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Dr. Marwan Affandi 2010 Dr. Marwan Affandi 2010

MACHINE DESIGN ENT 256/4

MARWAN AFFANDI SCHOOL OF MECHATRONICS

UNIMAP Email: [email protected]

Telp: 9798300 Hp: 0124225604


TEACHING PLAN

• WEEK 1 & 2:

• Introduction To Design Process

• DESCRIBE Design process,

• DISCUSS and ILLUSTRATE Design product,

• EXPLAIN Design considerations and Design phases,

• DISCUSS Designing a product


Content

• Introduction to Design

Process

• Design Product

• Mechanical Engineering

Design

• Design Considerations

• Phases in Design

• Designer Responsibilities


INTRO TO DESIGN PROCESS

• To design is either to formulate a plan for the satisfaction of a specified need or to solve a problem.

• Design is an innovative and highly iterative process.

• It is very rare that a product can be developed instantly unless it is just replicated from another.

• Design is also a decision making process.


• Designing is an activity directed toward an anticipated future goal.

• An optimal product must be delivered in good time and at acceptable cost.

• Creativity requires open mindedness.

• Students cannot become creative if they just follow what is instructed to them. They should offer their own opinion freely.


• Some people are just happy with their obselete designs; few others are aggressive to go ahead with their unusual designs.

• Look at the picture in the following pages. They are biped walking and running robots designed in Technische Universität München, Waseda University and Honda, respectively.

• Can you state various fields that are involved in designing these robots?



Two bipedal

humanoid

robots:

Johnnie (left)

and Lola

From Zimmermann,

Zeiding, and

Behn (2009)


Wabian-2R (Waseda

University) From Chevallereau et al., (2009)

ASIMO humanoid robot

(Honda)

• Designing a humanoid robot is very difficult. There are various knowledges needed, among others:

• Robotics

• Electrics

• Electronics

• Kinematics and dynamics

• Fluid mechanics

• Material science

• Biomechanics

• Machine vision


Design Product


Requirements:

Functional

Safe

Reliable

Competitive

Usable

Manufacturable

Marketable

This will be valid

regardless of who

build it or use it.

Design Product

• Observe the balloon in the previous page. Do you think that it has fulfilled the requirements for a good design product?

• Think several good products that you have seen or known around you and discuss them in your group.

• Write a short report on a good product that you know.


Design Product


Robot fuel filling station

From Wolf, Steinmann, and Schunk (2002)

Design Product

• The picture in the previous page shows a robot refuelling a car.

• Can you describe how it works?

• Do you think that it has fulfilled the requirements for a good design product?

• Do you think it is practical for us?

• Consider various aspects that you may feel important regarding this robot.


Dr. Marwan Affandi 2010

Case study • The best design is one which is simple but

useful when it is implemented into a product.

• A design can be complicated but the simpler one is better.

• Bread clip, paper clip, and squeeze ketchup container are examples of simple designs that every one knows.

• Looking at those product, we may wonder why just those simple designs are very useful to our life.



Case study

• Bread clip (bread tab, bread crimp, bread tie) or its brand name Kwik Lok is used to close a plastic bag for holding bread or any other food products.

• When the bag has been opened, it can be easily reclosed by just clipping the clip.

• Apart from clipping the bag, information on the price of the product and its expiry date can be printed on the bread clip; this feature increases its usefulness.



Case study

• The bread clip was invented by Floyd G. Paxton in 1952.

• The company where he worked produced equipment used for nailing wooden crates.

• Since sales were expected to decrease, the company needed a new product that would be commercially viable.

• While flying on an airliner, Paxton opened a bag of peanuts and realized that there was no way he could close up the bag.


http://en.wikipedia.org/wiki/Floyd_Paxton

http://en.wikipedia.org/wiki/Floyd_Paxton


Case study • From his wallet he found an expired credit

card and hand-carved his first bag clip with his small pen knife.

• When a fruit packer, Pacific Fruit, wanted to replace rubber bands with a better bag closure for its new plastic bags, Paxton remembered his bag of peanuts.

• He hand-whittled another clip from a small sheet of Plexiglas.

• He then designed and constructed a manual machine to manufacture the clips.



Case study

• Later, a high-speed die punching machine was developed, enabled the clips to be mass produced.

• Nowadays, the clips are manufactured by the Kwik Lok Corporation based in Yakima, Washington with manufacturing plants in Yakima and New Haven, Indiana.

