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Embodiment Design in PDP

Embodiment Design:
Product Architecture & Configuration Design

Chapter 8
Part 1

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Introduction
 We have divided the embodiment phase of design
lectures into three groups of:
 Product Architecture:
 Arranging the physical elements of a design in order to carry out it’s
functions
 Setting the arrangement of the physical elements of the design into
groupings, called modules.
Configuration Design:

8.2 Product Architecture
 The design of special-purpose parts and the selection of standard
components, like pumps or motors.
 Parametric Design:
What is product architecture?
 Determining the exact values, dimensions, or tolerances of the
components or component features that are deemed critical-to-
quality.
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Product Architecture Integral Architecture

 Product architecture is the arrangement of the physical
elements of a product to carry out its required functions.
 A product’s architecture is related to its function structure,
but it does not have to match it.
 A product’s architecture is selected to establish the best
system for functional success once a design concept has been
chosen.
 There are two entirely opposite styles of product
architecture:
 modular
 integral
 In an integral architecture the implementation of functions
is accomplished by only one or a few modules.
 In integral product architectures, components perform
multiple functions.
 When a component provides more than one function it
enables function sharing.
 Product architecture has strong implications for
manufacturing costs.

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Modular Architecture Types of Modular Architectures

 A modular architecture makes it easier to evolve a design
over time.
 The product can be adapted to the needs of different
customers by adding or deleting modules.
 Modular design may even be carried to the point of using
the same set of basic components in multiple products,
creating a product family.
• Slot-modular: Each of the interfaces between modules is of a different type
from the others.
• Bus-modular: The modules can be assembled along a common interface, or
bus.
• Sectional-modular: All interfaces are of the common type, but there is no
single element to which the other chunks attach.
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Four-Step Process for Establishing

Product Architecture
 Ulrich and Eppinger propose a four-step process for establishing
product architecture:

 Create a schematic diagram of the product

 Cluster the elements of the schematic

 Create a rough geometric layout

8.3 Steps in Developing Product
Identify the interactions between modules
Architecture 

What are the steps in developing product architecture?

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Schematic Diagram: Schematic Diagram:

Shot-Buddy Example Showing Flows Shot-Buddy Example Clustered into Modules

Adapted from J. Davis, J. Decker, J. Maresco, S. McBee, S. Phillips, and R. Quinn, “JSR Design Adapted from J. Davis, J. Decker, J. Maresco, S. McBee, S. Phillips, and R. Quinn, “JSR Design
Final Report: Shot-Buddy,” unpublished, ENME 472, University of Maryland, May 2010. Final Report: Shot-Buddy,” unpublished, ENME 472, University of Maryland, May 2010.
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Geometric Layout: Define Interactions & Determine

Shot-Buddy Example Performance Characteristics
 The most critical task in determining a product’s
architecture is accurately modeling the interactions
between the modules and setting the performance
characteristics for the modules.
 Function happens primarily at the interfaces between
modules, and unless modules are carefully thought out,
complexity can build up at these interfaces.
 The most critical items in the module description are the
descriptions of the interfaces and the modeling of
interactions between neighboring modules.

Adapted from J. Davis, J. Decker, J. Maresco, S. McBee, S. Phillips, and R. Quinn, “JSR Design
Final Report: Shot-Buddy,” unpublished, ENME 472, University of Maryland, May 2010.
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Interactions Between Component

Documentation of Module Modules
 The documentation on each module should include:  There are four types of interactions possible between
component modules:
 Functional requirements  Spatial interactions describe physical interfaces between
 Drawings or sketches of the module and its component parts modules.
 Preliminary component selection for the module  Energy flows between modules represent another important
type of interaction.
 Detailed description of placement within the product
 Information flow between modules often takes the form of
 Detailed descriptions of interfaces with neighboring modules
signals to control the product’s operation or feedback relative
 Accurate models for expected interactions with neighboring to that operation.
modules
 Material can flow between product modules if that is an
element of the product’s functionality.

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Configuration Design
 In configuration design we establish the shape and general
dimensions of components.
 Exact dimensions and tolerances are established in
parametric design.
 The term component is used in the generic sense to
include special-purpose parts, standard parts, and
standard assemblies.
8.4 Configuration Design
 A part is characterized by its geometric features such as
holes, slots, walls, ribs, projections, fillets, and chamfers.
What is configuration design?  The arrangement of features includes both the location and
orientation of the geometric features

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Terms Used in Configuration Design Possible Configurations of Features

 A standard part is one that has a generic function and is  Four possible configurations of features for a right-angle
manufactured routinely without regard to a particular bracket:
product.
 Bolts, Washers, Rivets, and I-beams.
 A special-purpose part is designed and manufactured for a
specific purpose in a specific product line.
 An assembly is a collection of two or more parts.
 A subassembly is an assembly that is included within another
assembly or subassembly.
 A standard assembly is an assembly or subassembly that has
a generic function and is manufactured routinely.
 Electric motors, Pumps, Gearboxes.
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Interrelationship between Function and

