Engineering 11
Configuration
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-04_Chp7_Configuration_Design.ppt
OutLine  Configuration Design
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
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What is a product configuration?
What is a part configuration?
Product architecture design
Part configuration design
Evaluating Configurations
Computer Aided Design (CAD)
Computer Aided Engineering (CAE)
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
OverView – Config Design
 The Configuration Design moves the
Design-Concept from the diagram
phase to the one where specific
components are now identified so that
we can proceed to manufacture.
• Start to Develop Specific Sizes, Shapes,
and Orientations
• Begin to Apply Highly Quantitative
Science and Mathematics
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
What is Configuration Design?
 Example Design Problem 
Reduce Rotational Speed
 Design Concept  Gear Pair
Physical principle:
PowerIn = PowerOut
geometry & material
T1  1 T2  2
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Possible GearPair Configurations
 Alternative configuration 1
 ARRANGE Part Differently
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Possible GearPair Configurations
 Alternative configuration 2
Spur
Gears
Helical gears
 Use different FEATURES or PARTS
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Possible GearPair Configurations
 Alternative configurations 3 & 4
Wide Gear Face
Similar Diameters
 Use different RELATIVE DIMENSIONS
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
What is Configuration Design?
 Example Design Problem 
Support Vertical Load
 Design Concept  Wall Bracket
Physical principle:
Force Equilibrium
geometry & material
F  0
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Wall Bracket
Configurations
Different
Features
Engineering-11: Engineering Design
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Abstract
Embodiment
Different
Arrangements
Different
Dimensions
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Configuration Decisions
 To Create Different Configs
Change one or more of these
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Select the BEST Configuration
 Use the General
Design Process as
DESIGN
a Model for
Choosing
ReDesign
Between
Iteration
Configuration
Alternatives
Formulating
Problem
Specs
Generating
Alternatives
ALL
Alternatives
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-04_Chp7_Configuration_Design.ppt
Iterate
Best
concept(s)
Configuration
Design
Configure
Product
Product architecture
Integral / modular
Standard / special purpose
Configure
Part(s)
Re-examine EDS
Research sources
Configuration requirements sketch
Analyze
and
Refine
Design for Function
Design for Assembly
Design for Manufacture
Evaluate
Pugh’s Method
Weighted Rating Method
Best
configuration(s)
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Product Architecture
 Analogous to Building Architecture
Architecture Style
COLONIAL
RANCH
Scheme
1st Floor Rms: dining, living
2nd Floor Rms: Bedroom, Office
all rooms on ground floor
 Rooms arranged Using a logical “scheme.”
• Before the details of the house are designed
we determine the general layout or
“architecture.”
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Example  Product Architecture
 This “System
Architecture” Shows
the Major
SubSystems (the
“rooms”), and their
Physical Locations
relative to each
other (the “Floor
Plan”)
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Example  Product Architecture
March 1992
Engineering-11: Engineering Design
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Jun 1994
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
ReCall Product DeComposition
Product
Standard Special purpose
Part
Part

Shows
Subassembly A
Subassembly B
Special purpose part
Special purpose part
Standard part
a) type, number, arrangement of
components
b) standard or special purpose
(buy vs. make)
Engineering-11: Engineering Design
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Subassembly B1
Standard part
Special purpose part
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Product Architecture
 PRODUCT ARCHITECTURE is the
scheme/plan by which the functional
elements of a product are arranged into
physical building blocks (components,
subsystems or subassemblies) that
interact with each other to perform the
overall function of the product
 Product architectures can be “modular”
or “integral”
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Modular Architecture
Product examples
Flashlight
Refrigerator
Automobile
Personal computer
Modular components
Batteries, bulbs
Motors, compressor, switches
Tires, radios, seats, brakes, engines
Drives, keyboards, mice, Displays
 “Chunks” implement one or a few
functions
 Interactions between chunks are well
defined (standard interfaces and/or
connections)
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Integral Architecture
Product examples
Car Body/Chassis
Printer case
Shaft
Beverage cup
Integral components
One-Piece Welded Structure
integral snap-fasteners
machined bearing race
integrated handle
 a single chunk implements many
functions
 Interaction is ill defined
 Physical element “shares” functions
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Developing Architectures
1. Create a schematic of functional and physical
elements
2. cluster elements into logical chunks to:
 exploit standard components
 to exploit standard interfaces (e.g. 115 VAC, USB)
 fully utilize manufacturing process(es), or suppliers
 provide for maintenance
3. sketch a rough geometric layout
4. identify interactions between elements
5. refine layout
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Example  Design Printer
 Identify
• SubFunctions
• InterActions
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Example  Design Printer
