Configuration Design Architecture Abstract embodiment Special Purpose Parts: Features Arrangements Relative dimensions Attribute list (variables) Standard Parts: Type Abstract embodiment Physical principles Material Geometry Architecture

Product or Part Product configuration = “architecture” Part configuration Start with the big picture.... i.e. Product architecture

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

Product First… Use component decomposition diagrams penlight bulb   battery body spring screw cap glass lens filament base anode cathode electrolyte plastic cover switch case   elements are arranged into “physical building blocks”

Generalized component decomposition Product Subassembly A Standard Part Standard part Special purpose part Special purpose Subassembly B   Subassembly B1 a. type, number, arrangement of components b. standard or special purpose (make or buy)

Product architecture …like house architecture Architecture style Scheme colonial dining, living rooms 1st floor bedrooms on 2nd floor ranch 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.”

Product Architecture (Ullrich & Eppinger) 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

Printer Example

Cluster elements into logical chunks

Sketch rough geometric layout

Sketch interaction diagram

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

What is a part configuration? For example: Design problem: support vertical load ---- Concept: wall bracket Physical principle geometry & material embodiment What are some possible “configurations” for a wall bracket?

Part configuration design geometric features include: walls rounds cubes notches ribs bosses spheres chamfers projections cylinders holes grooves fillets tubes slots

How can we “generate” alternative part configurations? Abstract embodiment Recall bracket configurations different features alternative arrangements different relative dimensions

Configuration decisions Change one or more of these… memorize Configuration decisions How do we create different configurations?

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!

Configuration design - analysis Best concept(s) Configuration design - analysis Product architecture Integral / modular Standard / special purpose Configure Product Re-examine EDS Research sources Configuration requirements sketch Configure Part(s) Iterate Design for Function Design for Assembly Design for Manufacture Analyze and Refine Pugh’s Method Weighted Rating Method Evaluate Best configuration(s) Continue on Tuesday

To analyze configurations, we ask… Will it likely function? Will it likely assemble? Will it be likely 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. Reliable 12. Human factors/ergonomics 13. Safe 14. Easy to use 15. Maintain 16. Repairable 17. Durable (wear, corrosion) 18. Life-cycle costs 19. Styling/aesthetics Use knowledge from math, eng’g and sciences…

Will it assemble? What do we mean by assemble? Assembly - a process of handling components to bring them together (inserting) and then fastening them.

DFA Design for Assembly - a set of design practices which reduce the manpower time required to handle, insert and fasten components of a product. 1. Design Guidelines (written and graphical) 2. Cost estimating methods

DFA Graphical 1

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

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

DFM – Injection molding / casting avoid designing parts with thick walls or heavy sections design parts without undercuts choose polymer 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

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

Graphics during Configuration Design Sketches are used a lot 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

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

Configuration Design Architecture Abstract embodiment Special Purpose Parts: Features Arrangements Relative dimensions Attribute list (variables) Standard Parts: Type Abstract embodiment Physical principles Material Geometry Architecture