Download - What is a different “configuration?”
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Configuration Design
What is a product configuration?
What is a part configuration?
Product architecture design
Part configuration design
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What is configuration design?
For example:
Design problem: reduce speed ---- Concept: gear pair
What are some possible “configurations” for a gear pair?
geometry & material Physical principle
2211 TT
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Alternative configuration #1
arrange
parts
differently
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Alternative configuration #2
Spur gears Helical gears
use different
features or parts
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Configuration #3 and #4
use different
relative dimensions
wide teeth similar diameters
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What is a part configuration?
For example:
Design problem: support vertical load ---- Concept: wall bracket
What are some possible “configurations” for a wall bracket?
geometry & material Physical principle
0
mEquilibriuForce
F
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Wall bracket configurations
different
features
alternative
arrangements
different
relative dimensions
Abstract
embodiment
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Configuration decisions
Change one or more of these… How do we create different configurations?
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Obtaining the “best” configuration
To be selective, we need a selection!
How should we start our configuration design efforts?
To choose the “best” alternative….
Implies that we have a number of feasible alternatives!
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Configuration design
Configure
Part(s)
Configure
Product
Analyze
and
Refine
Iter
ate
Re-examine EDS
Research sources
Configuration requirements sketch
Best
concept(s)
Design for Function
Design for Assembly
Design for Manufacture
Best
configuration(s)
Pugh’s Method
Weighted Rating Method Evaluate
Product architecture
Integral / modular
Standard / special purpose
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Part configuration design
geometric features include:
Configuration Problem Required Decisions
Special purpose part Geometric features (type & no.)
Arrangements of features
Relative dimensions
Design variable / Parameter list
walls rounds cubes notches
ribs bosses spheres chamfers
projections cylinders holes grooves
fillets tubes slots
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How can we “generate” alternative part configurations?
different
features
alternative
arrangements
different
relative dimensions
Abstract
embodiment
Recall bracket configurations
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Dixon & Poli Method using “configuration requirements” Example: configuring a sponge holder
Step 1. Prepare configuration requirements sketch
sponge holder
Step 2. Prepare non-contiguous config. requirements sketch
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Step 3. Prepare alternative contiguous configuration sketches
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Step 4. Refine configurations
with hole in back wall with hole in offset wall
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Configuration Design
Analyzing configurations
DFA
DFM
Evaluating Configurations
CAD
Solid modeling
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Configuration design - analysis
Configure
Part(s)
Configure
Product
Analyze
and
Refine
Iter
ate
Re-examine EDS
Research sources
Configuration requirements sketch
Best
concept(s)
Design for Function
Design for Assembly
Design for Manufacture
Best
configuration(s)
Pugh’s Method
Weighted Rating Method Evaluate
Product architecture
Integral / modular
Standard / special purpose
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Analyzing Configurations
Design for Function
Design for Assembly
Design for Manufacture
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To analyze configurations, we ask…
Will it function?
Will it assemble?
Will it be manufacturable?
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Design for function
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
Will the part or product perform its function(s)?
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Will it assemble?
Assembly - a process of handling components
to bring them together (inserting) and then
fastening them.
What do we mean by assemble?
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DFA
Design for Assembly - a set of design practices which reduce the manpower time required to handle, insert and
fasten components of a product.
1. Design Guidelines (written and graphical) 2. Cost estimating methods
(designing part features for a more effective assembly of the parts)
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Example of DFA Graphical
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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
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Pros and Cons of DFA methods
1. Design Guidelines pros: fast, easy, non-coupled cons: non-quantitative, can’t compare alt. designs
2. Assembly Efficiency (Boothroyd & Dewhurst)
Efficiency = theoretical min. assembly time estimated assembly time pros: systematic, comparative cons: takes time to code & calculate
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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
(designing parts for less costly fabrication)
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DFM Graphical – machining examples
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DFM Guidelines – Example: 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
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Configuration design - evaluation
Configure
Part(s)
Configure
Product
Analyze
and
Refine
Iter
ate
Re-examine EDS
Research sources
Configuration requirements sketch
Best
concept(s)
Design for Function
Design for Assembly
Design for Manufacture
Best
configuration(s)
Pugh’s Method
Weighted Rating Method Evaluate
Product architecture
Integral / modular
Standard / special purpose
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Evaluation using Weighted Rating Method
