Engineering 11
Engineering
Design
Bruce Mayer, PE
Licensed Electrical & Mechanical Engineer
BMayer@ChabotCollege.edu
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
OutLine  Engineering Design
 What is engineering design, really?
 Function to form
 Design process
 Phases of design
 Product Realization/Development Process
 Concurrent engineering
 Teamwork
 Summary
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
Design vs. Ambiguity
 Design ≡ a “valid” or “acceptable” Solution
to an OPEN-ENDED Problem
• e.g.; Design a Cell-Phone that OUTSELLS All Others
 All design challenges are ambiguous.
• Unlike answers to mathematical expressions there
are always several “right” answers to ANY design
challenge.
 The answer is always uncertain or ambiguous.
 Not all design solutions are equally good
however, and some are definitely wrong.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
Well-Defined vs. Open-Ended
 Design Problems Have NO “Correct” Solution;
• Have only: Successful and UNsucessful Solutions
• Compare to Skills-Development (practice) problems
 Skills Development
(Textbook Type)
• Well-defined,
• Complete (correctly
stated, unique)
• Correct answer exists
• Money not involved
• You know When You
Arrive at the Answer
• Requires Application of
Very Specific Knowledge
Engineering-11: Engineering Design
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 Design Problems
(Open Ended)
• Poorly-defined
• No Unique Solution;
Depends on Approach
• Cost & Schedule are
Critical Factors
• “Done Point” Very Hard
to Identify
• Need MultiDisciplinary
Knowledge
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
Analysis vs. Synthesis
 Analysis → Know What IS/OCCURS and
Then Try to EXPLAIN it
• A separating or breaking up of a whole into its
parts, with an examination of these parts to reveal
their nature, proportion, function,
interrelationships, etc.
 Synthesis → Know What IS NEEDED and
Then Try to CREATE (Design) it
• The putting together of parts or elements so as to
form a whole
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
Example  MechEngr Design
 Analysis
•
•
•
•
•
•
•
•
Forces
Moments
Flow
Pressure
Machines
Mechanisms
Motion
Energy
Conversion
Engineering-11: Engineering Design
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 Synthesis &
Testing
• Sketch/Draw
• Predict
Behavior
– Model or Test
• SubScale
Tests or
Experiments
• Materials
• Manufacturing
 Realization
• Customer
needs
• Company
Requirements
• Manufacturing
Costs
• Performance
– Analysis
– Testing
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
Design vs. Analysis

Which of the following is design and
which is analysis?
a) Given that the customer wishes to fasten
together two steel plates, select appropriate
sizes & materials for the bolt, nut & washer
b) Given the cross-section geometry of a new
airplane wing then determine the lift it
produces using Fluid Mechanics principles
 Form is the solution to a design problem
• In this Case the Bolt SIZE & Material
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
Form FOLLOWS Function
 Function “Directs” Form
 Form ≡ Shape, Size, Configuration,
Weight, Human InterFace Appearance,
Materials of Construction, etc.
 DESIGN connects Form (the OutPut) to
the desired Function (the InPut) Thru a
DECISION-MAKING PROCESS
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
FunctionForm Graphically
Function
 Control, hold, move, protect,
heat/cool, store, amplify, etc.
DESIGN
 Decision-Making Process
Form
 Shape, configuration, size,
materials, manufacturing
processes, etc.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
Engr-Design as Decision-Making
 Design Definition  Short Version
• Set of decision making processes and
activities to determine the FORM of an object,
given the customer’s desired FUNCTION
 Design Definition  Long Version
• The process of devising a system, component,
or process to meet desired needs. It is a
decision-making process (often iterative), in
which basic-science, mathematics and the
engineering-sciences are applied to optimally
convert resources to meet a stated objective
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
Decision-Making  Design Process
Formulating
Problem
DESIGN Specs
Generating
Alternatives
 Establish Functional Requirements
 Determine Constraints
 Set Performance Goals
 CREATE Alternative Forms
(Shape, Configuration, Size,
Materials, Power-Sources, etc.)
ALL
Alternatives
ReDesign
Iteration
Analyzing
Alternatives
FEASIBLE Alternatives
Evaluating
Alternatives
BEST Alternative
MANUFACTURING Specs
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
“Phases” of Engineering Design
 How do design decisions change over
time?
 Is there a logical grouping of decisions?
 Illustrate with an Example: Design a
Brake for stopping a Spinning Shaft.
• Requirements for Brake
– 8” Diameter, Horizontal shaft
– 4330 Ni/Cr/Mo Alloy-Steel shaft material
– 1000 Pound shaft weight
– 3600 rpm maximum rotational speed
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
FORMULATION Phase - Brake
 Early in the design process, we decide
upon the nature of the Functional
Requirements, and Inputs for the Design
 Decide upon a
satisfactory rate of
deceleration
 Determine the
length of the shaft
 Determine where it
is supported
Engineering-11: Engineering Design
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 Determine what
actuating energy is
available
 Decide to Learn
From existing similar
products
 Choose to research
brakes in the library
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
CONCEPT Design Phase - Brake