• As far as Kwik Lok is concerned, both their corporation and the bread clips they make share the same name.


http://en.wikipedia.org/wiki/Yakima,_Washington

http://en.wikipedia.org/wiki/Yakima,_Washington

http://en.wikipedia.org/wiki/New_Haven,_Indiana

http://en.wikipedia.org/wiki/Indiana


Case study

• A paper clip is usually a thin wire in a looped shape made from steel, some other metal or plastic.

• The clip has the elasticity and strength of the materials of its construction to compress and therefore holds together two or more pieces of paper by means of torsion and friction.

• The inventor of the first paper clip was accredited to Johan Vaaler from Norway.


http://en.wikipedia.org/wiki/Metal

http://en.wikipedia.org/wiki/Plastic

http://en.wikipedia.org/wiki/Paper

http://en.wikipedia.org/wiki/Torsion_%28mechanics%29

http://en.wikipedia.org/wiki/Friction


Case study

• However, the first patent for a bent wire paper clip was awarded in the United States to Samuel B. Fay, in 1867.

• This clip was originally intended primarily for attaching tickets to fabric, although the patent recognized that it could be used to attach papers together.

• Vaaler probably did not know that a better product was already on the market, although not yet in Norway.



Case study

• His version was never manufactured and never marketed, because the superior Gem (earlier paper clip) was already available.

• His design was obviously impractical.

• Without the two full loops of the fully developed paper clip, it was difficult to insert sheets of paper into his clip; see the illustration in the following slide.



Case study

• However, the myth that he was the inventor of paper clips found its way into history of technology and much of the international literature on paper clips.


http://en.wikipedia.org/wiki/File:Vaaler_clip.jpg


Case study


To recognize its

importance,

a giant paper

clip was built

in Sandvika,

Norway.

http://en.wikipedia.org/wiki/File:BI-binders.jpg


Case study

• Ketchup and tomato sauce can be stored in glass bottles.

• However, pouring the content of the bottle is often uneasy particularly when the sauce or the ketchup is very thick.

• The high viscosity of the liquid or semi solid-liquid makes it difficult to flow.

• Here comes the invention of a squeeze ketchup container.



Case study

• While it is not glamorous, the design is superbly ergonomic.

• The compliant wall is just the right thickness to make squeezing effortless.

• Since the wall is translucent, the user can see how much ketchup is left inside.

• Its small pointed spout will dispense the content exactly where it is needed.

• If the content is not much left, just thump the base hard to force it to flow out.


Mechanical Engineering Design

• Mechanical engineering design involves all the disciplines of mechanical engineering

• As an example, a simple journal bearing involves fluid flow, heat transfer,

friction, energy transport,

material selection,

thermomechanical

treatments,

statistical descriptions…

• What does this means?



• A journal bearing is mounted on a shaft. To reduce friction between the bearing and the shaft, the bearing’s surface must be lubricated.

• The lubricant also absorbs heat dissipated due to the friction that takes place. Here, there is energy transport to the lubricant.

• The bearing must endure high pressure exerted by the shaft. The material of the bearing must be hard enough to ensure long term application.



• Here, the bearing’s material must be treated thermomechanically before it can be used. Experiments are conducted extensively; results are analyzed statistically.

• Feedbacks from experiments are used to manufacture the bearings that they will perform well when they are being used.

• Here, we can see that various disciplines of mechanical engineering are involved.




Cross section of an engine



Front of a boiler burner



Boeing V76 tilt wing research rotorcratf From Seddon and Newman (2002)


Robotic Design


Left: HUBO; Right: Schematics of joints and links From Park et al. (2007)


Robotic Design


3D actuated arced feet walkers: a) Cornell biped,

b) Toddler (MIT), c) Pneu-man (Osaka Univ.),

d) Denise (Delft Univ.) From Hobbelen and Wisse (2007)

a) b) c) d)


Robotic Design


QRIO in a dance act From Vanderborght (2010)

QRIO stands for

quest for curiosity.

It was developed

by Sony in 2003.

QRIO was the

successor of AIBO,

a commercial

robotic dog.


Robotic Design


HRP-2 playing the drum From Vanderborght (2010)

HRP stands for Humanoid

Robotic Project. It was

developed by Kawada

Industries. Various

research institutes and

universities are currently

using the HRP-2.

HRP-2 can be leased for

400,000 euros for 4 years.


