MECHANICAL ENGINEERING

Recitationweek2:project
managementplanandproduct
levelbenchmarking

Recitationweek3:
designrequirements

WEARE
HERE

Recitationweek4:
developmentof
morphologies

Recitationweeks5:
designconcept
selectionandmidterm
documentation
Recitationweek6:analyses
anddesignofexperiments

Recitationweek8:presentationprep
Recitationweek7:
costanalysis

ME395: Introduction to Mechanical Design

Recitationweek9:presentations
Recitationweek10:exam

MECHANICAL ENGINEERING

FunctionalDecomposition
READINGthrough2weeks:
Otto,K.N.,K.L.Wood(1997)Conceptualand
ConfigurationDesignofProductsand
Assemblies,Section1.3inASMHandbook,
Volume20:MaterialsSelectionandDesign

JoyceCooper
DesignforEnvironmentLab
UniversityofWashington
cooperjs@u.washington.edu
UWMEDFELab:
http://faculty.washington.edu/cooperjs/
ME395: Introduction to Mechanical Design

Plan,
decompose,
&benchmark

Formulate&
analyze

Communicate
&justify

MECHANICAL ENGINEERING

StartingwithDesignRequirements
Itseemsthateveryoneagreesthatdesign
requirementsmustdescribewhatmustbe
donenothowsomethingshouldbedone.
Solid Fuels Processing Technologies
Thereseemshowevertobedisagreement
concerningdefinitiveness.Shouldyou
AvoidusingthewordsmustandshouldOR
Defineeachrequirementasanexplicitstatementthat
containsa shall wordthatfullydefineswhatthedesign
mustdo.
ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

StartingwithDesignRequirements

Thechoiceislargelydefinedin
designtheoryasitisdeveloped
forleanproductdevelopment.
Inshort,leanproduct
developmentisbasedona
continuousflowprocessdepicted
Solid Fuels Processing Technologies
asafunnel.
Thefunnelstartswithan
uninhibitedcreative
brainstormingphase.The
theoryisthatatthisphase,if
youenforcetheuseof
shallwordsyouwillbe
inhibited.

Seeforexample
Mascitelli,R.(2006)TheLeanProductDevelopmentGuidebook:EverythingYourDesignTeamNeedstoImproveEfficiencyandSlash
TimetoMarket,availableongooglebooks

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

StartingwithDesignRequirements
Soifwekeeparoundamixofrequirementsthat
AvoidusingthewordsmustandshouldAND
Defineeachrequirementasanexplicitstatementthatcontainsa
shall wordthatfullydefineswhatthedesignmustdo.
Solid Fuels Processing Technologies
WefindthattheformerVERYOFTENiswherethe
realinnovationopportunitiesarefound.

Avariationonthisthemeistheuseofaschemetorankorweight
needsorrequirementsinthecustomerexperience.ThisCANALSO
inhibitedcreativebrainstorming.
Forexample,OttoandWood(1997)suggestamethodofSummarizing
CustomerNeedsbasedonascale(0to1,1to10,etc.)..wewillusesimilar
methodsAFTERwehaveaBIGsetofconceptstoconsider.
ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

FunctionalDecomposition
Productresearch
Definingcustomerexperience
needs
Translatingresearchandneeds
Solid Fuels Processing Technologies
torequirements
Developingproduct
morphologiesusingfunctional
decomposition

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Productmorphologies
Morphologyisthestudyof
shapeorform
Morphologicalanalysis
Solid Fuels Processing Technologies
createsnewshapesorforms
Thepurposehereisto
uncovercombinationsof
ideas(subfunction concepts)
thatcombineintodesign
concepts
Dieter,G.,2000,EngineeringDesignAMaterialsandProcessing
Approach,ThirdEdition,McGrawHill

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Developingtheproductmorphology

Twotypesofdecomposition
DecompositioninthePhysicalDomain
decomposetheproductintosubassemblies/
Solid Fuels Processing Technologies
components
Improveoneach

DecompositionintheFunctionalDomain
decomposetheproductintosubfunctions
Innovateoneach
Emphasisisplacedonwhatistobeachievednothowitis
achieved.
Dieter,G.,2000,EngineeringDesignAMaterialsandProcessing
Approach,ThirdEdition,McGrawHill

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

FunctionalDecomposition
Afunction ofaproductisaclear,
reproduciblerelationshipbetweenthe
availableinputsandthedesiredoutputsofa
Solid Fuels Processing Technologies
product,independentofanyparticularform.
Theproductfunction istheoverallintended
functionoftheproduct whatitistodo.

FromOttoandWood(2001)ProductDesign:TechniquesinReverseEngineeringandNewProductDevelopment

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

FunctionalDecomposition
Theproductfunctionisthesimplestrepresentation
oftheproduct,usuallyjustanactiveverbanda
noun:
Solid Fuels Processing Technologies
Ironclothes,chopbeans,makecopies,
loosenscrews,

Basedontheoverallfunction,wenextdecompose
thefunctionintosubfunctions andsoon
FromOttoandWood(2001)ProductDesign:TechniquesinReverseEngineeringandNewProductDevelopment

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Theroleofsubfunctions infunctionaldecomposition
Infunctionaldecomposition,theoverallfunctionisdividedinto
identifiablesubfunctions correspondingtosubtasks.
OttoandWood(1997)notethateachsubfunction isintendedtobe
atomic: itcanbefulfilledbyasinglesolutionprinciple.
Eachsolutionprinciple,canbefulfilledbymultiplesubfunction
concepts.
Solid Fuels Processing Technologies
Forexample,thesubfunction shutdustcoverisfulfilledbyasolution
principleforshuttingorclosingwhichisfulfilledbyanyofthefollowing
concepts:
Bend,fold,wrap,weld,bolt,close,clip,roll,solder,lock,clamp,
enclose,seal,nail,twist,screw,rivet,glue,mold,pin,orpress

So,ifyouhaveagoodsetofatomicsubfunctions,youcanbuildupawiderangeof
productdesignconceptsbyfindingthebestcombinationofsubfunction concepts!
Further,ifthesubfunctions areidentifiedandanalyzedonthebasisofthedesign
requirements,thesuperiordesignconceptswillmeetthegoalofthedesign!