Decide PHYSICAL PRINCIPLES that
will perform the braking function
1. surface friction (e.g. drum brake,
disk/caliper)
2. opposing magnetic fields (e.g., inverse
motor)
3. air friction (e.g. fan blades)

Assume we DECIDE on
surface friction
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
CONFIGURATION Dsgn Phase
 Decide upon PRODUCT components
& how they are arranged/configured
 Product configuration:
• disk/caliper, or drum, or band brake
• location on shaft (right, left, middle)
 Assume we decide on a disk/caliper
brake
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
CONFIGURATION Dsgn Phase
 Decide upon PART features & how
they are arranged/configured
 Part configuration:
• relative size of hub
to disk
• relative size of
rotor thickness
to diameter
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
PARAMETRIC Design Phase

Decide upon SPECIFIC VALUES for
design variables/parameters
1. rotor diameter (outer)
2. rotor thickness
3. brake pad area
4. pad material
5. hydraulic pressure
on piston
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
DETAIL Design Phase
 Decide upon the remaining
MANUFACTURING specifications
• Machined rotor tolerances
• Pad bonding resin cure
time & temperature
• Assembly procedure
• Testing procedure
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
Final FORM is the Design Solution
 FUNCTION  stop a spinning shaft
 FORM 
• rotor: 10 inch diameter, Cast Iron, 3/8-inch
thick, cooling passages
• Forged 4140 steel caliper/housing
• brake pads, 2 opposing, 4 sq. in., metal
particles in epoxy matrix
• Stainless steel 304 piston,1.25-inch
diameter, with elastomeric seals
• 105 psi hydraulic piston pressure
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
Problem Formulation
Concept Design
Preliminary
Design
Design
Phase
Summary
Configuration Design
Embodiment
Design
ParaMetric Design
Detail Design
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
Alternative Design-Phases

Another, more Detailed, Description of the
Stages/Phases of Design
1. ID Problem or Needed-Fcn
2. Define the Goals/Performance
3. Research & Gather-Data
4.
5.
6.
7.
BrainStorm/Creative-Solutions
Analyze Potential Solutions
Preliminary
Design
Develop & Test Models
Critical Design Review
Make the Decision
8. Communicate & Specify
9. Implement & Commercialize
Engineering-11: Engineering Design
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Conceptual
Design
Final
Design
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
Product Realization Process
 Also Known as the Product LIFE CYCLE
• Design Occurs during PRODUCT
DEVELOPMENT Process
Fully
Realized
Product
Disposal
Production Design
Service
Engineering Design
Distribution
Industrial
Manufacturing
Design
Sales &
(Production)
Marketing
Customer Need
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
The Product Life Cycle
Design
Manufacture
Use
Retire
Engineering-11: Engineering Design
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 establish function, determine form
 fabricate, purchase, assemble,
test, ship/distribute
 set up, operate & maintain, repair
 TearDown/disassemble,
recycle/dispose
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
Product Life Cycle - Graphically
Innovation Cycle time
Definition Freeze
Investigation
Profit
Release
Zone
Break Even time
Obsolescence
Opportunity
Product Development
 Product Development “Kicks Off” the
Product Life Cycle
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
ConCurrent Engineering
 Also Known as Simultaneous
Engineering, this Method Reduces the
time spent in Product Development
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
ConCurrent ENGR Elements
 non-linear product design approach
 all phases of product development
operate at the same time – simultaneously
• Both product & process design run in parallel
and occur in the same time frame
 Product and Process are closely
coordinated to achieve Optimum Results
in a short amount of time
 Decision making involves full team
participation and involvement
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
WJ-2000 Concurrent Engineering
B. Mayer
B. Mayer
Z. Yuan
AKPlumley
Engineering-11: Engineering Design
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L. Harlamoff
AKMcGrogan
HSPaek
CEErickson
MSWalton
FSMenagh
RSMurphy
R. Reghitto
MSWalton

