Introduction to Engineering Design

Hemendra Arya
Department of Aerospace Engineering
Indian Institute of Technology Bombay
Mumbai 400076, India
1
 Introduction to Engineering Design

• What is Engineering?

• What is Design?

2
Was there any design?

6
Was there any design?

Yes

7
 What is design?

• To connect or to arrange existing things in a

new way to satisfy a recognized need of
society

• Ability to design is both science and art

8
Was there any Engineering?

9
Was there any Engineering?

10
 What is engineering?

• Application of science and mathematics for

solving problems

• Ability to use principles of science and create

confidence in what is to be created

11
Which engineering
principles can be used
for designing?
Which engineering principles can be used
for designing?
Which engineering
principles can be
used for
designing?
 Example of a design advancements - Mobile phone

http://www.jorymon.com/product-design/transparent-mobile-phone-concepts-by-mac-funamizu/

Here's how it works: Instead of hearing your cell phone

squeal when you get a call, a tiny light starts blinking on your
ring. The phone number of the person calling is displayed on
the watch. You answer the phone by pressing a button on
your watch. Next, you hear the call through your earring,
which has a tiny speaker embedded in it. You then speak to
the necklace, which has a tiny microphone inside and acts
as a mouthpiece.
http://www.pcworld.com/article/33322/ibm_gets_fashionable_with_wearable_cell_phone.html
 Example of a design – highly functional

http://adayinlife.timesofindia.com/photos/design-we-call-it-jugaad/24767
 Example of a design – alternative material

“Those who are allergic to chappals made from synthetic materials like PVC
(Polyvinyl chloride) and PVA (Polyvinyl Alcohol) prefer these”, points out K A Joseph.
His Multicare Company in Thrissur, Kerala, is producing Areca leaf chappals apart
from dinner plates.” http://www.indiatogether.org/2011/apr/env-chappal.htm
 A Recent Example

• What do you think this woman Or kid is doing?

• Drinking water through „LifeStraw”!
• Cost – Rs 1000, Life - 700 litres (1 persons annual requirement)
• 'One of the Ten Things that will Change the Way We Live´ by
Forbes Magazine
18
http://www.vestergaard-frandsen.com/
Packaged for everybody

• Utility increased by packaging

• Attractive for urban population

19
 Another Example

Need – “20 million premature and low-birth-weight

(LBW) babies are born every year. 80% of these
births occur in rural areas of developing countries.
3.5 million of these babies die. In India alone, a
third of all babies born are LBW”

• Innovative use of Phase-Change Material (PCM)

• Sleeping bag design to provide kangaroo comfort
• Hot water recharges the PCM
• No electric power, no knobs, no digital read out!
• $25 incubator 20
 Summary of What it takes!

• Be sensitive & recognize needs#

• Be alert to happenings! What is new?
• Acquire knowledge in a form that lends itself to
application
• Foster ability to solve open ended problems
• Attempt design to meet needs

#
• What are „The 8 Millennium Development Goals meant to cut worlds
poverty in half by the year 2015‟
• Self generated. Our students : “Sense & alert mom who is a single
cylinder cooking gas user”, “Self cooling soft-drink container”, “System to
reduce food wastage in canteen”, etc.
21
 Bridges over the years

The Arkadiko Bridge in Greece (13th century BC), one of the oldest arch
bridges in existence. A bridge that allowed people to cross and yet allowed
water to flow!
Many bridges were built since then, and many must have collapsed due to
excess weight, excess winds, etc. The learning that accrued helped improve
subsequent bridges
Bridge performance thus improved over the years - longer bridges, larger
unsupported spans, more weight bearing, higher wind load bearing, . . .
Broughton Suspension Bridge built 1826 (Europe) collapsed on
12 April 1831 when troops marched in step. The British Army
passed a rule "break step when crossing a bridge”. British slowly
understood excitation at natural frequency!

Angers suspension bridge, Maine River, France built it in 1839;

collapsed 1850, while French soldiers marched across in windy
condition, killing over 200 of them.

Tacoma Narrows Bridge, suspension bridge,

Washington, USA. Opened July 1, 1940, dramatically
collapsed Nov 7, 1940.
https://www.youtube.com/watch?v=lXyG68_caV4
Interaction of structure with winds  understanding of
Flutter.

Millennium Bridge for pedestrians ,Thames, London ;

opened in June 2000 for charity walk for Save the
Children. Bridge wobbled. Closed and reopened in
2002
https://www.youtube.com/watch?v=eAXVa__XWZ8
Steven Strogatz, Cornell Univ explained why –
synchronisation in agent based systems?
 Very early shoes

Leather shoe found in Armania

- 3500 year old Shoe made out of grass found in
Oregon
- 10000 year old
 Very recent shoes

Shoes designed to connect well

with surface

Shoes designed to store and

supply energy
 What is important?

