ENGG1000 2013 Semester 1

School of Mechanical and Manufacturing Engineering

Week 05: Design Phase 2 of 3 Conceptual Design

Housekeeping Monday Week 05

1. CPR Phase 1, Parts 2 and 3 (Calibrations and Reviews) are due tomorrow. 2. CPR Phase 2, Part 1 (Text Tubmission) is due next Friday (Week 06). 3. Hardware Lab 2 is on this time next week. It will be in the SIRF Building (on the south side of the Library/Mathews) rather than Tyree. Remember to (try to) book a place but dont panic if you cant.

The Phases of the Design Process

Dyms Model (p. 23) We have practised translating a Clients problem statement into our engineering problem statement. Now to generate solutions for solving that problem!

Phase 2: Conceptual Design

Previously Dyms Phase 1: 1.1 Clarify Objectives. 1.2 Establish Metrics for Objectives. 1.3 Identify Constraints. 1.4 Revise the Clients Problem Statement. Then.. 1.5 Identify the Functions needed of the Device. Articulate the Problem Definition in Engineering terms.
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Phase 2: Conceptual Design

For ENGG1000: 1.4 Revise the Clients Problem Statement. Now 2.1 Identify the Functions needed of the Device. Articulate the Problem Definition in Engineering terms (Dyms Step 5). 2.2 Establish the Requirements 2.3 Establish the Means for achieving the Functions. 2.4 Generate design alternatives!

Notes regarding Phase 2:

The aim of the Conceptual Design Phase is to generate a wide range of possible solutions to the problem specified in the design brief and revised and re-stated by your team in Phase 1. Facilitators should be aware of and alert to a tendency among some team members to judge solutions rather than generate them. A brainstorming approach means accepting all proposed solutions without judging them at this stage.

Phase 1 Only..

Phase 1: Problem Definition

Clients Request

Objective Tree

OBJECTIVES

PCC

Constraints

Problem Statement

Establish METRICS

Short List of Concepts 8

Elucidating the Design Problem: From the Clients Request through to the Generation of Concepts

Phase 1: Problem Definition

Clients Request

Objective Tree

OBJECTIVES

PCC

Constraints

Problem Statement

Phase 2.1: Identifying Functions

Black Box

Establish METRICS

Reverse Eng

Enumeration

FUNCTIONS

Determine REQUIREMENTS

Specs

Function-Means Tree

MEANS
C-Sketch

Phase 2.2: Generating Concepts

Morph Chart

6-3-5

Short List of Concepts 9

Gallery

2.1 Putting the Problem Definition into Engineering Terms:

Identifying and Establishing Functions
So far weve been Client-centric with our thinking. Now we move from the Clients perspective into engineering practice and we translate the Clients needs into quantitative, engineering terms that enable us to ensure those needs are met. We must identify Functions that the design must perform and formulate requirements that specify how we may assess the performance of those functions. Function Dyms definition (p. 80): The action for which a person or thing is especially fitted or used or for which a thing exists; or One of a group of related actions contributing to a larger action.
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Simply, a Function: Transforms from State A to State B (energy, material, information etc.). Transforms from Inputs and Outputs. Describes what the design is supposed to do. Functions are the things that a Device needs to do to be successful.

Expressing Functions: Typically a verb-object couple (e.g. Carries dog, moves bale, turns wheel). c.f. Objectives which are typically adjectives (e.g. fast, safe, light, small). But wait Remember to remain solution-independent!

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A Method using Sequential Steps for Identifying Functions: 1. Black (and Transparent) Boxes 2. Reverse-Engineering 3. Enumeration 4. Function-means trees

Example: Establishing the Functions of a Drill

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2.1.1. A Black Box for a Cordless Drill

The inputs and single output of the black box are all related to achieving just one top-level Function that is, to turn the chuck (Dym, Figure 4.1).
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But clearly devices have more than just one (top-level) Function.

2.1.2. Making the Box Transparent: Reverse Engineering the Drill

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Again note: the inputs and single output of the black box are all related to achieving just the one top-level Function. But upon lifting the lid on the black box, we see that inside there are Secondary Functions.

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Be careful when reverse-engineering: Its easy to get distracted from your original Problem Statement i.e. the Clients needs.

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2.1.3. Enumeration
Here we actually tally-up and list Functions. If youre struggling to list the Functions, Dym suggests considering the Omnipotence Paradox (St Anselms Riddle, p. 88).

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2.1.4. Function-Means Trees

This tool allows us to graphically represent the primary and secondary Functions. It also introduces us to progressing from thinking about: what our Device must do to how it will do it; i.e. providing the Functions with Means for achieving them. The top level of the (upside-down) tree states the basic Function. Going down the levels, we alternate between Means and secondary Functions for achieving those means.
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A Function-Means Tree for a cigarette lighter (Dym, Figure 4.5). See how we alternate between Functions and Means.
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This tool allows us to graphically represent the primary and secondary Functions. It also introduces us to progressing from thinking about: what our Device must do to how it will do it; i.e. providing the Functions with Means for achieving them. The top level of the (upside-down) tree states the basic Function. Going down the levels, we alternate between Means and secondary Functions for achieving those means. But be careful: Were now starting to stray into solution dependent territory. Were not quite ready to go fully there. Commitment-phobes are valued here: You must never marry your first design!
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A Function-Means Tree for a cigarette lighter (Dym, Figure 4.5). See how we alternate between Functions and Means.
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Before An Idiot Abroad, Karl Pilkington appeared on The Ricky Gervais Show on radio in the UK (~2010). Karl fancies himself as a bit of an inventor: Karl Introduces his Diary... (1:50 2:45) Can Karl open the lid on the Black Box for his watch? Can he identify the secondary Functions? Can he or is he ever likely to be able to identify any Means for achieving them?
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Before An Idiot Abroad, Karl Pilkington appeared on The Ricky Gervais Show on radio in the UK (~2010). Karl fancies himself as a bit of an inventor: Karl Introduces his Diary... (1:50 2:45) Can Karl open the lid on the Black Box for his watch? Remember to work within the bounds of your capabilities. Innovate: Go stupid: YES NO You need to be able to achieve the Functions !!!
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Elucidating the Design Problem: From the Clients Request through to the Generation of Concepts

