140211 emaro aria conceptualdesign caro stephane
TRANSCRIPT
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Conceptual Design of Products
Stephane CARO
Institut de Recherche en Communications et Cybernetique de NantesNantes, France
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 1 / 109
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Outline
1 Introduction
2 Engineering Design
3 Axiomatic Design
4 Robust Design
5 Complexity-Based Design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 2 / 109
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Outline
1 Introduction
2 Engineering Design
3 Axiomatic Design
4 Robust Design
5 Complexity-Based Design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 2 / 109
-
Outline
1 Introduction
2 Engineering Design
3 Axiomatic Design
4 Robust Design
5 Complexity-Based Design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 2 / 109
-
Outline
1 Introduction
2 Engineering Design
3 Axiomatic Design
4 Robust Design
5 Complexity-Based Design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 2 / 109
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Outline
1 Introduction
2 Engineering Design
3 Axiomatic Design
4 Robust Design
5 Complexity-Based Design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 2 / 109
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Introduction
1 Introduction
2 Engineering Design
3 Axiomatic Design
4 Robust Design
5 Complexity-Based Design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 3 / 109
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Introduction
Introduction
Course ObjectivesTo show how to identify customer needs and to transform it intospecificationsBasic knowledge in product design developmentFunctional analysis and value analysisInterviews and focus groupIntroduction to Kansei engineering
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 4 / 109
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Introduction
Introduction (Contd)
Design is an engineering activity that:affects almost all areas of human life;uses the laws and insights of science;builds upon special experience; andprovides the prerequisite for the physical realisation of solutionideas.
(Martyrer, 1960)
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 5 / 109
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Introduction
Introduction (Contd)
Design Process1 Task definition2 Conceptual design3 Embodiment4 Detailed design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 6 / 109
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Introduction
Introduction (Contd)
Design Process1 Task definition2 Conceptual design3 Embodiment4 Detailed design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 6 / 109
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Introduction
Introduction (Contd)
Design Process1 Task definition2 Conceptual design3 Embodiment4 Detailed design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 6 / 109
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Introduction
Introduction (Contd)
Design Process1 Task definition2 Conceptual design3 Embodiment4 Detailed design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 6 / 109
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Introduction
Introduction (Contd)
Conceptual DesignA distinct phase75% of total product life-cycle cost is committedTwo sub-phases of the conceptual design
Obtaining a rich solution setSelection of most suitable solutions
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 7 / 109
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Introduction
Introduction (Contd)
Cost of Making Changes During Different Phases of the Design LifeCycle
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 8 / 109
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Engineering Design
1 Introduction
2 Engineering Design
3 Axiomatic Design
4 Robust Design
5 Complexity-Based Design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 9 / 109
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Engineering Design
Engineering Design
References1 French, M. J. Conceptual Design for Engineers, 3rd ed., 1999
(Springer)2 Pahl, G. and Beitz, W. Engineering Design: A Systematic
Approach, 2nd ed. Wallace, K.M. (editor); Blessing, L., Bauert, F.and Wallace, K.M. (translators), 1996 (Springer-Verlag, London)
3 Pahl, G. and Beitz, W. Konstruktionslehre: Grundlageerfolgreicher Produktentwicklung. Methoden und Anwendung,2005 (Springer, Berlin-Heidelberg)
4 Angeles, J., Design Theory and Methodology, MECH593 LectureNotes, McGill University, Montreal, Canada
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 10 / 109
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Engineering Design
Engineering Design
References1 French, M. J. Conceptual Design for Engineers, 3rd ed., 1999
(Springer)2 Pahl, G. and Beitz, W. Engineering Design: A Systematic
Approach, 2nd ed. Wallace, K.M. (editor); Blessing, L., Bauert, F.and Wallace, K.M. (translators), 1996 (Springer-Verlag, London)
3 Pahl, G. and Beitz, W. Konstruktionslehre: Grundlageerfolgreicher Produktentwicklung. Methoden und Anwendung,2005 (Springer, Berlin-Heidelberg)
4 Angeles, J., Design Theory and Methodology, MECH593 LectureNotes, McGill University, Montreal, Canada
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 10 / 109
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Engineering Design
Engineering Design
References1 French, M. J. Conceptual Design for Engineers, 3rd ed., 1999
(Springer)2 Pahl, G. and Beitz, W. Engineering Design: A Systematic
Approach, 2nd ed. Wallace, K.M. (editor); Blessing, L., Bauert, F.and Wallace, K.M. (translators), 1996 (Springer-Verlag, London)
3 Pahl, G. and Beitz, W. Konstruktionslehre: Grundlageerfolgreicher Produktentwicklung. Methoden und Anwendung,2005 (Springer, Berlin-Heidelberg)
4 Angeles, J., Design Theory and Methodology, MECH593 LectureNotes, McGill University, Montreal, Canada
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 10 / 109
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Engineering Design
Engineering Design
References1 French, M. J. Conceptual Design for Engineers, 3rd ed., 1999
(Springer)2 Pahl, G. and Beitz, W. Engineering Design: A Systematic
Approach, 2nd ed. Wallace, K.M. (editor); Blessing, L., Bauert, F.and Wallace, K.M. (translators), 1996 (Springer-Verlag, London)
3 Pahl, G. and Beitz, W. Konstruktionslehre: Grundlageerfolgreicher Produktentwicklung. Methoden und Anwendung,2005 (Springer, Berlin-Heidelberg)
4 Angeles, J., Design Theory and Methodology, MECH593 LectureNotes, McGill University, Montreal, Canada
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 10 / 109
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Engineering Design
Engineering Science vs Engineering Design
Characteristics of an Engineering Science ProblemProblem statement is compact and well-posedProblem has a readily identifiable closureSolution is unique and compactProblem uses specialized knowledge
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 11 / 109
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Engineering Design
Engineering Science vs Engineering Design
Characteristics of an Engineering Science ProblemProblem statement is compact and well-posedProblem has a readily identifiable closureSolution is unique and compactProblem uses specialized knowledge
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 11 / 109
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Engineering Design
Engineering Science vs Engineering Design
Characteristics of an Engineering Science ProblemProblem statement is compact and well-posedProblem has a readily identifiable closureSolution is unique and compactProblem uses specialized knowledge
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 11 / 109
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Engineering Design
Engineering Science vs Engineering Design
Characteristics of an Engineering Science ProblemProblem statement is compact and well-posedProblem has a readily identifiable closureSolution is unique and compactProblem uses specialized knowledge
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 11 / 109
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Engineering Design
Engineering Science vs Engineering Design (Contd)
According to (Glegg, G., 1970)An engineer is a creative artist. He [sic] creates by arranging inpatterns the discoveries of science.A scientist can discover a new star but he [sic] cannot make one.He [sic] would have to ask an engineer to do it for him [sic].
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 12 / 109
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Engineering Design
Engineering Science vs Engineering Design (Contd)
According to (Glegg, G., 1970)An engineer is a creative artist. He [sic] creates by arranging inpatterns the discoveries of science.A scientist can discover a new star but he [sic] cannot make one.He [sic] would have to ask an engineer to do it for him [sic].