Robotic Design


Humanlike robots: a) Robovie II, b) Android

Repliee Q2, c) Geminoid HI-1 and its human

source From Nishio, Ishiguro and Hagita (2010)

a) b) c)

Design Considerations

• Functionality

• Distortion/deflection/stiffness

• Strength/Stress

• Corrosion

• Wear



• Safety

• Reliability

• Manufacturability

• Utility

• Cost



• Friction

• Weight

• Life

• Noise

• Styling


Space shuttle main

engine (Mattingly, 2006)


• Shape

• Size

• Control

• Thermal properties

• Surface


Phases in Design

• If you look at a product, consider the following questions:

• What is the design process?

• How does it begin?

• Does the engineer simply sit down at a desk with a blank sheet of paper and jot down some ideas? What happens next?

• What factors influence the decisions?

• How does the design process end?


Phases in Design


Figure 1

Phases in Design • The complete design process, from start to

finish, is often outlined as shown in Fig. 1 (Budynas and Nisbeth, 2008).

• The process starts with an identification of a need and what to do about it.

• Usually we need many iterations before ending the process, presenting the plans that has satisfied the need.

• It is important to plan our design properly to reduce unnecessary iterations.


Phases in Design • Recognizing the need and phrasing it are often

uneasy. The need may be vague because we feel dissatisfied or sense that something is not right. But at least the need is there.

• For example, we may feel that the vacuum cleaner is not very good because it is quite noisy and it cannot suck the dust properly.

• Here, we identify a need for a better vacuum cleaner.


Phases in Design • After identifying the need, we must define the

problem. The problem must be specific and must include all the specs for the object to be designed.

• The specs define the cost, the noise level, the sucking pressure, the operating temperature, the dimensions etc.

• Here, the designer must equip himself with knowledge needed in order to clearly define the problem.


Phases in Design • Next, we synthesize or put together a scheme

connecting possible elements. This process is sometimes called the invention of the concept or concept design.

• Various schemes must be proposed, investigated, and quantified in terms of standards parameters.

• Schemes are then analyzed to assess the system performance.


Phases in Design • Schemes that do not satisfy the requirements

or pass the analysis are revised, improved, or discarded.

• Potential schemes are optimized to determine the best performance of which the scheme is capable.

• Here, these two phases, synthesis and analysis and optimization are closely and iteratively related.


Phases in Design • In order to conduct the analysis and

optimization phase we must construct mathematical models.

• We hope one of the model can simulate the real physical system very well.

• Here, we evaluate the model, which will prove whether the design is successful or not.

• We also must test the prototype in the laboratory or in the field.


Phases in Design • The last phase is to communicate the design

to others or to make presentation about it.

• Why must we waste our time and effort if we do not want to make it publicly known?

• Of course we only let other people know about the design if we are sure that it is worth.

• We may want to get a patent for our design in order to commercialize it.


Design Process

• Design process is not unique. Different people have different ideas.

• As mentioned by Norton (2009), a design process consists of ten steps as follows:

1) Identification of need

2) Background research

3) Goal statement

4) Performance specification

5) Ideation and invention


Design Process

6) Analysis

7) Selection

8) Detailed design

9) Prototyping and testing

10) Production

• In general, these steps will hold for many designs although some steps may not be detailed in a simple design. The designer just jumps up from one step to another.


Design Process

• Remember that design process is iterative. It is very rare that people do not make any mistake to solve the problem and find the solution straight forward.

• In general, there is some flaw in one step. Here, we rectify it, find the correct solution. We iterate it, go back to the point where it is wrong. We may do the iteration several times until we complete the design process.


Design Process • A designer has the following responsibilities:

1) Understand the problem

2) Identify the known

3) Identify the unknown and formulate

4) State all assumptions and decisions

5) Analyze the problem

6) Evaluate solution

7) Present solution


Designing A Cleaning Machine

• In the following slides an example of designing a cleaning machine using the design process is shown.

• The example is not realistically enough and may lack of proper data.

• However, this example is expected to open the students’ minds in understanding the design process.

• Actual design is quite complex since it needs various disciplines of knowledge.


Identification of need

• Suppose that somebody says: ”We need a good robot to clean the floor.”

• This is a problem statement. It is typically brief and lacking in detail.

• But at least we know from the statement that there is a need for a robot.

• Whether we do need a robot or some thing else which can function similarly does not matter at this stage.


Background research

• This step is the most important phase in the design process. But many people often neglect this.

