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Product function combination design based on functional redundancy

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Article  in  Concurrent Engineering Research and Applications · September 2017

DOI: 10.1177/1063293X17705180

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Concurrent Engineering: Research

and Applications
Product function combination design 2017, Vol. 25(3) 229–244
Ó The Author(s) 2017
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analysis DOI: 10.1177/1063293X17705180

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Chunfu Lu, Hao Chai, Mengyang Tian, Xiang Peng and Shaofei Jiang

Abstract
Function combination designs integrate multiple product functions into a single product carrier. In this article, we pro-
posed a function combination design method based on the functional redundancy analysis of parent products for the
conceptual design process. According to the design task, we analyzed each parent product function carrier, established
an expression model of functional elements based on the functional basis approach, and constructed a functional struc-
ture of the parent product based on relationships among energy, material, and signal flow. Then, we established a prod-
uct function redundancy matrix and carrier redundancy matrix, and obtained redundancy functions and the principle
structure carrier. We constructed a function carrier matrix for function combination products, sought the appropriate
principle, established a design structure matrix, analyzed the coupling relationship between the principle scheme and
structure carrier, and obtained a conceptual scheme of combination products through operations including reuse, var-
iant, removal, and increase. Moreover, we used a sticker removal machine as an example to verify the validity of our
function combination method.

Keywords
function combination, conceptual design, functional structure, functional redundancy, functional basis