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 12 / 109
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Engineering Design
Engineering Science vs Engineering Design (Contd)
Typical Engineering Science Problem StatementA simply supported steel beam with a 10 cm diameter circularcross-section is loaded as shown. Determine the maximum stressand deflection.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 13 / 109
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Engineering Design
Engineering Science vs Engineering Design (Contd)
Another Typical Engineering Science Problem StatementHow much current is flowing through the circuit 0.1 sec after theswitch is closed?
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 14 / 109
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Engineering Design
Engineering Science vs Engineering Design (Contd)
Characteristics of an Engineering Design ProblemProblem statement is incomplete, ambiguous, andself-contradictoryProblem does not have a readily identifiable closureSolutions are neither unique nor compactProblem requires integration of knowledge from many fields
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 15 / 109
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Engineering Design
Engineering Science vs Engineering Design (Contd)
Characteristics of an Engineering Design ProblemProblem statement is incomplete, ambiguous, andself-contradictoryProblem does not have a readily identifiable closureSolutions are neither unique nor compactProblem requires integration of knowledge from many fields
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 15 / 109
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Engineering Design
Engineering Science vs Engineering Design (Contd)
Characteristics of an Engineering Design ProblemProblem statement is incomplete, ambiguous, andself-contradictoryProblem does not have a readily identifiable closureSolutions are neither unique nor compactProblem requires integration of knowledge from many fields
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 15 / 109
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Engineering Design
Engineering Science vs Engineering Design (Contd)
Characteristics of an Engineering Design ProblemProblem statement is incomplete, ambiguous, andself-contradictoryProblem does not have a readily identifiable closureSolutions are neither unique nor compactProblem requires integration of knowledge from many fields
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 15 / 109
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Engineering Design
Engineering Science vs Engineering Design (Contd)
Typical Engineering Design Problem StatementDesign a system for lifting and moving loads of up to 1500 Kg in amanufacturing facility . The facility has an unobstructed span of15 m. The lifting system should be inexpensive and satisfy allrelevant safety standards.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 16 / 109
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Engineering Design
Engineering Science vs Engineering Design (Contd)
Topography of Engineering Science and Engineering Design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 17 / 109
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Engineering Design
Engineering Science vs Engineering Design (Contd)
Contemplating Engineering Design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 18 / 109
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Engineering Design
Engineering Science vs Engineering Design (Contd)
Guidance Provided by Design Professor
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 19 / 109
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Engineering Design
Engineering Science vs Engineering Design (Contd)
Benefits of Understanding Engineering Design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 20 / 109
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Engineering Design
Engineering Science vs Engineering Design (Contd)
Possible Logo for Engineering Design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 21 / 109
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Engineering Design
Definition of Design
Engineering design is the process of devising a system,component, or process to meet desired needs.It is a decision-making process (often iterative), in which the basicsciences and mathematics, and engineering sciences are appliedto convert resources optimally to meet a stated objective.Among the fundamental elements of the design process are theestablishment of objectives and criteria, synthesis, analysis,construction, testing, and evaluation.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 22 / 109
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Engineering Design
Definition of Design
Engineering design is the process of devising a system,component, or process to meet desired needs.It is a decision-making process (often iterative), in which the basicsciences and mathematics, and engineering sciences are appliedto convert resources optimally to meet a stated objective.Among the fundamental elements of the design process are theestablishment of objectives and criteria, synthesis, analysis,construction, testing, and evaluation.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 22 / 109
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Engineering Design
Definition of Design
Engineering design is the process of devising a system,component, or process to meet desired needs.It is a decision-making process (often iterative), in which the basicsciences and mathematics, and engineering sciences are appliedto convert resources optimally to meet a stated objective.Among the fundamental elements of the design process are theestablishment of objectives and criteria, synthesis, analysis,construction, testing, and evaluation.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 22 / 109
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Engineering Design
Nine Step Model of Design Process
1 Recognizing the need2 Defining the problem3 Planning the project4 Gathering information5 Conceptualizing alternative approaches6 Evaluating the alternatives7 Selecting the preferred alternative8 Detailed design9 Communicating the design
10 Implementing the preferred design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 23 / 109
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Engineering Design
Step 1: Recognizing the Need
Sandra: Jane, we need you to design a stronger bumper for ournew passenger car.Jane: Why do we need a stronger bumper?Sandra: Well, our current bumper gets easily damaged inlow-speed collisions, such as those that occur in parking lots.Jane: Well, a stronger bumper may be the way to go, but theremay be better approaches. For example, what about a moreflexible bumper that absorbs the impact but then returns to itsoriginal shape?Sandra: I never thought of that. I guess I was jumping toconclusions. Lets restate the need as there is too much damageto bumpers in low-speed collisions. That should give you moreflexibility in exploring alternative design.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 24 / 109
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Engineering Design
Step 1: Recognizing the Need
Sandra: Jane, we need you to design a stronger bumper for ournew passenger car.Jane: Why do we need a stronger bumper?Sandra: Well, our current bumper gets easily damaged inlow-speed collisions, such as those that occur in parking lots.Jane: Well, a stronger bumper may be the way to go, but theremay be better approaches. For example, what about a moreflexible bumper that absorbs the impact but then returns to itsoriginal shape?Sandra: I never thought of that. I guess I was jumping toconclusions. Lets restate the need as there is too much damageto bumpers in low-speed collisions. That should give you moreflexibility in exploring alternative design.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 24 / 109
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Engineering Design
Step 1: Recognizing the Need
Sandra: Jane, we need you to design a stronger bumper for ournew passenger car.Jane: Why do we need a stronger bumper?Sandra: Well, our current bumper gets easily damaged inlow-speed collisions, such as those that occur in parking lots.Jane: Well, a stronger bumper may be the way to go, but theremay be better approaches. For example, what about a moreflexible bumper that absorbs the impact but then returns to itsoriginal shape?Sandra: I never thought of that. I guess I was jumping toconclusions. Lets restate the need as there is too much damageto bumpers in low-speed collisions. That should give you moreflexibility in exploring alternative design.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 24 / 109
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Engineering Design
Step 1: Recognizing the Need
Sandra: Jane, we need you to design a stronger bumper for ournew passenger car.Jane: Why do we need a stronger bumper?Sandra: Well, our current bumper gets easily damaged inlow-speed collisions, such as those that occur in parking lots.Jane: Well, a stronger bumper may be the way to go, but theremay be better approaches. For example, what about a moreflexible bumper that absorbs the impact but then returns to itsoriginal shape?Sandra: I never thought of that. I guess I was jumping toconclusions. Lets restate the need as there is too much damageto bumpers in low-speed collisions. That should give you moreflexibility in exploring alternative design.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 24 / 109
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Engineering Design
Step 1: Recognizing the Need
Sandra: Jane, we need you to design a stronger bumper for ournew passenger car.Jane: Why do we need a stronger bumper?Sandra: Well, our current bumper gets easily damaged inlow-speed collisions, such as those that occur in parking lots.Jane: Well, a stronger bumper may be the way to go, but theremay be better approaches. For example, what about a moreflexible bumper that absorbs the impact but then returns to itsoriginal shape?Sandra: I never thought of that. I guess I was jumping toconclusions. Lets restate the need as there is too much damageto bumpers in low-speed collisions. That should give you moreflexibility in exploring alternative design.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 24 / 109