• We should find out if the cleaning machine is already available in the market. If it is, why should we design it? It is much cheaper to buy than to develop a new one.

• Remember: Don’t reinvent the wheel!


Background research • However, we can still design our robot

because we want to develop our skill. In this case, we can buy a cleaning machine, disassemble the components, learn its mechanism, and try to design a new one.

• The process we do can be termed as reverse engineering. However, we must be careful about the machine’s patent. So, our design should be different from the existing one.


Background research • Where will we find information for our

research? We can find it in books, engineering journals, brochures, magazines, or in internet.

• Internet can provide us with a lot of information; most is free. However, we must be careful in extracting the information, separating the garbages from the useful ones. Two useful sites are http://www.howstuffworks.com and http://www.inventorsabout.com.


http://www.howstuffworks.com/

http://www.inventorsabout.com/

Goal Statement • If we have understood the background of the

problem area, we are ready to recast the problem statement into a more coherent goal statement.

• The goal statement should have three characteristics: it should be concise, be general, and be uncolored by any term that predict a solution.

• The goal statement should be functional visualization, meaning to visualize its function.



Goal Statement • Now, instead of Designing a good robot to

clean the floor, as our problem statement, our goal statement maybe better phrased as Designing a means to clean the floor.

• The old problem statement has a colored word a good robot.

• This will trap us in the thought of a device that is sophisticated and moves awkwardly around a room.



Goal Statement • It is necessary to avoid such image in order to

be successful in the next step: ideation and invention.

• What comes to your mind various ways to clean the floor?

• You should not limit your creativity by just thinking an object such as a robot to clean the floor.


Performance Specifications

• Performance (task) specifications can be formulated once the background is understood and the goal has been clearly stated.

• Remember that these are not design specifications!

• Performance specs define what the system must do while design specs define how the system must do it.




• The performance specs will carefully define and constrain the problem so that it both can be solved and can be shown to have been solved after the fact.

• If the specs are not deep enough, the design produced may not satisfy the need. However if the specs are too wide, it maybe quite difficult to complete the design in a stipulated time.




• For our design, some performance specs maybe like these:

• Device must have self-contained power supply.

• Device must cost less than RM 1000.

• Device should be able to clean a floor area of 20 m2 in less than 10 minutes.

• Device must not emit noise greater than 75 dB at 5 m.


Ideation and Invention • While many people do not always have bright

ideas in their minds, some people seemed to be born with almost inexhaustible ideas.

• Remember Thomas Alva Edison who had invented many things, ranging from electric bulb to phonograph to motion picture camera? He had 1093 U.S. patents in his name!

• Or Leonardo da Vinci (1452-1519), maybe the greatest scientist ever born?



Leonardo da Vinci is very famous

as the painter of Monalisa.

Actually, he had designed many

mechanisms which could not be

constructed at his time because the

technology needed was not

available.

It may surprise you that he had

designed the first ‘robot’ in 1495!

He was also accredited as the

father of helicopter.

Leonardo da

Vinci


Ideation and Invention

• As quoted from Moon (2007) , Leonardo da Vince had drawn many figures for various machines such as:

• Lathe, screw cutting machine, rope making machine, needle making machine, wine and olive press, mechanical saw, crane, swing bridge, pulley systems, water power systems, and odometer cart.

• The two following slides show two of his drawings.



Preliminary of automaton: Leonardo’s design (Rosheim, 2006)


Sketch of Leonardo’s textile spinning machine (Moon ,2007)


Ideation and Invention • How is about Al-Jazari (1136-1206)? Some

historians accredited him as having laid down the foundation of automatic mechanical control perceived today

• Al-Jazari had designed various machines; the two remarkable ones were a sophisticated clock at that time and a water pump using a crank-slider-like system.

• The latter was the first known machine to use a crank.



(a) Water-powered saqiya chain device

(b) Reciprocating pump (Ceccarelli, 2010)

Al-Jazari

(a) (b)


Ideation and Invention • Al-Jazari was a very creative person.

• His book entitled:”Book of knowledge of ingenious mechanical devices” presents a whole range of devices and machines, with a multiplicity of purposes.

• There are 50 different devices mentioned in this books; they are:

Ten different clocks;

Ten designs of automata vessels dispensing wine and water for drinking sessions;




Ten designs of water dispensers for ritual ablution;

Ten fountains and musical automata;

Five different design of water raising machines;

Five miscellaneous machines.

