Design Embodiment

Dictionary definition of embodiment

• the embodiment of someone or something
that represents a quality or an idea exactly
The TOTAL DESIGN Activity
Model
Market
Specification
Conceptual Design
Embodiment Design
Detail Design
Manufacture
Sales

Pugh, modified Dowlen

 Embodiment Design
• Begins with a preferred concept
• Ends with a determined layout
– knowledge of where all the components are
– how the parts are configured
– how things are generally to be manufactured
 IMPLEMENT CONCEPTS
As you implement concepts, the reality
become less and less fuzzy
With each iteration of the concept, you get
less fuzziness
More iterations = more drafts = less
fuzziness = more clarity > production
Coffee maker example
Coffee maker example
 General process 1

• Start with the concept

• Identify crucial requirements from your
specification
• Identify modules – ‘things’ – ‘parts’ – ‘bits’
• Develop preliminary layouts to get the
modules placed in 3D space
• Evaluate layouts for module placement
and select effective ones
Concept Layout
 General process 2
• Fill in spatial form with scale or full size
drawings
• Inventory required supporting functionality
• Develop possible layouts for supporting
functions
• Evaluate and select effective layouts

Preliminary Layout
 General process 3
• Complete form determination with
detailed product definitions
• Engineer and determine component
dimensions
• Check for robustness and errors
• Prepare parts lists, trees, assembly
drawings, component drawings,
materials requirements, product process
plans

Detailed Layout
 Embodiment checklist
• Function • Quality control
• Working principles • Assembly
• Layout, geometry, • Transport
materials • Operation
• Energy and • Life Cycle
kinematics • Maintenance
• Safety • Costs
• Ergonomics • Schedules
• Production
 Some principles
• Systems, energy and material modelling
• Alignment of forces
• General alignment of components and
parts
• Deflection reduction
• Arrangement of forces in members
• Vibration reduction
Failure modes and effects analysis
• Remember Murphy’s Law!
• In what way could each component fail?
• To what extent might it fail?
• What hazards are produced by the failure?
• What steps are you implementing to
prevent failure?
 Examples of failure modes

• Corrosion • Deflections • Ringing

• Fracture • Deformations • Loose
• Material Yield • Seizure • Leaking
• Electrical Short • Burning • Ingress
• Open circuit • Misalignment • Vibrations
• Buckling • Stripping • Whirl
• Resonance • Wear • Sagging
• Fatigue • Overshooting • Cracking
(control)
 Examples of failure modes
• Stall • Embrittlement • Bonding failure
• Creep • Loosening • Lubrication loss
• Thermal
expansion • Scoring • Staining
• Oxidation • Radiation • Inefficient
• UV deterioration damage • Fretting
• Acoustic noise • Delamination • Thermal fatigue
• Scratching • Erosion
• Unstable • Sticking
• Unbalanced • Thermal shock • Inermittent
• Surge • Thermal operation
relaxation • Egress
 FMEA Process

• List each component

• Identify potential failures for each
• List causes or mechanisms of failure
• List effects of failure
• Rate likelihood of failure
• Estimate severity of failure
• List controls for detecting
• Calculate priority of risk
• Develop recommended actions for failure
• Implement