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

1. Engineering 11 EngineeringDesign Bruce Mayer, PE Licensed Electrical & Mechanical EngineerBMayer@ChabotCollege.edu

2. OutLine Engineering Design • What is engineering design, really? • Function to form • Design process • Phases of design • Product Realization/Development Process • Concurrent engineering • Teamwork • Summary

3. Design vs. Ambiguity • Design ≡ a “valid” or “acceptable” Solution to an OPEN-ENDED Problem • e.g.; Design a Cell-Phone that OUTSELLS All Others • All design challenges are ambiguous. • Unlike answers to mathematical expressions there are always several “right” answers to ANY design challenge. • The answer is always uncertain or ambiguous. • Not all design solutions are equally good however, and some are definitely wrong.

4. Well-Defined vs. Open-Ended • Design Problems Have NO “Correct” Solution; • Have only: Successful and UNsucessful Solutions • Compare to Skills-Development (practice) problems • Skills Development (Textbook Type) • Well-defined, • Complete (correctly stated, unique) • Correct answer exists • Money not involved • You know When You Arrive at the Answer • Requires Application of Very Specific Knowledge • Design Problems (Open Ended) • Poorly-defined • No Unique Solution; Depends on Approach • Cost & Schedule are Critical Factors • “Done Point” Very Hard to Identify • Need MultiDisciplinary Knowledge

5. Analysis vs. Synthesis • Analysis → Know What IS/OCCURS and Then Try to EXPLAIN it • A separating or breaking up of a whole into its parts, with an examination of these parts to reveal their nature, proportion, function, interrelationships, etc. • Synthesis → Know What IS NEEDED and Then Try to CREATE (Design) it • The putting together of parts or elements so as to form a whole

6. Analysis Forces Moments Flow Pressure Machines Mechanisms Motion Energy Conversion Synthesis & Testing Sketch/Draw Predict Behavior Model or Test SubScale Tests or Experiments Materials Manufacturing Example  MechEngr Design • Realization • Customer needs • Company Requirements • Manufacturing Costs • Performance • Analysis • Testing

7. Design vs. Analysis • Which of the following is design and which is analysis? • Given that the customer wishes to fasten together two steel plates, select appropriate sizes & materials for the bolt, nut & washer • Given the cross-section geometry of a new airplane wing then determine the lift it produces using Fluid Mechanics principles DESIGN ANALYSIS • Form is the solution to a design problem • In this Case the Bolt SIZE & Material

8. Form FOLLOWS Function • Function “Directs” Form • Form ≡ Shape, Size, Configuration, Weight, Human InterFace Appearance, Materials of Construction, etc. • DESIGN connects Form (the OutPut) to the desired Function (the InPut) Thru a DECISION-MAKING PROCESS

9. FunctionForm Graphically Function • Control, hold, move, protect, heat/cool, store, amplify, etc. DESIGN • Decision-Making Process • Shape, configuration, size, materials, manufacturing processes, etc. Form

10. Engr-Design as Decision-Making • Design Definition  Short Version • Set of decision making processes and activities to determine the FORM of an object, given the customer’s desired FUNCTION • Design Definition  Long Version • The process of devising a system, component, or process to meet desired needs. It is a decision-making process (often iterative), in which basic-science, mathematics and the engineering-sciences are applied to optimally convert resources to meet a stated objective

11. Decision-Making  Design Process • Establish Functional Requirements • Determine Constraints • Set Performance Goals FormulatingProblem DESIGN Specs • CREATE Alternative Forms (Shape, Configuration, Size, Materials, Power-Sources, etc.) GeneratingAlternatives ReDesignIteration ALLAlternatives AnalyzingAlternatives FEASIBLE Alternatives EvaluatingAlternatives BEST AlternativeMANUFACTURING Specs

12. “Phases” of Engineering Design • How do design decisions change over time? • Is there a logical grouping of decisions? • Illustrate with an Example: Design a Brake for stopping a Spinning Shaft. • Requirements for Brake • 8” Diameter, Horizontal shaft • 4330 Ni/Cr/Mo Alloy-Steel shaft material • 1000 Pound shaft weight • 3600 rpm maximum rotational speed

13. FORMULATION Phase - Brake • Early in the design process, we decide upon the nature of the Functional Requirements, and Inputs for the Design • Decide upon a satisfactory rate of deceleration • Determine the length of the shaft • Determine where it is supported • Determine what actuating energy is available • Decide to Learn From existing similar products • Choose to research brakes in the library

14. CONCEPT Design Phase - Brake • Decide PHYSICAL PRINCIPLES that will perform the braking function • surface friction (e.g. drum brake, disk/caliper) • opposing magnetic fields (e.g., inverse motor) • air friction (e.g. fan blades) • Assume we DECIDE on surface friction

