enginnering design methodology

ENGINEERING TEAM PROJECT (ETP)Code : MCB3053

Facilitator:

Dr. Syed Ihtsham-ul-Haq Gilani

Mechanical Engineering Dept.

1

TOPICS

Introduction to engineering design Engineering design process Implementation of Engineering

Principles in ETP design. Group management Project Management

3rd. June, 2015

Your expectations of UTP & ETP

Get good grades

Try new ideas

Getting your hands dirty

Experience working in a team

Have fun!!

Color your CV - medals /papers

LEARNING OUTCOMES of ETP

1. Apply engineering knowledge and solve engineering

design problem.

2. Work in a multi disciplinary team-based project work.

3. Apply the principle of project management.

4. Apply proper design process to produce creative and

innovative solution.

5. Demonstrate effective communication, report writing,

presentation and entrepreneur skills.

Engineering is...

the profession in which a knowledge

of mathematics and natural sciences

gained by study, experience, and practice

is applied with judgment to develop

ways to utilize, economically, the

materials and forces of nature for the

benefit of mankind."(ABET) Accrediting Board for Engineering and Technology

4

STAGES OF MAIN ETP ACTIVITIES

Commencement of Project

Design

Fabrication

Presentations

Introduction

What is design ?

Websters dictionary says, to fashion after a plan

Another definition says, design is the essence ofengineering

Actual definition would be,

Design establishes and defines solutions to andpertinent structures for problems not solvedbefore, or new solutions to problems which havepreviously been solved in a different way

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Putting ideas on papers

Concept finalized. Whats next?

Design your product (then fabricate)

Make use of all the engineering & non-engineering knowledge.

DESIGNING YOUR PRODUCTS

Dont Just Do It

The Four Cs of Design

Creativity:

Requires creation of something that has not existed before

or has not existed in the designers mind before

Complexity:

Requires decisions on many variables and parameters

Choice:

Requires making choices between many possible solutions

at all levels, from basic concepts to the smallest detail of

shape

Compromise:

Requires balancing multiple and sometimes conflicting

requirements 8

Whats wrong with these?

Basic module in the design processExample (Design of a Ball pen)

General

information

Specific

InformationDesign operation Outcome

Evaluation

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size, ink type, mechanism, etc.

Material, color, weight, etc.

Yes No

Ideas, software, calculations, etc.

Purpose and Nature

Science is the search for knowledge and understanding

Technology is the application of knowledge to satisfy human needs

They are both creative problem solving methods!

12

Existing knowledge

Scientific curiosity

Hypothesis

Logical analysis

Proof

Co

mm

un

ica

tio

n

State of the art

Identification of need

Conceptualization

Feasibility analysis

Production

Acce

pta

nce

Scientific method Design Method

Comparison between scientific method and

the design method

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The Engineering design process steps

The five steps used for solving engineering design problems are:

1. Define the problem2. Gather pertinent

information3. Generate multiple

solutions4. Analyze and select a

solution5. Test and implement

the solution

14

AnalyzeEvaluateSolutions

Engineering Design Process

Define Problem or Need

Select & Test

Propose Design

Solutions

ResearchInvestigateGather Info

What similarthings exist?

Does solution

meet need?Proof of

concept

Does it work?

Modify & redesign

The design process steps

Recognition of a needDissatisfaction with the existing system is called need and it is generated by customer, marketing personnel or consultant etc.

Definition of a problem

A problem should express as specifically as possible what the

design is intended to accomplish. It should also suggest clearly :

1. Musts (set of requirements that must be met)

2. Must nots. (a set of constraints)

3. Wants (Requirements that are worth starting, but are not hard and fast)

4. Dont wants.

16

A user wants a new swing for the children to be placed on the tree

17

Definition of a problem (Importance)

Needs assessment

The aim is not to solve the problem but to understand what the problem is

What does this client want?

What is the problem that the design is to solve?

The objectives (goals) and constraints of the problem should be identified

Objectives: summary of the needs that the design is to satisfy (helps us to choose among alternative design configurations)

Constraints: the design must satisfy (takes logical values 0 or 1, helps to decide acceptable or not)

18

Gathering of information

Question the customer

To define the design problem

Where can I find it ? How can I get it ? How accuratethe information is ? Interpretation of the information ?Any particular decision extracted from the information ?

To understand budget and schedule constraints Reliability and maintenance constraints

Explore resources Expertise (knowledge and experience) Technical literature (books, journals,www) Measurement and testing equipments (equipment suppliers) Similar designs (competitors, patent search)

The design process steps

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There are no hard and fast rules for a designer. Designs vary atlarge, geometrically, functionality and aesthetically, dependingupon the visualization of the designer. Some guidelines for anovice designer are:

1. Dont follow traditional design procedures.

2. Make a complicated design for a component instead making the

whole system a complication.