Introduction and optimization in accordance with a certain relation-

Product function combination design involves a variety
of parent products in the same or different fields of use,
with similar or different functions as a combination
object. These products are analyzed for commonality
among functional structures, and some or all functions
are assigned to a new structure, thereby solving for a
design approach that can integrate multiple functions
on a new product. This type of design can meet cus-
tomer demand for multi-functional products, is adap-
tive as opposed to creating an entire new design (Beitz
and Pahl, 1992), and can significantly reduce the design
effort. It also improves design efficiency and reduces
cost and development risks.
Scholars carried out extensive research on product
function combination design. Chen (1997) proposed
that function combination was the combination and
integration of multiple functions into one product to
meet diversity demands of various target markets and
users, and explored the design principle of functional
integration. Conversely, Cao et al. (2012) proposed that
function combination was a process of combination
ship of functional elements with combination proper-
ties based on functional requirements, and the
functions should be combined in accordance with the
classification of functions and functional relationships.
Singh et al. (2007) illustrated the importance of multi-
functional product design methods using real-life exam-
ples. Malatesta et al. (2015) proposed a method for a
preliminary validation of new configurations at the
marketing stage. These studies focused on the concept
and criteria of function combination design, and
although product design case studies emphasized the
importance of function combination design methods,
Key Laboratory of Special Purpose Equipment and Advanced
Manufacturing Technology, Ministry of Education, Zhejiang University of
Technology, Hangzhou, China
Corresponding author:
Shaofei Jiang, Key Laboratory of Special Purpose Equipment and
Advanced Manufacturing Technology, Ministry of Education, Zhejiang
University of Technology, Zhejiang Province, Hangzhou 310014, China.
Email: jsf75@zjut.edu.cn
230
specific design methods were not proposed. Wang
(2001) proposed the reuse theory for minor modifica-
tion of existing product parts for use in new products.
Duhovnik et al. (2001) developed an n-T looping meth-
odology for the whole development process of new
products, which covered goal setting, conceptual
design, process planning, manufacture and assembly,
and so on. Hu et al. (2012) proposed the fuzzy reconfi-
gurable design theory of complex mechanical product
design according to user functional requirements and
emphasizing reuse of existing product components.
Zheng et al. (2017) proposed a system framework in
support of one-of a-kind product conceptual design
process in a cloud-based design (CBD) environment.
Reconfigurable design can provide innovative design
space by fully reusing design knowledge and resources.
Prasad (2001) established a concept for product, pro-
cess, and methodology systematization to handle both
structural complexity and computational complexity
in the new product realization. Lewis and
Kalyanasundaram (2011) identified shared functions
and components of two products by establishing a
function share matrix and component share matrix
according to the reconfigurable principle, and com-
bined functional structures of parent products to
obtain a new product. The key of this kind of research
was reconfigurable product design. Through recon-
struction design on two or more single-functional prod-
uct structures, they generated multi-functional product
solutions, and focused on solving the product reconfi-
guration problem. The main objective of the above
studies is to reuse parent product components, but they
neither selectively combine parent product’s functions,
nor study how to best use product function carriers.
Lin (2008) used fuzzy clustering method to explore the
possibility of function integration among different
products, and through case studies, explored several
typical approaches suitable for function integration
innovation from function combination, functions bal-
ance, functions synergy, and other design point of view.
Wu et al. (2013) used the function analysis system tech-
nique (FAST) to sort product functions according to
their primary and secondary relationships, examined
interdependencies between the functions, and then
combined the functions. Kang and Tang (2013) studied
a matrix-based conceptual scheme solution, used func-
tional models, a functional similarity matrix, a func-
tional element matrix, and an element association
matrix to realize new multifunctional product design
by discarding, retaining, or modifying elements. Li
et al. (2009) established a functional structure and ana-
lyzed contradictions of functional principles based on
functional product integration and innovation, and
applied the TRIZ theory (theory of the resolution of
invention-related tasks) to generate problem solutions.
Concurrent Engineering: Research and Applications 25(3)
Liu et al. (2014) and Fu et al. (2014) proposed model
product integration approaches for product innovation
based on function combination and TRIZ.
Furthermore, Fu et al. (2013) built a function-oriented
new product integration and innovation design model
through a combination of axiomatic design and TRIZ
theory. Borgianni and Dominik (2015) and Chechurin
and Borgianni (2016) put attentions on the sources that
manifest skepticism with respect to the combination of
axiomatic design and TRIZ. Prasad (2016) developed a
simple icon-based flowcharting methodology for cap-
turing concurrency of tasks and activities during prod-
uct design and development phase, and the
methodology can be used to construct the functional
structure of product. These studies primarily used com-
