Introduction to Engineering
Design
Bo Hu
John Nieber
Foundational Questions
What is an engineer?
What is engineering design?
Difference between engineering analysis and engineering design
What is the difference between product and process design?
What is the context of the design process?
Engineering design vs. design in other academic disciplines?
Why design?
What is engineering?
“…the purposive adaptation of means to reach a pre-conceived end…” E.T. Layton, Jr.
“Technological activity to solve problems”
Human creativity
Engineering as a “Thinking-Making” Activity
The use of technology to make products and systems
for societal benefit.
Historical Questions
What role of engineers in history?
Irrigation and farming equipment, dam projects, water and wind mills building construction,
the Pyramids, the Great Wall, Leonardo’s contraptions, the printing press, the Wright brothers’
aircraft, fermented beverages, nuclear power, the Space Shuttle, Tacoma Narrows Bridge,
electric appliances, petroleum products, pharmaceuticals.
When did the engineering disciplines begin?
3000 BC
1000 BC
AD 1700
AD 1800
AD 1900
AD 1950
Civil
Military
Mechanical
Materials
Agricultural
Electrical
Chemical
Aerospace
Computer, Nuclear, Biochemical
Biomedical
[ Holtzapple, M. T., Reece, W. D. (2005) ]
Product Realization Process
(PRP)
•
•
•
•
•
•
•
•
•
Engineering design
Industrial design
Production planning
Manufacturing
Distribution
Sales
Marketing
Service
Disposal
•
•
•
•
•
•
Environmental assessment
Stakeholder involvement
Engineering design
Construction planning
Construction
Effectiveness monitoring,
control, and maintenance
Problem solution
Engineering as Problem Solving
Problem identification
Synthesis
Orderly stepwise approach
Analysis
Application
Qualitative/general
 quantitative/detailed
Comprehension
[ Holtzapple, M. T., Reece, W. D. (2005) ]
Solution
Process of Engineering
Think
Think
Sketch
Sketch
Make
Make
Show
Show
Use
Use
Math
Analysis
Politics
Physics
Chemistry
Biology
Law
Ethics
Environmental
Economy
Process of Engineering
Need
Analysis of Problem
Statement of Problem
Conceptual Design
Brainstorming
Rule : There are
no stupid ideas
in a brainstorm
Selected Schemes
Embodiment of Schemes
Detailing
Working drawings, etc..
[ Ferguson, E. S. , (1992) ]
• What is a product or process?
Object produced, substance, material, arrangement, service, step sequence,
manufactured good, transformation of something, system, organization.
Example 1 : Water bottle made of biodegradable plastic
Example 2 : Biorefinery for ethanol production from biomass
Example 3 : Bio-repellant coatings
Example 4 : Flood control structures
Example 5: Contaminant/pollutant removal systems
Example 6: Structures for wildlife migration
Examples in bio-based products
Materials and Chemicals
- Wood
- Wood-based
- Paper
- Biodiesel fuel
- Bio-based plastics
- Biodegradable plastics (e.g. drink bottles)
- Ethanol (bio-based)
-
Examples in bioprocessing
Utilization of living cells or their components to obtain
desired products
- Ethanol fermentation from corn
- Antibody production via fungal fermentation
- Anaerobic digestion to treat wastewater
- Biodegradable plastics (e.g. PLA) production from corn
- Enzymatic hydrolysis to produce sugar from cellulose
-
What is engineering design?
• Engineering design is the set of decision-making processes
and activities used determine the form of an object given the
functions desired by the customer. (Gov of MA)
• Engineering design is the process of devising a system,
component, or process to meet desired needs. It is a decisionmaking process (often iterative), in which the basic science
and mathematics and engineering sciences are applied to
convert resources optimally to meet a stated objective. Among
the fundamental elements of the design process are the
establishment of objectives and criteria, synthesis, analysis,
construction, testing and evaluation. (ABET)
Context of Design
Historical
Precedents
Cosmological
Government
Non-profit NGO’s
Global
Regional
State
Military
City
Industry
Biology
Ward
Chemistry
Commercial
House
Physics
Family
Mathematics
Person
Bodypart
Organ
Cell
Organelle
Molecular
Atomic
Ideal Society
Projections
Product Design
• New products are critical for corporate
prosperity
• Approximately 33% of revenues come
from products that did not sell 5 years ago
• Successful new products are profitable
– Median achieve 33% ROI or better
– Median have payback of 2 years or less
– Median achieve market share of 35%
• Significant R&D expenditures and
investment
Manufacturing of Chemical Products
Process Engineering Design
Environmental Design
• Changing human needs mean the need
for the design of new infrastructures
• Design with a focus on natural processes
• Designs should mimic nature – i.e., selfadaptive, self-sustaining, and resilient
Engineering Design vs Engineering Analysis
•
Engineering analysis: Predicted behavior is the solution
to an analysis problem
– Formulating
– Solving
– Checking
• Engineering design:
–
–
–
–
Formulating
Generating
Analyzing
Evaluating
Design Step
Process of Engineering
Map
[ SSL (2004) ]
Process of Engineering (cont.)