Phase 1: Problem Definition

Clients Request

Objective Tree

OBJECTIVES

PCC

Constraints

Problem Statement

Phase 2.1: Identifying Functions

Black Box

Establish METRICS

Reverse Eng

Enumeration

FUNCTIONS

Determine REQUIREMENTS

Specs

Function-Means Tree

MEANS
C-Sketch

Phase 2.2: Generating Concepts

Morph Chart

6-3-5

Short List of Concepts 26

Gallery

Now for some numbers (because Engineers like numbers!)

2.2 Establishing Requirements (Functional Specs)

Setting Performance Levels

Note the Law of Diminishing Returns (as illustrated by Dym Figure 4.6). e.g. Sir Jack Brabham. TaRFU Functions & Requirements:
Transverse small duct: Comply with mass limit: Collect peas quickly: < 400 mm < 4 kg < 120 s ?

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Just pause a minute to tidying-up the nomenclature: Objectives Something toward which effort must be directed our aims or goals. Usually adjectives are involved: e.g. Be small, be light, be fast. We should be able to measure our Objectives using Metrics. Functions The actions we need to undertake to achieve our Objectives. Usually a verb-object couple: e.g. traverse paddock, deliver payload. We use Requirements to specify the performance level required of each Function.

Metrics are applied to Objectives so as to assess the overall efficacy of our design. They are applied in the past tense, whereas: Requirements are requisite for (and so applied to) each of the discrete Functions. They are things we talk about in a future tense.
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2.3 Bounding our Design Space Examining Means for achieving Functions
The Morph Chart as a tool for bounding the design space and listing Means.
Consider the Objectives that you identified when developing your problem statement then the Functions that you have since identified. Then list all the Means by which these can be achieved. This will result in a table or chart of Function or attribute by Means of achieving it (see Dym 5.1.1). Check for agreement on whether the diagram captures the important relationships between ideas. Remember to list Functions that are on the same level: i.e. either the top-level or secondary.
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Dyms example of a Morph Chart for mapping the means by which the functions of a drink container can be met (Dym, Figure 5.1). How big is our design space, i.e. how many potential design solutions do we have? A lot. Or not?
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An example: Dym refers to the Chinese Menu style of the Morph Chart. What about something more parochially Australian? What about something more relevant to Engineering?

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Back to our example using Formula SAE

From Phase 1 we have a Problem Statement: Design and construct a vehicle for competition that accelerates as quickly as possible in any required direction. Performance must be maximised and cost minimised whilst adhering to the rules regarding size and safety. Lets use the accelerate as quickly as possible in any direction part as a Function for which we need to find Means. 1. Construct a Morph Chart 2. Prune the design space by: - Identifying and excluding incompatible alternatives. - Identifying and excluding Karl Pilkington-type ones. - Work-out which Objectives are most important.
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2.4 (Actually) Generating Design Alternatives

2.4.1 A bit about being creative

Lets watch a short video: Edward de Bono on Creative Thinking More from Edward de Bono: Edward de Bonos Six Thinking Hats

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2.4.2 Tools to help you be Creative

Its hard to teach creativity and hard to be (constructively) creative. Personally, I dont really like the expression brainstorming Here are a couple of tools to help get the creative juices flowing: 2.4.2.1 The 6-3-5 Method (Dym 5.2.3.1) Also known as Brainwriting. The team sits around a table. Each member writes down 3 design ideas in brief form on a piece of paper. The papers are rotated around the table with each member writing comments or additions to each of the ideas on each piece of paper. Then the papers are spread out and the design ideas discussed. Ideas are identified that should be discussed further.
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2.4.2.2 The C-sketch method (Dym 5.2.3.2)

Each Team member draws an annotated sketch of their ideas for that aspect of the design. Allow about 5 minutes for sketching. The sketches are them passed around as-per the 6-3-5 method. Each member then adds some notes to or makes some mods to the sketches.

2.4.2.3 The Gallery Method (Dym 5.2.3.3) Each Team member draws an annotated sketch of their ideas for that aspect of the design. Allow about 5 minutes for sketching. The sketches are then put on the wall and there is an open group discussion to identify which concepts have the most potential.
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Elucidating the Design Problem: From the Clients Request through to the Generation of Concepts

Phase 1: Problem Definition

Clients Request

Objective Tree

OBJECTIVES

PCC

Constraints

Problem Statement

Phase 2.1: Identifying Functions

Black Box

Establish METRICS

Reverse Eng

Enumeration

FUNCTIONS

Determine REQUIREMENTS

Specs

Function-Means Tree

MEANS
C-Sketch

Phase 2.2: Generating Concepts

Morph Chart

6-3-5

Short List of Concepts 36

Gallery

What now?
1. Check-out the Group Facilitation Guide. Decide on which tools suit your Team best. 2. Download the templates for the CPR Exercise relating to Conceptual Design. 3. CPR first submission for Phase 2 is due on Friday Week 6. (Remember though to do Calibrations and Reviews for Phase 1 by tomorrow!)

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