binations of fuzzy clustering methods, TRIZ theory,
axiomatic design, functional analysis system technology
methods, and matrix methods as design tools to solve
functional contradictions appearing in function combi-
nation design. Methods for discovering function con-
flicts and handling structure repulsion were not
explored. In another direction, Liu et al. (2016) pro-
posed a multi-mode product structure design, estab-
lished a multi-mode module using structure sharing in
different modes of partial module structure, and
achieved multi-mode switching product operation. Li
et al. (2016) introduced a function module partition
approach for conceptual design of complex product
through community detection using weighted and
directed complex networks. However, this shared struc-
ture could only operate in one mode at a time.
In conclusion, existing studies proposed some ideas
about product function combination and using existing
design methods to assist product functions. However,
the following issues require further study: (1) remove
function redundancy and carrier redundancy, (2) create
variant designs of function extension, carrier distribu-
tion, and function carriers, and (3) establish a set of
complete systematic design methods for function
combination.
In this article, we proposed a product function com-
bination approach for conceptual design based on
product functional structure and a design structure
matrix (DSM). We aimed to find and solve function
redundancy and carrier redundancy issues among par-
ent products to be combined, make reasonable alloca-
tion among functions and carriers, and generate a
conceptual scheme of combination products through
carrier variation design. The remainder of this article is
organized as follows: Section ‘‘Design process and
implementation’’ focuses on our product function com-
bination method implementation based on functional
redundancy analysis, section ‘‘Design example’’ pre-
sents a sticker removal machine as an example to vali-
date our function combination design method, and
Lu et al.
Figure 1. Parent product analysis.
section ‘‘Conclusion’’ presents our conclusions and
ideas for future studies.
Design process and implementation
Design process
Product function combination design is divided into
three stages. In the first stage, according to the design
task, multiple parent product structures are analyzed,
functional elements are abstracted, and functional con-
figurations are generated. In the second phase, func-
tional redundancy and carrier redundancy between
parent products are analyzed. Then, finally, in the third
stage, new product functions and function carriers are
rationally allocated, and a conceptual combination
product design model is solved.
Analysis of parent product functions
Product function combination design integrates func-
tions of existing multiple parent products into a new
product. Therefore, we must first analyze parent prod-
uct structures and generate the functional structures
before determining what function redundancies possi-
bly exist among the parent products.
The parent products are selected based on the func-
tional requirement. The performance functions are
acquired through analyzing design specification, and
then the functions are decomposed to required func-
tions (which must be achieved in the designed product)
and expected functions (which can be considered in the
designed product). Considering the requirement of
required functions, the parent products are selected. If
there are multiple parent products, the expected func-
tions are considered in the selection of parent products.
231
We disassemble parent products into function car-
riers and abstracted detailed functional elements from
function carriers (Figure 1). Functional elements are
expressed as ‘‘verb + noun.’’ For example, cell function
is expressed as ‘‘store energy’’ and ‘‘supply power.’’ We
use verbs and nouns from standard vocabulary in func-
tional basis (Stone and Wood, 2000) and according to
the functional vocabulary expansion provided by litera-
tures (Hirtz et al., 2002; Hubka and Eder, 2001;
Szykman and Racz, 2001).
Definition 1—function carrier. This is the physical struc-
ture for achieving product functions or sub-functions.
For example, the function carrier of thermos liners
achieves two functions: maintaining internal tempera-
ture and secure storage of contents.
A new or modified design establishing functional
structure is a major step in the design process. Product
functional structure show connections between func-
tional elements and provide evidence for functional
redundancy analysis.
The steps for creating a parent product functional
structure are as follows:
Establishment of a functional white box. Since function
combination design is re-designed by combining exist-
ing products, the product functional system is known.
In this article, we refer to this as a functional white
box. Energy flow is indicated by solid lines, material
stream represented by broken lines, and signal flow
indicated by dotted lines.
Functional decomposition. The traditional functional
decomposition method (Beitz and Pahl, 1992) is greatly
232
affected by the designer experience and personal prefer-
ence, and therefore, the same decomposition method
might yield different results for different designers.
This article presents a new decomposition method,
which was based on three kinds of flow: energy, mate-
rial, and signal flow. We conducted functional decom-
position on parent products, subdivided main flow,
and summarized functional elements operating on
flows. The functional tree generated by this method
showed correspondence between functions and flows to
facilitate subsequent establishment of functional
structures.
Construct function chain and generate functional structure of
parent product. According to the logic between flow
sequence and the function of flow, and starting from
the function tree, we arranged functional elements and