 Cluster
Elements into
Logical
“Chunks”
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Example
 Design
Printer
 Sketch rough
geometric “layout”
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
a REFINED
LayOut
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Example  Design Printer
 Sketch the Interaction Diagram
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Iterate
Best
concept(s)
Part Configuration
Design
Configure
Product
Product architecture
Integral / modular
Standard / special purpose
Configure
Part(s)
Re-examine EDS
Research sources
Configuration requirements sketch
Analyze
and
Refine
Design for Function
Design for Assembly
Design for Manufacture
Evaluate
Pugh’s Method
Weighted Rating Method
Best
configuration(s)
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Part Configuration Design
Configuration Problem Required Decisions
Special Purpose Part Geometric Features
Feature Arrangement
Relative Dimensions
Design Variable List
 Many Issues Associated with Each Decision
• Consider just Geometric Features
walls
rounds
cubes
ribs
bosses
spheres chamfers
projections cylinders holes
fillets
Engineering-11: Engineering Design
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tubes
notches
grooves
slots
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Generating Alternatives
 Recall
Bracket
Configurations
Different
Features
Engineering-11: Engineering Design
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Abstract
Embodiment
Different
Arrangements
Different
Dimensions
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Example  Sponge Holder
1. Prepare configuration requirements
sketch
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Example  Sponge Holder
2. Prepare NON-Contiguous
configuration requirements sketch
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Example  Sponge Holder
3. Prepare alternative CONTIGUOUS
configuration sketches
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Example  Sponge Holder
4. Refine
Configs
hole in back wall
Engineering-11: Engineering Design
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hole in offset wall
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Best
concept(s)
Iterate
Configure
Product
Configure
Part(s)
Configuration
Analysis
Product architecture
Integral / modular
Standard / special purpose
Re-examine EDS
Research sources
Configuration requirements sketch
Analyze
and
Refine
Design for Function
Design for Assembly
Design for Manufacture
Evaluate
Pugh’s Method
Weighted Rating Method
Best
configuration(s)
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Analysis Queries
 Will the Configuration Perform the
Desired FUNCTION?
 Can all the Parts be MADE
(manufactured)?
 Can the
Configuration be
ASSEMBLED?
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Design for Function (DFF)
 Functional Considerations List
 Strong
 Stiff or flexible
 Buckling
 Reliable
 Human
factors/ergonomics
 Thermal expansion
 Vibrate
 Quiet / Noise
 Safe
 Easy to use
 Maintain
 Heat transfer
 Fluid(s) transport
and/or storage
 Energy efficient
 Repairable
 Durable (wear,
corrosion)
 Life-cycle costs
 Stable
Engineering-11: Engineering Design
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 Styling/aesthetics
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Design for Assembly (DFA)
 Assembly ≡ a process of handling
components to bring them together
(inserting) and then fastening them.
 Design for Assembly ≡ a set of design
practices which reduce the manpower
time required to handle, insert and
fasten components of a product.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
DFA  Reduce Handling
 Handling  GMOP: Grasping, Moving,
Orienting, Placing.
 Design parts or products to reduce the
influence on handling
 Size
 Thickness
 Weight
 Fragility,
 Flexibility,
 Slipperiness,
 Nesting
 Tangling
 Stickiness
 need for: 2 hands, tools, optical magnification,
mechanical assistance, etc
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
DFA  Reduce Insert & Fasten
 Insertion & Fastening  Mating a part to
another part or sub-assembly.
 Design parts or products to reduce the effort
associated with inserting & fastening
 Accessability
 Resistance (force) to
Insertion
 Depth of insertion
 Separate operation
required
 Visibility
 Ease of Alignment &
Positioning
 Fastener used
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
DFA GuideLines from the SME










minimize part count
minimize levels of assembly (number of assemblies)
encourage modular assembly
use standard parts
stack sub-assemblies from the bottom up (use gravity)
design parts with self-fastening features (snap-fits,
press-fits)
facilitate parts handling (grasp, orient, move)
design parts with self-locating features (e.g. chamfers,
aligning recesses/dimples)
eliminate reorientation (i.e. insertion from 2 or more
directions)
eliminate (electrical) cables
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
PROs & CONs of DFA
 Design Guidelines
• pros: fast, easy, non-coupled
• cons: non-quantitative; no metric to
compare alterative designs
 Assembly Efficiency
Theoretica l Minimum Assy Time
 ma 
Actual Assy Time
• pros: systematic, comparative
• cons: takes time to code & calculate
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Best
concept(s)
Iterate
Configure
Product
Configure
Part(s)
Configuration
Evalualtion
Product architecture
Integral / modular
Standard / special purpose
Re-examine EDS
Research sources
Configuration requirements sketch
Analyze
and
Refine
Design for Function
Design for Assembly
Design for Manufacture
Evaluate
Pugh’s Method
Weighted Rating Method
Best
configuration(s)
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Evaluation Methods
 Once the design concepts are generated and
evaluated for feasibility, the surviving design
concepts need to be evaluated to determine
which one is “BEST.”