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

CoffeeGrinderFunctionalDecomposition
Grindcoffeebeans

Overallfunction

Firstlevelofsub
functions
Input
beans

Input
power

Hold
beans

Grind
beans

Dispense
grind

Permit
cleaning

Secondlevelof
subfunctions
Ensure
safety

ME395: Introduction to Mechanical Design

Grind
beans

Contain
beans

Contain
noise

Asuperiorcoffeegrinderdesign
conceptisthesuperiorcombinationof
subfunction concepts.

ScrewdriverFunctionalDecomposition
Loosen/tightenscrews
Pickup& hold
screwdriver

Interface
withuser

Uninstall&
installbits

Grip

Energy
status

House
electronics

Safety/
off switch

Accept
and reject
bit

Torque
status

Supply or store
energy/ recharge

Supply
power

Generate torque

Actuate
energy

Rotatescrew

Storebits,&screws

Apply torque

Secure bit

Use energy
Interface
with user

Securescrew

Overallfunction

Regulate
energy

Convert
energy
to torque

Transmit
torque

Change
torque

Rotate
screw

Transmit
torque

Withstand
forces

Dissipate
torque

Rotate bit

Asuperiorscrewdriverdesignconceptisthe
superiorcombinationofsubfunction concepts.

MECHANICAL ENGINEERING

Theroleofsubfunctions infunctionaldecomposition
Sincesubfunctions aresoimportanttobuildingupthesuperior
designconcept,itseemstheidentificationofsubfunctions isvery
important.
Forfunctionaldecomposition,OttoandWood(1997)describea5
phaseprocess: Solid Fuels Processing Technologies
Phase1:Developactivitydiagrams
Developafunctionstructure
Phase2:Formulatesubfunctionsthroughblackboxmodelingandtasklisting
Phase3:Aggregatesubfunctions intoarefinedfunctionstructure

Developandvalidatesubfunction concepts
Phase4:Validatethefunctionaldecomposition
Phase5:Establishandidentifyproductarchitectureandassemblies
Here,forthepurposeofexecutingtheprocessinjust10weeks,wepresentan
alternativetophases25basedonahierarchicalinformationstructure.

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

ProcessDescriptionsasActivityDiagrams
Phase1:DevelopProcessDescriptionsasActivityDiagrams.
Tostartthefunctionalmodelingprocess,anactivity
diagramisanimportanttoolistospecifytheprocessby
whichtheproductbeingdesignedwillbefunctionally
Solid Fuels Processing Technologies
implemented.
Aprocessorprocessdescription,inthissense,includes
threephases:preparation,execution,andconclusion.
Withineachphase,wenetworkhighleveluseractivitiesto
depict
ATLEASTthecustomerexperience(frominstalltoupgrade)
ATMOSTthefulllifecycleofaproduct.
ME395: Introduction to Mechanical Design

Otto,K.N.,K.L.Wood(1997)

MECHANICAL ENGINEERING

Phase1:ProcessDescriptionsasActivityDiagrams
fingernailclipperexample

preparation
execution

InOttoandWoodsfingernail
clipperexample,theprocess
descriptionisrepresentedasan
activitydiagram(Fig.5).This
diagramshowsanumberof
subprocesses thatdescribethe
customerexperience.

conclusion

ME395: Introduction to Mechanical Design

Otto,K.N.,K.L.Wood(1997)

MECHANICAL ENGINEERING

Phases23:Developafunctionstructure
OttoandWoodsmethod
Developafunctionstructure

Phase2:Formulatesubfunctions throughblackboxmodelingandtask
listing
Phase3:Aggregatesubfunctions intoarefinedfunctionstructure
OttoandWood(1997)presentamethodfordevelopingsubfunctions
Solid Fuels Processing Technologies
thatstartswithablackboxmodelwhichdepictsallinputandoutput
flowsfortheprimary,highlevelfunctionofthedesigntask.
Next,atranslationofdesignrequirementsintomaterials,energy,and
informationflowsisusedtodecomposetheblackboxmodelintoa
tasklist.
Next,subfunctions withinthetasklistareaggregatedtoformarefined
functionstructure.

