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conceptual design
John E E Sharpe, Engineering Design Centre, Engineering Department,
Lancaster University, Lancaster LA1 4YR, U K
This paper outlines the conceptual design process with reference to the
integrated computer-aided design tool known as Schemebuilder, and the
related work of the Lancaster University Engineering Design Centre. The
aim of the Lancaster EDC is to provide highly integrated support for the
rapid creation and evaluation of a wide range of outline design schemes.
Particular attention is paid to the design of mechatronic systems and
devices.
Keywords: engineering design, conceptual design, decision making,
mechatronics
1 Bracewell, R H, Chaplin, R V,
Langdon, P M, Li M, Oh V,
Sharpe J E E and Yan, X T
'Integrated computer support for
interdisciplinary systems design',
technical report, EDC 1994101,
Lancaster University, 1994
471
Thus there is an overwhelming need to provide support decision throughout the design process, particularly during the early phases of the
conceptual design when the major decisions affecting the commitment of
resources are made. It is widely agreed that the first 5% of the design
process commits 80% of the overall costs to market the product 2.
Any design requires the integration of a number of different disciplines.
Mechatronic systems and many modern manufacturing systems present
many choices across multidisciplinary boundaries, with a commensurate
expansion in alternatives and the need to provide active support to those
unfamiliar with the alternative technologies. In a modern machine a
function may be embodied mechanically, hydraulically, pneumatically, as
an electronically controlled servomechanism or as an embedded software
function with the appropriate interfaces 34. The designer must be supported to consider all of these and make appropriate decisions. The
Schemebuilder integrated suite of computer-aided tools researched at the
Lancaster Engineer Design Centre, does .just this.
472
analyses of design concepts and procedures. Much less attention has been
given in industry and academe to the early stages of the design process in
terms of addressing the potential for computer-based design support tools
at the conceptual stage. The aim of the centre is, therefore, to provide
highly integrated support for the rapid creation and evaluation of a wide
range of outline schemes incorporating a range of technologies and to
enable the comparison of technological alternatives to take place before
large commitments are made and irrevocable decisions taken on the basis
of partial or biased information.
The broad objectives of the Lancaster E D C can therefore be summarized
as"
The means adopted for achieving these aims is a set of linked research
projects under the general title of Schemebuilder, embracing knowledge
systems for conceptual design, the qualitative development of schemes
from first principles, generic function and component databases, configuration layout of schemes, function maps and multiple criteria decisionmaking and simulation and optimization, which together will deliver
powerful practical aids to the designer as shown in Figure 1.
Relating to the exploitation of the work, the further following aims have
been established
473
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2.1
Systems research
Mechatronics as expressed by J Buur (Technical University Denmark), Kajitani and Salminen and Verho
Bond graph analysis created by Paynter at MIT in the early 1960s and
developed for use specifically in design by Sharpe in 1978 at QMW,
University of London; Finger and Rinderle at Carnegie Mellon;
Welch and Dixon at University of Massachusetts and Breedveld et aL
at University of Twente
Physical system simulation as presented in the work of Delgado
(Simon Bolivar University, Venezuela) Breedveld (University of
Twente) Thoma (University of Waterloo) and Karnopp, Rosenberg
and Margolis (University of Stanford, California at Davis and Michigan, respectively).
Structured analysis, including Ross, Ward and Mellor and Yourdon
and the work at VTT Finland
Mixed mode simulation such as the work of Dauphin-Tanguy (Uni-
475
2.2
476
Research team
9 French, M J, Bradley, D A
and Dawson. D Case for support: establishment of engineering design centre', application to
SERC, by Lancaster, UK, 1989
10 Bracewen, R H, Chaplin, R
V. Langdon, P M, Li M, Oh, V K,
Sharpe. J E E and Yan, X T
'Integrated platform for AI support of COmplex design (part I):
rapid development of schemes
from first principles' International
Workshop on Engineering Design, Lancaster, UK, 1995
1 1 Bracewell, R H, Chaplin, R
V, Langdon, P M, Li M, Oh, V K,
Sharpe. J E E and Yan, X T
'Integrated platform for AI support of complex design (part II):
supporting the embodiment process' International Workshop on
Engineering Design, Lancaster,
UK, 1995
12 Oh, V K 'Conflict management in interdisciplinary design'
International Workshop on Engineering Design Lancaster, UK,
1995
13 Yah, X T and Sharpe, J E E
'Reasoning and truth maintenance of causal structures in interdisciplinary product modelling
and simulation' International
Workshop on Engineering Design Lancaster, UK, 1995
14 French, M J and Wldden. M
B 'Function-costing: a promising
aid to early cost estimation'
ASME Conference on Design for
Manufacturability,
Chicago,
1993. Vol 52, pp 85-90
1 5 Oh, V K, Chap.n, R V, Yan,
X T and Sharpe, J E E 'A generic
framework for the complete description of components in the
design and simulation of meehatronic products', HungarianBritish Mechatrenics Conference,
Budapest, 1994
16 Brncewell, H R, Chaplin, R
V
and
Bradley,
D
A
'Schemebuilder and Layout computer based tools to aid in the
design of Meehatronic systems',
IMech Conference on Mechatron i c s - The Integration of Engineering Design, Dundee, UK,
1992, pp 1-7
17 Shame, J E E and
Bracewell, R H 'Application of
bond graph methodology to concurrent conceptual design of interdisciplinary systems'. IEEE/
SMC Conference, Le Touquet,
France, 1993
Research achievements
4.1
477
4.2 Function-costing
18 Tjalve,
industrial
E A short course in
design,
Newnes-
478
on the market offering the sort of value that should be possible, and so
identify a niche for a new product. Function costing may be seen as a
rationalization of widely followed practices such as value engineering,
which it advances to an early stage of design 2.