A water clock and an elephant clock as replicated in Dubai’s Ibn Battuta mall are shown below.



(a) Al-Jazari water clock

(b) Replication of the elephant clock (Ceccarelli, 2010)

(a) (b)



• In this step, we define the design specs, how the system must do it.

• Here, we must answer the following questions:

• How can we power the machine: using battery, main electricity, or internal combustion engine?

• How can the machine move around the room?



Ideation and Invention • How can we design the absorber needed to

reduce the noise up to 75 dB?

• How can we choose the materials for the machine that it will be low cost?

• How can the machine move around the room?

• How can we design the machine that it can suck the dust or light materials in the floor?

• These are just a few questions that must be answered.




• Ideation and Invention are closely related to creativity.

• Although some people maybe born to be more creative than the others, creativity can be enhanced through various techniques such as:

a) studying other people’s work,

b) observing the nature,

c) and unlocking constraints in our minds .




• Ideation and invention consists of four sequential steps:

1) Idea generation through brainstorming, analogies, and inversion

2) Frustration

3) Incubation

4) Eureka (Flashing Idea)!



Ideation and Invention • Whatever means we use, the purpose of the

ideation is to generate ideas.

• In this step, we often find in one time that we feel ‘blank’, nothing crosses our mind. In this case we have arrived the step what is called frustration.

• Here, leave the problem. Enjoy yourself, do something else.

• Even we do not think our problem, it is still occupying our mind. This step is called incubation.



Ideation and Invention • And suddenly, an idea flashes out of our mind

that solves our problem clearly. Eureka, as Archimedes said when he leapt out from his bath tub nakedly.

• Later, we may find that there is still some flaw in our solution. In this case, just iterate the process. Go back to the step where it is wrong. Refine the solution.



Lightbulb • A light bulb can be found in almost every

house (except in regions where there is no electricity).

• Even the design looks simple, it took a long time and many people to make it in its current form.

• Thomas Alva Edison was typically accredited as the inventor of the light bulb but before him, a lot of people had contributed significantly to its development.


http://www.inventionreaction.com/inventors/Thomas-Alva-Edison


Lightbulb • The very first electric light was invented in

1800 by English inventor, Humphry Davy.

• In 1860, Sir Joseph Wilson Swan attempted to develop a practical, long-lasting form of electric light.

• He realized that carbon paper filament worked well, however did burn up relatively quickly.

• In 1877, Charles Francis Brush developed a series of carbon arcs in order to illuminate a public square in Ohio, USA.



Lightbulb • Thomas Alva Edison experimented with

thousands upon thousands of alternative filaments to find the best material for a long-lasting, high glow solution.

• In 1879, Edison finally realized that a carbon filament within an oxygen-free bulb glowed, but would not burn up for approximately 40 hours.

• Later, he invented a bulb that would not expire for over 1500 hours.



Lightbulb • In 1881, Lewis Howard Latimer patented bulb

with carbon filament.

• His work was an improvement from Edison's bulb with a new carbon filament which he patented in 1881.

• Latimer was part of Edison's research team and in 1882 began to manufacture and distribute his own carbon filaments.



Lightbulb • In 1903, Willis R. Whitney introduced a 'fix' to

the light bulb, which prevented the inside of the bulb darkened as the filament began to glow; this resulted in more vivid and bright light.

• Later, William David Coolidge invented a tungsten version of the traditional filament, which lasted longer than any other filament.

• This incandescent light bulb revolutionised the way in which we live today.



Thomas Alva Edison was an

American inventor (1847 -1931).

He invented many things; among

others: phonograph, picture

camera and durable light bulb.

He was attributed with many tele-

commnucation patents.

Edison was named The wizard of

Menlo Park by a newspaper due

to a lot of inventions he made.

Thomas Alva

Edison

Light bulb


Safety razor • Most of us are certainly familiar with a razor,

an instrument used to shave beards, moustaches or unwanted hair.

• A razor blade is a thin sharp piece of metal that is used in razor; it can be thrown away after being used several times, making it no longer sharp.

• The design of a razor blade looks very simple but it actually take many years to evolve from its initial design.

• Gilette is almost synonim with a razor blade even the brand is different.




Safety razor • A patent for a safety razor was granted to King

Camp Gilette in November 1904.

• To support himself, Gillete was as a travelling salesman.

