / individual(s) responsible for specific requirements

Modifications / Date ... the date and type of modification made to requirements

Requirements ... particular characteristics of the intended solution, quantified (if possible) and clearly

arranged

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Requirements List Document

Problem Statement:

DW

1. Devices on the yoke: (If necessary suggestions for changes possible) Marc,

D clearance for machanical signals (switches: main,dimmer,cut-off; led's; contacts) Tord &

D hold button and faceplate Christ.

D allow for ground (according to UL 1472, 4.5 & 5.8 / UL 486B) for all

W possibility to adjust dimmer in misaligned box points

D screw holes and possibilities to assemble parts of the dimmer

D interface with back housing

2. Geometric constraints:

D interface with standard wall box (according to UL 1472, 4.4 / UL 514)

D installation directly next to other dimmers must be possible

3. Heat transfer:

D temperature must be less then 90 dgr. C at the contact areas with the fiberboard

wall according to UL 1472, 5.5 & table 10)

W determine best material properties (trade-off with temperature)

4. Manufacturing

W determine most cost effective design

W easy to manufacture

D use same manufacturing line

D must be stamped

W single piece

W easy to assemble

Fri, Oct-23 D maximum press force: P= 0.7(UTS)(t)(L) ; Pmax= 1.5 tons

UTS = ultimate tensile strength (Al or Cu)

t = thickness

L = perimeter (including interior holes

Fri, Oct-23 D maximum bending force: P = (1/W)*K(UTS)LT2; Pmax= 1.5 tons

K = 1.25; L,T,W see page 392,404 Manufacturing processes for ME

Fri, Oct-23 W determine best material properties (trade-off with stamping force)

5. Electrical safety

D yoke cannot extend past face plate (prevent contact with user)

6. Quality/Cost Goal

W consolidate as many yokes as possible

ME 6170

Resp.

October 16, 1998

Issued on:Requirements List for Yoke Design

RequirementsChanges

Redesign a yoke component to fit in the existing switch

assembly, attach to and hold the necessary

components, provide required structural support, and

dissipate a known amount of heat to ensure safe

operation. Further, as much as possible, the design

must facilitate standardization with respect to design

reusability and manufacturing process for the four

existing products addressed.

w

h

Interfaces

Problem Statement

Demands / Wishes

Modifications / Date

Project ID /

Issue Date

Group or

IndividualResponsible

Requirements

ME870

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Categories of Requirements

Geometry size, height, breadth, length, diameter, space

requirement, number, arrangement, connection

Kinematics type of motion, direction of motion, velocity,

acceleration

Forces direction and magnitude of force, frequency, weight,

load, deformation, stiffness, elasticity, stability,resonance

Energy output, efficiency, loss, friction, ventilation, state,

pressure, temperature, heating, cooling, supply,storage, capacity, conversion

Material physical and chemical properties of the initial and

final product, auxiliary materials, prescribed materials(food regulations, etc.)

Signals inputs and outputs, form, display, control equipment

Safety ...

direct safety principles, protective systems, operatorand environmental safety

Ergonomics ... man-machine relationship, type of operation,

clearness of layout, lighting, aesthetics

Production ... factory limitations, maximum possible dimensions,

preferred production methods, means of production,achievable quality and tolerances

Quality Control ... possibilities of testing and measuring, application of

special regulations and standards Assembly

special regulations, installation, siting, foundations

Transport ... lifting, clearance, transportation

Operation ... quietness, wear, destination/environment, special

uses, market

Maintenance ... service, inspection, repair, painting, cleaning

Recycling ... reuse, reprocessing, waste disposal, storage

Costs ... maximum permissible manufacturing costs,

investment, depreciation

Schedules ... end date of development, project planning and

control, delivery date

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Outcome of Phase 1

Deliverables:

Detailed Product Proposal

Requirements List

Make a decision to proceed to Phase 2

Answer the following questions:

Has the task been clarified sufficiently to allow for development of a solution in the

form of a design?

Must further information be acquired?