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Developafunctionstructure
OttoandWoodsmethod

Developablackboxmodel

Solid Fuels Processing Technologies

Ablackboxmodeldepictsallinputandoutputflowsfortheprimary,highlevelfunction
ofthedesigntask,statedinactiveverbnounphrases.Inthecontextofinputoutput
modeling,aflowentersanoperationorsubfunction,ismanipulatedbythesubfunction,
andexitsinanewstate.
Aflowisaphysicalphenomenon(e.g.,material,energy,orsignal)thatisintrinsictoa
productoperationorsubfunction.Inthecontextofinputoutputmodeling,aflowenters
anoperationorsubfunction,ismanipulatedbythesubfunction,andexitsinanewstate.
ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Developafunctionstructure
OttoandWoodsmethod

Developablackboxmodel

Solid Fuels Processing

Materialflowscanbe

Whoflows whichAREanimate
(asintheuserofyourproduct)
Whatflows whichARE
inanimate

Exampleenergyflows(Table5)
displacement
power
deflection/strain
electricity
humanforce
frictionforce
Technologies
solarenergy
light
rotation
time
vibration

Informationflowscanbe

Visual
Audible
Olfactory
Signal

Theuseofthewordmaterialkindofstinks
ME395:(apersonshandisamaterialflows?).
Introduction to Mechanical Design

magnetism
pneumaticpower
oscillatingforce
sound(acoustic)
linearforce
stress
torque
heat
noise
hydraulicpower
pressure

Eachmaterial,energy,
orinformationflow
entersasubfunction,is
manipulatedbythe
subfunction,andexits
inanewstate.

MECHANICAL ENGINEERING

Developafunctionstructure
OttoandWoodsmethod

Atranslationofdesignrequirementsintomaterials,energy,and
informationflowsisusedtodecomposetheblackboxmodelintoa
tasklist.
Translationof
requirementstoflows

Decompositionoftheblackboxtoatasklist

Solid Fuels Processing Technologies

Need/
Requirement

Material,Energy,and
InformationFlows

Productcuts
well

generatedcuttingforce
(energy),fingerforce
(energy),andfingernail
(material)

Productis
easytohold

fingerforce(energy)and
hand(material)

Productis
comfortable

fingerforce(energy)and
hand(material)

Sothisisatasklistfor3requirements:productcuts
well,productiseasytohold,andproductis
comfortable.

Theactiveverbnounphrasesintheboxes
ARETHESUBFUNCTIONS.
ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Developafunctionstructure
NOTESONOttoandWoodsmethod

WhenOttoandWoodtranslatethefulllistofneeds/requirementsinthe
fingernailclipperexample,theydonotconsidercost.Theynotethat
Costisnotanaspectofusingtheproduct,sowedonotmodelnot
expensive.Theyfailinthisarticletodelveintothisimportantconcept.
theconceptofrequirementsthatarereallyconstraints.
Solid Fuels Processing Technologies

Need/Requirement

Material,Energy,andInformationFlows

Not expensive

none (thismeanstheyaredesignatingthisrequirementasaconstraint)

Productiscompact

hand(material),fingernaildimensions(material),storagecompartments(material)

Productfileswell

handmotion(energy),fingernail(material),fingernailroughness(signal)

Productcutswell

generatedcuttingforce(energy),fingerforce(energy),andfingernail(material)

Productis easyto
open/close

handmovements(energy)andhand(material)

Productiseasytohold

fingerforce(energy)andhand(material)

Productiscomfortable

fingerforce(energy)andhand(material)

Producthassharpcutting
surface

generatedcuttingforce(energy)andfingernail(material)

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Developafunctionstructure
NOTESONOttoandWoodsmethod

Infunctionaldecomposition,requirementsthroughoutthe
productlifecyclearemetbyfunctions/subfunctions OR
constraints.
OttoandWood(2000)notethat
Solid Fuels Processing Technologies

Aconstraint isarequirementthatrequiresconsiderationof
theentireproducttodeterminethecriterionvalue.
Requirementsthataremetbyconstraintsareservednotby
whattheproductdoes,butratherbyhowtheproductis
instantiatedinform.
See
Otto,K.,Wood,K.(2000)ProductDesign:TechniquesinReverse
EngineeringandNewProductDevelopment
ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Developafunctionstructure
NOTESONOttoandWoodsmethod

Aconstraint isarequirementthatrequiresconsideration
oftheentireproducttodeterminethecriterionvalue.
AIRCRAFTWEIGHTASACONSTRAINT
Airlinesarecustomersthatpurchaseairplanes,andtheyhaverequirementsthatrefertodry
Solid Fuels Processing Technologies
airplaneweight.Theneedforlightweightaircraftcannotberepresentedasafunction,
sincetheairplanedoesnotdoanythingtomakelightness.Thereisnotidentifiable
subsystemthatgenerateslightness.Rather,everycomponentontheairplanecontributes
toweightitisanintrinsicpropertyoftheairplane.
PRODUCTCOMPACTNESSASACONSTRAINT,ORNOTACONSTRAINT
Forthecompactnessofaproduct,onemightconsiderconceptsthatmaketheoverall
productcompact(asinafoldingproduct).Ontheotherhand,someproductswillmeetthe
requirementofcompactnessbysimplybeingsmall.Forthesmallproduct,compactness
wouldbeaconstraintandwouldhaveavolumetriccriteriafortheoverallproduct.
ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Developafunctionstructure
NOTESONOttoandWoodsmethod

Typicalexamplesofconstraintsincludecriteriaofcost,
compactness,footprint,mass,andreliability.Herewe
addergonomicsandaestheticstothelist.ALLexamples
arecontextdependent:theycanbeconstraintsforone
Solid Fuels Processing Technologies
productandfunctions/subfunctions
foranother.
ItisVERYimportanttonotethatsincefunctions/
subfunctions areusedtodevelopdesignconceptsand
constraintsareusedtoomitconcepts,immediately
designatingarequirementasaconstraintLIMITSthe
innovationprocess!!!!
ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Developafunctionstructure
AnalternativetoOttoandWoodsmethod

