Engineering Design Curriculum

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Engineering Design Curriculum

• Courtesy of
• www.engineering-ed.org/documents/week_1_design_pro
  cess.ppt

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Course Objectives

• Apply the engineering design process
• Define a problem (need) and develop alternatives
  for solving
• Build, test, evaluate prototypes
• Create and use engineering drawings
• Demonstrate drafting techniques

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Engineering design is

• the process of devising a system, component or
  process to meet needs
• a decision-making process in which science and
  mathematics are applied to convert resources to
  meet objectives
• establishing objectives criteria, synthesis,
  analysis, construction, testing, and evaluation

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Problem Characteristics

• Engineering Problem
• Problem statement incomplete, ambiguous
• No readily identifiable closure
• Solutions neither unique nor compact
• Solution needs integration of many specialties

• Science Problem
• Succinct problem statement
• Identifiable closure
• Unique solution
• Problem defined and solved with specialized
  knowledge

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Typical Design Problems
Design a system for lifting and moving loads of
up to 5000 lb in a manufacturing facility. The
facility has an unobstructed span of 50 ft. The
lifting system should be inexpensive and satisfy
all relevant safety standards.
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Studying Engineering Design

• Develop student creativity
• Use open-ended problems
• Use design theory and methods
• Formulate design problem statements and
  specifications
• Consider alternative solutions
• Consider feasibility

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Studying Engineering Design

• Know and apply production processes
• Understand concurrent engineering design
• Create detailed system descriptions
• Include realistic constraints such as
• Economic factors, safety, reliability
• aesthetics, ethics, social impacts

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Awesome Engineers

• Place ethics and morals above all else
• Are team players
• Follow a deterministic design process
• Follow a schedule
• Document their work
• Never stop learning

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Module Organization The Design Process

1. Identify a need, who is the customer
2. Establish design criteria and constraints
3. Evaluate alternatives (systems or components)
4. Build a prototype
5. Test/evaluate prototype against criteria
6. Analyze, tweak (?), redesign (?), retest
7. Document specifications, drawings to build

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Engineering Design ProcessBackup Chart

1. Identify a need
2. Establish design criteria and constraints
3. Evaluate alternatives
4. Build prototype
5. Test/evaluate against design criteria
6. Analyze, redesign, retest
7. Communicate the design

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The Engineering Design Process
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Design is an Iterative Process

• Models or prototypes are made and problems that
  arise may require new ideas to solve and a return
  to an earlier stage in the process
• Finally drawings are released to manufacturing
  for production

• Begins with a recognition of need for a product,
  service, or system
• During the idea phase encourage a wide variety of
  solutions through brainstorming, literature
  search, and talking to users
• Best solutions are selected for further refinement

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Engineering Design Defined

• The crux of the design process is creating a
  satisfactory solution to a need
  Harrisberger

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Engineering Design Process
Customer Need or Opportunity
Source Accrediting Board For Engineering and
Technology
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Primary Design Features

1. Meets a need, has a customer
2. Design criteria and constraints
3. Evaluate alternatives (systems or components)
4. Build prototype (figuratively)
5. Test/evaluate against test plans (criteria)
6. Analyze, tweak (?), redesign (?), retest
7. Project book record, analyses, decisions, specs

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Step 1 Need

• Have a need, have a customer
• External vs internal Implied vs explicit
• Often stated as functional requirement
• Often stated as bigger, cheaper, faster, lighter
• Boilerplate purpose The design and construction
  of a (better____something)_____ for (kids,
  manufacturing, medicine) to do __________.

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Step 2 Criteria Constraints
Design criteria are requirements you specify for
your design that will be used to make decisions
about how to build the product
Aesthetics Geometry Physical Features Performance
Inputs-Outputs Use Environment Usability Reliabili
ty
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Some Design Constraints

• Cost
• Time
• Knowledge
• Legal, ethical
• Physical size, weight, power, durability
• Natural, topography, climate, resources
• Company practices

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Activity/Demonstration

• Product index cards
• Pair up as customer-designer
• Variation on 20 questions
• Identify some design criteria and constraints for
  sample products
• Discuss

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Step 3 Evaluate Alternatives

• Needs best stated as function, not form
• Likely to find good alternatives for cheapest,
  fastest, lightest, and encourage discovery
• Research should reveal what has been done
• Improve on what has been done
• Play alternatives off criteria and constraints
• Brainstorming helps

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Simulation
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Best Design

• Choose best design that meets criteria
• Demonstrate tradeoff analyses (among criteria and
  constraints) are high quality
• Cost (lifecycle) is always consideration
• Resist overbuilding drives complexity, cost,
  time, resources

A quality design meets customers expectations!
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Step 4 Prototype

• Prototype is implementation of chosen design
  alternative
• It is a proof of design, production and
  suitability
• Prototypes are often cost prohibitive Models and
  simulations may suffice
• Quality design does not include redesigning a lot
  of prototypes

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Prototype
Prototype picture of 747
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Step 5 Test it Well

• Test and optimize design against constraints and
  customer expectations.
• Create a test plan showing how to test
• Test in the conditions of use
• Good test plan shows what test, expected results
  how to test, and what analyses will be. It
  relates to specification requirements
• e.g. test plan for light bulb (activity)

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Activity Light Bulb Test
Production assembly-time-demonstration
Robustness-vibration, temperature-test article
Life-hours-statistical sample
Duty cycle-count on/off-prototype
Brightness-lumens-measure
Packaging-drop test-do last
Base fit-yes/no-first article demo
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Step 6 Test and Redesign
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Test Results
Successful Test Satisfying
Test Failure Priceless
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Step 7 Documentation

• Project data book

A complete record All key decisions Good
drawings Test plans Results Conclusions Things
learned
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Draw a Good Picture

• Drawings for project notebook, application,
  display
• Photos, sketches, CAD 2-D or 3-D
• Show assembly, components, materials

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Product Sketches
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Other Drawings