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Phase 2 - Conceptual Design

Define the goals

Clarify boundary conditions

Dispel prejudice

Search for variants

Evaluate

Make decisions

Remove false functionsEliminate functions that do not havebearing on the product

Start in the function domain-What must the product do?NOT- What must the product look like

Specification

Abstract to identify essential problems

Establish function structures

Search for working principles

Combine working principles into working

structures

Select suitable combinations

Firm up into principle solution variants

Concept

Evaluate against technical and economic

criteria

P&B: Chapter 6.

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Overview of Conceptual Design

The main goals in conceptual design:

by the identification of the essential problems through abstraction, by the establishment of function structures, and

by the search for appropriate working principles and their combination,

The basic solution path is laid down through the elaboration of a solutionprinciple

Concepts are developed from the solution principle

The difference between

What and how

Principle and principal

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Abstracting to Identify Essential Problems

What is Abstraction?

Ignoring what is particular or incidental and emphasizing what is general

Identifying fictitious constraints and eliminating all but genuine restrictions

Why is Abstraction Necessary?

To establish the crux or essence of the design task

Essential constraints become clear without prejudicing the choice of a particular

solution.

To overcome prejudices, or conventions which, coupled with risk aversion, may

lead to solution fixation

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Abstracting Essential Requirements

Abstracting the requirements list

1. Eliminate personal preferences from the requirements list

2. Consider only requirements that affect function and essential constraints

3. Transform quantitative into qualitative data, reducing them to essential ideas

4. Broaden essential ideas systematically (generalize)

5. Formulate the design problem in solution-neutral terms

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*** Identification of essential requirements ***


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Establishing Function Structures

P&B: Fig. 2.3

What is a function?

A function specifies the relationship between inputs and outputs.

Why function structures?

Express relationships between inputs and outputs independently of thesolution. Facilitate the subsequent search for solutions.

Where do I start?Use abstraction to identify the crux or essence of the problem. Thisbecomes the overall function.

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Hair Dryer Function Structure

Provide

Interface

Input signal

Interface energy

Flow signal

Interface

energy

Heat signal

Air @ v1, T1

Wasted flow

energy

Air @ v2, T1Heat Air

Electrical

energy

Wasted heat

energy

Air @ v2, T2Provide Airflow

Human

Human

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???


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Hair Dryer Function Structure (cont.)

SupplyElectricity

Transfer Heatto Air

Electricalenergy

Electricalenergy

Heatenergy

Heat signal

Wastedheat energy

Electricalenergy

ProvideElectricity

Convertelectricity to

rotational

Convey Flow

Control flow

Electricalenergy

Electricalenergy

Electrical energy

Flow signal

MechanicalEnergy

Wastedheatenergy

Wastednoiseenergy

Protect User

Interfaceholdingenergy

Interface holding energy +Interface signal energy

Human

Interface signal energy

Human signalInterfaceenergy

UnharmedHuman

Harmful {material, signal, energy}

Provide handle

Interface signal energy

Support flowgeneration

Air @ v1, T1

Supply AirAir @ v1, T1 Air @ v1, T1

Air @ v2, T1

Air @ v2, T2Air @ v2, T2

WastedAir @ v, T2

Convertelectric to Heat

ControlTemperature

Convertrotational to

flow

ProvideControls

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Search for Solution Principles

Search for solution (working) principles to fulfill all leaf-functions.

Working principles represent a physical effect and preliminary embodiment (e.g.,cartoon sketch).

Use ideation techniques, searches, and analysis of known or existing systems todetermine as many working (solution) principles as possible

Catalog the solution principles for all of the sub-functions

P&B: Fig. 6.13.

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Working Structures

Combine solution (working) principles into working structures.

Use a morphological chart to help identify combinations (i.e., workingstructures)

Each combination of working principles should fulfill the overall function (i.e.,assure both physical and geometric compatibility and a smooth flow ofEnergies, Materials, and Signals)

P&B: Figure 4.18.

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i i i C i


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Working Principles to Concept Variants

Selecting suitable combinations of working principles

Are the combinations of working principles likely to meet budgetary and otherrequirements?