SoOttoandWoodgotustothefunctionstructure.
Inrelatedworks,OttoandWood(2000)heraldtheblackbox
modeltotasklistmethodasrobust.Theyalsoadmitthatitisnot
asimpleprocedure.
Solid Fuels Processing Technologies
Wehavefoundthatina10weekclassroomsetting,theprocessofcreatinga
tasklistcanloosethesentimentofrequirementsandinvolvesdetailandtime
consuminginputoutputflowmappingthatdoesnotalwayspayoff.
Wearethereforeinterestedinamethodtodefinesubfunctions thatstilltracks
material,energy,andinformationflows;thatmakesuseoftheinformationin
theactivitydiagram;andthatrecognizesthepotentialroleofconstraintsvs.
functions/subfunctions.
So,alteringthemethodpresentedbyOttoandWood,herewedevelopa
methodfordefiningsubfunctions basedontheflowofinformationfromthe
requirementsthroughthefinallistofsubfunctions.
ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Developafunctionstructure

AnalternativetoOttoandWoodsmethod
StartingwiththedesignrequirementsinthecustomerexperienceAND
anactivitydiagram,afunctionstructureisdevelopedin5steps:
1.
2.

Identifyrequirementsthatareconstraints.
Editoromitrequirementssotheydonotpresumeasolution,thusre
emphasizingrulefordevelopingrequirementsthateveryoneagreedupon.describe
whatnothow

3.
4.

Solid Fuels Processing Technologies

Identifymaterial,energy,andinformationflowsthataretransformed/
impactedbyeachremainingrequirement.
DevelopFLOWSTATEMENTSforeachremainingrequirement, notingthat

youMUSTmentionALLFLOWSidentifiedinstep3andyouCANaddquantifying
criteria(e.g.,withstandatemperatureof500F;withstandadropfrom5ft)iftheyare
notalreadyintherequirement.

5.

Definesubfunctions byassigningflowstatementstoactivities,thus
formingafunctionstructure.

OttoandWoods(2000)notethatifitisnoteasytoconceiveofflowsforarequirement,thatitmightbe
becauseitisaconstraint.
Rememberthatconstraintsarecontextdependent:compactnesscanbeaconstraintforoneproductandafunction/
subfunction foranotherandthatsincefunctions/subfunctions areusedtodevelopdesignconceptsandconstraints
areusedtoomitconcepts,immediatelydesignatingarequirementasaconstraintLIMITStheinnovationprocess!!!!
ME395:
Introduction to Mechanical Design

MECHANICAL ENGINEERING

Developafunctionstructure
AnalternativetoOttoandWoodsmethod

HOWABOUTANEXAMPLE!!!!!
Letsexplorethedesignofanewsystemtoautomaticallystir
thefoodcontainedandcookedinapot.
Solid Fuels Processing Technologies
TheAutomaticpotstirrerdesign

IsinspiredbyWeissman etal.(2009,2011)
Whoinvestigatetheuseofstructuredrequirementsphrasingand
informationhierarchiesindesign.
See
Weissman,A.,Gupta,S.K.,Fiorentini,X.,Sudarsan,R.,Sriram,R.D.(2009)FormalRepresentationofProductDesign
SpecificationsforValidatingProductDesigns,preparedfortheUSDepartmentofCommerceNationalInstituteof
StandardsandTechnology,NISTIR7626,availableathttp://www.nist.gov/customcf/get_pdf.cfm?pub_id=902722
Weissman,A.,M.Petrov,S.K.Gupta(2011)Acomputationalframeworkforauthoringandsearchingproductdesign
specifications,AdvancedEngineeringInformatics,25,516534

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Fromproductresearchtodesignrequirements
Automaticpotstirrerdesign

Productresearch
FromAmazon
RoboStir byTelebrands
TheStirChef Handsfree Stirrer
EzStir
Solid Fuels Processing Technologies

ToPatents
Codesandstandards
Customerinterview
ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING
Examplecustomerreviewsfrom
Amazon
Good

Idon'thave3040minutestodevotetoonetask.Iboughta
StirChef anduseditforthefirsttimelastnight.Itworkedvery
well.Thehousingisalittlebulky,butIjustkeptpouringladlesof
brothpastitandintheendhadverygoodrisottowhilebeing
abletocooktherestofthemealandpickupthehousealittle.
Thiswasgreatforatimechallengedcook.
Iboughttwoofthemfiveyearsagoandmodifiedthemtostirmy
12quarteachcaramelbatches.Ireplacedtheplasticpaddlewith
asheetofwhite1/16thinchthickTeflonsheet.Ireplacedthe
armswithbentmetaltongsandwiredthebatteryleadstoa6
voltDCpowersupply.Theyhaveworkedlikeacharmandnever
getsboggeddownevenwhenthecaramelgetsverythick.Early
onwhenusingtheoriginalplasticpaddleitmeltedawayintothe
caramelbatchhencetheTeflonsheetIusenow.

Bad

Poorlyconstructedanddoesnotdoasdesigned/pieceofjunk
Withinjustafewminutesofuse,theplasticbegantomeltand
stainbeyondrecognition.
Afterabout4minutestheflimsyplasticbladesbegantomelt,
addinganinterestingbutunwantedtastetothevegetables.
BiggestproblemIhavewiththeunit(nexttothe4deadbatteries
thatitcamewith)isthespeedatwhichitturns;theconstant
turnsettingseemsalittleslow.Ifoundthatatthespeeditturns,
IneededtokeepmyheatataslowmediumorIgotbuildupand
scorching.Notaproblemthatyoucan'tovercome,butlower
tempsmeanlongercookingtimes.