Map
[ SSL (2004) ]
Issues in design
Utility and cost
Single and multi-functionality
Batch or mass production
Patents
Aesthetics
Integrity of product (wholeness)
Whole life-cycle planning
Health effects and safety
Recycling and disposal
End of product life and replacement issues
Failure modes
Effects on society
Ethical issues design
Philosophical and practical ethics
Codes of Ethics
- Health and welfare of humans and nature
- Informing client/employers of consequences
- Statements and information in truthful manner
- Treating people fairly (avoiding conflict of interest)
- Limits of professional competence
- Building professional reputations according to merits
- Continuing professional development
- Issues with intellectual property.
Issues
Life systems preservation
Maintenance of quality of life
Maintaining high standards of personal and professional conduct
Managing intra-professional customs, identifiers, habits, and limits.
[ SSL (2004) ]
Economic analysis
What is the relevance of economic analysis to design?
Economic assumption : Measure of value is “monetary”
Process cost in context of the company
Reporting costs, financial status, and transactions.
Value today, value tomorrow.
Material cost, labour cost, indirect cost
Manufacturing cost, storage cost, transport cost
Product cost scaling and correction factors
Statistical analysis
What relevance is statistics to design?
Statistical focus : “The one and the many”
Measures of central tendency
Measures of variation
Probability
Uncertainty analysis
Linear regression
Six sigma quality concept
Optimization and development of designs
Statistics in process control for quality
AspenTech HYSYS Modeling Code
• Menu driven, Mouse driven.
• Flowsheets, Modular units.
– Mixers, Reactors, Flash separators,
Distillation units, Heat exchangers.
• Reaction databases.
• Chemical property calculations.
• Species, Mass, Momentum, Heat Balances.
• Equipment Sizing.
• Economic calculations.
• Optimization.
CAD, MAPWindow/ArcGIS, WAM,
HEC-RAS
• CAD – develop engineering drawings
• MAPWindow/ArcGIS – work with mapping
systems for various geographical analyses
• WAM – one of many models for watershed
assessments
• HEC-RAS – a model for water flow in open
channels
30
Notes of S. Takagaki, H. P. Huang, S. Ramaswamy
Introduction to Engineering Design
Minnesota context
Products from Minnesota
Sources : Inventing Tomorrow Magazine
Minnesota context
Environmental analysis and design;
• Assessment of impaired waters – water quality
• Wetland loss mitigation
• Stormwater control and mitigation
• Drainage of lands for food production and
development
• Liquid and solid waste treatment
References
deCamp, L. Sprague, (1963) The Ancient Engineers, Bantam books
Ferguson, E. S. , (1992) Engineering and the Mind’s Eye, MIT Press, Cambridge.
Cussler, E.L., Moggridge, G.D. (2001) Chemical Product Design, MIT Press, Cambridge
Holtzapple, M. T., Reece, W. D. (2008) Concepts in Engineering, 2nd Edition, McGrawHill.
also Holtzapple, M. T., Reece, W. D. (2005) Concepts in Engineering, McGraw-Hill.
Kangas, P.C., Ecological Engineering, Principles and Practice, Lewis Publishers, 2004
Ogot, M. G. Okudan-Kremer, Engineering design: a practical guide, Togo Press, LLC.
2004, 544 pages.
Seider, W. D., Seader, J. D., Lewin, D. R. (2004) Product and Process Design Principles,
Second Edition, Wiley.
Smith, R. (2005) Chemical Process, Wiley.
Assignment 1 – Bioproducts and
bioprocessing students
1.
2.
3.
Search through issues of “Inventing Tomorrow” for
articles on product and process design. Read and make
notes, especially those related to bio-based products and
processes. List your favorite three examples and explain
their design process, for example: what is the problem?
What are the alternative solutions? Why they choose the
one and how do they do that?
Find library resources related to chemical and physical
properties. find the flash point of ethyl alcohol and
propylene
- CRC Handbook of Chemistry and Physics
- Perry’s Chemical Engineers’ Handbook.
Find (free) websites which catalog Material Safety Data
Sheets (MSDS) and find an entry for isopropyl alcohol and
propylene. Also check other safety data archives esp.
governmental.
Assignment 1 – EEE students
1.
2.
3.
Search through issues of “Transactions of the American
Society of Agricultural and Biological Engineers” , “Applied
Engineering in Agriculture” , and “Journal of Ecological
Engineering” for articles on the design of systems for
water quality improvement, flood control, etc. Read the
abstracts for these articles and make notes. List your
favorite three examples.
Find website resources related to chemical and physical
properties of soils, geological materials, and water.
Go to the MnDNR website to find out about the waters of
the state. Find out how many lakes and miles of
rivers/streams we have in Minnesota. How much is the
mean annual precipitation, and how much of the water flows
out of the state? How many of the waters of the state are
known to be impaired (see MPCA website,
http://www.pca.state.mn.us/water/tmdl/index.html)