By Assignment
•
DMDobkin•
•
•
•
Sales Engineer
Safety Engineer
Manufacturing Engineer
Reliability Engineer
Service
Bruce
Mayer,Engineer
PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
The Need for Engineering Teams
 Increasing Technology Content
• Complex Engineered Systems Have Too
Much Information Content for Any One
Person to Address
 Speed
• Time-To-Market Often Means the
Difference Between Profits & Losses
• Teams Allow work to Be Done in
PARALLEL (at the SAME TIME)
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
A Team  What is it?
 A Team Is A Small Group Of People
With Complementary
Skills Who Are
Committed To A
Common Purpose,
Performance Goals,
and Approach For
Which They Hold
Themselves
MUTUALLY ACCOUNTABLE
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
Team Attributes
 Common Goal
• This Must Be Clearly Communicated to
Generate a Feeling of Common Purpose
 Leadership
• A Critical Function To Keep The
Team Focused
 Complementary Skills
• Resources are Limited; Each Team
Member Should have a CLEARLY
DEFINED and UNIQUE Role
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
Team Attributes cont.
 Effective Communication
• A CRITICAL Leadership Function
• Honest & Productive Communication is
Needed for Design/Solution Integration
• Greatest advantage Humans have over the
rest of the Animal Kingdom is communication
 Creativity
• A “Close Knit” & Motivated Team Generates
Creative Energy Thru
Goal-Oriented Interaction
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
All Done for Today
Dilbert
Design
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
Engineering 11
Appendix
Engineering Rolls
Bruce Mayer, PE
Registered Electrical & Mechanical Engineer
BMayer@ChabotCollege.edu
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
LifeCyc Engineering Activities
Sales &
Marketing
Research &
Development
Job Title
Sales Engineer
Description
Meets customers, determines
needs, presents product offerings
Applications Engineer Assists sales & marketing solving
technical issues with respect to the
use of product
Field Service Engineer Installs, maintains and repairs
equipment at customers’ sites
Industrial Designer
Establishes essential product
appearance, human factors
Design Engineer
Decides part or product form
including: shape, size,
configuration, materials, and
manufacturing processes
Investigates and develops improved
materials
Designs and conducts performance
and safety tests
Materials Engineer
Test Engineer
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
LifeCyc Engineering Activities
Manufacturing
Industrial Engineer
Manufacturing
Engineer
Processing /
Operations
Quality Control
Engineer
Establishes and maintains
raw materials and finished
goods quality controls
Plant Engineer
Designs and maintains
processing plant facilities
Coordinates project work
tasks, budgets and
schedules
Project Engineer
Engineering-11: Engineering Design
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Designs fabrication,
assembly and warehousing
systems
Develops manufacturing
tools and fixtures
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
The HYPE Cycle
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
 Optyx® WPS for whole potatoes
achieves a three-way sort using
a combination of air ejectors to
remove foreign material (FM)
and a unique deflector system to
separate potatoes for rework
from good potatoes. Maximizing
the removal of foreign material
and providing extremely gentle
handling to avoid potato
bruising, Optyx WPS improves
product quality and protects
downstream equipment while
reducing labor costs and
increasing yields.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-01_Intro_Engr_Design.ppt
http://www.key.net/products/optyx/optyx-wps-sorter/default.html
Potato Sorting Machine