ME395: Introduction to Mechanical Design

Ensureadequate
power.
Ensureproductis
reliable.
Ensurepartsdo
notmelt.
Operateupto
3040minutesat
atime.

MECHANICAL ENGINEERING

Fromproductresearchtodesignrequirements
Automaticpotstirrerdesign

Productresearch
Patents
Thedeviceshallnotinfringeon.

Solid Fuels Processing Technologies

USPatent5863121:fortheStirChef
USPatent6026735A:assemblyincludesUshapeddevice
whichprovidesheat(sonotusedonastove)andstirring
energytopotswithintegratedstirrer(supplied).
USPatentUS8376608B2:Stirringapparatuswithdeflector
thatsitsinthebottomofapot.
USPatent????forRoboStir byTELEBRANDS

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Fromproductresearchtodesignrequirements
Automaticpotstirrerdesign

Productresearch
Codesandstandards(directlyfromWeissman,etal.)
ThedeviceshallconformtoregulationsofASTM
Solid Fuels Processing Technologies
International.
Thedeviceshallconformtoregulationsofthe
UnderwritersLab.

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Fromproductresearchtodesignrequirements
Automaticpotstirrerdesign

Productresearch
Customerinterviews
Solid Fuels Processing Technologies

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Fromproductresearchtodesignrequirements
Automaticpotstirrerdesign

Productresearch
Customerinterviews

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Fromproductresearchtodesignrequirements
Automaticpotstirrerdesign
Adaptedfromthe
R1:ConductMarketResearch
DesignInformation
R1.1:ConductMarketResearch/PatentInfringement
Database
ThedeviceshallnotinfringeonUSPatent5863121.
ThedeviceshallnotinfringeonUSPatent6026735A.
ThedeviceshallnotinfringeonUSPatent8376608B2.
Solid Fuels Processing Technologies
ThedeviceshallnotinfringeonUSPatentforRoboStir byTELEBRANDS.
R1.4:ConductMarketResearch/Cost
Minimizethepurchasecost.
R2:Design
ThedeviceshallconformtoregulationsofASTMInternational.
ThedeviceshallconformtoregulationsoftheUnderwritersLab.
R3:Procure
Usestandardpartsandprocesseswheneverpossible.
Usepurchasedcomponentsandpartswheneverpossible. Coveredelsewhere
ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Fromproductresearchtodesignrequirements
Automaticpotstirrerdesign
R4:Manufacture/Assembly

Thedeviceshallbeabletobemanufacturedwithin30minutesperunit.
Thedeviceshallbeshippedalreadyassembled.
Designpartssothattheycanbeassembledonlyinthecorrectway.
Minimizemanufacturingandassemblytime,givingprioritytotheuseofpurchasedcomponents.
Avoidtoxicorotherwisehazardousmaterialsinproduction.
Solid Fuels Processing Technologies
Avoidverysmallpartsincomponentsthatarenotpurchasedsubassemblies.
Minimizethenumberofassemblyoperations.
Minimizethenumberoftoolsneededforassembly.
Minimizethenumberoffabricationoperations.
Minimizenumberofpartstobeassembled.
Minimizethequantityandvarietyoftoolingrequiredforassembly.
Minimizevarietyofpartstobeassembled.
Modularizesubassembliesasapproapriate
Adaptedfromthe
Preferableprocessesavoidgeneratingwaste.
DesignInformation
Specifyloosetolerances.
Database
Specifyfabricationprocessesthatcanbedoneinhouse.

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Fromproductresearchtodesignrequirements
Automaticpotstirrerdesign
R5:Test/Inspect
Designtheproduct,itsmajorsubassemblies,andothercomponentssothatthey
canbeeasilytested.
R6:Ship/Transport
ThedeviceshallbeabletoendureadropofXfeetwhilenotinoperation.
Solid Fuels Processing Technologies
Designminimizestheneedforpackaging
R7:Warehouse
Thedeviceshallbeabletobestackedupto6unitshighoncepackaged.
R8:Display
Thedesignofthedeviceshallbecleanandsleek.
R9:Install

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Fromproductresearchtodesignrequirements
Automaticpotstirrerdesign
R10:Use/Operate
R10.1:Use/Operate/MoveorSecure
Thedeviceshallbeabletoautomaticallystirthefoodafteractivation.
Thesolidswithinthefoodshallnotbechoppedupduringoperation.
Thedeviceshallstirfoodofvariousviscosities.
Solid Fuels Processing Technologies
Thedeviceshallstirfoodwithdensitiesthatareloworhigh.
Donotpermitstickingofthefoodtothecookingvessel.
R10.2:Use/Operate/Structure&physicalcharacteristics
Thefoodcapacityofthecookingvesselshallbe1.54.5quarts.
R10.3:Use/Operate/Energyflows
Thedeviceshallprovideortransferenergytostirthefood.
Thedeviceshallprovideortransferenergytoheatthefood.

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Fromproductresearchtodesignrequirements
Automaticpotstirrerdesign

Adaptedfromthe
DesignInformation
Database

R10:Use/Operate
R10.4:Use/Operate/Interface
Thedeviceshallinterfacewithakitchenstove.
R10.5:Use/Operate/Duration
Operateupto3040minutes.
Solid Fuels Processing Technologies
R10.6:Use/Operate/Reliability/Innernoise
Thesurfacesofthedeviceshallbeabletoenduresplatteringofthefood.
Maximizeproductreliability.
R10.7:Use/Operate/Env.conditions/Inducedcondition
Thedeviceshallnotabsorbodors.
Thedeviceshallbeabletoenduretemperaturesupto500Fonthestove.

