design functions and solutions - me 2110: creative decisions and...
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Design Functions and Solutions
C h r i s t o p h e r S a l d a n a , P h . D .W o o d r u f f S c h o o l o f M e c h a n i c a l E n g i n e e r i n gG e o r g i a I n s t i t u t e o f T e c h n o l o g yA t l a n t a , G e o r g i a , U S A
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Phases of DesignCustomer
• Understand the Design Process
Specification Development• Specification of Information
Conceptual Design• Specification of a Principle• Functional Decomposition• Generate Concepts• Concept Evaluation• Concept Selection• Preliminary Design/Embodiment
Detail DesignSpecification of Production
• Process Planning
Manufacture
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Concept Generation/SelectionCreating, screening, scoring alternatives
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5
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Apple’s design approachPixel-perfect design mockups
10 to 3 to 1 design down-select
Paired design meetings – brainstorming/production
Pony meetings – design review for managers
Integrated business process design
Customer experience focus
Alternatives (Project Purple - iPhone)
Walters, Helen. "Apple's Design Process, Bloomberg Businessweek." (2008).
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Alternatives (Project Purple - iPhone)
Samsung Electronics Co., Ltd., et al. v. Apple Inc. (2016), SCOTUS Case 15-777.Kahney, L. (2013). Jony Ive: The Genius Behind Apple's Greatest Products. Penguin.
Kahney, L., ”Birth of the iPhone”, Cult of Mac, June 26, 2017
Initial Concepts
‘Sandwich’ ‘Extrudo’
Alternative 1 - P1 design
Alternative 2 - P2 design
Design IterationsP2 design prototypes P2 refined designs
Concept screen,
prototype and score
Make, iterate
and finalize
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Identify design functions and sub-functions (Function Tree)
Identify solutions for different functions/sub-functions (Morphological Chart)
Combining individual solutions to generate conceptual alternatives
Learning Objectives
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Consider what not how• Draw a box• Identify a verb• Identify a noun(s) on which the verb acts
Follow flows of energy, material, and information/signals. Consider interactions with external energy, materialBreak the function down as finely as needed• Fine enough to address customer needs• Fine enough for a single basic solution principle to satisfy each sub-function.
Guidelines for Functional Modeling
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Define overall functionIdentify system boundariesIdentify flows of Energy (E), Material (M), and Information (I)Identify interfacing objects that exchange E, M, or IConserve E and M
Black Box Models
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Material Flow Main Function System Boundary
Stamp Form
Length
Separate Offcuts
Check Quality
Count Squares
Combine in lots Pack DispatchMaterial
Overall Function
Loose carpet squares stamped out of the length
Carpet squares packed in lots
Function Structure
Function Block DiagramsExample: Packing of Carpet Squares
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Test Specimen (Force
Deformation)
E load
Specimen
E deformationSpecimen deformedI forceI deformationI
Change energy into
force & movement
Measure force
Measure deformation
Load specimen
I F
I ∆
E load
I
Specimen E deformationSpecimen deformed
Function Block DiagramsExample: Material Testing Machine
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Change energy into
force & movement
Measure force
Measure deformation
Load specimen
I F
I ∆
E load
I
SpecimenE deformationSpecimen deformed
Hold specimen
Adjust energy flow
Compare target with actual
values
Amplify measurements
E auxil.
I F targetI ∆ target
E loss
Function Block DiagramsExample: Material Testing Machine
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Determining Functional Variants
Shape DoughShaped Dough
ElossDoughAdditives
I
E
1 2 3 54 6
7
1 2 3+4 5 6
7
Feed in1
Prepare2
Dispense3
Shape4
Separate5
Feed Out6
Return7
Dough ShapedDough
Waste Waste WasteAdditives
1 2 3+4+5 6
7
1 2+3 4+5 6
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Overall function and function structure variants of a dough-shaping machine for the manufacture of biscuits (in respect of the main flow only)
Example: Dough Shaping Machine
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Function Tree
Function
SF1 SF2 SF3
SF11 SF12 SF13 SF21 SF22 SF23 SF31 SF32 SF33
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Function Tree Example
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Developing Solution Principles
Sub-FunctionPhysical Effect
(Independentof Solution)
Physical Principle(Sub-function
& Physical Effect)
Solution Principle(Physical Principle &
form Design Features)
TransferTorque
TT
Amplifymuscular
force
FA FB
Closecontact
when T≥Ta
LL
T
TransferTorque by
FrictionFT=FF=µFN
TT
AmplifyMuscular
Force by LeverFB=FA(a/b)
FA FB
Close Contactby Expanding
Mercury∆L=(α)(L)(∆T)
LL
T
FF=µFN
Friction
bFB=aFA
Lever
∆L=(α)(L)(∆T)
Expansion
Fulfilling sub-functions by solution principles built up of physical principlesand form design features
FF
FN
VFBFA ba
Friction Surface
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Solution Principle Matrix
Sub-func.