established a function chain. There were four basic
types of function chains: the tandem function chain
refers to the ordered arrangement of functional ele-
ments, and the output of the former function element
is the input of the later functional element; the parallel
function chain refers to the various functional elements
working in parallel that have a common input or out-
put; the recursive function chain refers to functional
elements forming a feedback loop; and the Diego
union-style function chain, in which each element has
its own action, obtains its final output from the out-
puts of various functional elements.
Construction of functional structure of parent product. Using
the parent product analysis method in Figure 1, the
parent product is decomposed into multiple carriers
with multiple functional elements, and the relations
among these carriers are acquired. The functional
chains of functional elements in every carrier are con-
structed, and then, the total functional structure of par-
ent product is constructed through connecting these
functional chains of carriers using their relationship in
parent product analysis.
Table 1. Functional redundancy matrix (FRM).
Function redundancy matrix (FRM)
Parent product B Carrier 1 Functional element 1
Functional element 1
Carrier 2 Functional element 1
Functional element 1
Concurrent Engineering: Research and Applications 25(3)
Analysis of function redundancy among parent
products
This section addresses function redundancy analysis
among products. In product function combination
design, there must be function redundancy and carrier
redundancy among multiple parent products, namely,
the same, similar, or repulsive capabilities. Redundancy
has two meanings: (1) having extra unnecessary por-
tions, hereinafter referred to as passive redundancy; (2)
copying some part, or adding duplicate portions to
enhance security, hereinafter referred to as active
redundancy. In this study, we focused on reducing pas-
sive redundancy.
Our steps in function redundancy analysis are as
follows:
Establish functional redundancy matrix
Definition 2—functional redundancy matrix (FRM).
Functional elements of different parent products as
matrix row and column elements. Matrix cells repre-
sent connections among corresponding rank elements.
By analyzing interactions among rank elements, we
found redundancy among functional elements of differ-
ent parent products to facilitate subsequent processing.
FR represents the redundancy among functions in
FRM. Its size is (0-1), FR = 1 indicates a fully redun-
dant state, FR = 0 indicates no redundancy status, and
FR = 0-1 shows a partially redundant state (Table 1).
The following four aspects are the basis for deter-
mining redundancy degree:
1. Description of functional elements. D represents the
degree of similarity described by functional ele-
ments, and its size is (0-1). Examples include sepa-
rate, divide, fence out, and remove.
2. Input flow of functional elements. Compare similar-
ity degrees of the three kinds of flow of input func-
tional elements. The similarity degree is represented
by I, and its size is (0-1).
Parent product A
Carrier 1 Carrier 2
Functional Functional Functional Functional Functional
element 1 element 2 element 3 element 1 element 2
0 0 0 0 0
0 0 0 0 0
0 1 0 0 0
0 0 0 0 1
Lu et al.
Table 2. Carrier redundancy matrix (CRM).
Carrier redundancy matrix (CRM)
Parent product B Carrier 1 Functional element 1
Functional element 2
Carrier 2 Functional element 1
Functional element 2
3. Output flow of functional elements. Compare simi-
larity degrees of the three kinds of flow output
from functional elements. The similarity degree is
represented by O, and its size is (0-1).
4. Function carrier corresponding to functional ele-
ments. The similarity degree is represented by C,
and its size is (0-1). For example, the correspond-
ing function carrier to start power is a switch.
Redundancy is determined according to the weights
of these four aspects:
FR = aD + bI + gO + lC
where a, b, g, and l are the corresponding weights of
the four aspects, and a + b + g + l = 1. Hereinafter,
all corresponding weights are averaged.
Functional redundancy analysis. Redundancy value analy-
sis and treatment among different functional elements
of parent products was conducted on three main cases.
(1) When FR = 1, the product functional element was
fully redundant. The redundant functional element was
removed because for a plurality of same functionality,
only one must be kept. (2) When FR = 0, the product
functional elements had no redundancy. All functional
elements were preserved, but no other operations. (3)
When 0 \ FR \ 1, the product functional elements
had partial redundancy. In this case, we partially com-
bined redundant functional elements into a new func-
tional element, not only to meet the functional
requirements, but also to reduce the number of func-
tional elements. At the same time, the appropriate car-
rier was also changed (see the carrier processing
method described in the next section). If the functional
elements could not be combined, this process followed
the method in step 2.
Establish a carrier redundancy matrix
Definition 3—carrier redundancy matrix (CRM).
Function carriers of different parent products as row
and column elements in a matrix. Matrix cells represent
connections of ranked elements. By analyzing rank
233
Parent product A
Carrier 1 Carrier 2
Functional Functional Functional Functional Functional
element 1 element 2 element 3 element 1 element 2
1 21 0 0 0
0 21 0 0 0
0 0 0 21 0
0 0 0 0 1
element interactions, we found redundancy among car-
riers of different parent products to facilitate subse-
quent processing.
CR represents redundancy among carriers in the CRM,
its size is (21, 0), CR = 1 indicates a fully redundant
state, CR = 0 indicates an irrelevant state, and
CR = 21 shows a repulsive state (Table 2).
Function carrier relationships of parent products
