5-Embodiment Design

Introduction to
Engineering Design
Embodiment Design
Dr. Kıvanç Azgın

Middle East Technical University
Department of Mechanical Engineering
Ankara 06531, TURKEY
1956
The Design Steps
2
Embodiment Design
• The bridge between conceptual design
and detailed design
• It is the effort of turning your
“Frankenstein” best concept to a design
as “operational” and “handsome” as
possible.
• Also referred to as:

– Analytical Design
– Preliminary Design 3
Steps in Embodiment Design
• Product Architecture
• Configuration Design
• Parametric Design
• Detail Design
4
Product Architecture
• Arrangement of the physical elements to carry
out its required functions (system level design)
– Create a schematic diagram of the product
– Cluster the elements of the schematic
– Create a rough geometric layout
– Identify the fundamental and incidental
interactions
5
Terminology
• Component: includes special-purpose parts, standard parts,
and standard assemblies / modules
• Part: a designed object that has no assembly operations in its

manufacture
• Standard Part: generic function and manufactured routinely

without regard to a particular product
• Special-Purpose Part: designed and manufactured for a

specific purpose in a specific product line
6
Terminology2
• Assembly: collection of two or more parts
• Subassembly: assembly that is included within

another assembly or subassembly
• Standard Assembly / Module: assembly or

subassembly that has a generic function and is
manufactured routinely (ex: electric motors,
gearboxes)
7
Product Architecture Styles
• Two opposite approaches to product
architecture:
– Modular Architecture
• Designed of maintainability, expandability
– Integral Architecture
• Designed for performance, compactness
8
Product Architecture Steps
• STEP 1: Create a schematic diagram of the product
• STEP 2: Cluster the elements of the schematic
• STEP 3: Create a rough geometric layout
• STEP 4: Identify the fundamental and incidental

interactions
9
Example: Laser Fusing Rapid Prototyping Machine
10
Schematic Diagram of a Laser Fusing Rapid
Prototyping Machine
• The functional
relationship
among the blocks.
• The blocks are

loosely arranged
according to their
geometric
configurations.
11
Cluster Elements of Schematic
12
Rough Geometric Layout
13
Configuration Design
• Establishing shape and general dimensions of components
– Standard parts
– Special purpose parts
– Assembly / standard assembly / standard module
– Sub-assembly
• Preliminary selection of materials and manufacturing process
Use CAD!!
14
Step by Step
• Establish spatial constraints
• Create / refine the interface or connections between

components
• Maintain functional independence in design of an assembly or

component
• Question the design

– Parts can be eliminated / combined?
– Standard module / part ?
• Iteratively fefine and patch

15
Parametric Design
• Objective of parametric design is to set values for
design variables such that they will produce the
best possible design considering the performance
and manufacturing.
• Attributes identified in configuration design

becomes design variables in parametric design.
Some such variables are dimensions, tolerances,
material, surface finish, heat treatment, etc.
• Set dimensions and tolerances so as to maximize

quality & performance and minimize cost!
16
Aspects of Parametric Design
• Failure modes and effects analysis (FMEA)
• Design for reliability
• Robust design
• Tolerance design
• By the end of the parametric design, a

prototype of the product should be
developed.
17
Detailed Design
• Last phase of your Detail Design work.
– Preparation of detailed technical drawings.

– All dimensions, tolerances and surface finish information
should be completed.
– Material information (Bill of Materials).
– Deciding on manufacturing operations.
18
Other Aspects of Emb. and Detailed Design
– Industrial Design (Ch.6 Sec.6)
– Human factors in design (Ch.6 Sec.7)
– Design for the Enviroment (Ch.1 Sec.13, Ch.6 Sec.8, Ch.8
Sec.14)
– Design for …
• Cost (Ch.9 and Ch.14)
• Assembly (Ch.9)
• Manufacture (Ch.9)
• Quality (Ch.12 Sec.1-3)
• Reliability (Ch.11)
• Safety (Ch.11)
• Serviceability (Ch.6 Sec.7)
Considering all these aspects in the design process

requires the use of concurrent engineering approach. 19
Concurrent Engineering
• Started as Simultaneous engineering
– Integration of manufacturing process development into the
early design phases.
• Key aspect of Concurrent Engineering

