Design Engineering

1. Design Engineering Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

2. Creativity is intelligence having fun... Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

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7. A design engineer is a general term for a person who may be involved in any of various engineering disciplines including electrical, mechanical, chemical, textiles, aerospace, nuclear, manufacturing, civil, systems, and structural /building/architecture & Computers. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

8. Design & its Objectives. • Design – is a creative process. • Imagination..? • Knowledge...? • Engineeing students in class Learns theory.. • Is there a chance of students to fail. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

9. When work is based on familier models/design...no problem • ( knowlege will help.) • Entirely new project- higher level of understanding. • Aim of design process- • Enable students to follow a systamatic approach of design. • Identify customer need.( he gives a generic statement). • Engineer- to identify the real need of customer. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

10. What is important ? • Is Mathematics important ? • Eg. Making of a chair for a child. • Functions are manipulated by reasoning.( Safety , Colour). Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

11. Design Engineer • Think Independently. • Draw conclusions. • Combine solutions. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

12. Not all engineers built are sucessful. • 1. Chernobyl nuclear power plant. • 2. World trade centre collapse.. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

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17. 65 percent of the batteries used in the Note 7, was at fault. Samsung SDI made batteries for all Note 7 phones sold outside China. Note 7 devices sold in China used batteries made by Amperex Technologies Limited (ATL).Batteries shorting and exploding under certain situations. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

18. Reasons for failures • Incorrect or overextended assumptons. • Poor understanding of the problem to be solved. • Incorrect design specifications. • Faulty manufacturing & assembly. • Error in design calculations. • Incomplete experimentation • Inadequate data collection. • Errors in drawings. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

19. “Engineering is a profession in which a knowledge of mathematical & natural sciences, gained by study, experience & practice is applied with the judgement to develop the ways to utilize, economically , the materials and forces of nature for the benefit of mankind” Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

20. Syllabus Module 1 • Design and its objectives; Design constraints, Design functions, Design means and Design from; Role of Science, Engineering and Technology in design; Engineering as a business proposition; Functional and Strength Designs. Design form, function and strength; • How to initiate creative designs? Initiating the thinking process for designing a product of daily use. Need identification; Problem Statement; Market survey custom requirements; Design attributes and objectives; Ideation; Brain storming approaches; arriving at solutions; Closing on to the Design needs. • An Exercise in the process of design initiation. A simple • problem is to be taken up to examine different solutions- • Ceiling fan? Group Presentation and discussion Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

21. After your graduation you should have... • Problem solving skills.( define problem,develop alternative solution, implement the solution finally selected) • Effective communication skills. • Highly ethical & professional behavior. • Open minded & positive attitude. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

22. Proficiency in math & science. • Technical skills ( In choosen profession). • Motivation to continue learning.( Scientific knowledge are expanding). • Knowledge of business strategies & management practices.( if you want to suceed in industry). • Computer litracy ( latest computer technology). Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

23. General terms • Design Objective- Feature / behavior. • Design constraint- limit or restriction on features or behavior. • Functions- things a designed device or a system is supposed to do. • Means – a way or method to make a function happen. • Form-the shape & structure of a something as distinguished from its material. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

24. Delhi Metro Rail corporation. Delhi Metro is the world's 12th largest metro system in terms of both length and number of stations • Objective – • transport system serving Delhi,Gurgaon,Noida,Ghaziabad. • City crosses 1 million population • Automobiles contributed 2/3 of atmospheric pollution. • More registered vehiches than kolkata,chennai, mumbai put toether. • Constarint- • Globally metros are financially unviable. • All staff recruited are personally interviewed by E. Sreedharan. • Cost in phase 1 jumped from 60 billion to 90 billion. • Problem of skill shortage,training,experience, corruption. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

25. Functions- • DMRC appointed a special quality assurance team. • Each empoyee has to prepare a detailed report aganist benchmark. • Every Monday HOD has to meet to refix target. • Means- • DMRC used primavera project planner. • DMRC employeed only 45 persons per kilometer.( Kolkotha 130) • Contact with delhi transco. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

26. Form- • Line 1- RED- caused minimum disturbance to traffic. • Line 2- YELLOW- underground tunnelling, cut & cover method. • Line 3-BLUE- used U shaped griders. • Unique features of DMRC- • Lines -6 • Stations-142. • Train strength-4- 6 coaches. • No of vehichles- 210 trains. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

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28. Some Extended notes. • The Delhi Metro Rail Corporation has been certified by the United Nations as the first metro rail and rail-based system in the world to get "carbon credits for reducing greenhouse gas emissions" and helping in reducing pollution levels in the city by 630,000 tonnes every year. • DMRC operates around 2000 trips daily between 05:30 till 00:00 running with a headway varying between 1–2 minutes and 4–10 minutes. • The trains are usually of four, six and eight-coach. • Planning for the metro started in 1984, • Delhi Metro Rail Corporation (DMRC) was incorporated in May 1995, construction started in 1998, and the first section, on the Red Line, opened in 2002. • The development of network was divided into phases, Phase I containing 3 lines was completed by 2006, and Phase II in 2011. Phase III is scheduled for completion by 2017 (originally planned for 2016). Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