have the following four conditions. (1) If carriers and
carrying functional elements are the same, ‘‘1’’ is filled
in the corresponding matrix position. (2) If carriers are
the same but carrying functional elements are different,
‘‘21’’ is filled in the corresponding matrix position. (3)
If carriers are different but carrying functional elements
are the same, ‘‘21’’ is filled in the corresponding matrix
position. (4) If both carriers and carrying functional
elements are different, ‘‘0’’ is filled in the corresponding
matrix position.
Analyzing and processing methods of redundancy
value among function carriers of different parent prod-
ucts was conducted for three main cases. (1) When
CR = 1, the product function carriers were fully
redundant. Redundant carriers were removed and only
one of the multiple carriers with the same functionality
was kept. (2) When CR = 0, the product function car-
riers had no redundancy. In this case, the carrier was
kept and no further action was required. (3) When
CR = 21, product function carriers were repulsive to
each other. In situations with different carriers and
same carrying functional elements, same functional ele-
ments and their corresponding carriers were deleted
based on the functional redundancy processing method.
In situations with same carriers but different carrying
functional elements, we transformed the carrier and
integrated a plurality of functional elements into it to
realize its full use.
Carrier transformation. Operations for removing and
retaining carriers are relatively easy, with focus and dif-
ficulty on how to design the transformation of carriers.
Our four operating methods of carrier transformation
are summarized as follows:
234
1. Size ratio variations. Through enlarging or reducing
the carrier size ratio, the corresponding suitable struc-
ture was obtained and requirements for structural
dimensions in product structure design were met.
2. Position variations. By changing carrier positions,
the space was re-allocated to eliminate repulsion
among carriers in spatial positions and position
requirements were met.
3. Morphological appearance variations. Morphological
changes can be endless under circumstance that
ensures no functionality change, and therefore, mor-
phological appearance modification was used to
meet requirements in some special cases.
4. Carrier assembly variations. Using a combination
of carrier variation methods, we organically com-
bined multiple carriers, thereby reducing the total
number of function carriers and simplifying carrier
processing and assembly.
In engineering design, relevant carrier variations
often require the integrated use of these four methods.
Solving for a new product conceptual model
According to the aforementioned redundancy analysis
result, we conducted functional combination of multi-
ple products to generate a conceptual model of new
product. Based on desired requirements in the design
task requirement table and full use of carriers, we either
borrowed the original carrier function or added a few
new carriers to extend functionality of the new product.
Finally, to meet customer expectations and require-
ments, the number of new carriers and product cost
were reduced as much as possible.
Function and carrier configuration. Appropriate carrier
selection and configuration is the key step in design. In
accordance with the function and carrier redundancy
analysis results, a function carrier matrix (FCM) was
established to conduct function and carrier
configuration.
Definition 4—FCM. Functional elements and carrier
required for combination design as matrix column and
Table 3. Function carrier matrix (FCM).
Function and carrier matrix (FCM) Carrier 1 Carrier 2
Functional element 1 0 0
Functional element 2 0 0
Functional element 3 0 0
Functional element 4 0 0
Functional element 5 0 0
Concurrent Engineering: Research and Applications 25(3)
row elements. Matrix cells represent connections
among ranked elements. Through element interactions,
we analyzed and obtained the carrier required by the
functional elements, and completed function and car-
rier configuration.
In the FCM, ‘‘1’’ indicates that the carrier was
involved in functional element achievement, while ‘‘0’’
means the carrier was unrelated to the functional ele-
ment achievement (Table 3).
Solving for the conceptual mode
Establish DSM. The DSM (Liu, 2009) is ranked
elements with the same order forming a square, with
non-diagonal cells showing connections among corre-
sponding ranked elements. The carrier in FCM was
taken as rank elements in DSM to determine the con-
nections among ranked elements and connection direc-
tivity. To obtain more detailed information about the
connections among ranked elements, we divided these
connections into four categories: space connection,
energy connection, material connection, and signal con-
nection. The relation among these carriers is acquired
from the constructed functional structure of parent
product in section ‘‘Analysis of parent product func-
tions.’’ The element in the DSM is determined using
the following rules:
1. Space connection. If there are connection (depen-
dency, containment, orientation, etc.) between the
two carriers, such as the carrier A is located at the
front of carrier B, or the carrier A is located inside
carrier B, the element of space connection is 1, else
the element is 0.
2. Energy connection. If there are energy transmissions,
transformation between the two carriers, the element
of energy connection is 1, else the element is 0.
3. Material connection. If there are material transmis-
sions, transformation between the two carriers, the
element of material connection is 1, else the ele-
ment is 0.
4. Signal connection: If there are signal transforma-
tions between the two carriers, the element of mate-
rial connection is 1, else the element is 0.
Carrier 3 Carrier 4 Carrier 5
0 0 0
0 0 0
0 0 0
1 0 1
0 0 0
Lu et al. 235