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Engineering Design
Step 3: Planning the Project
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 25 / 109
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Engineering Design
Step 5: Conceptualizing alternative approaches
MotivationA filtering methodology at the conceptual stage that wouldcleverly filter-out less prospective design variants
The aim is to reduce the set of design variants. To come up with asingle design solution is too limited
BenefitWill cut the development cost and time
ChallengeTo quantify the quality of the design alternatives in the absence ofa mathematical model
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 26 / 109
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Engineering Design
Step 7: Selecting the Best Alternative
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 27 / 109
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Engineering Design
Step 8: Detailed design
Models and PrototypesRapid PrototypingProduction PrototypesTesting
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 28 / 109
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Engineering Design
Step 9: Communicating the Design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 29 / 109
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Axiomatic Design
1 Introduction
2 Engineering Design
3 Axiomatic Design
4 Robust Design
5 Complexity-Based Design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 30 / 109
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Axiomatic Design
Axiomatic Design (AD)
References1 Suh, N.P. The Principles of Design, 1990 (Oxford University Press,
Oxford)2 Suh, N.P. Axiomatic Design. Advances and Applications, 2001
(Oxford University Press, Oxford)
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 31 / 109
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Axiomatic Design
Axiomatic Design (AD)
References1 Suh, N.P. The Principles of Design, 1990 (Oxford University Press,
Oxford)2 Suh, N.P. Axiomatic Design. Advances and Applications, 2001
(Oxford University Press, Oxford)
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 31 / 109
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Axiomatic Design
Axiomatic Design (AD)
References1 Suh, N.P. The Principles of Design, 1990 (Oxford University Press,
Oxford)2 Suh, N.P. Axiomatic Design. Advances and Applications, 2001
(Oxford University Press, Oxford)
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 31 / 109
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Axiomatic Design
Definition of design
mapping process from the functional space to the physical space tosatisfy the designer-specified FRs
FRs: Functional Requirements, DPs: Design Parameters
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 32 / 109
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Axiomatic Design
The concept of domains
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 33 / 109
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Axiomatic Design
The concept of domains (Contd)
Characteristics of the four domains of the design world for variousdesigns
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 34 / 109
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Axiomatic Design
Can the field of design be scientific?
Motivations of the axiomatic designestablish a scientific basis for design and improve design activitiesby providing the designer with a theoretical foundation based onlogical and rational thought processes and toolsmake human designers more creativereduce the random search processminimize the iterative trial-and-error processdetermine the best designs among those proposedendow the computer with creative power through the creation of ascientific base for the design field
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 35 / 109
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Axiomatic Design
Can the field of design be scientific?
Motivations of the axiomatic designestablish a scientific basis for design and improve design activitiesby providing the designer with a theoretical foundation based onlogical and rational thought processes and toolsmake human designers more creativereduce the random search processminimize the iterative trial-and-error processdetermine the best designs among those proposedendow the computer with creative power through the creation of ascientific base for the design field
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 35 / 109
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Axiomatic Design
Can the field of design be scientific?
Motivations of the axiomatic designestablish a scientific basis for design and improve design activitiesby providing the designer with a theoretical foundation based onlogical and rational thought processes and toolsmake human designers more creativereduce the random search processminimize the iterative trial-and-error processdetermine the best designs among those proposedendow the computer with creative power through the creation of ascientific base for the design field
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 35 / 109
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Axiomatic Design
Can the field of design be scientific?
Motivations of the axiomatic designestablish a scientific basis for design and improve design activitiesby providing the designer with a theoretical foundation based onlogical and rational thought processes and toolsmake human designers more creativereduce the random search processminimize the iterative trial-and-error processdetermine the best designs among those proposedendow the computer with creative power through the creation of ascientific base for the design field
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 35 / 109
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Axiomatic Design
Can the field of design be scientific?
Motivations of the axiomatic designestablish a scientific basis for design and improve design activitiesby providing the designer with a theoretical foundation based onlogical and rational thought processes and toolsmake human designers more creativereduce the random search processminimize the iterative trial-and-error processdetermine the best designs among those proposedendow the computer with creative power through the creation of ascientific base for the design field
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 35 / 109
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Axiomatic Design
Can the field of design be scientific?
Motivations of the axiomatic designestablish a scientific basis for design and improve design activitiesby providing the designer with a theoretical foundation based onlogical and rational thought processes and toolsmake human designers more creativereduce the random search processminimize the iterative trial-and-error processdetermine the best designs among those proposedendow the computer with creative power through the creation of ascientific base for the design field
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 35 / 109
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Axiomatic Design
Design Axioms
Axiom 1: The Independence Axiom. Maintain the independence ofthe functional requirements (FRs).
Axiom 2: The Information Axiom. Minimize the information contentof the design.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 36 / 109
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Axiomatic Design
Design Axioms
Axiom 1: The Independence Axiom. Maintain the independence ofthe functional requirements (FRs).
Axiom 2: The Information Axiom. Minimize the information contentof the design.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 36 / 109
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Axiomatic Design
Functional Requirements
Beverage Can Design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 37 / 109
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Axiomatic Design
Corollaries
The origin of corollaries
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 38 / 109
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Axiomatic Design
Corollaries (Contd)
Corollary 1: (Decoupling of Coupled Design)Decouple of separate parts or aspects of a solution if FRsare coupled or become interdependent in the designsproposed.
Corollary 2: (Minimization of FRs)Minimize the number of FRs and constraints.
Corollary 3: (Integration of Physical Parts)Integrate design features in a single physical part if FRscan be independently satisfied in the proposed solution.
Corollary 4: (Use of Standardization)Use standardized or interchangeable parts if the use ofthese parts is consistent with the FRs and constraints.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 39 / 109
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Axiomatic Design
Corollaries (Contd)
Corollary 1: (Decoupling of Coupled Design)Decouple of separate parts or aspects of a solution if FRsare coupled or become interdependent in the designsproposed.
Corollary 2: (Minimization of FRs)Minimize the number of FRs and constraints.
Corollary 3: (Integration of Physical Parts)Integrate design features in a single physical part if FRscan be independently satisfied in the proposed solution.
Corollary 4: (Use of Standardization)Use standardized or interchangeable parts if the use ofthese parts is consistent with the FRs and constraints.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 39 / 109
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Axiomatic Design
Corollaries (Contd)
Corollary 1: (Decoupling of Coupled Design)Decouple of separate parts or aspects of a solution if FRsare coupled or become interdependent in the designsproposed.
Corollary 2: (Minimization of FRs)Minimize the number of FRs and constraints.
