Configuration Design

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Configuration Design
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Product or Part

• Product configuration architecture
• Part configuration

Start with the big picture.... i.e. Product
architecture
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Configuration design
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
Pughs Method Weighted Rating Method
Evaluate
Best configuration(s)
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Product First Use component decomposition
diagrams
                           
elements are arranged into physical building
blocks
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Generalized component decomposition
a. type, number, arrangement of components b.
standard or special purpose (make or buy)
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Product architecture like house architecture
Rooms are arranged according to a logical
scheme. Before the details of all the house are
designed we determine the general layout or
architecture.
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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

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Modular architecture
Product examples Flashlight Refrigerator Automobi
le 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)

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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

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Printer Example
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Cluster elements into logical chunks
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Sketch rough geometric layout
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Sketch interaction diagram
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Part configuration design
Best concept(s)
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
Pughs Method Weighted Rating Method
Evaluate
Best configuration(s)
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What is a part configuration?
For example Design problem support vertical
load ---- Concept wall bracket
geometry material
Physical principle
embodiment
What are some possible configurations for a
wall bracket?
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Part configuration design
geometric features include
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How can we generate alternative part
configurations?
Recall bracket configurations
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Configuration decisions
memorize
How do we create different configurations?
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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!
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Configuration design - analysis
Best concept(s)
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
Pughs Method Weighted Rating Method
Evaluate
Best configuration(s)
Continue on Tuesday
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To analyze configurations, we ask
Will it likely function? Will it likely
assemble? Will it be likely manufacturable?
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Design for function
Will the part or product perform its function(s)?
Use knowledge from math, engg and sciences
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Will it assemble?
What do we mean by assemble?
Assembly - a process of handling components to
bring them together (inserting) and then
fastening them.
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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
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DFA Graphical 1
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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

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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
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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

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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

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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

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Configuration design - evaluation
Best concept(s)
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
Pughs Method Weighted Rating Method
Evaluate
Best configuration(s)
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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

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Configuration design summary
Best concept(s)
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
Pughs Method Weighted Rating Method
Evaluate
Best configuration(s)
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Configuration Design