 How does one define “BEST”?
 One common method is to use the criteria for
the design and weight the relative
importance of these facotor to determine the
“BEST” OverAll Design
• Note: the designers must be careful not to rig the
weighting to make a favorite come out “best.”
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Evaluate Sponge Holder ConFigs
hole in back wall
Engineering-11: Engineering Design
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hole in offset wall
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Eval by Weighted Rating Method
1. List evaluation criteria (in a column).
2. Determine importance weights (in an
adjacent column)
3. List alternatives (along the top row)
4. Rate each alternative on each criterion
5. Compute the weighted rating for each
criterion
6. Sum the ratings to produce the
Overall Weighted Rating
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Eval Sponge Holder ConFigs
Criteria
Function
drains well
dries quickly
stays clean
sponge inserts easily
Importance
Weight
Manufacture
material usage
tooling costs
processing costs
Assembly
handling
insertion
number of parts
Weighted rating
Engineering-11: Engineering Design
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Sponge Holder Configuration Ratings
With hole
With bracket
Rating
Wt. Rating
Rating
Wt. Rating
15
10
10
15
3
3
2
2
0.45
0.30
0.10
0.40
3
3
3
4
0.45
0.30
0.15
0.80
10
15
5
3
3
3
0.30
0.45
0.15
2
2
3
0.20
0.30
0.15
5
5
10
100%
3
3
3
0.15
0.15
0.30
3
3
3
0.15
0.15
0.30
2.75
2.95
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Iterate
Best
concept(s)
Config Design
Summary
Configure
Product
Product architecture
Integral / modular
Standard / special purpose
Configure
Part(s)
Re-examine EDS
Research sources
Configuration requirements sketch
Analyze
and
Refine
Design for Function
Design for Assembly
Design for Manufacture
Evaluate
Pugh’s Method
Weighted Rating Method
Best
configuration(s)
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Using Sketches in ConFig Dsgn
 Sketches are used often in configuration
design
 Sketches assist creativity
 Sketches are not
typically used to
“document” the
“design”
• But CAN be used to
Document“IDEAS”
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Creative Visualization
 Sketching Stimulates Creativity And
Helps Visualization
• Sketching Ideas That Are Partially
Developed Often Aids The Design Process
 Do Not Wait Until You Have A Clear Picture Before
You Start Sketching
 Allow Yourself The Freedom To Make Mistakes
 Visualization Of The Entire Design Is
Essential But Often IMPOSSIBLE
Without the Aid Of Sketches
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Sketches for Patent Doc.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
USA Patent App. 20030113451
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
CAD DWGs for ConFig Design
 Typically used to Produce “LayOuts”
 LayOut Characteristics
• If Physical Object, then drawn PRECISELY
to Scale showing ALL Parts
– Check for Form and Fit
• If Schematic, the shows precisely ALL
Components and InterConnections
– Check for Proper Control of Fluid, Electrical,
Optical, Magnetic, or Information “Flow”
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
LayOut For FC CCA Enclosure
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
LayOut for 800mm Glass Coater
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Elect Pwr & Control Schematic
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Uses of Accurate LayOuts
 LayOuts often serve as Input to CAE
Software which aids Feasibility Checks
 Partial List of CAE tools
 Structural
Mechanics (FEA)
 Computational Fluid
Dynamics (CFD)
 ElectroMagnetics
 SPICE (Analog
Electrical Circuit)
 Coupled Physics
 Wire/Pipe Routing
Software
 Rapid ProtoTyping
 Kinematics
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Computational Fluid Dynamics
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
All Done for Today
LayOuts:
Transistor
Plumbing
 Transistor LayOut by
MAGIC Software
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Engineering 11
Appendix
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-04_Chp7_Configuration_Design.ppt
WJ-1000 Product
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Method 6-3-5 (Brain-Writing)
 The traditional brainstorming relies on verbal
communications.
• Idea generation may be dominated by a small
number of aggressive members.
 Guidelines for 6-3-5 method
 Team members are arranged around a
circular table to provide continuity. Six (6)
members are ideal.
 Each member sketches three (3) ideas for the
product configuration or functions. Sketches
should be the focus of this activity. The top
five product functionswith respect to the
customer needs are considered.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-04_Chp7_Configuration_Design.ppt