introduction to engineering design
DESCRIPTION
Engineering DesignTRANSCRIPT
What is an engineer?
What is engineering design?
Difference between engineering analysis and engineering design
What is the difference between product and process design?
What is the context of the design process?
Engineering design vs. design in other academic disciplines?
Why design?
Foundational Questions
What is engineering? “…the purposive adaptation of means to reach a pre-conceived end…” E.T. Layton, Jr.
“Technological activity to solve problems”
Human creativity
The use of technology to make products and systems
for societal benefit.
Engineering as a “Thinking-Making” Activity
What role of engineers in history? Irrigation and farming equipment, dam projects, water and wind mills building construction,
the Pyramids, the Great Wall, Leonardo’s contraptions, the printing press, the Wright brothers’
aircraft, fermented beverages, nuclear power, the Space Shuttle, Tacoma Narrows Bridge,
electric appliances, petroleum products, pharmaceuticals.
When did the engineering disciplines begin? 3000 BC Civil
1000 BC Military
AD 1700 Mechanical
AD 1800 Materials
Agricultural
Electrical
AD 1900 Chemical
Aerospace
AD 1950 Computer, Nuclear, Biochemical
Biomedical
Historical Questions
[ Holtzapple, M. T., Reece, W. D. (2005) ]
Product Realization Process
(PRP) • Engineering design
• Industrial design
• Production planning
• Manufacturing
• Distribution
• Sales
• Marketing
• Service
• Disposal
• Environmental assessment
• Stakeholder involvement
• Engineering design
• Construction planning
• Construction
• Effectiveness monitoring,
control, and maintenance
Problem solution
Problem identification
Synthesis
Analysis
Application
Comprehension
Solution
Engineering as Problem Solving
[ Holtzapple, M. T., Reece, W. D. (2005) ]
Orderly stepwise approach
Qualitative/general
quantitative/detailed
Process of Engineering
Think
Sketch
Make
Show
Think
Sketch
Make
Show
Analysis
Physics
Chemistry
Biology
Economy
Environmental
Ethics
Use Use
Math
Law
Politics
Brainstorming
Rule : There are
no stupid ideas
in a brainstorm
Process of Engineering Need
Analysis of Problem
Statement of Problem
Conceptual Design
Selected Schemes
Embodiment of Schemes
Detailing
Working drawings, etc.. [ Ferguson, E. S. , (1992) ]
• What is a product or process? Object produced, substance, material, arrangement, service, step sequence,
manufactured good, transformation of something, system, organization.
Example 1 : Water bottle made of biodegradable plastic
Example 2 : Biorefinery for ethanol production from biomass
Example 3 : Bio-repellant coatings
Example 4 : Flood control structures
Example 5: Contaminant/pollutant removal systems
Example 6: Structures for wildlife migration
Examples in bio-based products
Materials and Chemicals
- Wood
- Wood-based
- Paper
- Biodiesel fuel
- Bio-based plastics
- Biodegradable plastics (e.g. drink bottles)
- Ethanol (bio-based)
-
-
Examples in bioprocessing
Utilization of living cells or their components to obtain
desired products
- Ethanol fermentation from corn
- Antibody production via fungal fermentation
- Anaerobic digestion to treat wastewater
- Biodegradable plastics (e.g. PLA) production from corn
- Enzymatic hydrolysis to produce sugar from cellulose
-
-
What is engineering design?
• Engineering design is the set of decision-making processes
and activities used determine the form of an object given the
functions desired by the customer. (Gov of MA)
• 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 basic science
and mathematics and engineering sciences are applied to
convert resources optimally to meet a stated objective. Among
the fundamental elements of the design process are the
establishment of objectives and criteria, synthesis, analysis,
construction, testing and evaluation. (ABET)
Context of Design Historical
Precedents
Ideal Society
Projections
Cosmological
Global
Regional
State
City
Ward
House
Person
Bodypart
Organ
Cell
Organelle
Molecular
Atomic
Government
Commercial
Industry
Military
Non-profit NGO’s
Biology
Chemistry
Physics
Mathematics Family
Product Design
• New products are critical for corporate
prosperity
• Approximately 33% of revenues come
from products that did not sell 5 years ago
• Successful new products are profitable – Median achieve 33% ROI or better
– Median have payback of 2 years or less
– Median achieve market share of 35%
• Significant R&D expenditures and
investment
Environmental Design
• Changing human needs mean the need
for the design of new infrastructures
• Design with a focus on natural processes
• Designs should mimic nature – i.e., self-
adaptive, self-sustaining, and resilient
Engineering Design vs Engineering Analysis
• Engineering analysis: Predicted behavior is the solution
to an analysis problem
– Formulating
– Solving
– Checking
• Engineering design: – Formulating
– Generating
– Analyzing
– Evaluating
Issues in design Utility and cost
Single and multi-functionality
Batch or mass production
Patents
Aesthetics
Integrity of product (wholeness)
Whole life-cycle planning
Health effects and safety
Recycling and disposal
End of product life and replacement issues
Failure modes
Effects on society
Ethical issues design
Philosophical and practical ethics
Codes of Ethics
- Health and welfare of humans and nature
- Informing client/employers of consequences
- Statements and information in truthful manner
- Treating people fairly (avoiding conflict of interest)
- Limits of professional competence
- Building professional reputations according to merits
- Continuing professional development
- Issues with intellectual property.