• This work led him to William Painter, the inventor of the disposable Crown Cork bottle cap

• Painter assured Gillette that a successful invention was one that was purchased over and over again by satisfied customer





Safety razor • Gillete worked very hard several years to

implement the idea by considering and rejecting possible inventions.

• In 1895, Gillette suddenly had a brilliant idea while shaving one morning.

• It was an entirely new razor and blade that flashed in his mind—a razor with a safe, inexpensive, and disposable blade.

• It took six years for Gillette’s idea to evolve from its embryo to mature.



Safety razor • During that time, technical experts told Gillette

that it would be impossible to produce steel that was hard, thin, and inexpensive enough for commercial development of the disposable razor blade.

• Gilette had tried many times to produce a thin, sharp blade but he failed.

• The material he chose was not suitable.

• Even the industry he approached were reluctant to provide samples for him.



Safety razor • The solution to his problem came in 1901 when

William Nickerson, a MIT graduate agreed to try.

• By 1903, Nickerson had succeeded to realize Gillete’s idea.

• Production of the Gillette ® safety razor and blade began as the Gillette Safety Razor Company started operations in South Boston.



Safety razor • Sales soared when the US Government

Government issued Gillette safety razors to the entire armed forces.

• Barbers were also fond of the new razor because they could save time for shaving their customers.

• The following slide shows drawings for the patent granted to Gillete.



Analysis • In this step, you have structured the problem.

• Now, more sophisticated analysis techniques can be applied to examine the performance of the design.

• Here, we need to write the detailed design, sizing the components against failure.

• We do mathematical calculations using available formulas.



Analysis • These are just a few questions we must

answer:

• What’s the power needed to run the machine?

• What’s the pressure needed to suck the dust or any light waste in the floor?

• What’s the highest temperature the machine can endure?

• What are the optimum thickness of the cover of the machine?



Selection • Technical analysis may indicate that you have

some alternative designs.

• Here, you have to select the best available one.

• You can compare one design from the others using various techniques.

• One popular technique is decision matrix. Here, each design is judged according to some important factors. Each factor is given a weight.



Detailed design • In this step, we create a complete set of detail

drawings for each part of the design.

• All dimensions and material specs necessary to make that part must be specified.

• The drawings can be hand-made, which are tedious and time consuming.



Detailed design • Nowadays, most drawings are made using

software such as AutoCAD, Solidwork and Mdesign.

• From these drawings a prototype must be made for physical testing.

• Further iteration maybe needed if the tests find any flaw.



Prototyping and testing • Unless we develop a simple design, we cannot

be sure the correctness or viability of our design until it is built and tested.

• Therefore, we make a prototype from the design. The prototype should imitate closely the product that will result from the design.

• A prototype can be a working scale model or a full-size but simplified version of the concept.



Prototyping and testing • After a prototype is built, it is time to test it.

• Testing can be done by actuating it or measuring its important parameters.

• Testing should be done in almost similar surrounding where the actual product will be used. In many occasions, the prototype even will undergo harsher tests such as at high temperature and humidity, higher than it will supposedly experience later.



Production • The final step of the design process is

production.

• Maybe there is only a single product to produce but there will likely be thousands of products to be marketed.

• It is time now to enjoy your sheer work after enduring frustration in the first steps in designing the product. As Edison said: Genius is 1% inspiration and 99% perspiration.



Discussion • We can compare design process between Budynas

and Nisbett and Norton.

• Budynas and Nisbett is succint while Norton is more detailed.

• However, there are similarities among them.

• Both start with identification of need.

• They then move to other steps using different terms.

• Study the following slide slide to see the comparison between the two design processes.


Discussion


Identification of need Identification of need

Definition of problem Background research

Goal statement

Performance specs

Synthesis Ideation and invention

Analysis and

Optimization Analysis

Evaluation Selection

Detailed design

Prototyping and testing

Presentation Production


Discussion • Although there are many needs in our every

day life, but identifying one which is really our problem is not easy.

• We may feel discontent about something, but this is often vague, not very clear.

• If we cannot identify the true need, our solution will not be correct.

• We will waste our time to solve a problem which is not really our problem!



Discussion • Students are often trapped in the idea of

identification of need.

• Instead of thinking a small need, they often think something beyond their capability.

• It is of course good to be creative but is it really creative?

• Identification of need is just the first step of design process.



Discussion • If we adopt it as our need and later on we

cannot realize it as a complete product, we will waste our time and effort.

• The idea maybe good but our knowledge is not enough to develop it.