 Experienced gained with time is used in design

 Advancement in science helps you in improving

design
 Understanding new phenomena
 New material
 New manufacturing methods

 Above is used to create better design

 What is expected of an Engineer?

• Create things that may not exist

• Strive to improve quality of life, through such
creative endeavors?
How do we
acquire that?

• What does it take?

• Engineers use their knowledge of science,
mathematics, and appropriate experience to
find suitable solutions to a problem (Wiki)

27
 Design

• Process of Engineering a Product to meet a

need
• Recognized as a creative activity
• Design  Problem Solving (Open ended)

Process of engineering a product using

scientific principles to
meet a need

Need Design Product

28
 Problems that we shy away from!

Problem Problem Solving ? Solution

Vague? Did not have all data, did not state all
that was required

Open ended problem

Define the Problem Learn to do this

Problem to be solved

Problem Solving Solution

 Need to Design

Unable to use mobile Need energy source

phone for long to charge mobile
duration when I am phone which can be
travelling because it carried while
discharges travelling

Details to the level that it Form of the object,

can be produced and used connectivity, material etc.
30
Detailed Design Conceptual Design
 Need to Design

For India‟s growth it Need to install more

needs 9% growth in power plants for
electricity generation electricity generation

Details to the level that Location, capacity,

it can be installed, resources (land,
produce and supply energy source, funds
electricity etc), technology etc.

Detailed Design Conceptual Design

31
Life Cycle Model

System
Life Cycle Model

Operated to
achieve
desired
output

System
Life Cycle Model

Operated to
achieve
desired
output

Need support
System to operate as
desired
Life Cycle Model

Operated to
achieve
desired
output

Need support
System to operate as
desired

Limited life
 Life Cycle Model

Operated to
achieve
desired
output

Design the Need support

system to System to operate as
meet need desired

Limited life
 Life Cycle Model

Operated to
achieve
desired
output

Design the Need support

system to System to operate as
meet need desired

Limited life
 Life Cycle Model

Operated to
achieve
desired
output

Design the Need support

system to System to operate as
meet need desired

Limited life
 Who are stakeholders?
INCOSE handbook
Stakeholders is any entity (individual or organization) with a
legitimate interest in the system. Typical stake holder includes
users, operators, organization decision‐makers,
parties to the agreement, regulatory bodies, developing a
gencies, support organizations, and society‐at‐large. When
direct contact is not possible, systems engineers
find agents, such as marketing or non‐governmental
organizations, to represent the concerns of a class of
stakeholders, such as consumers or future generations.
 Stakeholders
Life cycle Related stakeholders
processes
Engineering Acquirer, panel of potential users, marketing division,
research and development department, standardization
body, suppliers, verification and validation team,
production system, regulator/certification authorities,
etc.
Development Acquirer, suppliers (technical domains for components
realization), design engineers, integration team, etc.
Transfer for Quality control, production system, operators, etc.
Production or for
Use
Logistics and Supply chain, support services, trainers, etc.
Maintenance
Operation Normal users, unexpected users, etc.
Disposal Operators, certifying body, etc.
 System /Product life cycle

Concept stage Development stage Production stage

Utilization stage Support stage Retirement stage

41
 Concept Stage
 Recognition of need
 Exploratory research activity
 New system of interest at later stage
 To find out enabling systems
 Creativity is possible
 Concept generation and evaluation
 Preliminary concepts are evaluated for risk
 Early concepts helps in cost and schedule
projections
 Concept stage may include element-level concept,
architecture definition, integration, verification,
validation planning
 Development Stage
 Defines and realizes system of interest meeting
stakeholder requirements
 Can be produced
 Can be supported
 Can be retired
 Full system is developed from concept
 Key activities
 System elements specified, analyzed, and designed
 Interfaces are understood, hardware and software are
realized
 Operator interfaces, maintenance and training procedures
are developed
 Detailed planning of integration, verification and validation
 Production Stage
 Production and manufacturing plan available from
development stage
 System is produced and manufactured
 Product modifications may be required to resolve
production problems
 May influence system requirements
 May require re-verification and re-validation
 Amy increase cost and schedule
Utilization Stage and Support Stage
 Utilization stage – where the system is operated in
its intended environment to deliver its intended
services
 Product upgrades may be planned during utilization
stage and it is part of design process
 For large complex systems mid-life upgrades could
be quite complex and may need SE efforts

 Support stage – system is provided services that

enable continued operation
 Modifications may be proposed for better
supportability. Changes will require SE assessment
to avoid system capabilities
 Retirement Stage
 In this stage system and related services are
removed from operation
 Focus is to ensure disposal requirements are
satisfied
 Execute retirement as decided during concept
stage
 Developer is responsible for proper end-of-life
disposal of the system
System /Product life cycle