Corollary 3: (Integration of Physical Parts)Integrate design features in a single physical part if FRscan be independently satisfied in the proposed solution.
Corollary 4: (Use of Standardization)Use standardized or interchangeable parts if the use ofthese parts is consistent with the FRs and constraints.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 39 / 109
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Axiomatic Design
Corollaries (Contd)
Corollary 1: (Decoupling of Coupled Design)Decouple of separate parts or aspects of a solution if FRsare coupled or become interdependent in the designsproposed.
Corollary 2: (Minimization of FRs)Minimize the number of FRs and constraints.
Corollary 3: (Integration of Physical Parts)Integrate design features in a single physical part if FRscan be independently satisfied in the proposed solution.
Corollary 4: (Use of Standardization)Use standardized or interchangeable parts if the use ofthese parts is consistent with the FRs and constraints.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 39 / 109
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Axiomatic Design
Corollaries (Contd)
Corollary 5: (Use of Symmetry)Use symmetrical shapes and/or arrangements if they areconsistent with the FRs and constraints.
Corollary 6: (Largest Tolerance)Specify the largest allowable tolerance in stating FRs.
Corollary 7: (Uncoupled Design with Less Information)Seek an uncoupled design that requires less informationthan coupled designs in satisfying a set of FRs.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 40 / 109
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Axiomatic Design
Corollaries (Contd)
Corollary 5: (Use of Symmetry)Use symmetrical shapes and/or arrangements if they areconsistent with the FRs and constraints.
Corollary 6: (Largest Tolerance)Specify the largest allowable tolerance in stating FRs.
Corollary 7: (Uncoupled Design with Less Information)Seek an uncoupled design that requires less informationthan coupled designs in satisfying a set of FRs.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 40 / 109
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Axiomatic Design
Corollaries (Contd)
Corollary 5: (Use of Symmetry)Use symmetrical shapes and/or arrangements if they areconsistent with the FRs and constraints.
Corollary 6: (Largest Tolerance)Specify the largest allowable tolerance in stating FRs.
Corollary 7: (Uncoupled Design with Less Information)Seek an uncoupled design that requires less informationthan coupled designs in satisfying a set of FRs.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 40 / 109
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Axiomatic Design
Mathematical Representation of Axiom 1
Independence Axiom - a 3-FR Example FR1FR2FR3
= 0 00 0
0 0
DP1DP2DP3
Uncoupled Design (1) FR1FR2
FR3
= 0 0 0
DP1DP2DP3
Decoupled Design (2) FR1FR2
FR3
=
DP1DP2DP3
Coupled Design (3)
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 41 / 109
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Axiomatic Design
Mathematical Representation of Axiom 1
Independence Axiom - a 3-FR Example FR1FR2FR3
= 0 00 0
0 0
DP1DP2DP3
Uncoupled Design (1) FR1FR2
FR3
= 0 0 0
DP1DP2DP3
Decoupled Design (2) FR1FR2
FR3
=
DP1DP2DP3
Coupled Design (3)
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 41 / 109
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Axiomatic Design
Mathematical Representation of Axiom 1
Independence Axiom - a 3-FR Example FR1FR2FR3
= 0 00 0
0 0
DP1DP2DP3
Uncoupled Design (1) FR1FR2
FR3
= 0 0 0
DP1DP2DP3
Decoupled Design (2) FR1FR2
FR3
=
DP1DP2DP3
Coupled Design (3)
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 41 / 109
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Axiomatic Design
Ideal Design, Redundant Design and Coupled Design
Case 1: Number of DPs < Number of FRs: Coupled DesignCase 2: Number of DPs > Number of FRs: Redundant DesignCase 3: Number of DPs = Number of FRs: Ideal Design
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Axiomatic Design
Ideal Design, Redundant Design and Coupled Design
Case 1: Number of DPs < Number of FRs: Coupled DesignCase 2: Number of DPs > Number of FRs: Redundant DesignCase 3: Number of DPs = Number of FRs: Ideal Design
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 42 / 109
-
Axiomatic Design
Ideal Design, Redundant Design and Coupled Design
Case 1: Number of DPs < Number of FRs: Coupled DesignCase 2: Number of DPs > Number of FRs: Redundant DesignCase 3: Number of DPs = Number of FRs: Ideal Design
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Axiomatic Design
The Second Axiom: Minimize Information Axiom
Minimize the information content (I)
I = log2
(1
p1p2 pn
)(4)
pi - probability of satisfying the i th functional requirement
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Axiomatic Design
Example 1
Cutting a Rod to a Length
Suppose we need to cut Rod A to 1 0.000001 m and Rod B to1 0.1 m.
Which has a higher probability of success?How does the probability of success change if the nominal length ofthe rod is 30 m rather than 1 m?
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-
Axiomatic Design
Example 1
Cutting a Rod to a Length
Suppose we need to cut Rod A to 1 0.000001 m and Rod B to1 0.1 m.
Which has a higher probability of success?How does the probability of success change if the nominal length ofthe rod is 30 m rather than 1 m?
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 44 / 109
-
Axiomatic Design
Example 1
Cutting a Rod to a Length
Suppose we need to cut Rod A to 1 0.000001 m and Rod B to1 0.1 m.
Which has a higher probability of success?How does the probability of success change if the nominal length ofthe rod is 30 m rather than 1 m?
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 44 / 109
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Axiomatic Design
Example 1 (Contd)
Solutiondepends on the cutting equipment availablethe one that has to be cut within 1 m will be more difficultbecause the probability of success is smallerthe job with the lower prob. of success is more complexthe probability of introducing errors increases with the nominallength.
P = f(
tolerancenominal length
)(5)
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 45 / 109
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Axiomatic Design
Example 1 (Contd)
Solutiondepends on the cutting equipment availablethe one that has to be cut within 1 m will be more difficultbecause the probability of success is smallerthe job with the lower prob. of success is more complexthe probability of introducing errors increases with the nominallength.
P = f(
tolerancenominal length
)(5)
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Axiomatic Design
Example 1 (Contd)
Solutiondepends on the cutting equipment availablethe one that has to be cut within 1 m will be more difficultbecause the probability of success is smallerthe job with the lower prob. of success is more complexthe probability of introducing errors increases with the nominallength.
P = f(
tolerancenominal length
)(5)
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 45 / 109
-
Axiomatic Design
Example 1 (Contd)
Solutiondepends on the cutting equipment availablethe one that has to be cut within 1 m will be more difficultbecause the probability of success is smallerthe job with the lower prob. of success is more complexthe probability of introducing errors increases with the nominallength.
P = f(
tolerancenominal length
)(5)
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 45 / 109
-
Axiomatic Design
Example 1 (Contd)
Solutiondepends on the cutting equipment availablethe one that has to be cut within 1 m will be more difficultbecause the probability of success is smallerthe job with the lower prob. of success is more complexthe probability of introducing errors increases with the nominallength.