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Fromproductresearchtodesignrequirements
Automaticpotstirrerdesign
R10:Use/Operate
Adaptedfromthe
R10.8:Use/Operate/Safety
DesignInformation
Avoidburningtheoperator.
Database
Preventsplatteringofthefoodontheoperator.
Ensurewarningsareabletobeseen.
Solid Fuels Processing Technologies
Avoidtoxicorotherwisehazardousmaterialsinproducts
R10.9:Use/Operate/Ergonomics
Thedeviceshallbeabletobeliftedbytheoperatorwithtwohands.
Theweightofthedeviceshallbelessthan8pounds.
Thedeviceshallbeabletobeoperatedbyoneperson.
Easy/intuitivetouse
Ensurestrongandweakusersareaccomodated.
R10:Use/Operate/Aesthetics
Theacousticnoiseofthedeviceshallbelessthan110dBA.

Thedesignofthedeviceshallmatchconventionaldesignschemes.

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Fromproductresearchtodesignrequirements
Automaticpotstirrerdesign

Adaptedfromthe
DesignInformation
Database

R11:Store
Thedeviceshallbestoredinastandardkitchencabinetordrawer.
R12:Service/Repair
Thedeviceshallnotrequireanyothermaintenancebesidescleaning.
Thecookingvesselshallbeabletoendurethetemperatureandhumidityinthedishwasher.
Solid Fuels Processing Technologies
Thedeviceshallresistcorrosionfromwaterandhouseholdcleaningchemicals.
R13:Upgrade
R14:Dismantle
Thedeviceshallbeabletobedismantledusingaphillips screwdriverforpurposesof
recycling.
R15:Recycle
Thedeviceshallbemadefromfullyrecyclablematerials.
Thedeviceshallbemadefromrecycledmaterials.
Labelpartstoinstructforrecycling.
R16:Dispose
Useofenvironmentallyhazardousmaterialsinthedeviceshallbeprohibited.

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Fromdesignrequirementstosubfunctions
Automaticpotstirrerdesign

Wecameupwithatotalof63requirementsfortheautomatic
potstirrer.Giventhese,weproceedthrough.

Phase1:DevelopProcessDescriptionsasActivityDiagrams
Phase2:Developafunctionstructure,in5steps
1.
2.
3.
4.
5.

Solid Fuels Processing Technologies

Identifyrequirementsthatareconstraints.
Editoromitrequirementssotheydonotpresumeasolution.
Identifymaterial,energy,andinformationflowsthataretransformed/
impactedbyeachremainingrequirement.
DevelopFLOWstatementsforeachremainingrequirement.
Definesubfunctions byassigningflowstatementstoactivities,thus
formingafunctionstructure.

Phase3:Developandvalidatesubfunction concepts

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Phase1:DevelopProcessDescriptionsasActivityDiagrams
Automaticpotstirrerdesign
Purchase

Transport
inpackage

Unpackage

Use/operate

Store

preparation

Contain
food

execution

Stirfood
Heatfood

conclusion

Remove
food

Storedevice
andany
attachments

Service/
repair
Cleanup

Anactivitydiagramspecifiestheprocessbywhichtheproductbeingdesignedwillbefunctionallyimplemented.
ME395: Introduction to Mechanical Design
Theprocessdescription,includesthreephases:preparation,execution,andconclusion.

MECHANICAL ENGINEERING

Phase2:Developafunctionstructure
Automaticpotstirrerdesign

Fortherequirementsinthecustomerexperience
STEP1:Identifyrequirementsthatareconstraints

Solid Fuels Processing Technologies

DURATION

OVERALLWEIGHTOFDEVICE
OVERALLERGONOMICS
OVERALLAPPEARANCE
OVERALLSIZEOFDEVICE
OVERALLRELIABILITY

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Phase2:Developafunctionstructure
Automaticpotstirrerdesign

STEP2:Editoromitrequirementssotheydonotpresumeasolution
Remembertherulefordevelopingrequirementsthateveryoneagreed
upon.Describewhatnothow

Solid Fuels Processing Technologies

PRESUMES
THEUSEOF
ASTOVE

Presumesacooking
vesselwillbeprovided
withtheproduct

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Phase2:Developafunctionstructure
Automaticpotstirrerdesign

STEP3:Identifymaterial,energy,andinformationflowsthatare
transformed/impactedbyeachremainingrequirement

Solid Fuels Processing Technologies

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Phase2:Developafunctionstructure
Automaticpotstirrerdesign

STEP4:DevelopFLOWstatementsforeachremainingrequirement,
notingthatyouMUSTmentionALLFLOWSidentifiedinstep3andyouCANaddquantifying
criteria(e.g.,withstandatemperatureof500F;withstandadropfrom5ft)iftheyarenotalready
intherequirement.

