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Multidisciplinary Senior Design I

Multidisciplinary Senior Design I. System Design. Agenda. Tuesday End-State Deliverables Functional Analysis Example Team Project Work Concept Generation Morphological Analysis Thursday Concept Generation Develop Alternatives Engineering Analysis Concept Selection.

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Multidisciplinary Senior Design I

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  1. Multidisciplinary Senior Design I System Design

  2. Agenda • Tuesday • End-State Deliverables • Functional Analysis • Example • Team Project Work • Concept Generation • Morphological Analysis • Thursday • Concept Generation • Develop Alternatives • Engineering Analysis • Concept Selection

  3. End-state Deliverables – Week 6

  4. Functional Decomposition

  5. Alternatives Considered

  6. Selected Concept • Updates: • Electronic controls (decrease size/more options) • Smaller pump • Reliable and smaller battery • Additions: • Ability to monitor and record vitals • Pulse oximeter feedback • Voice alerts/instructions • Carbon dioxide sensor

  7. Architecture

  8. Risk Assessment There is no shame in this being a large list, especially at this stage. Demonstrates that you are being realistic.

  9. Test Plan (First Cut) • Test Pump Test • Verify Mass Flow Rate • Test Mass Flow Sensor • Verify Readings Match Pump Test Results • Test Pressure Sensor • Compare against Flow Characteristics chart of the Pressure sensor. • Test User Interface • Verify ease of use

  10. System Design

  11. Considerations • Physical Decomposition • Subsystem Identification • Functional Decomposition • Specification Decomposition • Need to flow-down specifications

  12. Functional Analysis

  13. What is a function? • Function – active verb, noun • A clear, reproducible relationship between the available input and the desired out of the product, independent of any particular form • Examples: • Make Copies, Chop Beans, Clip Nails Product Represented as a Functional System Energy Energy Material Material Information Information Otto, K., Wood, Kristin L., Product Design: Techniques in Reverse Engineering and New Product Development, Prentice Hall, Upper Saddle, NJ 2001, pp. 152 – 151.

  14. Example

  15. What is the function of this? Product Represented as a Functional System Energy Energy Material Material Information Information Energy could be manual, electric, kinetic, potential, etc. depending on solution, so typically only worry about flows that will not change What is the function? What flows will not change? Open Can Can Can, Lid, Contents Sealed Can Opened Can

  16. Decompose Function WHY HOW

  17. Subtract and Operate – Bill of Materials Generating a Hardware Tree Can Also be Very Helpful Source: http://gicl.cs.drexel.edu/wiki/Can_Opener

  18. Subtract & Operate Added Functions Protect Opener Capture Lid Actuate Opener

  19. Subtract & Operate Method • Bottom-up approach • Assumes product or product concept exists • Steps • Remove one component of the assembly • Literally or Figuratively • “Operate” system through its full range • Analyze effect • Deduce the sub-function of the missing component • Repeat for all components • Modify function tree Otto, K., Wood, Kristin L., Product Design: Techniques in Reverse Engineering and New Product Development, Prentice Hall, Upper Saddle, NJ 2001, Chapter 5.

  20. Modified Functional Decomposition

  21. Process Flow Can Also be Helpful High-Level View Access Can Secure Can Actuate Opener Separate Lid Capture Lid Access Contents Low-Level View Grasp Can Attach Opener Apply Lever Pierce Can Rotate Handle Transmit Torque Capture Lid Access Content

  22. Functional Analysis workshop

  23. Exercise - Define your project’s top level function (5 minutes) • Remember that the top level function should manipulate material, energy and/or information that is external to your system

  24. Functional Decomposition Exercise – (20 minutes) • Generate the 1st level (& 2nd Level, if possible) of Decomposition for your top level-function • Ensure that it is as solution independent as possible

  25. Subtract & Operate Exercise – (20 minutes) • Develop a hardware tree/bill of materials based on an existing solution or a benchmarked solution • Go to level that makes sense • Determine if the function the component is performing is • Represented in the function decomposition –or- • Is connected to a function in your decomposition • Modify function tree

  26. Concept Generation

  27. 5-Step Process (Ulrich & Eppinger, pg. 100) 1. Clarify the Problem • Clarify the Problem • Start from Product Definition • Decomposition • Prioritize • Search Externally • Lead users • Experts • Patents • Benchmarking • Search Internally • dfX Analysis • Field Feedback • Institutional Knowledge • Supply Chain • Explore Systematically • Classification Tree • Combination Tree • Morphological Analysis • TRIZ • Reflect on Process & Solutions Sub-problems 2. Search Externally 3. Search Internally Existing Concepts New Concepts 4. Explore Systematically Integrated Solutions 5. Reflect on Solutions

  28. Secrets of Concept Generation • Employ many techniques • Focus on values / functions • Avoid premature closure • Generate several alternatives • “Sky High” • “Challenging technology” • “Low Risk” • Screen ideas systematically • e.g., Pugh selection process Ishii, 2004

  29. Pahl and BeitzMorphological Analysis • Morphology • Study of shape and form • Morph. Analysis • Systematic study to analyze the possible shape and form • Morphological Diagram • Example: Potato Harvesting Machine

  30. Support Subject Conv. Mass to Signal Measure Weight Indicate Signal Hold Parts Together Start with Functional Diagram • Bathroom Scale Example • Expand Functions to manageable sub-functions Ishii, 2004

  31. Use the Function Diagram to Generate Concepts • Bathroom Scale Support Subject Plate Box Bubble Conv. Mass to Signal Strain Gauge Count Molecules Corn Flakes Spring Measure Weight Indicate Signal Dial Voice Sound Digital Display Hold Parts Together Screws Glue Ishii, 2004

  32. Generate Feasible Solutions • Feasible (Conventional) Bathroom Scale Support Subject Plate Box Bubble Conv. Mass to Signal Strain Gauge Count Molecules Corn Flakes Spring Measure Weight Indicate Signal Dial Voice Sound Digital Display Hold Parts Together Screws Glue Ishii, 2004

  33. Plate Box Bubble Strain Gauge Count Molecules Corn Flakes Spring Dial Voice Sound Digital Display Glue Generate “Sky high” Ideas too... • “Sharper Image” Bathroom Scale Support Subject Conv. Mass to Signal Measure Weight Indicate Signal Hold Parts Together Screws Ishii, 2004

  34. MorphChart Douglas Axtell, Don Moran, Jason Stanbro, Jim Vermeire, 0303-786 & 0303-788 Class Project, 2010

  35. Can Opener Example

  36. Can Opener Example grasp

  37. Concept Generation Exercise – Morphological Table(30 minutes) • Start generating your morphological table and finish for homework

  38. Desired Output • Function Tree • 2-3 Layers of Decomposition • Subsystem Identification • Should be based both on existing artifact and functional analysis • Specification Flow-down • If you identify functional modules and/or subsystems, need to understand how you will assess them • Conceptually no different than what you did at the system-level This will set you up for developing good solution alternatives

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