P = f(
tolerancenominal length
)(5)
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 45 / 109
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Axiomatic Design
Example 1 (Contd)
Design range, system range, common range, and system pdf for afunctional requirement
I = log21Acr
(6)
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Axiomatic Design
Example 1 (Contd)
Design range, system range, common range, and system pdf for afunctional requirement
I = log21Acr
(6)
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Axiomatic Design
Example 1 (Contd)
Cutting of the Rod with Hacksaw
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 47 / 109
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Axiomatic Design
Example 2
Refrigerator Door Design
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Axiomatic Design
Example 3
Refrigerator DesignFR1 Freeze food for long-term preservation.FR2 Maintain food at cold temperature for short-term
preservation.
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 49 / 109
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Axiomatic Design
Example 3 (Contd)
Refrigerator DesignFR1 Freeze food for long-term preservation.FR2 Maintain food at cold temperature for short-term
preservation.
DP1 The freezer section.DP2 The chiller (i.e., refrigerator) section preservation.
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Axiomatic Design
Example 3 (Contd)
Refrigerator DesignFR1 Freeze food for long-term preservation.FR2 Maintain food at cold temperature for short-term
preservation.
DP1 The freezer section.DP2 The chiller (i.e., refrigerator) section preservation.
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-
Axiomatic Design
Example 3 (Contd)
FR1FR11 Control the temperature of the freezer section in the
range of 18 2.FR12 Maintain a uniform temperature throughout the freezer
section at the preset temperature.FR13 Control humidity of the freezer section to relative humidity
of 50%.
FR2FR21 Control the temperature of the chiller section in the range
of 2 to 3.FR22 Maintain a uniform temperature throughout the freezer
section within 0.5 of the preset temperature.
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Axiomatic Design
Example 3 (Contd)
FR1FR11 Control the temperature of the freezer section in the
range of 18 2.FR12 Maintain a uniform temperature throughout the freezer
section at the preset temperature.FR13 Control humidity of the freezer section to relative humidity
of 50%.
FR2FR21 Control the temperature of the chiller section in the range
of 2 to 3.FR22 Maintain a uniform temperature throughout the freezer
section within 0.5 of the preset temperature.
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Axiomatic Design
Example 3 (Contd)
FR1
FR11 Control the temperature of the freezer section in the range of18 2.
FR12 Maintain a uniform temperature throughout the freezer section at thepreset temperature.
FR13 Control humidity of the freezer section to relative humidity of 50%.
DP1
DP11 Sensor/compressor system that turns the compressor on (off) whenthe air temperature is higher (lower) than the set temperature in thefreezer section.
DP12 Air circulation system that blows air into the freezer section andcirculates it uniformly throughout the freezer section at all times.
DP13 Condenser that condenses the moisture in the returned air when itsdew point is exceeded.
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Axiomatic Design
Example 3 (Contd)
FR1
FR11 Control the temperature of the freezer section in the range of18 2.
FR12 Maintain a uniform temperature throughout the freezer section at thepreset temperature.
FR13 Control humidity of the freezer section to relative humidity of 50%.
DP1
DP11 Sensor/compressor system that turns the compressor on (off) whenthe air temperature is higher (lower) than the set temperature in thefreezer section.
DP12 Air circulation system that blows air into the freezer section andcirculates it uniformly throughout the freezer section at all times.
DP13 Condenser that condenses the moisture in the returned air when itsdew point is exceeded.
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Axiomatic Design
Example 3 (Contd)
Design equation 1 FR12FR11FR13
= 0 0 0 0
DP12DP11DP13
(7)
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Axiomatic Design
Example 3 (Contd)
FR2FR21 Control the temperature of the chiller section in the range
of 2 to 3.FR22 Maintain a uniform temperature throughout the freezer
section within 0.5 of the preset temperature.
DP2DP11 Sensor/compressor system that turns the compressor on
(off) when the air temperature is higher (lower) than theset temperature in the chiller section.
DP12 Air circulation system that blows air into the chiller sectionand circulates it uniformly throughout the freezer sectionat all times.
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-
Axiomatic Design
Example 3 (Contd)
FR2FR21 Control the temperature of the chiller section in the range
of 2 to 3.FR22 Maintain a uniform temperature throughout the freezer
section within 0.5 of the preset temperature.
DP2DP11 Sensor/compressor system that turns the compressor on
(off) when the air temperature is higher (lower) than theset temperature in the chiller section.
DP12 Air circulation system that blows air into the chiller sectionand circulates it uniformly throughout the freezer sectionat all times.
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-
Axiomatic Design
Example 3 (Contd)
Design equation 2 [FR22FR21
]=
[ 0
] [DP22DP21
](8)
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-
Axiomatic Design
Example 3 (Contd)
Schematic
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-
Axiomatic Design
Example 4
Hot and Cold Water Faucet
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Axiomatic Design
Example 4
Hot and Cold Water FaucetFR1: Control the water flow rate Q without affecting the water
temperatureFR2: Control the temperature T without affecting flow rate
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-
Axiomatic Design
Example 4
Hot and Cold Water FaucetFR1: Control the water flow rate Q without affecting the water
temperatureFR2: Control the temperature T without affecting flow rate
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-
Axiomatic Design
Example 4
Hot and Cold Water FaucetFR1: Control the water flow rate Q without affecting the water
temperatureFR2: Control the temperature T without affecting flow rate
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-
Axiomatic Design
Example 4 (Contd)
A coupled hot water (HW) and cold water (CW) faucet
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-
Axiomatic Design
Example 4 (Contd)
A coupled hot water (HW) and cold water (CW) faucet
[QT
]=
[
] [12
](9)
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-
Axiomatic Design
Example 4 (Contd)
A uncoupled hot water (HW) and cold water (CW) faucet
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-
Axiomatic Design
Example 4 (Contd)
A uncoupled hot water (HW) and cold water (CW) faucet
[QT
]=
[ 00
] [12
](10)
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-
Axiomatic Design
Example 4 (Contd)
Another uncoupled hot water (HW) and cold water (CW) faucet
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-
Axiomatic Design
Example 4 (Contd)
Another uncoupled hot water (HW) and cold water (CW) faucet
[QT
]=
[ 00
] [Y
](11)
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-
Axiomatic Design
Example 4 (Contd)
Another uncoupled hot water (HW) and cold water (CW) faucet
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 65 / 109
-
Axiomatic Design
Example 4 (Contd)
Another uncoupled hot water (HW) and cold water (CW) faucet
[QT
]=
[ 00
] [XY
](12)
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-
Axiomatic Design
Example 4 (Contd)
Implication of the Information Axiom
[QT
]=
[ 00
] [X
](13)
only one moving part the information content is lower
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 67 / 109
-
Axiomatic Design
Example 4 (Contd)
Implication of the Information Axiom
[QT
]=
[ 00
] [X
](13)
only one moving part the information content is lower
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-
Axiomatic Design
Example 5
Two-degree-of-freedom Robot Arm
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-
Axiomatic Design
Example 5 (Contd)
FRsFR1: The overall stiffness, K (i.e., resistance to deflection when
the load is applied at the end effector)FR2: the overall accuracy in positioning the end effector FR3: acceleration of joint 1 (1)FR4: acceleration of joint 2 (2)
DPsDP1: Stiffness of the motor 1 (torque exerted by the rotor of the
motor 1 divided by rotation) = 1/1DP2: Stiffness of the motor 2 (torque exerted by the rotor of the
