Bruce Mayer, PE Licensed Electrical & Mechanical Engineer BMayer@ChabotCollege

1. Engineering 11 Engineering Designfor Small-Volume Electro-Mechanical Systems Bruce Mayer, PE Licensed Electrical & Mechanical EngineerBMayer@ChabotCollege.edu

2. Technical Product Creation • “Every Technological Product Has To Be Designed and its Fabrication Overseen, and this is what Engineers DO” • Samuel Florman, The Civilized Engineer

3. To Build a Designed Object • Say you were Asked to BUILD or CONSTRUCT From-ScratchSomething using Basic Hand Tools • You would need (at a minimum) • A list of Parts with P/N’s and Qtys • Parts FABRICATED specially for this Object • Parts PURCHASED from Catalogs for this Object (a.k.a. “Standard Parts”) • Instructions on how ASSEMBLE the Object

4. Small-Volume Object Design Raw-Material in Basic-Shapes (chosen by the Engineer) Parts Purchased from Technical Catalogs (Selected by the Engineer) Parts Fabricated per Specialized Designs (your BluePrints) Assembly Documentation (Parts-List, BluePrints, Instructions, etc.) Written/Drawn by the Engineer

5. When Designing Something… • Think About CRITICAL Issues • Will It WORK • Will it Meet the SCHEDULE & BUDGET • Can it be BUILT from MY Design Documentation? • Ask Yourself: “If I were Building this object What Info would I need?”

6. Discussion Scope • We Examine what it takes to BUILD small quantities (dozens to hundreds per year)of Engineering-Designed ElectroMechanical Systems for Sale • This Discussion Does NOT Address the FUNCTIONAL PERFORMANCE of the design; only what it takes to actually BUILD IT, regardless of how Well it works

7. BUILDING SomeThing is HARD • Designing on Paper is MUCH EASIER than Designing Something that must be BUILT and Ultimately Sold • The Build-Process exposes • Incomplete Design Documents • Wrong Parts Purchased • Incorrect Order Number • Part-Purchase Delayed • Incorrect Supplier Phone Number • $-Costs much higher than estimated

8. BUILDING SomeThing is HARD • The Build-Process exposes • Incomplete Design Documents • Not Sufficient Information to Construct • BluePrints Missing/Incorrect Dimensions or Notes; e.g., • Inconsistent Material CallOut • Missing/Confusing Lines • Missing Surface Finish • Schematics or Assembly Drawing Missing/Incorrect ID-Information; e.g., • Missing Balloon CallOut for O-Ring, Bolt, Valve, etc. • Missing Value for Resistor or Capacitor

9. BUILDING SomeThing is HARD • The Build-Process exposes • Design Errors • Mechanical Elements do NOT FIT • Electrical Elements SHORT or do notPowerUp • Can Not be Fabricated or Assembled as Designed • Mechanical Structures are NonRigid • “Floppy” or “Doingy” or “Cheesy” of “Wobbly” • Electrical or Fluid Systems are UnderPowered or Noisy or Unstable • “Whimpy” or “Flakey” or “Glitchy”

10. To BUILD an Engineered Design • CORRECT & COMPLETE information on PURCHASED-Parts Given to the “Purchasing Department” • NAMES & PHONE-NUMBERS of ALL Suppliers • Correct Catalog-Numbers for ALL Purchased Parts • Correct Order-Quantities and Estimated $-Costs

11. To BUILD an Engineered Design • Dot “i’s” & Cross “t’s” on All FABRICATION Drawings (the “BluePrints”) • A single Missing-Dimension or Superfluous Line or Missing Feature-Callout Brings Production to a HALT • OMISSIONS result in ReWork or Scrap; e.g.; • Forgetting a needed Removed-Feature (Hole or Slot or Notch or Groove) • Superfluous Removed-Feature (‘extra” hole)

12. Designed Part (Piece Part)

13. To BUILD an Engineered Design • COMPLETE Bill of Materials (“BoM”, also called the “Parts List”) • EVERY Nut, Bolt, Washer, Wire-Connector, Plumbing-Fitting, etc.,Listed on the BoM Table • Complete CallOuts ALL parts shown with “Balloons” containing part ID-number • Clearly UNDERSTOOD AssyDwgs • Don’t Confuse the Assemblers

14. Typical Assembly Drawing Balloon CallOut On-DwgBoM

15. Tools at the Engineer’s Disposal • INGENUITY & CREATIVITY • MOST Important • Knowledge of SCIENCE and MATHEMATICS • Technical CATALOGS • “BluePrint” Making Software • Standard Fabrication Methods • Machining, Welding, Injection-Molding, etc.

16. Summary: Design Docs Include • Purchased Part Information • What Mfr-PN, Who Supplies, How Much $ • Fabricated Parts Drawings (BluePrints) • 100% Accurate; generate NO Questions from Fabricators • BoM or Parts List • 100% Accurate as it is used to “Pull Parts from Stock” to Make an “Assembly Kit” • NonConfusing Assembly Drawings

17. Small Volume Design FlowChart SupplierContact Info Purchased Part Catalog No. Physical Design to Scale (LayOut) MaterialSelection Fabrication Notes PurchasedParts Formal “BluePrints”(Use Std TitleBlock) Order & ReceivePurchased Parts Assy Parts List(Bill of Materials) To FabricatorMachine Shop, etc. Fabricatorcontact Info Assembly Drawing & Documentation FabricatedPiece-Parts Physical Assembly and/or Construction

18. All Done for Today EngineeringDesign Pyramid

19. Engineering 11 Appendix Bruce Mayer, PE Registered Electrical & Mechanical EngineerBMayer@ChabotCollege.edu