Function-costing has so far been applied to pressure vessels, various forms
of linear actuators, bearings, electric motors and A/D converters. The
results have been excellent, with much more precision being achieved
than was expected, or is needed, to make the technique of practical value,
with normal standard deviations in predicted costs of single components
of less than 0.1521 . Cost is only one attribute that relates to function, mass
and size, and the limits on the functional variables or efficiency of
operation are others. Attention has recently turned to the importance of
these relationships or mappings to the designer, in the pursuance of
alternative schemes.
Progress is in line with the proposed time scale in terms of the modelling
of cost functions, which was originally envisaged as occupying a 36 month
period from its initiation in 1991. The research into function mapping is in
addition to this.
4.3
During function-means development, some five different types of principles have been identified and applied. These are: the initial or working
principles, that form the basis of a design; the principles that guide the
development of the function-means tree; the principles of embodiment;
the principles of detail design that relate to specific embodiments in
479
4.4 Summary
The present implementation of the set of design tools and aids researched
and implemented during the first period of the EDC as shown in Figure 2,
is potentially of great value to designers, particularly those in the field of
mechatronics. Figure 3 shows a montage of the computer-aided design
process for an exemplary drug infuser.
It is a very valuable tool in educating professional engineers and students
in design. It is anticipated that an educational version of Schemebuilder
will be used in Lancaster and Cambridge for computer-aided design make
and test activities in 1995/b.
In summary
48<)
The newly funded programme of research from October 1994 will build on
the success of the EDC over the past four years in researching and
implementing a number of integrated design methodologies for the
conceptual design of mechatronic systems. The programme relates closely
to the objectives of the EDC as expressed above. The programme is
divided into six closely related projects covering different aspects of
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Statement of Need
FTSTER
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lfigure 3 Screendump
482
il
1) Design and test a suitable classification structure for a central knowledge base of functions, means, working principles and embodiments,
used to
Aid the transformation of textual expressions of need into a
well-defined design context and one or more alternative required
function structures
Support the designer's informed choice of stored working principles and functional embodiments
Provide the basis for a semi-automated functional reasoning
capability, in the form of the decomposition rules
In addition to bond graph inspired areas of functionality, the
classification will also cover information processing, with means
residing on both sides of the 'mechatronic interface' between
energetic and essentially non energetic domains 19
2) Research and demonstrate functions-means development rules for
mixed energetic and information systems, including spatial transformation functions
3) Research methods for relaxing the strict hierarchical requirement of
the existing function-means tree, whilst retaining its capability for
automatic generation of all distinct complete schemes. In particular,
we must cater for the possibility of
'Function sharing' - a single means performing more than one
function 23
Repeated references to the first occurrence of a function which
appears at several places in the tree, so its decomposition and
embodiment need only be performed once.
4) Research the necessary requirements to demonstrate controlled multi-
483
user access to scheme generation, development and evaluation facilities, thus facilitating team design and concurrent engineering
484
5 . 8 Overview
In addition, the director will continue his related programme of research
involving research students in the areas of working principles, bond
graphs and comparative design methodologies.
The relationship of each project may be seen in Figure 2 which shows the
overall structure of the integrated procedure for conceptual design. Each
of the projects is indicated with reference to a key. Each area is clearly
defined despite being highly interactive with each other.
The collaborative research with industry is concentrated into the project
485
486
The Institute for Engineering Design and the Institute for Product
Development at the Technical University of Denmark, Lyngby
The Norwegian Institute of Technology, Trondheim
VT]" in Finland, at Tampere and Oulu
Universities of Twente and Delft, in the Netherlands
University of Leuven, Belgium
487
ETH Zurich
Chambers University, Gothenburg and Royal Institute of Technology, Stockholm
MIT, and the Universities of Carnegie Mellon, Stanford, Michigan
and California, in the USA
Academia Sinica Institute for Systems, Beijing *and University of
Wuhan in China
Simon Bolivar University in Venezuela +
National Autonomous University of Mexico ~
8 Finally
The centre has shown the importance of the use of computer-aided
conceptual design. It has proved itself to be capable of undertaking
advanced research in the field of design and mechatronics and established
a world-wide reputation in both industry and academia. The centre looks
forward to continuing this work, as outlined here and in its five-year plan,
with the support of the EPSRC and an increasing contribution from
industry.
*Application made to the Royal Society under RSoc/CAST agreement for
academic exchange
~The British Council is providing support for academic exchange and the
sending of research students to the EDC
488