motor 1 divided by rotation) = 2/2DP3: Inertia of arm 1 = (Hij)1DP4: Inertia of arm 2 = (Hij)2
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 69 / 109
-
Axiomatic Design
Example 5 (Contd)
FRsFR1: The overall stiffness, K (i.e., resistance to deflection when
the load is applied at the end effector)FR2: the overall accuracy in positioning the end effector FR3: acceleration of joint 1 (1)FR4: acceleration of joint 2 (2)
DPsDP1: Stiffness of the motor 1 (torque exerted by the rotor of the
motor 1 divided by rotation) = 1/1DP2: Stiffness of the motor 2 (torque exerted by the rotor of the
motor 1 divided by rotation) = 2/2DP3: Inertia of arm 1 = (Hij)1DP4: Inertia of arm 2 = (Hij)2
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 69 / 109
-
Axiomatic Design
Example 5 (Contd)
FRsFR1: The overall stiffness, K (i.e., resistance to deflection when
the load is applied at the end effector)FR2: the overall accuracy in positioning the end effector FR3: acceleration of joint 1 (1)FR4: acceleration of joint 2 (2)
DPsDP1: Stiffness of the motor 1 (torque exerted by the rotor of the
motor 1 divided by rotation) = 1/1DP2: Stiffness of the motor 2 (torque exerted by the rotor of the
motor 1 divided by rotation) = 2/2DP3: Inertia of arm 1 = (Hij)1DP4: Inertia of arm 2 = (Hij)2
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 69 / 109
-
Axiomatic Design
Example 5 (Contd)
Design equation 1K
12
= 0 0
1/12/2(Hij)1(Hij)2
(14)
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-
Axiomatic Design
Example 5 (Contd)
Two-degree-of-freedom Robot Arm
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 71 / 109
-
Axiomatic Design
Example 5 (Contd)
FRsFR1: The overall stiffness, KFR2: the overall accuracy in positioning the end effector FR3: acceleration of joint 1 (1)FR4: acceleration of joint 2 (2)
DPsDP1: Stiffness of the motor 1 = 1/1DP2: Stiffness of the motor 2 = 2/2DP3: Inertia reflected on motor 1DP4: Inertia reflected on motor 2
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 72 / 109
-
Axiomatic Design
Example 5 (Contd)
FRsFR1: The overall stiffness, KFR2: the overall accuracy in positioning the end effector FR3: acceleration of joint 1 (1)FR4: acceleration of joint 2 (2)
DPsDP1: Stiffness of the motor 1 = 1/1DP2: Stiffness of the motor 2 = 2/2DP3: Inertia reflected on motor 1DP4: Inertia reflected on motor 2
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 72 / 109
-
Axiomatic Design
Example 5 (Contd)
FRsFR1: The overall stiffness, KFR2: the overall accuracy in positioning the end effector FR3: acceleration of joint 1 (1)FR4: acceleration of joint 2 (2)
DPsDP1: Stiffness of the motor 1 = 1/1DP2: Stiffness of the motor 2 = 2/2DP3: Inertia reflected on motor 1DP4: Inertia reflected on motor 2
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 72 / 109
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Axiomatic Design
Example 5 (Contd)
Design equation 2FR1FR2FR3FR4
= 0 0 0 00 0 0 0
DP1DP2DP3DP4
(15)
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-
Axiomatic Design
Example 6
Buying a House
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 74 / 109
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Axiomatic Design
Example 6 (Contd)
Probability distribution ofcommuting time Probability distribution of the
quality of schools
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-
Axiomatic Design
Example 6 (Contd)
Conclusions
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-
Axiomatic Design
Remarks
Does a smooth nonlinear function exist? Minimize the number ofFRs and constraints.The design matrix is more a binary matrixUncoupled design may lead to weak design, i.e., design matrixwith high condition numberDo we really need decoupling?What about units? (Semangularity and Reangularity)Functional requirements are usually phrases
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 77 / 109
-
Axiomatic Design
Remarks
Does a smooth nonlinear function exist? Minimize the number ofFRs and constraints.The design matrix is more a binary matrixUncoupled design may lead to weak design, i.e., design matrixwith high condition numberDo we really need decoupling?What about units? (Semangularity and Reangularity)Functional requirements are usually phrases
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 77 / 109
-
Axiomatic Design
Remarks
Does a smooth nonlinear function exist? Minimize the number ofFRs and constraints.The design matrix is more a binary matrixUncoupled design may lead to weak design, i.e., design matrixwith high condition numberDo we really need decoupling?What about units? (Semangularity and Reangularity)Functional requirements are usually phrases
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 77 / 109
-
Axiomatic Design
Remarks
Does a smooth nonlinear function exist? Minimize the number ofFRs and constraints.The design matrix is more a binary matrixUncoupled design may lead to weak design, i.e., design matrixwith high condition numberDo we really need decoupling?What about units? (Semangularity and Reangularity)Functional requirements are usually phrases
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 77 / 109
-
Axiomatic Design
Remarks
Does a smooth nonlinear function exist? Minimize the number ofFRs and constraints.The design matrix is more a binary matrixUncoupled design may lead to weak design, i.e., design matrixwith high condition numberDo we really need decoupling?What about units? (Semangularity and Reangularity)Functional requirements are usually phrases
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 77 / 109
-
Axiomatic Design
Remarks
Does a smooth nonlinear function exist? Minimize the number ofFRs and constraints.The design matrix is more a binary matrixUncoupled design may lead to weak design, i.e., design matrixwith high condition numberDo we really need decoupling?What about units? (Semangularity and Reangularity)Functional requirements are usually phrases
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 77 / 109
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Robust Design
1 Introduction
2 Engineering Design
3 Axiomatic Design
4 Robust Design
5 Complexity-Based Design
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Robust Design
Robust Design
References1 Taguchi, G., On Robust Technology Development. Bringing
Quality Engineering Upstream, 1993 (ASME Press, New York)2 Caro, S., Bennis, F. and Wenger, P., Tolerance Synthesis of
Mechanisms: a Robust Design Approach, ASME Journal ofMechanical Design, 127, pp. 8694
3 Caro, S., 2004, Conception Robuste de Mecanismes, The`se dedoctorat, Ecole Centrale de Nantes, Universite de Nantes, Nantes,France
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 79 / 109
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Robust Design
Robust Design
References1 Taguchi, G., On Robust Technology Development. Bringing
Quality Engineering Upstream, 1993 (ASME Press, New York)2 Caro, S., Bennis, F. and Wenger, P., Tolerance Synthesis of
Mechanisms: a Robust Design Approach, ASME Journal ofMechanical Design, 127, pp. 8694
3 Caro, S., 2004, Conception Robuste de Mecanismes, The`se dedoctorat, Ecole Centrale de Nantes, Universite de Nantes, Nantes,France
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 79 / 109
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Robust Design
Robust Design
References1 Taguchi, G., On Robust Technology Development. Bringing
Quality Engineering Upstream, 1993 (ASME Press, New York)2 Caro, S., Bennis, F. and Wenger, P., Tolerance Synthesis of
Mechanisms: a Robust Design Approach, ASME Journal ofMechanical Design, 127, pp. 8694
3 Caro, S., 2004, Conception Robuste de Mecanismes, The`se dedoctorat, Ecole Centrale de Nantes, Universite de Nantes, Nantes,France
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 79 / 109
-
Robust Design
Robust Design
References1 Taguchi, G., On Robust Technology Development. Bringing
Quality Engineering Upstream, 1993 (ASME Press, New York)2 Caro, S., Bennis, F. and Wenger, P., Tolerance Synthesis of
Mechanisms: a Robust Design Approach, ASME Journal ofMechanical Design, 127, pp. 8694
3 Caro, S., 2004, Conception Robuste de Mecanismes, The`se dedoctorat, Ecole Centrale de Nantes, Universite de Nantes, Nantes,France
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 79 / 109
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Robust Design
Robust Design
The roots of poor quality in goods or services are to be found inthe sensitivity of these to variations in operation conditions(Taguchi, 78).The design of a mechanism is robust when its performance is aslittle sensitive to variations in design variables and designenvironment parameters as possible (Caro, 03).