Issues
Life systems preservation
Maintenance of quality of life
Maintaining high standards of personal and professional conduct
Managing intra-professional customs, identifiers, habits, and limits.
[ SSL (2004) ]
Economic analysis
What is the relevance of economic analysis to design?
Economic assumption : Measure of value is “monetary”
Process cost in context of the company
Reporting costs, financial status, and transactions.
Value today, value tomorrow.
Material cost, labour cost, indirect cost
Manufacturing cost, storage cost, transport cost
Product cost scaling and correction factors
Statistical analysis
What relevance is statistics to design?
Statistical focus : “The one and the many”
Measures of central tendency
Measures of variation
Probability
Uncertainty analysis
Linear regression
Six sigma quality concept
Optimization and development of designs
Statistics in process control for quality
AspenTech HYSYS Modeling Code
• Menu driven, Mouse driven.
• Flowsheets, Modular units.
– Mixers, Reactors, Flash separators,
Distillation units, Heat exchangers.
• Reaction databases.
• Chemical property calculations.
• Species, Mass, Momentum, Heat Balances.
• Equipment Sizing.
• Economic calculations.
• Optimization.
CAD, MAPWindow/ArcGIS, WAM,
HEC-RAS
• CAD – develop engineering drawings
• MAPWindow/ArcGIS – work with mapping
systems for various geographical analyses
• WAM – one of many models for watershed
assessments
• HEC-RAS – a model for water flow in open
channels
Introduction to Engineering Design Notes of S. Takagaki, H. P. Huang, S. Ramaswamy 30
Minnesota context
Environmental analysis and design;
• Assessment of impaired waters – water quality
• Wetland loss mitigation
• Stormwater control and mitigation
• Drainage of lands for food production and
development
• Liquid and solid waste treatment
References
deCamp, L. Sprague, (1963) The Ancient Engineers, Bantam books Ferguson, E. S. , (1992) Engineering and the Mind’s Eye, MIT Press, Cambridge. Cussler, E.L., Moggridge, G.D. (2001) Chemical Product Design, MIT Press, Cambridge Holtzapple, M. T., Reece, W. D. (2008) Concepts in Engineering, 2nd Edition, McGraw-Hill. also Holtzapple, M. T., Reece, W. D. (2005) Concepts in Engineering, McGraw-Hill. Kangas, P.C., Ecological Engineering, Principles and Practice, Lewis Publishers, 2004 Ogot, M. G. Okudan-Kremer, Engineering design: a practical guide, Togo Press, LLC. 2004, 544 pages. Seider, W. D., Seader, J. D., Lewin, D. R. (2004) Product and Process Design Principles, Second Edition, Wiley. Smith, R. (2005) Chemical Process, Wiley.
Assignment 1 – Bioproducts and bioprocessing students
1. Search through issues of “Inventing Tomorrow” for articles on product and process design. Read and make notes, especially those related to bio-based products and processes. List your favorite three examples and explain their design process, for example: what is the problem? What are the alternative solutions? Why they choose the one and how do they do that?
2. Find library resources related to chemical and physical properties. find the flash point of ethyl alcohol and propylene
- CRC Handbook of Chemistry and Physics - Perry’s Chemical Engineers’ Handbook. 3. Find (free) websites which catalog Material Safety Data
Sheets (MSDS) and find an entry for isopropyl alcohol and propylene. Also check other safety data archives esp. governmental.
Assignment 1 – EEE students 1. Search through issues of “Transactions of the American
Society of Agricultural and Biological Engineers” , “Applied Engineering in Agriculture” , and “Journal of Ecological Engineering” for articles on the design of systems for water quality improvement, flood control, etc. Read the abstracts for these articles and make notes. List your favorite three examples.
2. Find website resources related to chemical and physical properties of soils, geological materials, and water.
3. Go to the MnDNR website to find out about the waters of the state. Find out how many lakes and miles of rivers/streams we have in Minnesota. How much is the mean annual precipitation, and how much of the water flows out of the state? How many of the waters of the state are known to be impaired (see MPCA website, http://www.pca.state.mn.us/water/tmdl/index.html)