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Configuration Design

Abstract embodiment Physical principles Material Geometry. Special Purpose Parts: Features Arrangements Relative dimensions Attribute list (variables) Standard Parts: Type Attribute list (variables). Architecture. Configuration Design. Configuration Design.

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Configuration Design

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  1. Abstract embodiment Physical principles Material Geometry Special Purpose Parts: Features Arrangements Relative dimensions Attribute list (variables) Standard Parts: Type Attribute list (variables) Architecture Configuration Design Configuration Design

  2. Product or Part • Product configuration = “architecture” • Part configuration Start with the big picture.... i.e. Product architecture

  3. Best concept(s) Configuration design 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 Pugh’s Method Weighted Rating Method Evaluate Best configuration(s)

  4. penlight bulb battery body screw cap switch glass lens filament base anode cathode electrolyte plastic cover case spring Product First… Use component decomposition diagrams elements are arranged into “physical building blocks”

  5. Product Standard Part Special purpose Part Subassembly A Subassembly B Special purpose part Special purpose part Standard part Subassembly B1 Standard part Special purpose part Generalized component decomposition a. type, number, arrangement of components b. standard or special purpose (make or buy)

  6. Product architecture …like house architecture Rooms are arranged according to a logical “scheme.” Before the details of all the house are designed we determine the general layout or “architecture.”

  7. Product Architecture (Ullrich & Eppinger) def – the scheme 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”

  8. Modular architecture • Product examples • Flashlight • Refrigerator • Automobile • Personal computer Modular components Batteries, bulbs Motors, compressor, switches Tires, radios, seats, pumps engines Drives, keyboards, mice, modems • chunks implement one or a few functions, • interactions between chunks are well defined • (standard interfaces / connections)

  9. Integral Architecture Product examples BMW Motorcycle engine Printer case Shaft Beverage cup Integrating aspects engine/frame integral snap-fasteners machined bearing race integrated handle • a single chunk implements many functions • interaction is ill defined • physical element “shares” functions

  10. Printer Example

  11. Cluster elements into logical chunks

  12. Sketch rough geometric layout

  13. Sketch interaction diagram

  14. 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)

  15. What is a part configuration? For example: Design problem: support vertical load ---- Concept: wall bracket Physical principle geometry & material embodiment What are some possible “configurations” for a wall bracket?

  16. Part configuration design geometric features include:

  17. Abstract embodiment different features alternative arrangements different relative dimensions How can we “generate” alternative part configurations? Recall bracket configurations

  18. Change one or more of these… Configuration decisions memorize How do we create different configurations?

  19. Obtaining the “best” configuration To choose the “best” alternative…. Implies that we have a number of feasible alternatives! To be selective, we need a selection!

  20. Best concept(s) Configuration design - 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) Continue on Tuesday

  21. To analyze configurations, we ask… Will it likely function? Will it likely assemble? Will it be likely manufacturable?

  22. 1.  Strong 2.  Stiff or flexible 3.  Buckle 4.  Thermal expansion 5.  Vibrate 6.  Quiet / Noise 7.  Heat transfer 8.  Fluids transport / storage 9.  Energy efficient 10. Stable 11. Reliable 12. Human factors/ergonomics 13. Safe 14. Easy to use 15. Maintain 16. Repairable 17. Durable (wear, corrosion) 18. Life-cycle costs 19. Styling/aesthetics Design for function Will the part or product perform its function(s)? Use knowledge from math, eng’g and sciences…

  23. Will it assemble? What do we mean by assemble? Assembly - a process of handling components to bring them together (inserting) and then fastening them.

  24. DFA Design for Assembly - a set of design practices which reduce the manpower time required to handle, insert and fastencomponents of a product. 1. Design Guidelines (written and graphical) 2. Cost estimating methods

  25. DFA Graphical 1

  26. Design for Assembly Guidelines from 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

  27. DFM Deign for Manufacture (manufacturability) - A set of practices that aim to improve the fabrication of individual parts 1. Design Guidelines (written and graphical) 2. Cost estimating methods

  28. DFM – Injection molding / casting • avoid designing parts with thick walls or heavy sections • design parts without undercuts • choose polymer for minimum total part cost • (i.e. tooling, processing, material) • design external threads to lie on parting plane/surface • add ribs for stiffening

  29. DFM – Sheet metalworking • avoid designing parts with narrow cutouts or projections • minimize manufactured scrap (cut-off versus blanking) • reduce number of bend planes • keep side-action features to a minimum or avoid completely

  30. DFM – Machining • employ standard features (e.g. holes, slots, chamfers, fillets, rounds) • use raw material available in standard forms (e.g. sheet, roll, bar, plate) • avoid sharp internal corners on turned parts • specify liberal tolerances and surface finishes

  31. Best concept(s) Configuration design - evaluation 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)

  32. Graphics during Configuration Design • Sketches are used a lot in configuration design • Sketches assist creativity • Sketches are not typically used to “document” the “design” • CAD Drawings need sizes (e.g. H, W, L, D) • CAD Takes time • But, some CAD may be useful

  33. Best concept(s) Configuration design summary 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. Abstract embodiment Physical principles Material Geometry Special Purpose Parts: Features Arrangements Relative dimensions Attribute list (variables) Standard Parts: Type Attribute list (variables) Architecture Configuration Design Configuration Design

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