Firm up into concept variants

Qualitative to Quantitative Transition

Simplified calculations

Geometrical sketches and studies

Experiments on essential properties, model building

Simulations

Market, literature or patent search

Evaluate concept variants against technical and economic criteria

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O t f Ph 2


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Outcome of Phase 2

Deliverables:

Abstract Requirements List

Function Structure

Morphological Matrix

Solution Selection and Evaluation

Make a decision to proceed to Phase 3

Answer the following questions:

Have sets of working principles (i.e. viable concepts) been identified to satisfy the

requirements of the design

Have I properly abstracted and searched broadly for working principles

Am I design fixated and have I put added constraints to the design space?

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Ph 3 E b di t D i


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Phase 3 - Embodiment Design

Begins with a concept and ends with

a definitive layout:

Working structure Concept

Technical details are added

Fleshing out a selected concept

Start with embodiment-determining

requirements and their functioncarriers or working principles

Proceed with requirements having

less impact on embodiment

Concept

Develop preliminary layouts

and form designs

Refine and evaluate against

technical and economic criteria

Select best preliminary layouts

Preliminary Layout

Eliminate weak spots

Check for errors & cost effectiveness

Prepare preliminary parts list

and production documents

Definitive Layout

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Ph 3 O i f E b di t D i


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Phase 3 - Overview of Embodiment Design

General steps of embodiment design: Preliminary layout and form design

Definitive layout and form design

Completion of checks & optimization (Only after

checks, can you move on to detail design!)

Characteristics of embodiment design: Complexity!! Many simultaneous, interdependent

activities!

Analysis and synthesis alternate and complement

each other! Optimization and error ID + solutionsearch and evaluation. Some steps must berepeated at a higher info level.

Proceed from qualitative to quantitative, fromabstract to concrete, from rough to detailed, withprovisions for checks and corrections (I.e.,iterations!).

Concept

Develop preliminary layouts

and form designs

Refine and evaluate against


Select best preliminary layouts

Preliminary Layout

Eliminate weak spots

Check for errors & cost effectiveness

Prepare preliminary parts listand production documents

Definitive Layout

Details: P&B Fig. 7.1. 201.

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Steps of Embodiment Design


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Steps of Embodiment Design

1. Identify requirements that have a crucial bearing on theembodiment of the design size determining requirements such as output, through-put, size

of connectors, etc.

arrangement determining requirements such as direction offlow, motion, position, etc.

material determining requirements such as resistance to

corrosion, service life, specified materials, etc.

2. Produce scale drawings of the spatial constraintsdetermining or restricting the embodiment design (e.g.,clearances, installation requirements, etc.) Top-down assembly modeling versus bottom-up modeling

3. Establish rough layout (based on concepts) whichemphasizes the embodiment-determining main functioncarriers, that is, the assemblies and components fulfillingthe main functions. Which main functions and function carriers determine the size,

arrangement and component shapes of the overall layout?

What main functions must be fulfilled by which functioncarriers jointly or separately?

4. Determine preliminary layouts and form designs for theembodiment-determining main function carriers.

Concept

Steps 1 - 4

Develop preliminary layouts and form designs

Steps 6-10: Refine and evaluate against


Step 5: Select best preliminary layouts

Preliminary Layout

Step 12: Eliminate weak spots

Step 13: Check for errors & cost effectiveness

Steps 14-15: Prepare preliminary parts

list and production documents

Definitive Layout


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Steps of Embodiment Design contd


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Steps of Embodiment Design, contd.

5. Select one or more suitable preliminarylayouts.

6. Develop preliminary layouts and formdesigns for remaining function carriers.

7. Determine which essential auxiliaryfunctions are needed.

Exploit known solutions if available (e.g.,catalogues).

Search for special solutions.

8. Develop detailed layouts and form designsfor main function carriers in accordance withembodiment design rules and guidelines.

Consider compatibility with auxiliaryfunctions

Divide into assemblies or areas to be

elaborated individually if necessary.


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Concept

Steps 1 - 4





Preliminary Layout





Definitive Layout

38 f 17Steps of Embodiment Design contd


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9. Develop detailed layouts and formdesigns for auxiliary function carriers

Use standard parts, if possible.

Combine all function carriers into overall

layouts10. Evaluate layouts against technical and

economic criteria Make sure all designs are at the same level of

embodiment, BUT

dont go beyond the level of detail required by

evaluation. You may need only a preliminarylayout, or you may need more details tochoose among alternative layouts.