1. List evaluation criteria (in a column).
2. Determine importance weights (in an adjacent column)
3. List alternatives (along the top row)
4. Rate each alternative on each criterion
5. Compute the weighted rating for each criterion
6. Sum the ratings to produce the Overall Weighted
Rating
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Evaluating alternative configurations
Criteria
Importance
Weight
Sponge Holder Configuration Ratings
With hole With bracket
Rating Wt. Rating Rating Wt. Rating
Function
drains well 15 3 0.45 3 0.45
dries quickly 10 3 0.30 3 0.30
stays clean 10 2 0.10 3 0.15
sponge inserts easily 15 2 0.40 4 0.80
Manufacture
material usage 10 3 0.30 2 0.20
tooling costs 15 3 0.45 2 0.30
processing costs 5 3 0.15 3 0.15
Assembly
handling 5 3 0.15 3 0.15
insertion 5 3 0.15 3 0.15
number of parts 10 3 0.30 3 0.30
100%
Weighted rating 2.75 2.95
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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
2-D model
Wireframe model
Surface model
Solid model
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Advantages of solid modeling
Design intent is captured- such as holes moving with bosses
Feature-based modeling– automating with features such as chamfer, fillet, flange-bolt
Constraint-based– geometric relations
Parametric- dimensions are placeholders
Fully Associative- one model controls all views
Assemble-ability check– interference, motion
Downstream benefits- CAE, FEA, CAM, rapid prototyping
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Configuration design summary
Configure
Part(s)
Configure
Product
Analyze
and
Refine
Iter
ate
Re-examine EDS
Research sources
Configuration requirements sketch
Best
concept(s)
Design for Function
Design for Assembly
Design for Manufacture
Best
configuration(s)
Pugh’s Method
Weighted Rating Method Evaluate
Product architecture
Integral / modular
Standard / special purpose
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Summary
• Product architecture design determines the type and number of components,
their arrangement, and their relative dimensions.
• Part configuration design determines the type and number of geometric
features, their arrangement, and their relative dimensions.
• Standard part configuration design involves determining part type and relative
dimensions.
• Part features include: walls, ribs, projections, fillets, bosses, rounds, cylinders,
tubes, cubes, spheres, holes, slots, notches, chamfers, and grooves.
• Configuration requirements sketches can be used to develop alternative part
configurations.
• Configuration analysis includes considerations of function, assembly and
manufacture.
• Alternative configurations may undergo significant revision during successive
iterations.
• Solid-modeling CAD systems can be useful during configuration design as
well downstream in parametric design and or manufacturing.
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Parametric Design
Information flow thru phases
Parametric design of a bolt
Systematic parametric design
Summary
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Example: Parametric Design of a Bolt
d
LT
L
shan
k
hea
d
thread
s
tensile
force
Mode of failure under investigation: tensile yielding
Configuration sketch
How fail?
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What steps did we just take to “solve” the problem?
• Reviewed concept and configuration details
• Read situation details
• Examined a sketch of the part – 2D side view
• Identified a mode of failure to examine – tensile yield
• Determined that a variable (proof load) was
“constrained”
• Obtained analytical relationships (for Fp and A)
• “Juggled” those equations to “find” a value – d Equation “juggling” is not always possible in
design, especially complex design problems.
(How do you “solve” a system of equations for a
complex problem?)
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Formulating the parameters
Determine the type of parameter
Solution evaluation parameters SEPs
Design variables DVs
Problem definition parameters PDPs
Identify specifics of each parameter
Name (parameter/variable)
Symbol
Units
Limits
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Example SEPs
Select one or more “engineering characteristics”….to measure performance … i.e. Solution Evaluation Parameters
Pong ball launcher – SEPs
Distance (ft/sec, init velocity)
Accuracy (points for 10 balls)
Launch rate (balls/min)
Cost of system ($)
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“Formulating” the formulas (constraints)
Recall from sciences:
physics, chemistry, materials
Recall from engineering:
statics, dynamics, fluids,
thermo, heat transfer, kinematics,
machine design, circuits
mechanics of materials
Conduct experiments
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Example Constraints
Ball launcher
Max motor power available?
Human factors (user, mfr, repair)?
Size (H, W, L)?
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Analytical relationships
ioio
oi
tf
NNddSR
PP
rVNF
IMFrT
maFmaF
//
0
0
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Assess Satisfaction
Determine satisfaction
Multiply by importance weight
Does “form” satisfy “function?”
Is “design” the best?
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Systematic Parametric Design
Determine best alternative
Predict Performance
Check Feasibility: Functional? Manufacturable ?
Generate
Alternatives
Formulate
Problem
Analyze
Alternatives
Evaluate
Alternatives
Re-Design
Re-Specify
Select Design Variables
Determine constraints
Select values for Design Variables
all
alternatives
feasible
alternatives
best alternative
Refine
Optimize
refined best alternative
read, interpret
sketch
restate constraints as eq’ns
guess, ask someone
use experience
calculate
experiment
calculate/determine satisfaction
select Qmax alternative
improve “best” candidate