Solution Principles(Idea/ Source)
1Idea: (Mechanical)Rub on Material
(Mechanical)Squirt Material
(Mechanical)Place Material(like Letterset)
(Chemical)Change paper composition
Source: Standard product Team #2 Letterset Acid etching
1(Chemical)
Change paper color(like Litmus paper)
(Electrical)Burn paper (spark)
(like old fashioned stripchart recorders)
(Electrical)Electrify Paper (glow
discharge)
(Electrical)Static charge to hold mark
on(like Etch-A-Sketch)
Fisher Scientific Team #3 Team #1 Etch-A-Sketch
1(Thermal)
Burn paper (flame)(Thermal)
Heat paper (glow discharge)(Thermal)
Melt on Mark(Magnetic)
Attach magnetic material(like refrigerator magnets)
Team #2 Team #2 Wax seals Gift Store
1(Biological)
Grow bacteria, fungus(Biological)
Modify (digest?) paper(Optical)
Change light properties ofpaper (reflectance, polarity)
(Optical)Change light (hologram)
Team #2 BioTech Magazine Team #2 Team #2
2(Mechanical)
Rub off Material(Mechanical)
Take off material(Mechanical)Cover mark
(like white out)
(Chemical)Change paper composition
Standard product Team #2 Team #1 Team #2
2(Chemical)
Change paper color(like dying fabric the same
color as a stain)
(Chemical)Change mark (e.g., bleach)
(Electrical)Burn off mark (spark)
ETC.
Team #1 Team #2 Team #2
Example: Design of a PencilSub-function 1: Make an Erasable MarkSub-function 2: Erase an Erasable Mark
Sub-func.
Solution Principles
(Idea/ Source)
1
Idea: (Mechanical)
Rub on Material
(Mechanical)
Squirt Material
(Mechanical)
Place Material
(like Letterset)
(Chemical)
Change paper composition
Source: Standard product
Team #2
Letterset
Acid etching
1
(Chemical)
Change paper color
(like Litmus paper)
(Electrical)
Burn paper (spark)
(like old fashioned strip chart recorders)
(Electrical)
Electrify Paper (glow discharge)
(Electrical)
Static charge to hold mark on
(like Etch-A-Sketch)
Fisher Scientific
Team #3
Team #1
Etch-A-Sketch
1
(Thermal)
Burn paper (flame)
(Thermal)
Heat paper (glow discharge)
(Thermal)
Melt on Mark
(Magnetic)
Attach magnetic material
(like refrigerator magnets)
Team #2
Team #2
Wax seals
Gift Store
1
(Biological)
Grow bacteria, fungus
(Biological)
Modify (digest?) paper
(Optical)
Change light properties of paper (reflectance, polarity)
(Optical)
Change light (hologram)
Team #2
BioTech Magazine
Team #2
Team #2
2
(Mechanical)
Rub off Material
(Mechanical)
Take off material
(Mechanical)
Cover mark
(like white out)
(Chemical)
Change paper composition
Standard product
Team #2
Team #1
Team #2
2
(Chemical)
Change paper color
(like dying fabric the same color as a stain)
(Chemical)
Change mark (e.g., bleach)
(Electrical)
Burn off mark (spark)
ETC.
Team #1
Team #2
Team #2
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Different Principles to Store Energy
Different working principles to satisfy the function “store energy” by varying the type of energy.