– Cross-functional teams
• Project members having varying specialties.
– Parallel design
• Development of product and manufacturing process simultaneously.
– Vendor partnering
• Involving the vendors in the design process
20
Important Tools Used in Detail Design
• Modeling
– Representation of the design.
• Simulation
– Representation of the performance of the design.
• Optimization
– Deciding on the design variables that will give the optimum
performance for the design.
• Computer aided design (CAD)
– Combination of modeling, simulation and optimization tasks in
computer environment.
• Computer aided manufacturing (CAM)
– Realization of the design using computer controlled machines.
21
Modeling (in a nutshell)
• There are different model classes:
– Descriptive vs. Predictive
– Static vs. Dynamic
– Deterministic vs. Probabilistic
– Iconic (or physical)
– Mathematical
– Geometrical modeling on the computer
• Levels of Physical Models

– Proof-of-concept model (Minimally operative, “String and chewing gum”
model)
– Scale model (Non-operating model, for visual communication and visualization
of space interferences and conflicts)
– Experimental Model (Functioning model but incomplete in appereance and
can be subject to extensive testing.)
– Prototype model (Technically and visually complete full scale working model)
22
Design Guidelines
• Avoid arbitrary decisions
• Search for alternatives
• Effectively use CAD tools
• Analyze problem at different depths of abstraction
• Develop competing design concepts
• Push some of the design concepts to its physical and
economical limits and then back off
• Clarify functions
• Exploit materails and manufacturing technology to the
fullest!
• Develop a logical chain of reasoning for design
23
An Embodiment Example: “Beetle”
24
25
26
27
Another Example: “Subaru”
28
Another Example: “Porsche”
29
One More Example: “Hammer”
30
Soyuz FG vs. Saturn V
31
RD-107A (3.7m Dia)
32
RD-107A (2m Dia)
33
An ME-407 Project Embodiment:
Automatic Vacuum Cleaner
Vaccum Clean a
Given Area
Make sure
Move to a Manage
Create Vacuum everywhere is
location Available Power
cleaned
Translate the Monitor Power

Chasis Source
Rotate the Decide time to

Chasis recharge
Avoid Collisions
34
Automatic Vacuum Cleaner: Elements
35
Automatic Vacuum Cleaner - Base
36
Automatic Vacuum Cleaner - Base
37
Automatic Vacuum Cleaner:
Transmission
38
Transmission
39
Automatic Vacuum Cleaner: Propeller
40
41
42
43
44
Automatic Vacuum Cleaner: Calc.
45
46
47
48
49
Automatic Vacuum Cleaner: Revisions and
Optimization
50
Automatic Vacuum Cleaner: Control
Architecture
51
Manufacturing and Assembly
52

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Introduction to

Dr. Kıvanç Azgın

• Also referred to as:

• Part: a designed object that has no assembly operations in its

• Standard Part: generic function and manufactured routinely

• Special-Purpose Part: designed and manufactured for a

• Subassembly: assembly that is included within

• Standard Assembly / Module: assembly or

• STEP 1: Create a schematic diagram of the product

• STEP 2: Cluster the elements of the schematic

• STEP 3: Create a rough geometric layout

• STEP 4: Identify the fundamental and incidental

• The blocks are

• Create / refine the interface or connections between

• Maintain functional independence in design of an assembly or

• Question the design

• Iteratively fefine and patch

• Attributes identified in configuration design

• Set dimensions and tolerances so as to maximize

• By the end of the parametric design, a

• Last phase of your Detail Design work.

– Preparation of detailed technical drawings.

Considering all these aspects in the design process

• Key aspect of Concurrent Engineering

• Levels of Physical Models

Translate the Monitor Power

Rotate the Decide time to

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