Configuration Design

What is a product configuration? What is a part configuration? Product architecture design Part configuration design Evaluating Configurations Computer Aided Design Solid modeling

      

What is configuration design?

For example: Design problem: reduce speed ---- Concept: gear pair

Physical principle

geometry & material

T1 [ 1! T2 [ 2

What are some possible configurations for a gear pair?

Alternative configuration #1

arrange parts differently

Alternative configuration #2

Spur gears

Helical gears

use different features or parts

Configuration #3 and #4

wide teeth use different relative dimensions

similar diameters

What is a part configuration?

For example: Design problem: support vertical load ---- Concept: wall bracket

Physical principle Force Equilibrium

geometry & material

F ! 0

What are some possible configurations for a wall bracket?

Wall bracket configurations

Abstract embodiment

different features

alternative arrangements

different relative dimensions

Configuration decisions

How do we create different configurations? Change one or more of these

Obtaining the best configuration

To choose the best alternative . Implies that we have a number of feasible alternatives! To be selective, we need a selection!

How should we start our configuration design efforts?

Use the design process as a guide?

Formulating Problem
Establish functional requirements Determine constraints Set performance targets Design specifications Create alternative forms (shape, configuration, size, materials, manufacturing processes)

Redesign iteration

Generating Alternatives

all alternatives

Analyzing Alternatives
feasible alternatives

Evaluating Alternatives
best alternative design candidate Manufacturing specifications

Best concept(s)

Configuration design
Configure Product Configure Part(s) Analyze and Refine Evaluate Product architecture Integral / modular Standard / special purpose Re-examine EDS Research sources Configuration requirements sketch Design for Function Design for Assembly Design for Manufacture Pughs Method Weighted Rating Method

Iterate

Best configuration(s)

Product architecture architecture

Architecture style colonial ranch

like house

Scheme dining, living rooms 1st floor bedrooms on 2nd floor all rooms on ground floor

Rooms are arranged according to a logical scheme. Before the details of all the house are designed we determine the general layout or architecture.

Recall: penlight component decomp. diagram

penlight

bulb glass lens filament base

battery anode cathode electrolyte plastic cover

body

screw cap switch case spring

elements are arranged into physical building blocks

Generalized component decomposition

Product

Standard Special purpose Part Part

Subassembly A Special purpose part Standard part

Subassembly B Special purpose part Subassembly B1 Standard part Special purpose part

a. type, number, arrangement of components b. standard or special purpose (make or buy)

Product Architecture
def the scheme by which the  functional elements of a product are arranged  into physical building blocks (components, subsystems or subassemblies)  that interact with each other  to perform the overall function of the product. Product architectures can be modular or integral

Modular architecture
Product examples Flashlight Refrigerator Automobile Personal computer Modular components Batteries, bulbs Motors, compressor, switches Tires, radios, seats, pumps engines Drives, keyboards, mice, modems

chunks implement one or a few functions, interactions between chunks are well defined (standard interfaces / connections)

Integral Architecture
Product examples BMW Motorcycle engine Printer case Shaft Beverage cup Integrating aspects engine/frame integral snap-fasteners machined bearing race integrated handle

a single chunk implements many functions interaction is ill defined physical element shares functions

Steps for developing a product architecture

1. create a schematic of functional and physical elements 2. cluster elements into logical chunks to:  exploit standard components  to exploit standard interfaces (e.g. 120 VAC, RS232 )  fully utilize manufacturing process(es), or vendors  provide for maintenance 3. sketch a rough geometric layout 4. identify interactions between elements 5. refine layout

Printer Example

Cluster elements into logical chunks

Sketch rough geometric layout

Sketch interaction diagram

Best concept(s)

Part configuration design

Product architecture Integral / modular Standard / special purpose Re-examine EDS Research sources Configuration requirements sketch Design for Function Design for Assembly Design for Manufacture Pughs Method Weighted Rating Method

Configure Product Configure Part(s) Analyze and Refine Evaluate

Iterate

Best configuration(s)

Part configuration design

geometric features include: walls ribs rounds bosses cubes spheres holes slots notches chamfers grooves

projection cylinders s fillets tubes

How can we generate alternative part configurations?

Recall bracket configurations

Abstract embodiment

different features

alternative arrangements

different relative dimensions

Example: configuring a sponge holder

Step 1. Prepare configuration requirements sketch sponge holder

Step 2. Prepare non-contiguous config. requirements sketch

Step 3. Prepare alternative contiguous configuration sketches

Step 4. Refine configurations

with hole in back wall

with hole in offset wall

Best concept(s)

Configuration design - analysis

Product architecture Integral / modular Standard / special purpose Re-examine EDS Research sources Configuration requirements sketch Design for Function Design for Assembly Design for Manufacture Pughs Method Weighted Rating Method

Configure Product Configure Part(s) Analyze and Refine Evaluate

Iterate

Best configuration(s)

To analyze configurations, we ask

Will it function? Will it assemble? Will it be manufacturable?

Design for function

Will the part or product perform its function(s)? 1. Strong 2. Stiff or flexible 3. Buckle 4. Thermal expansion 5. Vibrate 6. Quiet / Noise 7. Heat transfer 8. Fluids transport / storage 9. Energy efficient 10. Stable 11. 12. 13. 14. 15. 16. 17. 18. 19. Reliable Human factors/ergonomics Safe Easy to use Maintain Repairable Durable (wear, corrosion) Life-cycle costs Styling/aesthetics

Will it assemble?