Solid Fuels Processing Technologies

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Phase2:Developafunctionstructure
Automaticpotstirrerdesign

Step5.Definesubfunctions byassigningflowstatementsto
activities,thusformingafunctionstructure
(ThisstepisinspiredbytheOttoandWood(1997)designphasefor
aggregatingsubfunctions intoarefinedfunctionstructure.)
Youneedtocreateahierarchybyplacingrelevantsubfunctions
into
Solid Fuels Processing Technologies
theactivitystructure,REPEATINGSUBFUNCTIONSASNEEDED.
Youcan
Useflowstatementsasdeveloped
Youmayneedtolisttheflowstatementswithinmorethanoneactivity(ifthe
requirementappliestomorethanoneactivity)
Divide/combine/omitflowstatements
ASKIseachsubfunction "atomic?"Canthesubfunction befullfilled bya
single,basicsolutionprinciplethatsatisfiesthefunction?
Ifnot,canyoudividetheflowstatementup?orcombine/omitflow
statementsforoverlappingorredundantfunctionality?

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

Step5.Definesubfunctions byassigningflowstatementsto
activities,thusformingafunctionstructure
Activitydiagram

Useflowstatementsas
developed,multipletimes
ifneeded
Divide/combine/omit
flowstatements

Andnoticetheactivitystore
seemstobemissingbecause
therelatedrequirementshave
beendesignatedasconstraints.

ME395: Introduction to Mechanical Design

FunctionalDecomposition
Theprocess

Soletscomparethefunctionaldecompositionprocesses:

Phase1:Developprocessdescriptionsasactivitydiagrams
Phase2:Developafunctionstructure

UsingOttoandWoodsmethod
1.
Formulatesubfunctionsthrough
blackboxmodelingandtask
listing.
2.
Aggregatesubfunctions intoa
refinedfunctionstructure.

UsingthealternativetoOttoandWoodsmethod
1.
Identifyrequirementsthatareconstraints.
2.
Editoromitrequirementssotheydonotpresumeasolution.
3.
Identifymaterial,energy,andinformationflowsthatare
transformed/impactedbyeachremainingrequirement.
4.
DevelopFLOWstatementsforeachremainingrequirement.
5.
Definesubfunctions byassigningflowstatementstoactivities,
thusformingafunctionstructure.

Phase3:Developandvalidatesubfunction concepts

UsingOttoandWoodsmethod
1. Validatethefunctional
decomposition(ensuringthe
definedsubfunctions coverallof
therequirements)
2. Establishandidentifyproduct
architectureandassemblies
(usingamorphologicalchart)

UsingthealternativetoOttoandWoodsmethod
1.
Usethesubfunction structuretoprepareamorphological
chart.
2.
OMITsubfunction conceptsonthebasisofthelifecycle
requirementsandconstraints.

Butwhatisamorphologicalchart?

MECHANICAL ENGINEERING

Phase3:Establishandidentifyproductarchitectureand
assemblies
Giventhesubfunctions defined,aMorphologicalChartisa
matrixwhichcatalogscombinationsofalternativesubfunction
Sub function concepts
concepts.
(1)
(2)
(3)
(4)

Functions and subfunctions

THEROWSLIST
1. Level 1 purchase
2. Level 1 transport in package
SUBFUNCTIONCONCEPTS
3. Level 1 unpackage
Solid Fuels Processing
Technologies
4. Level 1 loosen/ tighten
screws
THECOLUMNS(withina
4.1 Level 2 pick up and hold
4.1.1 Level 3 grip
theme),MEANNOTHING.
4.1.2 Level 3 house electronics
4.1.2 Level 3 safety/off switch
Themorphologicalchart
4.2 Level 2 uninstall & install bits
4.2.1 Level 3 accept and reject bit
thereforedepictsMANY
4.2.2 Level 3 secure bit
4.3
Level 2 secure screw
SUBFUNCTION
4.4 Level 2 rotate screw
4.4.1 Level 3 supply power
COMBINATIONSandtherefore
BatteryElectricalinlet??
4.4.1.1 Level 4 use energy
manypossiblesuperiordesign
4.4.1.2 Level 4 generate torque
4.4.2 Level 3 apply torque
concepts.
4.5 Level 2 put down screwdriver
4.5.1 Level 3 recharge
4.5.2 Level 3 store bits
4.5.3 Level 3 store screws

ME395: Introduction to Mechanical Design

DesigninformationflowthroughOttoandWoodsmethod.
Blackboxmodel
Morphologicalchart

Refinedfunctionstructure

.
Here,constraints
arecalledglobal
functions

Here,thingsare
organizedinto
themes

DesigninformationflowthealternativetoOttoandWoodsmethod.
QUESTION inspiredbythecustomerexperience
hierarchy:Whatfeaturesmustapotstirrernothave?
Developalistofdesignrequirements
R10:Use/Operate/MoveorSecure Donotpermit
stickingofthefoodtothecookingvessel.

RESPONSE:Youshouldalsomake
surefooddoesnotsticktothepot.
DevelopProcessDescriptionsas
ActivityDiagrams:Use/operate
preparation

Containfood

Notaconstraintanddoesnotpresumeasolution
Relevantflows:food(material)
Flowstatement:Avoidstickingfood

execution

Stirfood

Developandvalidatesubfunction concepts

conclusion

Developafunctionstructure

Usethesubfunction structuretopreparea
morphologicalchartand OMITsubfunction conceptson
thebasisoflifecyclerequirementsandconstraints

Heatfood
Removefood

Phase3:Establishandidentifyproductarchitectureandassemblies
Theme1:
Designsthatcome
withbothastirrer
andapot
Usingthealternative
toOttoandWoods
method
1. Usethe
subfunction
structureto
preparea
morphological
chart.