3. Make allies of the materials from which you construct the design.

4. Divide the complex designs into smaller and simple designs.

5. Keep yourself abreast of developments in physical sciences.

6. Avoid inventions which are not supported by science or analysis

Conceptualization

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what s that
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Evaluation

Evaluation is used more in the sense of weighing and judging than in the sense of grading. Generally evaluation means :

Verification of detailed calculations (manual or computer)

Performance of design by an analytical model.

Simulation of service testing of a model or prototype.

While evaluating a design, two types of checks should be made :

1. Mathematical checks

2. Engineering sense check.

Evaluation of the alternatives, involves : Cost analysis, in terms of; Labor, Equipment and Payback Implementation issues Performance issues

The design process stepsCont,d..

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A morphological chart is a table based on the function analysis.

On the left side of the chart the functions are listed, while on the right side, different mechanisms which can be used to perform the functions listed are drawn.

It is a visual aid used to come up with different ideas.

The idea generation is accomplished by creating single systems from different mechanisms illustrated in the morphological chart.

It is advised to generate several feasible designs using different mechanisms for each function for each concept.

Morphological Chart and Concept GenerationMorphological Chart

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Concepts Generation

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For this concept, by looking at the morphological chart, the following options were chosen for the different functions which govern the mechanism.

Vegetable Picking Device = NONE Vegetable Placing Device = Option 1 Dirt Sifting Device = Option 3 Packaging Device = Option 1 Method of Transportation = Option 1 Power Source = Option 2

Method of operation: Pull from yokes in y-direction by horse. Front wheels turn belt which in turns provides torque on blade shaft. Blade and sifters sort debris from vegetables. Vegetables are then slung into carriage compartment where operator packages product.

Concept 1

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Vegetable Picking Device = Option 1 Vegetable Placing Device = Option 3 Dirt Sifting Device = Option 1 Packaging Device = Option 2 Method of Transportation = Option 1 Power Source = Option 2

The idea of this concept stems from modern potato harvesting equipment. The principle on which this mechanism operates with is the fact that vegetables are very close to the surface. By taking advantage of a plow the vegetables will be ripped free from the roots and travel up the plow to the conveyor system.

Concept 2

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Method of operation: Pulled by horse in the Y direction. Front wheels turn making the collecting wheel rotate. Tubes cut lettuce dragging it against the cart. Once lettuce is against cart it is guided inside the pipes until the pipe reaches the upper position. There is a hole at the bottom of each pipe where lettuce exits. At this point there is a slide that carries the lettuce to the back of the cart.

Concept 3

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Method of operation: Pull from support brackets in y-direction by horse. Plows pull vegetables up and onto runners, where unwanted debris falls through gap in middle. Sack is attached to end of runners and entire unit is tilted back on wheels to gather vegetables.

Concept 4

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Concept Selection Concept 1 Concept 2 Concept 3 Concept 4

Capable of harvesting several types of vegetables 10 10 10 10

Does not require manmade power source 9 7 7 7

Uses less than $100.00 worth of material other than wood 8 7 7 8

Can be operated by one person 10 10 10 10

Capable of harvesting several rows of vegetable simultaneously

10 8 6 4

Does not damage crops 7 5 5 4

High Storage Capacity 8 5 7 3

Capable of sifting out excess dirt from vegetables 7 7 6 4

Simple shapes for ease of construction and replacing broken parts

5 7 7 8

Few moving parts to increase lifespan and ease of manufacturing

7 4 4 9

Resistant to environmental elements 8 8 8 8

Useful for other aspects of farming as well as vegetable collection

10 9 8 8

Pre-cools vegetables for storage 1 1 1 1

Separate storage containers for different types of vegetables

1 1 1 1

Total Points 101 89 87 85

Concept Screening

The concepts arrived upon using the morphological chart are then screened against each other and against the customer needs. This is done as a preliminary decision matrix to see which concepts are going to be further analyzed.

As a result of detailed analysis, concept one was chosen to be the most compatible with the farmers needs. Also, model 1 supplied sufficient methods of the wants form the specification table.

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Analysis and Selection

For each concept embodied by using the morph chart, an analysis must be performed in order to choose one concept. This analysis can be done in a variety of manners. One such way is by using a CAD tool, such as ProE in this case, to carefully analyze the concepts. From this analysis, the results obtained will be used to choose the best concept.

Displacement and Stress analysis at point load on wheels of 100lbs/each. Data confirms stability of component.

Wheel displacement and stress

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Detailed Design

An engineering drawing for each of the components of the final assembly is generally needed for this phase.