Figure 2. Design structure matrix.

Figure 3. Parent products for function combination design: (a) pump-type water gun and (b) electric screwdriver.

Figure 4. Functional decomposition tree of pump-type water gun.

236
Figure 5. Functional decomposition tree of electric screwdriver.
Figure 6. Function chains A and B of electric screwdriver.
After analyzing all connection values between car-
riers, the DSM which represents the connections
between carriers is established, which is shown in
Figure 2.
Conceptual model for solving. DSM spatial connection
data were analyzed to obtain all positional relationships
among carriers and form a new product preliminary
Concurrent Engineering: Research and Applications 25(3)
conceptual model. Furthermore, the energy, material,
and signal connection data were analyzed to determine
which connections the carriers relied on, and how to
connect them to meet the connection in the matrix and
also meet corresponding process requirements.
By repeatedly checking spatial position arrange-
ments of function carriers and connections among car-
riers, the product preliminary conceptual model is
 Lu et al.

Figure 7. Functional structure of electric screwdriver.

237
238 Concurrent Engineering: Research and Applications 25(3)

Table 4. Functional redundancy matrix (FRM).

y1 y2 y3 y4 y5 y6 y7 y8 y9 y10 y11 y12 y13 y14 y15 y16 y17

x1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x4 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0
x5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x9 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x10 0 0 0 0 0 0 0.7 0 0 0 0 0 0 0 0 0 0
x11 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x12 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0
x13 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x14 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x15 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x16 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x17 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x18 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x19 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x20 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x21 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x22 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x23 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x24 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x25 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x26 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

optimize using fuzzy evaluation method (Zhang et al.,
2014), and then, the satisfactory final conceptual model
was realized.
Design example
Establish a parent product functional structure
We designed a new advertising sticker removal
machine. According to task requirements, we combined
two kinds of parent product functions: a pump type
water gun (Figure 3(a)) and an electric screwdriver
(Figure 3(b)). We then conducted functional combina-
tion design.
We constructed functional element structures of the
two parent products. Next, we established a functional
white box, and determined the input and output flow.
Then, we expanded functional decomposition based on
energy, material, and signal connections, as shown in
Figures 4 and 5. According to the functional decompo-
sition tree, we aggregated function chains to form func-
tional structures of each parent product, as shown in
Figures 6 and 7.
Redundancy analysis in parent products
We established an FRM among parent products, deter-
mined the redundancy value among functional
elements, and filled in the matrix cell (Table 4). In the
FRM, x1 x26 were elements of electric screw driver,
where x1 x2 were assemble parts and distribute heat
of shell; x3 x4 were install battery and handheld oper-
ation of handle; x5 x7 were input electric energy,
adjusting electric energy, and output electric energy of
charger; x8 x9 were storage electric energy and pro-
vide electrical energy of lithium battery; x10 x12 were
switch control, adjust speed, transfer pressure of button
switch; x13 was transmission electric energy of wire
way; x14 was converting electric energy into torque of
motor; x15 was transfer torque of shaft; x16 x17 were
transfer torque and adjusting torque of gear box; x18
was lighting use of LED lamp; x19 x22 were clamping
head, rotary screwdriver head, loose screw drive head,
and replace screw drive head of quick change chuck;
x23 was change steering of directional switch; x24 was
display power of display light; x25 x26 were detecting
electric quantity and control electric energy of control-
ler; y1 y17 were elements of pump-type water gun,
where y1 y3 were assemble parts, storage liquid, and
provide liquid of shell; y4 y5 were load liquid and
handheld operation of handle; y6 prevents leakage of
water plug; y7 y9 were switch control, transfer pres-
sure, and adjust water speed of trigger; y10 y11 gener-
ate pressure and transfer pressure of water pump;
y12 y13 were control flow and hydraulic pressure of
check valve; y14 y15 were guide liquid and output
Lu et al. 239

Table 5. Carrier redundancy matrix (CRM)

y1 y2 y3 y4 y5 y6 y7 y8 y9 y10 y11 y12 y13 y14 y15 y16 y17

x1 1 21 21 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x2 21 21 21 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x3 0 0 0 21 21 0 0 0 0 0 0 0 0 21 0 0 0
x4 0 0 0 21 1 0 0 0 0 0 0 0 0 0 0 0 0
x5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x9 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x10 0 0 0 0 0 0 1 21 21 0 0 0 0 0 0 0 0
x11 0 0 0 0 0 0 21 21 21 0 0 0 0 0 0 0 0
x12 0 0 0 0 0 0 21 1 21 0 0 0 0 0 0 0 0
x13 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x14 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x15 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x16 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x17 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x18 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x19 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x20 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x21 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x22 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x23 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x24 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x25 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
x26 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

