ES1050 – Introductory Engineering Design and Innovation Studio
Models and Prototypes
Prof. Paul Kurowski
This is a group assignment, only one copy per team should be submitted
Where to submit?
To the studio locker in TEB on the second floor
Prototype definitions
A prototype is an original type, form, or instance of
something serving as a typical example, basis, or
standard for other things of the same category.
http://en.wikipedia.org/wiki/Prototype
Models and Prototypes
Abstractions and simplifications of final design as needed to demonstrate, test and refine a design
Physical prototypes are needed to demonstrate, test and refine a design
Prototype Goals
Types of Prototypes 1
Proof-of-Principle Prototype
Form Study Prototype
Visual Prototype
Functional Prototype
http://en.wikipedia.org/wiki/Prototype
Types of Prototypes 2
Virtual (CAE) CAD models Mathematical models Numerical models
Physical Proof-of-concept Industrial design Experimental Alpha Beta Pre-production
DESIGN
PROTOTYPING
TESTING
PRODUCTION
CAD
PROTOTYPING
TESTING
PRODUCTION
CAE
FEA
Windows OS
solid CAD
TRADITIONAL PRODUCT
DESIGN PROCESS
SIMULATION DRIVEN PRODUCT
DESIGN PROCESS
affordable computers
CAE tools are implemented to move design iterations from physical prototypes to virtual space of numerical (computer) models
Why CAE?
Mathematical model
Vibration of a single degree of freedom system
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Numerical model
Motion of a mechanism
Numerical model
Modes of vibration of a tuning fork
Numerical model
Modes of vibration of a pumpkin
Types of Prototypes
Virtual (CAE) CAD models Mathematical models Numerical models
Physical Proof-of-concept Industrial design Experimental Alpha Beta Pre-production
Proof-of-concept Prototypes
Demonstrate feasibility Simple construction Often only a part or
subsystem Usually not fully
functional! Not sufficient for design
validation!
http://me118.stanford.edu/pictures/Win01Projects/TooShort/images/2nd%20prototype.JPG
Industrial Design Prototype How will the product look and feel? Simple materials (foam, wood, etc.) Usually non-functional
http://www.linternaute.com/auto/mondial-automobile-concept-car/audi-rsq3.jpg
1962 Prototype of Lunar Module
Industrial Design Prototype
Experimental Prototype Intended for
physical experiments and testing
Often only a subsystem
Prototype of shock-absorbing casterTest results
Alpha Prototype Include most but not all functions of the final design Answer questions about overall layout of the design
http://drwho.virtadpt.net/pictures/memorial-day-2004/apple-prototype.jpg
Beta Prototype
Fully functional prototype Final product form Purpose is final testing Different manufacturing
processes used Machining rather than
injection molding Made by hand
Pre-Production Prototype
Made using final production processes and tooling
Identical to the final product
Used to fine-tune the production process
Pre-production Prototypehttp://www.dpreview.com/articles/canoneos5d/
Prototype Goals
Answer simple questions (e.g. will an idea work?) Obtain feedback from customers Aid in visualization Provide realistic models for marketing and advertising Study the “look and feel” of the product Functional testing and evaluation
Prototype Construction in ES1050
Inexpensive Easy No special
tools Quick
http://www.ben.com/LEGO/rcx/picoscout/breadboard.jpg
Common Prototyping Materials in ES1050 Wood Plastic
Plexiglass Cardboard and
paper Metal
http://www.riscx.com/pyramac/proto_pics/proto_3_600.jpg
Prototyping Tools in ES1050
Simple hand tools Scissors Screwdrivers Wrenches
Simple joining methods Glue Duct tape Screws
Construction kits you may want to use in ES1050 Lego Meccano Others
http://www.sentex.net/~mwandel/legos/legos.html
Lego Many mechanical
and electrical parts
Inexpensive and easy
No tools required
http://www.hamster.dk/~purple/robot/iBOT/lego_robot_prototype.jpg
http://www.cs.rhul.ac.uk/eca/micromouse/lego/shakey/images/parts.jpg
Meccano Uses metal parts Simple tools
www.meccano.com
http://webperso.easyconnect.fr/esteve.jeanmax/j.e.o/fotopi%E8ces/MarklinPiecP.jpg
Rapid Prototyping is available to ES1050
Creates a physical prototype directly from a CAD model
Can include color Uses low-strength
materials
www.zcorp.com
Rapid Prototyping
www.zcorp.com
Rapid Prototyping
Types of prototypes commonly used in ES1050
ES050 Prototypes in 2006/2007
when the main Design Project was to “Demonstrate a Scientific Principle”
Select the incorrect statement about a prototype
A Does not have to be in the natural size
B Does not have to convey the essential design idea
C Can be material or virtual
D Can be made using simplified manufacturing processes
E Does not have to look identical as the indented final design