29. Desirble qualities of a Design Engineer • Problem solving skills- able to identify and define the problem to be solved. • Scientific temper and proficiency in STEM [ Science, Technology, Engineering and Mathematics] • Technical and Computer skills. • Ethical, moral and professional values. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

30. Design Process • Introduction to Design • Initiating Design • Structured Design Process • Defining the Design Space • Analogies • Thinking outside the box • Quality Function Deployment • Design Evaluation • Choosing a Design Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

31. Need Identification Design starts with need identification. Whose need? User , Client or Customer; Aircraft- Designer – Boeing or Airbus Client- Air India or IndiGo User: Passengers At times the user, the client and the customer could be the same or different. User - The entity that has the need to use the design. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

32. Designer User and Client Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

33. Designer should be aware of professional and social ethics and values. For any Design to be taken up, there should be a need gap or a problem that needs a solution. This gap or need could be identified by the user, an observer or by an organization. Is design same as invention? Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

34. Science- seeks answers to questions about the natural universe. ( Why ?) • Eg. Issac Newton. • Movement of planets. • Projectiles fall to the ground. • Technology- asks how things happen? Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

35. Role of Science/Technology/Engineering • Advances in technology and/or a scientific discovery may create the opportunityfor a new engineered product. • Human beings are usually comfortable when in temperatures between 20°C and 25°C • By the beginning of the twentieth century, air cooling systems of limited effectiveness had been installed. • in 1902, Willis H. Carrier (1876-1950), a mechanical engineer, was striving to eliminate the negative effect that humidity had upon color printing. • Carrier realized that cold air could absorb humidity from warm air. He designed a cold water spray system through which the relative humidity of the air within a room could be controlled by simply regulating the temperature of the spray. (He received a patent ). Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

36. Ammonia was used as the refrigerant in early air conditioning systems in 1920. • Unfortunately, ammonia is both corrosive and unpleasant. • Ammonia has been replaced by freon.( a nontoxic and nonflammable fluorocarbon discovered ) in 1930. • freon can be quite hazardous to the earth's ozone layer if it is allowed to escape to the atmosphere. • Hence, the need exists for further improvement in air conditioning systems. • R22 gas is presently used.( Chloro fluro methane). Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

37. Role of Science • Determine Function • Safety parameters • Rules & regulations • Units of measurement • Analyse & simulate the product • Various software packages for designing. • Various quality control tools to measure various factors of a component. • Integration of design process with manufacturing. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

38. Rocket Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

39. Rocket • Robert H. Goddard, the American scientist who built the first liquid-fueled rocket—which he successfully launched on March 16, 1926. • fascinated with spaceflight after reading an 1898 newspaper serialization of H.G. Wells’ classic novel about a Martian invasion, War of the Worlds. • Goddard would recall later, the concept of interplanetary flight “gripped my imagination tremendously.” Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

40. QuickTime • multimedia program QuickTime after watching an episode of “Star Trek: The Next Generation,” wherein one of the characters is listening to multiple music tracks on his computer. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

41. QuickTime Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

42. Cellphone Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

43. Cellphone • Martin Cooper, the director of research and development at Motorola, credited the “Star Trek” communicator as his inspiration for the design of the first mobile phone in the early 1970s. “That was not fantasy to us,” Cooper said, “that was an objective.” Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

44. Velcro Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

45. Velcro • After a hunting trip in the Alps in 1941, Swiss engineer George de Mestral’s dog was covered in burdock burrs. Mestral put one under his microscope and discovered a simple design of hooks that nimbly attached to fur and socks. • After years of experimentation, he invented Velcro — and earned U.S. Patent in October 1952. Benyus said it is probably the best-known and most commercially successful instance of biomimicry. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

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47. High-speed trains can literally cause headaches. That's why Japan limits their acceptable noise-pollution level, which can be particularly high when the trains emerge from tunnels. As they drive through, air pressure builds up in waves and, when the nose emerges, can produce a shotgun-like thunderclap heard for a quarter mile. • Eiji Nakatsu, a bird-watching engineer at the Japanese rail company JR-West, in the 1990s took inspiration from the kingfisher, a fish-eating fowl that creates barely a ripple when it darts into water in search of a meal. The train’s redesigned nose — a 50-foot-long steel kingfisher beak — didn't just solve the noise problem; it reduced power use and enabled faster speeds. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

48. Need & requirements of systematic design. • Technical,economic properties of product, commercial importance----->>>systematic design. • We cannot prove this importace to designers ( less domain knowledge) • Design Science..? • Scientefic methods to analyse the structure of technical systems, relationships... • Design Methedology..? • Set of actions taken from design science+ cognitive Physcology+pracical experience in diff domains. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

49. Systematic Design : • provides solutions that can be used again. • Stepwise approach- helps in selecting & optimise an early stage design with minimum effort. • Helps in getting computer support for design procees. • Easy to divide work between computers & designers. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL

50. Design Methedology must have.. • Problem directed approach.( What ever be the problem). • Foster inventiveness & Understanding. • Be compatible with concepts, methods & findings of other disciplines. • Not rely on finding solutions by a chance. • Be compatable with electronic data processing. • Reduce workload,savetime,prevent human error. • Provide guidance to your team leaders. Design Engineering- KTU Syllabus- VARGHESE S CHOORALIL