liquid of catheter; and y16 y17 were supplementary
liquid and dimensional stability pressure of water filled
cavity. The functional elements between two parent
products, such as mounting parts, hand-held operation,
and pressure delivery, had a redundancy value of 1,
and therefore were removed. Only one corresponding
functional element was kept. Finally, switch control
redundancy was 0.7, indicating its requirement for
functional element combination.
We then conducted actual usage analysis.
Advertising stickers were present in conspicuous loca-
tions, and the lighting function was not required; there-
fore, it was removed. Different from tightening and
loosening screws, removing the stickers do not need
reversing, therefore, we removed the changing steering
function.
Next, we established a CRM based on the carriers of
parent products, determined the redundancy value
among carriers, and filled in the matrix, as shown in
Table 5. Since the outer casing had redundancy and
repulsion among functional elements, we only kept one
outer casing. Meanwhile, we conducted variation design
on the outer casing, which was no longer used for stor-
ing liquids, and instead used an external storage kettle
for easy filling of cleaning fluid. The water plug could
also be removed, and therefore, the entire outer casing
did not need to be sealed. Not sealing the casing sets
aside cooling holes to help motor cooling. Handles
showed redundancy and repulsion among functional
elements, so we only kept one handle. Since we used an
external storage kettle to store liquid, the handle was
used to only store the battery. The switch also had
redundancy and repulsion among functional elements.
We only kept one switch, and conducted variation
design it. The switch was designed as two separate bod-
ies, with separate functions for regulating water and
power. Finally, since the functions of the direction
switch and LED lights were removed, these carriers
were deleted.
Solving for a new product conceptual model
Function extension. We combined the battery and han-
dle, creating a removable battery handle, which greatly
increased battery capacity and improved utilization of
the carrier. The original product holder held the batch
head, but we changed that to hold the rubbing head.
The clamp and release functions allow for different
types of cleaning rubbing heads to be used in different
situations. To be flexible to user needs, we also
increased the functions of the cleaning blade. By
designing it on the outer casing, the blade can be folded
and easily replace.
Table 6. Function carrier matrix (FCM).

m1 m2 m3 m4 m5 m6 m7 m8 m9 m10 m11 m12 m13 m14 m15 m16 m17 m18 m19 m20 m21 m22 m23
240

n1 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0
n2 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1 0 0 0 0 0 0
n3 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1 0 0 0 0 0 0
n4 0 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
n5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0
n6 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
n7 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
n8 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
n9 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0
n10 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0
n11 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0
n12 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0
n13 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0
n14 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0
n15 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 0 0 0 0 0
n16 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
n17 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
n18 1 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
n19 1 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
n20 1 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
n21 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
n22 0 0 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
n23 0 0 0 0 1 0 0 0 1 0 0 1 0 0 0 0 0 0 0 0 0 0 0
n24 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
n25 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
n26 0 0 0 0 0 0 0 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 1
n27 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0
n28 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 1
n29 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 1
n30 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 1
n31 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 1
n32 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1
n33 0 0 0 0 0 1 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0
n34 0 0 0 0 0 1 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0
n35 0 0 0 0 1 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0
n36 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0
n37 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0
n38 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0
n39 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0
n40 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0

m1: charger; m2: shell; m3: handle; m4: lithium battery; m5: button switch; m6: wire way; m7: motor; m8: transmission shaft; m9: gear box; m10: quick change chuck; m11: electric quantity display lamp; m12:
controller; m13: water storage kettle; m14: water pump; m15: check valve; m16: catheter; m17: water-filled cavity; m18: blade folding rod; m19: hinge; m20: blade; m21: blade drive retaining device; m22: rubber
ring; m23: cleaning head.
n1: load liquid; n2: storage liquid; n3: provide liquid; n4: handheld operation; n5: prevent leakage; n6: switch control; n7: transfer pressure; n8: adjust the water speed; n9: generate positive and negative
pressure; n10: control flow; n11: increase hydraulic pressure; n12: guide liquid; n13: output liquid; n14: supplementary liquid; n15: stability pressure; n16: distribute heat; n17: assemble parts; n18: input electric
Concurrent Engineering: Research and Applications 25(3)