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Robust Design
Robust Design
The roots of poor quality in goods or services are to be found inthe sensitivity of these to variations in operation conditions(Taguchi, 78).The design of a mechanism is robust when its performance is aslittle sensitive to variations in design variables and designenvironment parameters as possible (Caro, 03).
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 80 / 109
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Robust Design
Robust Design (Contd)
Principles due to G. Taguchi (1987):Minimum loss function;minimum sensitivity of the designed object to variations in thedesign environment.
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Robust Design
Robust Design (Contd)
Principles due to G. Taguchi (1987):Minimum loss function;minimum sensitivity of the designed object to variations in thedesign environment.
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Robust Design
Robust Design (Contd)
Taguchis philosophy is based on two conceptsThe loss function: measures the quality loss for the customer due to a
bad product design;Signal/Noise ratio: measures the sensitivity of the design performance
to variations in design environmental parameters.
=SN
= log10
(2
2
)(16)
: mean of the performance function : standard deviation in the performance function
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 82 / 109
-
Robust Design
Robust Design (Contd)
Taguchis philosophy is based on two conceptsThe loss function: measures the quality loss for the customer due to a
bad product design;Signal/Noise ratio: measures the sensitivity of the design performance
to variations in design environmental parameters.
=SN
= log10
(2
2
)(16)
: mean of the performance function : standard deviation in the performance function
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 82 / 109
-
Robust Design
Robust Design (Contd)
Taguchis philosophy is based on two conceptsThe loss function: measures the quality loss for the customer due to a
bad product design;Signal/Noise ratio: measures the sensitivity of the design performance
to variations in design environmental parameters.
=SN
= log10
(2
2
)(16)
: mean of the performance function : standard deviation in the performance function
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 82 / 109
-
Robust Design
Robust Design (Contd)
Taguchis philosophy is based on two conceptsThe loss function: measures the quality loss for the customer due to a
bad product design;Signal/Noise ratio: measures the sensitivity of the design performance
to variations in design environmental parameters.
=SN
= log10
(2
2
)(16)
: mean of the performance function : standard deviation in the performance function
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 82 / 109
-
Robust Design
Robust Design (Contd)
Taguchis philosophy is based on two conceptsThe loss function: measures the quality loss for the customer due to a
bad product design;Signal/Noise ratio: measures the sensitivity of the design performance
to variations in design environmental parameters.
=SN
= log10
(2
2
)(16)
: mean of the performance function : standard deviation in the performance function
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Robust Design
Taguchis Example
Quality levels of Sony color TV sets made in Japan and San Diego
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Robust Design
Example (Contd)
Process capability index
Cp =Tolerance
6 Standard deviation (17)
Cp(Japan) ' 1 (18)
Cp(San Diego) =Tolerance
6(Tolerance
12
) = 0.577 (19)
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Robust Design
Example (Contd)
Process capability index
Cp =Tolerance
6 Standard deviation (17)
Cp(Japan) ' 1 (18)
Cp(San Diego) =Tolerance
6(Tolerance
12
) = 0.577 (19)
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Robust Design
Example (Contd)
Process capability index
Cp =Tolerance
6 Standard deviation (17)
Cp(Japan) ' 1 (18)
Cp(San Diego) =Tolerance
6(Tolerance
12
) = 0.577 (19)
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Robust Design
When an objective characteristic y deviates from its target value m,some financial loss will occur.
Loss function
y m L(y) = L(m) = 0 (20)
L(m) = 0 (21)
by means of a Taylor series expansion of L around m
L(y) = L(m) +L(m)
1!(y m) + L
(m)2!
(y m)2 + (22)
L(y) =L(m)
2!(y m)2 + (23)
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Robust Design
When an objective characteristic y deviates from its target value m,some financial loss will occur.
Loss function
y m L(y) = L(m) = 0 (20)
L(m) = 0 (21)
by means of a Taylor series expansion of L around m
L(y) = L(m) +L(m)
1!(y m) + L
(m)2!
(y m)2 + (22)
L(y) =L(m)
2!(y m)2 + (23)
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Robust Design
When an objective characteristic y deviates from its target value m,some financial loss will occur.
Loss function
y m L(y) = L(m) = 0 (20)
L(m) = 0 (21)
by means of a Taylor series expansion of L around m
L(y) = L(m) +L(m)
1!(y m) + L
(m)2!
(y m)2 + (22)
L(y) =L(m)
2!(y m)2 + (23)
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Robust Design
When an objective characteristic y deviates from its target value m,some financial loss will occur.
Loss function
y m L(y) = L(m) = 0 (20)
L(m) = 0 (21)
by means of a Taylor series expansion of L around m
L(y) = L(m) +L(m)
1!(y m) + L
(m)2!