15. CONFIGURATION Dsgn Phase • Decide upon PRODUCT components & how they are arranged/configured • Product configuration: • disk/caliper, or drum, or band brake • location on shaft (right, left, middle) • Assume we decide on a disk/caliper brake

16. CONFIGURATION Dsgn Phase • Decide upon PART features & how they are arranged/configured • Part configuration: • relative size of hubto disk • relative size of rotor thickness to diameter

17. PARAMETRIC Design Phase • Decide upon SPECIFIC VALUES for design variables/parameters • rotor diameter (outer) • rotor thickness • brake pad area • pad material • hydraulic pressure on piston

18. DETAIL Design Phase • Decide upon the remaining MANUFACTURING specifications • Machined rotor tolerances • Pad bonding resin cure time & temperature • Assembly procedure • Testing procedure

19. Final FORM is the Design Solution • FUNCTION stop a spinning shaft • FORM • rotor: 10 inch diameter, Cast Iron, 3/8-inch thick, cooling passages • Forged 4140 steel caliper/housing • brake pads, 2 opposing, 4 sq. in., metal particles in epoxy matrix • Stainless steel 304 piston,1.25-inch diameter, with elastomeric seals • 105 psi hydraulic piston pressure

20. Problem Formulation DesignPhaseSummary Concept Design PreliminaryDesign Configuration Design EmbodimentDesign ParaMetric Design Detail Design

21. Alternative Design-Phases • Another, more Detailed, Description of the Stages/Phases of Design • ID Problem or Needed-Fcn • Define the Goals/Performance • Research & Gather-Data • BrainStorm/Creative-Solutions • Analyze Potential Solutions • Develop & Test Models • Make the Decision • Communicate & Specify • Implement & Commercialize ConceptualDesign PreliminaryDesign Critical Design Review FinalDesign

22. Product Realization Process • Also Known as the Product LIFE CYCLE • Design Occurs during PRODUCT DEVELOPMENT Process FullyRealized Product Product Development Process Disposal Production Design Service Engineering Design Distribution Industrial Design Manufacturing (Production) Sales & Marketing Customer Need

23. The Product Life Cycle Design • establish function, determine form Manufacture • fabricate, purchase, assemble, test, ship/distribute Use • set up, operate & maintain, repair Retire • TearDown/disassemble, recycle/dispose

24. Product Life Cycle - Graphically Innovation Cycle time Cash Flow Definition Freeze Profit Zone Release Investigation Obsolescence Break Even time Opportunity Time Product Development • Product Development “Kicks Off” the Product Life Cycle

25. ConCurrent Engineering • Also Known as Simultaneous Engineering, this Method Reduces the time spent in Product Development

26. ConCurrent ENGR Elements • non-linear product design approach • all phases of product development operate at the same time – simultaneously • Both product & process design run in parallel and occur in the same time frame • Product and Process are closely coordinated to achieve Optimum Results in a short amount of time • Decision making involves full team participation and involvement

27. WJ-2000 Concurrent Engineering B. Mayer SysEngr ME B. Mayer SWE ME FSMenagh ME RSMurphy MSWalton CEErickson R. Reghitto HSPaek IE ME ME ME L. Harlamoff EE MSWalton AKMcGrogan ME • By Assignment • Sales Engineer • Safety Engineer • Manufacturing Engineer • Reliability Engineer • Service Engineer Z. Yuan DMDobkin ME EngrPhysics ProcessEngr AKPlumley

28. The Need for Engineering Teams • Increasing Technology Content • Complex Engineered Systems Have Too Much Information Content for Any One Person to Address • Speed • Time-To-Market Often Means the Difference Between Profits & Losses • Teams Allow work to Be Done in PARALLEL (at the SAME TIME)

29. A Team  What is it? • A Team Is A Small Group Of People With Complementary Skills Who Are Committed To A Common Purpose, Performance Goals, and Approach For Which They Hold Themselves MUTUALLY ACCOUNTABLE

30. Team Attributes • Common Goal • This Must Be Clearly Communicated to Generate a Feeling of Common Purpose • Leadership • A Critical Function To Keep The Team Focused • Complementary Skills • Resources are Limited; Each Team Member Should have a CLEARLY DEFINED and UNIQUE Role

31. Team Attributes cont. • Effective Communication • A CRITICAL Leadership Function • Honest & Productive Communication is Needed for Design/Solution Integration • Greatest advantage Humans have over the rest of the Animal Kingdom is communication • Creativity • A “Close Knit” & Motivated Team Generates Creative Energy Thru Goal-Oriented Interaction

32. All Done for Today DilbertDesign

33. Engineering 11 AppendixEngineering Rolls Bruce Mayer, PE Registered Electrical & Mechanical EngineerBMayer@ChabotCollege.edu

34. LifeCyc Engineering Activities

35. LifeCyc Engineering Activities

36. The HYPE Cycle

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