Phase3:Establishandidentifyproductarchitectureandassemblies
Theme2:
Designsthatcome
onlywithastirrer

Usingthealternative
toOttoandWoods
method
1. Usethe
subfunction
structureto
preparea
morphological
chart.

Phase3:Establishandidentifyproductarchitectureandassemblies
Theme2:
Designs
that
come
onlywith
astirrer
Usingthe
alternative
toOtto
and
Woods
method
2.Omit
concepts
basedon
lifecycle
reqs.and
constraints

Likelyinfringes
ontheRoboStir
byTELEBRANDS.

Thismightneedtobelicensed

Radiatingarms
appeartoinfringeon
USPatent5863121

Teflonissuspected
tobehazardous

MECHANICAL ENGINEERING

ConceptGeneration:morphologicalideas
Therearesomeresourcesavailableforgenerating
morphologicalideas.
Sometableshavebeendeveloped
Conceptsforclamping

Conceptsforrotarymotion
Solid Fuels Processing Technologies

FromMagrab,E.B.,1997, IntegratedProductandProcess
DesignandDevelopment:TheProductRealizationProcess.

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

ConceptGeneration:morphologicalideas
Thereissoftware

Fromhttp://www.invention
machine.com
Watchforredirects,companywas
boughtbyHIS,anditseemsthey
callthetoolIHSGoldfire

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

TechOptimizer conceptstomoveliquid
Baseline:
Competingsubfunction concepts
screw

Solid Fuels Processing Technologies

Thesuperiorconcept?

bellows
airpressure

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

ConceptGeneration:morphologicalideas

Thereisbrainstorming
Substitute
whatifweusedinadifferentmaterials,process,
Solid Fuels Processing Technologies
person,powersource,place,orapproach?

Combine
couldwecombineunits,purposes,orideas?

Adapt
whatelseislikethis?whatotherideasdoesitsuggest?

ME395: Introduction to Mechanical Design

Dieter,G.,2000,EngineeringDesignAMaterialsandProcessing
Approach,ThirdEdition,McGrawHill

MECHANICAL ENGINEERING

ConceptGeneration:morphologicalideas

Brainstorming
Eliminateorstandardize
canweremoveorstandardizeapartorfunction
Solid Fuels Processing Technologies
withoutaffectingtheoutcome?

Rearrange,reverse
canweinterchangecomponents?canwemakethings
modular?canweuseadifferentsequenceofevents?
whatifwemovethingsaround,turnthingsupside
down,orinsideout?

ME395: Introduction to Mechanical Design

Dieter,G.,2000,EngineeringDesignAMaterialsandProcessing
Approach,ThirdEdition,McGrawHill

MECHANICAL ENGINEERING

ConceptGeneration:morphologicalideas

Brainstorming
Puttootheroradditionaluses
aretherenewwaystousethisasis?ifwemodifyit,
Solid Fuels Processing Technologies
willithaveotheroradditionaluses?

Modify,magnify,minify
couldweaddanewtwist?couldwechangethecolor,
motion,form,orshape?couldwemakeitstronger,
higher,faster,lighter,moreergonomic,usableinmore
environments?

ME395: Introduction to Mechanical Design

Dieter,G.,2000,EngineeringDesignAMaterialsandProcessing
Approach,ThirdEdition,McGrawHill

MECHANICAL ENGINEERING

ConceptGeneration:morphologicalideas

Brainstorming
Improvethelifecycle
canweusestandardcomponents?canwemakethings
Solid Fuels Processing Technologies
easiertomanufacture?canwemaketheproductsafer
ormoreergonomic?canwemakethingsmoredurable
orupgradable?canweuserecycled/recyclable
materials?

Seektoreducecosts

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

FunctionalDecomposition
Theprocess

Phase1:Developprocessdescriptionsasactivitydiagrams
Phase2:Developafunctionstructure

UsingOttoandWoodsmethod
UsingthealternativetoOttoandWoodsmethod
1.
Formulatesubfunctionsthrough
1.
Identifyrequirementsthatareconstraints.
blackboxmodelingandtask
2.
Editoromitrequirementssotheydonotpresumeasolution.
listing.
3.
Identifymaterial,energy,andinformationflowsthatare
2.
Aggregatesubfunctions intoa
transformed/impactedbyeachremainingrequirement.
Solid Fuels Processing
Technologies
refinedfunctionstructure.
4.
DevelopFLOWstatementsforeachremainingrequirement.
5.
Definesubfunctions byassigningflowstatementstoactivities,
thusformingafunctionstructure.

Phase3:Developandvalidatesubfunction concepts

UsingOttoandWoodsmethod
1. Validatethefunctional
decomposition(ensuringthe
definedsubfunctions coverallof
therequirements)
2. Establishandidentifyproduct
architectureandassemblies
(usingamorphologicalchart)

UsingthealternativetoOttoandWoodsmethod
1.
Usethesubfunction structuretoprepareamorphological
chart.
2.
OMITsubfunction conceptsonthebasisofthelifecycle
requirementsandconstraints.

ME395: Introduction to Mechanical Design

MECHANICAL ENGINEERING

FunctionalDecomposition
Theprocess

Phase1:Developprocessdescriptionsasactivitydiagrams
Phase2:Developafunctionstructure
Phase3:Developandvalidatesubfunction concepts

Whatisnext,theselectionofsuperiorconcepts
Solid Fuels Processing Technologies
Nextweekwewillusedecisionmatricestoselectamong
theMANYpossiblesubfunction combinationsultimately
justifyingyourdesign.

ME395: Introduction to Mechanical Design