Form Starting Steps for Configuration Design
 Review the product design specification and any
specifications developed for the particular subassembly to
which the component belongs.
 Establish the spatial constraints that pertain to the
product or the subassembly being designed.
 Create and refine the interfaces or connections between
components.
 Before spending much time on the design, answer the
following questions: Can the part be eliminated or
combined with another part?
 Can a standard part or subassembly be used?
Adapted from D. Ullman, The Mechanical Design Process, 4th ed., McGraw-Hill, New York,2010.
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Progression of a Design Configuration Activities of Configuration Design

 Refining is a natural activity as we move through the design process in
which we develop more specificity about the object as we move from an
abstract to a highly detailed description.
 Patching is the activity of changing a design without changing its level of
abstraction.
 Substituting looks for other concepts, components, or features that will
work in place of the current idea.
 Combining aims to make one component replace multiple components or
serve multiple functions.
 Decomposing is the opposite approach from combining.
 Magnifying involves making some feature of a component larger relative to
adjacent components.
 Minifying involves making some feature of a component smaller.
 Rearranging involves reconfiguring the components or their features.

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Details a Designer Must Consider in Analyzing and Evaluating

Configuring a Bolted Connection Configuration Designs
 The first step in analyzing the configuration design of a
part is the degree to which it satisfies the functional
requirement and product design specification (PDS).
 Alternative configuration designs of a part should be
evaluated at the same level of abstraction.
 The analysis used for this decision is fairly rudimentary,
because the objective at this stage is to select the best of
several possible configurations.
 A body of guidelines that result in best practice for design
for manufacture and design for assembly have been
developed to assist designers in this area.
Y. Hatamura, The Practice of Machine Design, Oxford University Press, Oxford, UK, 1999, p. 78.
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Typical Design For Function Best Practices for Configuration Design

 Clarity of function pertains to an unambiguous relationship
between the various functions and the appropriate inputs
and outputs of energy, material, and information flow.
 Simplicity refers to a design that is not complex and is
easily understood and readily produced.
 Safety should be guaranteed by direct design, not by
secondary methods such as guards or warning labels.
 Minimal impact on the environment is of growing important,
and should be listed as a fourth basic guideline.

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Design Guidelines Force Transmission

 Four special mentioned design guidelines given by Pahl  In mechanical systems the function of many components
and Beitz: is to transmit forces and moments between two points.
 This is usually accomplished through a physical
 Force Transmission connection between components.
 Division of Tasks  The force should be accommodated in such as way as to
 Self-help produce a uniformly distributed stress on the cross
 Stability section of the part.
 A method for visualizing how forces are transmitted
through components and assemblies called force-flow
visualization is to think of forces as flow lines, analogous to
low-turbulence fluid flow streamlines or magnetic flux.

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Yoke Connection Division of Tasks

 The question of how rigorously to adhere to the principle
of clarity of function is ever present in mechanical design.
 A component should be designed for a single function
when the function is deemed critical and will be
optimized for robustness.
 Assigning several functions to a single component
(integral architecture) results in savings in weight, space,
and cost by may compromise the performance of
individual functions, and it may unnecessarily complicate
the design.

Adapted from R. C. Juvinall, K.M. Marshek, Fundamentals of Machine Component Design, 4th ed., John
Wiley & Sons, Hoboken, NJ, 2006.
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Self-Help Stability
 The idea of self-help concerns the improvement of a  The stability of a design determines whether the system
function by the way in which the components interact will recover appropriately from a disturbance to the
with each other. system.
 A self-reinforcing element is one in which the required  The ability of a ship to right itself in high seas is a classic
effect increases with increasing need for the effect. example.
 A self-damaging effect is the opposite.  Sometimes a design is purposely planned for instability:
 A self-protecting element is designed to survive in the event  Toggle device on a light switch.
of an overload.
 One way to do this is to provide an additional force-
transmission path that takes over at high loads, or a
mechanical stop that limits deflection.

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Additional Design Suggestions Interfaces and Connections

 Tailor the shape to the stress or load distribution.
 Fixed, nonadjustable connection
 Avoid geometry that is prone to buckling.
 Use triangular shapes and structures.
 Adjustable connection
 Don’t ignore strain considerations in design.
 Separable connection

 Locator connection

 Hinged or pivoting connection

Figure above right J. G. Skakoon, “Detailed Mechanical Design,” ASME Press, New York, 2009, p. 114.
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Geometrical Constraint in 2-D Checklist for Configuration Design(1)

 Identify the likely ways the part might fail in service:
 Excessive plastic deformation
 Fatigue failure
 Stress Concentrations
 Buckling Shock or Impact loads
 Identify likely ways that part functionality might be
compromised:
 Tolerances
 Creep
 Thermal deformation

.
J. G. Skakoon, “Detailed Mechanical Design,” ASME Press, New York, 2009.
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Checklist for Configuration Design(2) Design Catalogs

 Materials and manufacturing issues:  Design catalogs are collections of known and proven
 Prevent failure modes in service solutions to design problems.
 History of use for the material  They contain a variety of information useful to design,
 Form and features such as:
 Standard quality specifications  Physical principles to achieve a function
 Material & manufacturing process  Solutions of particular machine design problems
 Standard components
 Design knowledge base:
 Properties of materials.
 Knowledge of the team
 Unfortunate, unlikely, or unlucky event

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Designs for Fixing and Connecting two

Components

Y. Hatamura, The Practice of Machine Design, Oxford University Press, Oxford, UK, 1999.
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