However, for the purpose of this web page and space limitations, a drawing for the final assembly is the only one shown.

This includes the creation of a complete set of assembly and detailed drawings. Each detailed drawing must specify all dimensions and material specifications necessary to make the part. From these drawings a prototype must be constructed for physical testing.

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Construction of a physical model is necessary since a mathematical model will never be as complete and accurate as the physical representation. Prototypes are often very expensive but are the cheapest way to build the design without building the entire device.

Usually, a working prototype is constructed to ensure the design works. Adjustments may have to be made for unexpected last minute problems that arise.

Testing of the model may range from simply actuating it to attaching extensive instrumentation to accurately measure physical properties and other parameters. Testing is needed for the optimization of the final product.

Prototyping and Testing

CHALLENGING YOUR DESIGN

Typical questions:

1. Is that the appropriate wheel?2. How many bolt and nuts for this joint?3. Can we use plastic for this structure?4. Should I use 50 mm pipe or 100 mm one?5. Is it fine to use rubber band to join those?6. Dont we need to use bearings?7. Can this float?8. Which option is more economical?9. How much heat can be removed by this?10. Why use aluminum?11. Will buckling happen?

Ask OUTSIDERS to challenge your design

Further considerations to detail design

Functional requirements

The essential requirement, of course would be that the design

must meet the required performance specifications. Besides, it

should present maintainability, availability & repairability.

Total life cycle

Material selection is a key element in total life cycle. The

properties of the selected material should be checked against

the service conditions. Environment protection is the latest

issue in the series, to be considered in material selection.

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Further considerations to detail designCont

Further major factors

1. Design as per Technical standards i.e. ASME, TEMA etc,

2. Design as per Health & Environment standards.

3. Aesthetics of the design

4. Cost

Design Strategies

1. One of-a-kind design

2. Design for mass production

3. Large expensive designs

4. Design to codes 34
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35

Design Group (Team)

Engineering design projects require diverse skills

This creates a need for group (team) work

Selection of team members is done by the ETP Coordinators and it is based on following skills.

1. Technical

2. Problem-solving

3. Interpersonal

36

Design Group (Team)

Develop decision making guidelines

1. Decision by authority (leader)

2. Expert Member

3. Average member opinion

4. Majority

5. Consensus

37

Design Group (Team)

Teams that spend time together tend to be successful teams

Respect each other

Listen actively

Consider your response to others

Constructively criticize ideas, not people

Respect those not present

Communicate your ideas effectively

Manage conflict constructively

38

Know the coworkers in person

Define and follow the rules

Communicate as much as you can

Share up-to-date information

Have regular meetings Have an agenda Show up prepared Pay attention Schedule time and place of next meeting Summarize

Discuss the project more often

Tips for Efficient Collaboration of Teams

Assign tasks and responsibilities

39

Step 1: Clarify what needs to be done and why it is important.The background and context to a task will give it more meaning for people. Why is this job

important now? What is the rationale behind it? Are there particular stakeholders for whom this is

especially important?

Step 2: Make your expectations clear.Spell out precisely what you expect and a date for its achievement. Express your confidence in the

persons ability to achieve the task

Step 3: Explain how results will be reviewed.You will probably have a timetable in mind for a regular review of progress so that you can keep

abreast of progress without micro-managing. Who will be involved in that review, and what will

you expect to see on the review dates?

Step 4: Outline the resources and support available.Finally, outline the resources that the team or individual will have access to, to help them do the

job. Let the person know who they can go to with questions or problems, and what level of support

they can expect.

EFFECTIVE TASKS ASSIGNMENT

41

Project Management

Define for each activity

1. Work to be done

2. Timeframe

3. Resources needed

4. Responsible person(s)

5. Previous dependent activities

6. Checkpoints/deliverables for monitoring progress

42

Project Management

Guidelines

Project plan after design plan complete

Double time estimates and add 10%

Assign a lot of integration and test time

Remember lead times for parts ordering

Assign tasks based on skills and interests

Track progress versus plan

Plans change

43

Project Time Management

Series or Paralell Gantt Chart.

Generally the Gantt Charts are series and parallel.

Zoned Gantt. Chart.

A Gantt chart, commonly used in project management, is one of the most popular and useful ways of showing activities (tasks or events) displayed against time.

44

Project Time Management

What the various activities are When each activity begins and ends How long each activity is scheduled to

last Where activities overlap with other

activities, and by how much The start and end date of the whole

project

On the left of the chart is a list of the activities and along the top is a suitable time scale. Each activity is represented by a bar; the position and length of the bar reflects the start date, duration and end date of the activity. This allows you to see at a glance:

45

Thank you

enginnering design methodology

Documents