Design Process; the basic module

General Information

Specific Information

Design Operation

Outcome

No Feedback loop

Evaluation

Yes

Go to The Next Step

Introduction limit behavior run-time performance measures

Problem Solving Methodology

Definition of the problem Gathering of information Generation of alternative solutions Evaluation of alternatives Communication of the result

Morphology of Design
Phase I: Phase II: Phase III: Phase IV: Phase V: Phase VI: Phase VII: Conceptual Design Embodiment Design Detail Design Planning for Manufacture Planning for Distribution Planning for Use Planning for Retirement of the Product

Conceptual Design Define problem

Problem statement Benchmarking QFD PDS Project planning

Gather information
Internet Patents Trade literature

Concept generation
Brainstorming Functional decomposition

Evaluation of concept
Decision matrices

Product architecture
Arrangement of physical elements to carry out function

Configuration design
Prelim. selection of material and mfg. Modeling and sizing of parts

Parametric design
Robust design Tolerances Final dimension DFM

Detail design
Detailed drawings and specifications

Embodiment Design

Concept Generation
Problem decomposition

Evaluation
Absolute criteria

Explore fore ideas

Go-no-go screening

External to team

Internal to team Brainstorming

Relative criteria Pugh concept selection Decision matrix Analytical hierarchy process

Explore systematically Morphological chart

Best concept

Approach towards Sustainable design

Pre-Design

Factory

Design

Prototype
Environmentally Conscious Construction

O&M

Material Selection Building Program Project Budget Team Selection Partnering Project Schedule Laws, Codes & Standards Research Site Analysis & Assessment Development of Layout Site Material & Equipment Passive Solar Design Materials & Specification Quality

Maintenance Plans Indoor Quality Energy Efficiency Resource Efficiency Renovation Housekeeping & Custodial Practices

Preservation of Features & Vegetation Waste Mgmt IAQ Issues Source Control Practices

Algorithm of Inventive Problem Solving

Original problem statement Formulate technical contradiction Formulate initial physical contradiction

Formulate main contradiction

Formulate ideal solution

Analysis of conflict domain & resource

Method of elimination of Physical contradiction

NO SOLUTION

Reformulation of problem statement

SOLUTION

Knowledge base of effects

Decomposition in the Physical Domain

Bicycle

Frame

Seat

Wheels

Brakes

Gears

Rim 1. 2.

Spokes

Tire

Decompose the product into subassemblies and components that are essential for the all functioning of the product. Need to understand the interactions and connections that each of these subassemblies and elements has with each other. The connection can be physical, energy, or force connection.

Summary of RCDM applied to the robotic manipulator

Start of RCDM Stage I: Definition of the robustness problem Stage II: Derivation of guiding principles Stage III: New concept synthesis Stage IV: Evaluation of alternative concepts Follow-on process

Case study - Material Forming Process

Extrusion Cross-linking Expansion

Robust Design The RCDM Robot Forming Process Conclusions

Specifications - Material Forming Process

Product dimensions Process constraints Productivity

Critical requirements
Lexp Expanded Wmin Lrec Wmax Recovered Expanded

 Wmin W ecc ! max Wmax

P af !

Lexp Lrec

Existing design concept

Front vacuum Rear vacuum

Inlet traction belts

Heating Cooling Cooling bath Front Die Rear die trough sealing die insert seal Tubing

Outlet traction belts

Free body diagram

Fpd Fin

Fcd Fp F

Causes of longitudinal stretch

CAUSES High frictional forces Contact area Contact pressure Friction coefficient Interference fit of tubing with sealing die Poor lubrication Excessive pressure forces Excessive cooling at intermediate expansion ratios Excessive longitudinal stretch EFFECT

Applied pressure differential

Poor thermal contact High cooling die Insufficient cooling between tubing and temperature cooling die during expansion Excessively high heating Short residence time in tank temperature contact with cooling die Low Poisson Insufficient effect cooling

Guiding principles
Fpd Fin Fcd Fp F

Reduce friction forces Reduce pressure forces Maximize Poisson effect Maximize cooling

Eccentricity model

Force

WA1 1 2 A WB1

Fh1

Fh2 A B

Section A Section B

Fh2 Fh1

B eB1 eA1 eB2 eA2 Engineering Strain

Causes of eccentricity
CAUSES Initial thickness variation Lubricant uniformity Coolant uniformity Axial alignment of tooling Product orientation during irradiation Circumferential cross-link density variation EFFECT

Extrusion process parameters Die design Die wear Eccentricity

Temperature nonuniformity

Guiding principles
Force Fh2 A B B eB1 eA1 eB2 eA2 Engineering Strain Section A Section B

WA1 1 2 A WB1

Fh1

Fh2 Fh1

Improve circumferential temperature uniformity

New concept synthesis

Multiple pressure port cooling die
P1 P2 P3 P4 Pressure port feed-throughs

Axial flow of coolant Coolant inlet Coolant outlet

New concept synthesis

Porous metal fluid film cooling die
Front pressure port Rear pressure port

Porous metal cooling die

Fluid film

New concept synthesis

Lubricant flooded forming zone
Front pressure port P1 Fluid supply Rear pressure port P2

Evaluation
Evaluation criteria Multiple pressure port cooling die Proposed design concepts Porous Custom Speed metal fluid contoured constraint film cooling die in heating cooling die tank + + + + + + 0 0 + 0 0 + + 0 + + 0 0 0 + + 0 0 0 0 + + 0 0 + 0 0 0 0 0 0 0 0 0 + + 0 0 Lubricant flooded cooling die

Robustness

Process constraints

Productivity

Robustness Longitudinal stretch Long stretch variation Eccentricity Other performance Inner diameter Skew Process constraints Feed tension Bursting Amnesia Snap-back Splitting Thermal degradation Productivity Yield Line speed Set-up effort Engineering design time

+ + 0 0 0 + + 0 0 0 0 + + 0

+ + + + + + 0 0 + 0 0 + + 0 0