Concept stage Development stage

Production stage
Retirement Utilization stage
stage
Support stage

Simultaneous in time

47
 System /Product life cycle

Concept stage Development stage

Production stage
Retirement Utilization stage
stage
Support stage

Simultaneous in time

Household systems,
Shorter design cycle common industrial
Shorter life systems, electronic
chips, road vehicles etc
48
System /Product life cycle

Concept stage Development stage

Production stage

Retirement Utilization stage

stage Support stage
Simultaneous in time

49
 System /Product life cycle

Concept stage Development stage

Production stage

Retirement Utilization stage

stage Support stage

Longer design cycle Aircraft, Ship, Submarine,

Longer life Airport, Train, sea port etc.

50
 System /Product life cycle
Activity
1. Concept stage
1, 2 2. Development stage
High
3. Production stage
1, 2
4. Utilization stage
Design team role

5. Support stage
3
6. Retirement stage
3

4, 5, 6
Low
4, 5, 6
Time

51
Complex Simple
 ENGINEERING DESIGN PROCESS

Define Problem Gather Information Concept Generation Evaluation of

Problem statement Internet Brainstorming concepts
Benchmarking Patents Functional Pugh concept
QFD Trade decomposition Selection
PDS Literature Morphological Decision
Project planning Handbooks chart matrices

Product Configuration Prarametric Detail

architecture design design design
Arrangement of Prelim. Selection Robust design Detailed
physical elements Materials & Mfg Tolerances drawings
to carry out Modeling/sizing of Final dimen and
function parts DFM specifications
 ENGINEERING DESIGN PROCESS

Define Problem Gather Information Concept Generation Evaluation of

Problem statement Brainstorming concepts
Benchmarking Internet Functional Pugh concept
QFD Patents decomposition Selection
PDS Trade Morphological Decision
Project planning Literature chart matrices

Conceptual Design

Product Configuration Prarametric Detail

architecture design design design
Arrangement of Prelim. Selection Robust design Detailed
physical elements Materials & Mfg Tolerances drawings
to carry out Modeling/sizing of Final dimen and
function parts DFM specifications
 ENGINEERING DESIGN PROCESS

Define Problem Gather Information Concept Generation Evaluation of

Problem statement Brainstorming concepts
Benchmarking Internet Functional Pugh concept
QFD Patents decomposition Selection
PDS Trade Morphological Decision
Project planning Literature chart matrices

Conceptual Design

Product Configuration Prarametric Detail

architecture design design design
Arrangement of Prelim. Selection Robust design Detailed
physical elements Materials & Mfg Tolerances drawings
to carry out Modeling/sizing of Final dimen and
function parts DFM specifications

Embodiment Design
 ENGINEERING DESIGN PROCESS

 Identifying customer needs: Figuring

out want customer wants? stated in a
qualitative language, do not reflect
Define Problem what customer wants, vagueness etc
Problem statement
Benchmarking
 From above writing problem as crisp
QFD statements and without ambiguity
PDS
Project planning
 Compare with the existing solution
 Use Quality function deployment
methods to arrive at PDS
 PDS: Product design specifications
 ENGINEERING DESIGN PROCESS

Gather Information
 Information is used for obtaining
existing knowledge
Internet
Patents
 Information aids in the generation of
Trade new knowledge
Literature
Handbooks
 Available in scattered manner
Standards  Ability to use is important for designer
 ENGINEERING DESIGN PROCESS

 Solutions for the given problem

Concept Generation  Systematic approach can help in
Brainstorming
Functional obtaining solutions
decomposition  Can help in creativity
Morphological
chart
 ENGINEERING DESIGN PROCESS

 To find out which is a good solution for

Evaluation of the given requirements
concepts  Applying constraints
Pugh concept
Selection  Using quantitative analysis for
Decision qualitative attributes
matrices
 Qualitative attributes to quantitative will
be based on designers experience
 ENGINEERING DESIGN PROCESS

 In legacy design architecture is known

Product
architecture  Open architecture
Arrangement of  Modular architecture
physical elements
to carry out  Architecture define interaction between
function the modules

Laser Fusing
Rapid Prototyping
Machine
 ENGINEERING DESIGN PROCESS

 To establish the shape and general

dimension of components
Configuration  Can help in reducing number of
design
Prelim. Selection independent parts (one part performing
Materials & Mfg two functions)
Modeling/sizing of
parts  Evaluating configuration design for
ilities
 Tentative dimensions and tolerances
 ENGINEERING DESIGN PROCESS