• Other students even do not know how to identify a need. They just take what other people have made. They are simply not creative; they do not want to think hard.



Screw mechanisms: (a) Left Leonardo’s design,

(b) Right Reulaux’s design. From Moon (2007)

Examples from students’ designs


Model of a coconut oil press machine by Logeswaran



Components of the prototype

stand Cap with pneumatic valve 4-inch diameter piston

Screw-Piston

Piping system



Assembled prototype



Manual robot by Group 3a



Autonomous robot-1 by Group 3a



Autonomous robot-2 by Group 3a


Humanoid robot modules


Subdivision of the total system From Albers, Brudniok and Ottnad (2010)


Humanoid robot modules


Design of the shoulder module From Albers, Brudniok and Ottnad (2010)

Class activity • Study the design of the coconut oil press machine

and discuss some of its design considerations in your group:

• 1. Functionality 2. Strenght/stress

• 3. Safety 4. Reliability

• 5. Manufacturability 6. Utility

• 7. Cost 8. Weight

• 9. Styling 10. Shape

• 11. Marketability 12. Control

• Any other design considerations you think maybe important?



Panoramic helmet: From Childs (2004)

a) b) c) d)


Class activity • The previous slide shows a panoramic helmet

designed by Alberto Meda and Denis.

• (a) The need: to be able to

• view behind you.

• (b) The idea: an optical link using fibre optics and lenses.

• (c) & (d) Practical sketches showing the

• concept.



Class activity • Study the design and discuss some of its

design considerations in your group:

• 1. Functionality 2. Strenght/stress

• 3. Safety 4. Reliability

• 5. Manufacturability 6. Utility

• 7. Cost 8. Weight

• 9. Styling 10. Shape

• 11. Marketability 12. Control

• Any else you think maybe important?



Further Readings • J. Seddon and S. Newman, Basic Helicopter

aerodynamics. Blackwell Science. 2002. • J. D. Mattingly, Elements of propulsion. AIAA

Education series. 2006. • A. Wolf, R. Steinmann, and H. Schunk, Grippers in

motion. Springer-Verlag. 2007. • K. Zimmermann, I. Zeiding, and C. Behn, Mechanics

of terresterial motion. Springer-Verlag. 2009. • M.E. Rosheim, Leonardo’s lost robots. Springer-

Verlag. 2006. • F.C. Moon, The machine of Leonardo Da Vinci and

Franz Reuleaux. Springer. 2007.



Further Readings • Marco Ceccarelli (Ed.), Distinguished figures in

mechanism and machine science. Springer Science+Business B.V. 2010.

• C. Chevallereau, G. Bessonet, G. Abba, and Y. Aoustin. Wiley. 2009

• A. Wolf, R. Steinmann, and H. Schunk, Grippers in motion. Springer-Verlag. 2007.

• K. Zimmermann, I. Zeiding, and C. Behn, Mechanics of terresterial motion. Springer-Verlag. 2009.

• M.E. Rosheim, Leonardo’s lost robots. Springer-Verlag. 2006.

• F.C. Moon, The machine of Leonardo Da Vinci and Franz Reuleaux. Springer. 2007.



Further Readings • Peter Childs, Mechanical Design.

Butterworth-Heinemann. 2004.

• Bram vanderborght of The biped Lucy Powered by Actuators With Controllable Stiffness. Springer-Verlag. 2010.

• Armando Filho (Ed.), Humanoid Robots: New Developments. Advanced Robotics Systems International. 2007.

• Matthias Hackel (Ed.), Humanoid Robots: Humanlike Machines. Advanced Robotics Systems International. 2007.


• Any question?

• If you have questions, you had better ask me now.

• The longer you keep it in your head, the less you will understand later.

• If you are shy to ask any question in this class, you can ask me later.

• You can also come to see me directly in my room. But please make an appointment first.

• If you like, you can ask me through email or phone me. But please don’t send me any sms.


Assignment -1 1) Summarize the article Educating for Creativity in

Engineering in the textbook. Write about 4 to 5 pages.

2) Search a good product from internet and write a two-page report about its design considerations.

• You are not allowed to use Word processor. Assignment must be hand-written.

• Submit your assignment by 08.30, 25 January 2011. Put it in my pigeon hole in the office or submit it directly to me.

• Late submission will be penalized.


dr. marwan affandi 2010 - portal.unimap.edu.myportal.unimap.edu.my/portal/page/portal30/lecture...

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