(y m)2 + (22)
L(y) =L(m)
2!(y m)2 + (23)
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Robust Design
Loss function
L(y) = k(y m)2 (24)with
k =Cost of a defective product
Tolerance2=
A2
(25)
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Robust Design
SolutionLet the adjustment cost be: A = $6
k =652
= $0.24 (26)
withL = $0.24(y m)2 (27)
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Robust Design
Solution
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Robust Design
Robust Design Problem Formulation
Design Variables (DVs)Nominal values are controllable;the real values are uncertain due to manufacturing errors, wear...
x = [x1, x2, . . . xl ]T (28)
Design Environmental Parameters (DEPs)are not controllableExamples: ambient temperature and pressure, behavior of theuser of the good under design
p = [p1, p2, . . .pm]T (29)
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Robust Design
Robust Design Problem Formulation
Design Variables (DVs)Nominal values are controllable;the real values are uncertain due to manufacturing errors, wear...
x = [x1, x2, . . . xl ]T (28)
Design Environmental Parameters (DEPs)are not controllableExamples: ambient temperature and pressure, behavior of theuser of the good under design
p = [p1, p2, . . .pm]T (29)
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Robust Design
Robust Design Problem Formulation (Contd)
Performance Functions (PFs)depend on DVs and DEPs
f = [f1, f2, . . . fn]T (30)
f = f (x,p) (31)
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Robust Design
Robust Design Problem Formulation (Contd)
Performance Functions (PFs)depend on DVs and DEPs
f = [f1, f2, . . . fn]T (30)
f = f (x,p) (31)
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Robust Design
Robust Design Problem Formulation (Contd)
Rocker-Crank Mechanism
x = [lc , lr , e]T
p = [fp, ]T
f = NObjective:
min(f, f)
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Robust Design
Robust Design Problem Formulation (Contd)
Rocker-Crank Mechanism
x = [lc , lr , e]T
p = [fp, ]T
f = NObjective:
min(f, f)
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Robust Design
Robust Design Problem Formulation (Contd)
Rocker-Crank Mechanism
x = [lc , lr , e]T
p = [fp, ]T
f = NObjective:
min(f, f)
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Robust Design
Robust Design Problem Formulation (Contd)
Rocker-Crank Mechanism
x = [lc , lr , e]T
p = [fp, ]T
f = NObjective:
min(f, f)
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 91 / 109
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Robust Design
Robust Design Problem Formulation (Contd)
Rocker-Crank Mechanism
x = [lc , lr , e]T
p = [fp, ]T
f = NObjective:
min(f, f)
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Robust Design
Optimization Problem
Minimize f(x) = {f1, . . . , fm}Subject to: hj(x) = 0, j = 1, . . . ,p
gk (x) 0, k = 1, . . . ,qx ll xl xul , l = 1 . . . ,n
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Robust Design
Robust Optimization Problem
Statistical formulation
Minimize(fi (x,p), fi (x,p)
), i = 1, . . . ,n
Subject to: gi (x,p) + kgi (x,p) 0, j = 1, . . . , rKnowing: p, p, x
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Robust Design
Robust Optimization Problem
Statistical formulation
Minimize(fi (x,p), fi (x,p)
), i = 1, . . . ,n
Subject to: gi (x,p) + kgi (x,p) 0, j = 1, . . . , rKnowing: p, p, x
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Robust Design
Robust Optimum Solution
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Robust Design
Robustness Index
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Robust Design
Sensitivity Jacobian Matrix
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Robust Design
Design Sensitivity
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Robust Design
Design sensitivity Hyper-ellipsod
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Robust Design
Robustness Index
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Robust Design
Robustness Index (Contd)
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Robust Design
Robustness Indices Comparison
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Robust Design
Selection of the Robustness Index
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Robust Design
Tolerance Synthesis Method
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Robust Design
Case Study: 3R manipulator
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Robust Design
Case Study: 3R manipulator (Contd)
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Robust Design
Conclusion
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Complexity-Based Design
1 Introduction
2 Engineering Design
3 Axiomatic Design
4 Robust Design
5 Complexity-Based Design
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Complexity-Based Design
Complexity-Based Design
References1 Khan, W.A., Caro, S., Pasini, D. and Angeles, J., Complexity
analysis of curves and surfaces: application to the geometriccomplexity of lower kinematic pairs. Submitted to Special Issue onComputer Support for Conceptual Design, Computer-AidedDesign, on Aug, 9th, 2006, CADD- 06-00171.
2 Khan, W.A., Caro, S., Pasini, D., Angeles, J., Complexity-BasedRules for the Conceptual Design of Robotic Architectures, 10thInternational Symposium on Advances in Robot Kine- matics,June 25-29, 2006, Ljubljana, Slovenia
3 Khan, W.A., Caro, S., Angeles, J. and Pasini, D., A Formulation ofComplexity-Based Rules for the Preliminary Design Stage ofRobotic Architectures, International Conference on EngineeringDesign, ICED07, August 28-31, 2007, Paris, France
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Complexity-Based Design
Complexity-Based Design
References1 Khan, W.A., Caro, S., Pasini, D. and Angeles, J., Complexity
analysis of curves and surfaces: application to the geometriccomplexity of lower kinematic pairs. Submitted to Special Issue onComputer Support for Conceptual Design, Computer-AidedDesign, on Aug, 9th, 2006, CADD- 06-00171.
2 Khan, W.A., Caro, S., Pasini, D., Angeles, J., Complexity-BasedRules for the Conceptual Design of Robotic Architectures, 10thInternational Symposium on Advances in Robot Kine- matics,June 25-29, 2006, Ljubljana, Slovenia
3 Khan, W.A., Caro, S., Angeles, J. and Pasini, D., A Formulation ofComplexity-Based Rules for the Preliminary Design Stage ofRobotic Architectures, International Conference on EngineeringDesign, ICED07, August 28-31, 2007, Paris, France
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 108 / 109
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Complexity-Based Design
Complexity-Based Design
References1 Khan, W.A., Caro, S., Pasini, D. and Angeles, J., Complexity
analysis of curves and surfaces: application to the geometriccomplexity of lower kinematic pairs. Submitted to Special Issue onComputer Support for Conceptual Design, Computer-AidedDesign, on Aug, 9th, 2006, CADD- 06-00171.
2 Khan, W.A., Caro, S., Pasini, D., Angeles, J., Complexity-BasedRules for the Conceptual Design of Robotic Architectures, 10thInternational Symposium on Advances in Robot Kine- matics,June 25-29, 2006, Ljubljana, Slovenia
3 Khan, W.A., Caro, S., Angeles, J. and Pasini, D., A Formulation ofComplexity-Based Rules for the Preliminary Design Stage ofRobotic Architectures, International Conference on EngineeringDesign, ICED07, August 28-31, 2007, Paris, France
S. Caro (IRCCyN) Conceptual Design of Products Feb. 11, 2014 108 / 109
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Complexity-Based Design
Complexity-Based Design
References1 Khan, W.A., Caro, S., Pasini, D. and Angeles, J., Complexity
analysis of curves and surfaces: application to the geometriccomplexity of lower kinematic pairs. Submitted to Special Issue onComputer Support for Conceptual Design, Computer-AidedDesign, on Aug, 9th, 2006, CADD- 06-00171.
2 Khan, W.A., Caro, S., Pasini, D., Angeles, J., Complexity-BasedRules for the Conceptual Design of Robotic Architectures, 10thInternational Symposium on Advances in Robot Kine- matics,June 25-29, 2006, Ljubljana, Slovenia
3 Khan, W.A., Caro, S., Angeles, J. and Pasini, D., A Formulation ofComplexity-Based Rules for the Preliminary Design Stage ofRobotic Architectures, International Conference on EngineeringDesign, ICED07, August 28-31, 2007, Paris, France
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Complexity-Based Design
see Conceptual Robot Design file
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IntroductionEngineering DesignAxiomatic DesignRobust DesignComplexity-Based Design