11. Fix preliminary overall layout

12. Optimize and complete form designs forthe selected layout.

Eliminate weak points.

Adopt suitable solutions from less favoredvariants.


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Concept

Steps 1 - 4





Preliminary Layout





Definitive Layout

39 of 17Steps of Embodiment Design contd


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13. Check layout design for errors

in function, spatial compatibility,etc.

achievement of objectives withrespect to cost and quality

14. Prepare preliminary documentation.

parts lists

production documents assembly documents

15. Fix definitive layout design and

pass on to detail design phase


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Concept

Steps 1 - 4





Preliminary Layout





Definitive Layout

40 of 17Considerations in Embodiment Design


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Considerations in Embodiment Design

Basic rules of clarity, simplicity, and safety are derived from general objectives,

fulfillment of the technical function and economic feasibility General considerations for evaluating alternatives

Durability, deformation, stability, expansion, ergonomics, aesthetics, ease ofassembly

Designer determines the value of solutions wrt specific objective(s).

Value of a concept is not absolute Establish objectives from:

requirements list

technical properties (e.g., Fig 7.3)

All embodiment designs must have same degree of correctness and information

content Production costs must be determined to the extent possible

Evaluation should include a search for weak spots. Look for opportunities tocombine strong aspects of different alternatives.

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41 of 17Outcome of Phase 3


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Outcome of Phase 3

Deliverables: General Layout Requirements

The requirements related to the layout of the design

Preliminary Layouts The general layout of the product solution neutral format

Solution Evaluation A systematic method to evaluate the more detailed design

Preliminary Diagram The general layout of the final design with minimal knowledge about the details of the final product

A definitive layout for which production documents can be prepared with minimal detaildesign.

Before proceeding to Phase 4, ask yourself: Am I satisfied that this definitive layout satisfies all relevant and appropriate requirements

(function, layout, assembly, costs, maintenance, etc.)?

Am I ready to prepare final production documents for this design (tolerances, assemblyprocesses, materials, tooling, etc.) without delay?

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42 of 17Detail Design (Section 7.8)


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Detail Design (Section 7.8)

Begins with a definitive layout and ends

with product documentation

The use of Computer-aided design tools

Final design specifications Form

Dimensions

Surface quality

Properties

Final chance to identify and correct

mistakes


Solution

Documentation

Definitive Layout

Steps 1-2: Finalize details

Step 3: Complete all documents

Step 4: Check all documents

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43 of 17Steps in Detail Design


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p g

1. Finalize the definitive layout Detailed drawings of components

Detailed optimization of shapes,

Materials, surfaces, tolerances and fits

2. Integrate individual components into assemblies

and assemblies into overall product include assembly drawings

Parts lists (BOM)

3. Complete production documents manufacturing

assembly

transport operating instructions

4. Check all documents, especially detail drawingsand parts lists for:

observation of general and in-house standards

accuracy of dimensions and tolerances

other essential production data

ease of acquisition, e.g., availability of standard parts


Solution

Documentation

Definitive Layout

Steps 1-2: Finalize details

Step 3: Complete all documents

Step 4: Check all documents

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44 of 17Key Deliverables Pahl and Beitz


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y

Phase Deliverable Value

Planning and

Clarification of Task

Requirements list Identifies customers want for the product

Conceptual Design Abstract

requirements list

Identifies the function specific requirements to form solution-

neutral problem statements

Function structure Identifies the functions and organized the flow of energy, matterand signal

Morphological

matrix

Catalogs the working principles and organizes them to meet the

functions

Solution evaluation Systematic method to evaluate concepts in order to proceed with

the design

Embodiment Design General layout

requirements

The requirements that only deal with the layout of the design are

identified

Preliminary layouts Form the general layout of the produce in still a solution neutral

format

Solution evaluation Again, systematic method to evaluate, in more detail, design as they

proceed

Preliminary Diagram Help to envision the layout of the design in with minimal

knowledge about the details of the product.

Detail Design Final Layout, forms,

dimensions

Enables the part to be made, operated, assembled, etc.

systematic design process

Documents