energy; n19: adjusting electric energy; n20: output electric energy; n21: storage electric energy; n22: provide electrical energy; n23: adjust speed; n24: transmission electric energy; n25: converting electric
energy into torque; n26: transfer torque; n27: adjusting torque; n28: clamp cleaning head; n29: rotary cleaning head; n30: loosen the cleaning head; n31: replace cleaning head; n32: remove stickers; n33: display
power; n34: detecting electric quantity; n35: control electric energy; n36: fixed blade; n37: folding blade; n38: clamping blade; n39: loosen the blade; n40: replace blade.
Lu et al.
Figure 8. Design structure matrix.
Functions and carrier configuration. We established an
FCM through the interactions among ranked elements,
and analyzed it to obtain the function carriers required
by functional elements, as shown in Table 6.
Solving for conceptual model. We established a DSM to
determine the connections among various ranked ele-
ments and their directivity, as shown in Figure 8.
According to DSM data, we then conducted a spa-
tial location arrangement of function carriers and con-
nections among carriers as follows:
1. Space and energy connections were between the
charger and battery. The charger was indepen-
dent from the product design, and since the bat-
tery could be removed and replaced, the charger
charged replacement batteries separately via
wires. This eliminated delayed product use.
241
2. The outer casing had spatial association with
many carriers such as the handle, switch, motor,
wires, gear box, battery indicator light, and cir-
cuit board. The outer casing must position and
secure other carriers, and thus, we reserved spaces
for other carriers in design.
3. The battery was connected to the button switch,
motor, battery indicator lights, and circuit board
via wires.
4. The button switch was mounted on the outer cas-
ing. A sub-button was connected to the battery
and motor, and controlled motor rotation and
stopping by starting or stopping power. Another
sub-button was connected to the water pump to
control pressure.
5. The motor was secured to the outer casing,
received power from the battery, and passed rota-
tional kinetic energy through the transmission
shaft via a gearbox to the rubbing head.
242
Figure 9. Conceptual model of sticker removal machine.
6. The holder was fixed to the turning shaft, and
clamped and released the rubbing head. It also
transferred torque energy to the rubbing head.
7. The battery indicator light was exposed by the
reserved hole on the outer casing. It connected to
the battery, circuit board, and switch via wires, and
displayed the remaining battery charge when in use.
8. The storage kettle was screwed on the outer casing
via a screw thread and with a rubber ring to pre-
vent leaking water. The kettle passed water to the
water cavity through a conduit and one-way valve.
9. The pump was connected to the button switch on
one side, with the other side connected to the
water cavity. It passed pressure through a one-
way valve and conduit to spray water, and relied
on negative pressure to suck water from the reser-
voir kettle into the cavity.
10. The one-way valve was between the conduit and
water cavity, and controlled fluid flow using water
pressure signals.
Concurrent Engineering: Research and Applications 25(3)
11. The blade was connected to the blade holder,
which was connected to the folding lever. The fold-
ing lever was fixed to the outer casing via a hinge.
Energy was transferred through these parts.
12. The rubbing head was mounted on the rubbing
head holder and received rotational energy passed
by the holder.
We repeatedly checked the spatial location arrange-
ment of function carriers and connections among car-
riers to optimize and improve the conceptual model of
the sticker removal machine (Figure 9).
Conclusion
In this article, we proposed a product function combi-
nation method for conceptual design based on prod-
uct functional structure and a design matrix. First, we
abstracted functional elements by analyzing known
products, created product functional structures based
Lu et al.
on decomposition of three types of flows. Then, we
combined the FRM, CRM, FCM, DSM, and other
methods to obtain a function combination conceptual
design model. We used a pump-type water gun and
an electric screwdriver as an example to generate a
conceptual design model of sticker removal machine.
This was realized by analyzing connections between
functions, carriers, and between functions and car-
riers, and using operations such as increasing, remov-
ing, and merging functionality, or removal, increase,
reuse, and variation of carriers. This example illu-
strated that our proposed method of function combi-
nation design helps with rapid and effective multiple
parent product function combination, and thereby
improves design efficiency and accuracy. Follow-up
research will focus on the weights of the four aspects
involved in parent product functional redundancy
analysis, and product conceptual scheme integration
after function combination.
Declaration of conflicting interests
The author(s) declared no potential conflicts of interest with
respect to the research, authorship, and/or publication of this
article.
Funding
The author(s) disclosed receipt of the following financial sup-
port for the research, authorship, and/or publication of this
article: This research work was supported by the National
Natural Science Foundation of China (51375451, U1610112,
and 51505421).
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Author biographies
Chunfu Lu is a professor of School of Art, Zhejiang University of Technology. His major
research areas are Product Innovation Design, Product Semantics, and Design Management.

Hao Chai is a PhD candidate of Zhejiang University of Technology. His research areas are
Design Theory and Methodology, and Product Modelling.

Mengyang Tian is a master candidate of Zhejiang University of Technology. His research areas
are Product Conceptual Design, and Product Function Combination Design.

Xiang Peng is a PhD candidate of Zhejiang University of Technology. His research areas are
Optimization Design Theory, Uncertainty Design, and Topology Optimization Design.

Shaofei Jiang is a professor of Zhejiang University of Technology. His research areas are Design
Theory and Methodology, Product Conceptual Design, Product Quality Design, and Mold
Design.

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