What do we mean by assemble?

Assembly - a process of handling components to bring them together (inserting) and then fastening them.

Reduce handling

1. Handling - (GMOP: grasping, moving, orient, place). design parts or products to reduce the influence on handling: size, thickness, weight, nesting, tangling, fragility, flexibility, slipperiness, stickiness, need for 2 hands, tools, optical magnification or mechanical assistance.

Reduce inserting and fastening effort

2. insertion & fastening - mating a part to another part or sub-assembly. design parts and products accessability visibility depth of insertion fastener used to reduce the influence of: resistance (force) to insertion ease of alignment & positioning separate operation required

DFA

Design for Assembly - a set of design practices which reduce the manpower time required to handle, insert and fasten components of a product.

Design for Assembly Guidelines from SME

minimize part count minimize levels of assembly (number of assemblies) encourage modular assembly use standard parts stack sub-assemblies from the bottom up design parts with self-fastening features (snap-fits, press-fits) facilitate parts handling (grasp, orient, move) design parts with self-locating features (e.g. chamfers, aligning recesses/dimples) eliminate reorientation (i.e. insertion from 2 or more directions) eliminate (electric) cables

DFA Graphical 1

DFA Graphical 2

DFA Graphical 3

DFA Graphical 4

Pros and cons of DFA methods

1. Design Guidelines pros: fast, easy, non-coupled cons: non-quantitative, can t compare alt. designs 2. Assembly Efficiency (Boothroyd & Dewhurst) Ema = theoretical min. assembly time estimated assembly time pros: systematic, comparative cons: takes time to code & calculate

DFM
Deign for Manufacture (manufacturability) - A set of practices that aim to improve the fabrication of individual parts

1. Design Guidelines (written and graphical) 2. Cost estimating methods (difficult w/o dimensions)

DFM

Injection molding / casting

avoid designing parts with thick walls or heavy sections design parts without undercuts choose material for minimum total part cost (i.e. tooling, processing, material) design external threads to lie on parting plane/surface add ribs for stiffening

DFM

Sheet metalworking

 

avoid designing parts with narrow cutouts or projections minimize manufactured scrap (cut-off versus blanking) reduce number of bend planes keep side-action features to a minimum or avoid completely

DFM - Machining
employ standard features (e.g. holes, slots, chamfers, fillets, rounds) use raw material available in standard forms (e.g. sheet, roll, bar, plate) avoid sharp internal corners on turned parts specify liberal tolerances and surface finishes

 

Obtaining the best configuration

To choose the best alternative . Implies that we have a number of feasible alternatives! To be selective, we need a selection!

How should we start our configuration design efforts?

Best concept(s)

Configuration design - evaluation

Product architecture Integral / modular Standard / special purpose Re-examine EDS Research sources Configuration requirements sketch Design for Function Design for Assembly Design for Manufacture Pughs Method Weighted Rating Method

Configure Product Configure Part(s) Analyze and Refine Evaluate

Iterate

Best configuration(s)

Let s evaluate the Sponge holder configurations

with hole in back wall

with hole in offset wall

Evaluation using Weighted Rating Method

1. 2. 3. 4. 5. 6. List evaluation criteria (in a column). Determine importance weights (in an adjacent column) List alternatives (along the top row) Rate each alternative on each criterion Compute the weighted rating for each criterion Sum the ratings to produce the Overall Weighted Rating

Evaluating alternative configurations

Importance Weight 15 10 10 15 Sponge Holder Configuration Ratings With hole With bracket Rating Wt. Rating Rating Wt. Rating 3 3 2 2 0.45 0.30 0.10 0.40 3 3 3 4 0.45 0.30 0.15 0.80

Criteria Function drains well dries quickly stays clean sponge inserts easily Manufacture material usage tooling costs processing costs Assembly handling insertion number of parts Weighted rating

10 15 5

3 3 3

0.30 0.45 0.15

2 2 3

0.20 0.30 0.15

5 5 10 100%

3 3 3

0.15 0.15 0.30 2.75

3 3 3

0.15 0.15 0.30 2.95

Best concept(s)

Configuration design summary

Product architecture Integral / modular Standard / special purpose Re-examine EDS Research sources Configuration requirements sketch Design for Function Design for Assembly Design for Manufacture Pughs Method Weighted Rating Method

Configure Product Configure Part(s) Analyze and Refine Evaluate

Iterate

Best configuration(s)

Using graphics during configuration design

  

Sketches are used often in configuration design Sketches assist creativity Sketches are not typically used to document the design CAD Drawings need sizes (e.g. H, W, L, D) CAD Takes time But, some CAD may be useful

 

CAD

Compact disk

demo of solid modeling

Computer Aided Design

data models

   

2-D model: (x1, y1), (x2, y2), faceted curves Wireframe model: (x1,y1,z1), (x1, y2, z2) Surface model: (pts, surface data) Solid model: (solid primitives, Boolean op s)

Advantages of solid modeling

Design intent is captured- such as holes moving with bosses Feature-based modeling automating with features such as chamfer, fillet, flange-bolt Constraint-based geometric relations Parametric- dimensions are placeholders Fully Associative- one model controls all views Assemble-ability check interference, motion Downstream benefits- CAE, FEA, CAM, rapid prototyping

    

Summary
       

Product configuration Part configuration Product architecture design Part configuration design Analyzing configurations Evaluating configurations Computer Aided Design Solid modeling