Prarametric
 Attributes of configuration items
design becomes design variable for parametric
Robust design
Tolerances
design
Final dimen  Optimisation is possible
DFM
 Is used to arrive at final dimensions
 ENGINEERING DESIGN PROCESS

 Lowest level in the hierarchy of design

 Specific and concrete activity
 Poor detail design can ruin good design
Detail concept
design
Detailed
 Good detail design cannot rescue a
drawings bad design
and
specifications
 Completes the design cycle
 Helps in manufacturing
 Will be costly to bring any changes at
this level
 Detail Design
Complete description of a tested and producible
product
Complete selection and sizing of components
Complete verification prototype testing
Detailed engineering drawing suitable for
manufacturing
Critical-to-quality parameters are confirmed
Assembly drawings and instructions
Detailed product specifications
Complete Bill Of Materials
Decision to buy or manufacture
Detailed cost estimation
Design project report
Design review before sent for manufacturing
65
 Detail Design
Detailed engineering drawing suitable for
manufacturing
Standard views of orthogonal projections – top,
front, side views
Auxiliary views which can help in visualising and
clarifying details
Dimensions – presented according to standard
GD&T (Geometric dimension and tolerances)
Material specification and special processing
instructions
Assembly drawings

66
67
68
 Embodiment Design
Product architecture: dividing overall design system
into subsystems or modules. Arrangement of these to
carry out functional duties of the design

Configuration design of parts and components: what

features will be present and how these will be arranges
with respect to each other. More specificity about
material and manufacturing

Parametric design of parts : Establish exact

dimensions and tolerances. Final decision on material
and manufacturing processes. Performance under
variable conditions

69
 Different types of Design Problems

Most of the complex system design is a mix of

different types of design problems.
Design problems could be:
Selection design; Parametric design; Configuration
design; Original design; Redesign;
 Selection design
Choosing one item or more from list of similar
items (electronic design)
It sound simple but it becomes difficult when listed
items are large
For such design need statement must be very
clear
Evaluate the potential solutions against the
requirements and make the right choice
 Selection design
Select a bearing to support the shaft so that
housing for the bearing can be designed

6675 N = 1500 lb
20 mm = 0.7878 in
Five are selected; more information is required to
arrive at single solution. It can introduce iteration in
the design cycle
 Configuration design
Little more complex type of design is configuration
design or packaging design.
All the components are designed and it is to
assembled for final product
- Arranging your hostel room. All the components
are available but arranged according to some
philosophy (comfort, look, view blocking; more
floor space for other activities etc)
 Configuration design
Methodology could be: How do we fit all the
components? Where do we put what? Randomly
select a position for a component from list and
satisfy all the constraints. Or select a position
based on function and try to fill the space.
Freedom in design can help to arrive at better
configuration (allowed to change the shape,
material etc.)
 Parametric design
Parametric design involves finding values for the
features that characterise the object being studied.
Design a cylindrical storage tank that must hold 4
m3 of liquid.
Tank is described by parameters r (radius) and
length (l)
V = r2l
It has infinite solutions. Solution may be limited by
tolerance limits, other physical constraints etc.
 Parametric design
Parametric design involves finding values for the
features that characterise the object being studied.
Design a cylindrical storage tank that must hold 4
m3 of liquid.
Tank is described by parameters r (radius) and
length (l)
V = r2l
It has infinite solutions. Solution may be limited by
tolerance limits, other physical constraints etc.
 Original Design
The design problem requires development of
process, assembly, or component not previously in
existence; or that information is not available with
designer; it is called as original design.
In general original design problem cannot be
reduced to algorithm. It is something new and
unique.
 Redesign

Most industry problems are redesign of existing

products.
Modification in existing products to meet new
requirements. Generally design domain is well
understood and it is available as handbook or
series of formulas /rules etc.
 THE MANY RESULTS OF THE DESIGN PROCESS
Design process knowledge

Resulting
Design products
need that meet
the need

Design process paths

Physics
Materials Electric
science motors
Manufacturing Thermodynamics
Engineering
processes
science Engineering
Domain
Welding economics
knowledge
design
Pumps
Kinematics
 THE DESIGN PROCESS PARADOX

100

80 Knowledge about the

design problem
Percentage

60

40

20 Design
freedom

0
Time into design process

The more we know about the design, less design freedom we

have i.e. ability to change product becomes increasingly limited
 Commitment to Technology, Configuration, Performance, Cost, etc

100

Cost Incurred
75
System Specific
Knowledge

50

25 Ease of Change

System use,
Conceptual Embodiment Detail Design Production Phaseout, and
Design Design Disposal
Kano model for customer
satisfaction
Basic features : assumed
function of the product
Performance features:
Better performance better
product
Excitement features: Not
expected features
Today‟s delight features
are tomorrow's basic
features