1
2
3
4
5
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Mechanical Hydraulic Electrical Thermal
FlowingLiquid
HeatedLiquid
SuperheatedSteam
Type of EnergyWorking Principle
Battery
Capacitor(Electric Field)
C
Pot. Energy
mh
Hydraulic reservoire.g, Piston
Moving Massm
v
MassM, s, T
Flywheelω
J
+V-
J
vωWheeloninclinePlane
Liquid Res. Pot. E.
h
F
Spring Other SpringsComp. GasF
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An Old Competition
20 ftSt
art L
ine
6.25 ft
12.5 ft
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Function Tree Diagram
Place Masson Target
Moveto
Target
Navigateto
Target
Brake onTarget
GeneratePower
TransmitPower
HitTarget
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Going from concept to physical reality
Morphological Chart
Generate Power
Transmit Power
Brake on Target
Move to Target
Navigate to Target
Gravity Mouse Traps
Car Hit by Trap Rip Cord Effect Ramp Catapult
Friction String Break Anchor Rubber Stopper Weighted Skid
Equal Size Wheels Larger Front Wheels
Rolling Sliding Projectile Launch
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Combining Solution Principles
Sub-Functions
\Solutions 1 2 j m
1 F1 S11 S12 S1j S1m2 F2 S21 S22 S2j S2m
i Fi Si2 Sij Sim
n Fn Sn1 Sn2 Snj Snm
Combination of Principles1 2Combination 1: S11 + S21 + … + Sn1Combination 1: S11 + S22 + … + Sn2
Sub-Functions
\Solutions
1
2
(
j
(
m
1
F1
S11
S12
S1j
S1m
2
F2
S21
S22
S2j
S2m
(
(
(
(
(
(
i
Fi
Si2
Sij
Sim
(
(
(
(
(
(
n
Fn
Sn1
Sn2
Snj
Snm
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Summary – Function Tree
Elements• List critical functions and sub-functions• Sub-branches from a function or sub-function must
number 2 or greater• Do not specify specifications that are dependent on
design decisions, design choices come later!
Describing this figure in text• Describe the contents, not the tool itself!• What are critical functions?
See Ch. 3 in book for detail
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Elements• Mechanisms for lowest level elements of
FT, match one-to-one• Diagrams to depict mechanisms• Labels to briefly name mechanisms
Describing this figure in text• Highlight key mechanisms/functions• Use a selection matrix to identify
mechanisms used in different designs• Use different mechanisms in designs
Summary – Morphological Chart
See Ch. 5 in book for detail
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Identify design functions and sub-functions (Function Tree)
Identify solutions for different functions/sub-functions (Morphological Chart)
Combining individual solutions to generate conceptual alternatives
Learning Objectives
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Other Morphological Chart Examples
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Function Structure with Auxiliary Functions
Material Flow Main Function System Boundary
Signal Flow Auxiliary Function
Stamp Form
Length
Separate Offcuts
Check Quality
Count Squares
Combine in lots Pack DispatchMaterial
Send Signal to combine
squares into one lot
Supply packing material
Remove rejects
Remove offcuts
Function Block DiagramsExample: Packing of Carpet Squares
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Example: Harvest Potatoes
Potatoes
Reject Potatoes
Leaves
Course Particles
Lift Sift Separate Separate Sort Collect
Change
Change
Change
Fine Particles
Potatoes inthe ground
E2
E1
E2
E2
I
Harvest PotatoesPotatoes inthe ground
Potatoes
Reject PotatoesLeavesSoil, etc.
I
E
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Example: Harvest Potatoes
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Example: Additive Manufacturing
Williams, C.B., Mistree, F. and Rosen, D.W. (2011), “A Functional Classification Framework for the Conceptual Design of Additive Manufacturing Technologies”, Journal of Mechanical Design, Vol. 133 No. 12, p. 121002.
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Example: Additive Manufacturing
Williams, C.B., Mistree, F. and Rosen, D.W. (2011), “A Functional Classification Framework for the Conceptual Design of Additive Manufacturing Technologies”, Journal of Mechanical Design, Vol. 133 No. 12, p. 121002.
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Example: Additive Manufacturing
Williams, C.B., Mistree, F. and Rosen, D.W. (2011), “A Functional Classification Framework for the Conceptual Design of Additive Manufacturing Technologies”, Journal of Mechanical Design, Vol. 133 No. 12, p. 121002.
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Example: Additive Manufacturing
Williams, C.B., Mistree, F. and Rosen, D.W. (2011), “A Functional Classification Framework for the Conceptual Design of Additive Manufacturing Technologies”, Journal of Mechanical Design, Vol. 133 No. 12, p. 121002.