MPD 575
Design for Product
Evolution
Jonathan Weaver
DFPE Development History
• Originally developed by MPD Cohort 3
team of Dwayne Moncrief, Paul Norton, Bo
Prudil, and Ben Saunders, in Fall 2002.
Design for Product Evolution
(DFPE)
• What’s DFPE?
• Why DFPE?
• Examples
• Conclusions
Design for Product Evolution
(DFPE)
Webster defines Evolution as “process of
continuous change from a lower, simple, or
worse to a higher, more complex, or better
state. ”
We interpret Product Evolution as
“ incremental changes that add functionality
or change product characteristics without
necessitating a wholesale product redesign.”
Design for Product Evolution
(DFPE)
• What’s DFPE?
• Why DFPE?
• Examples
• Conclusions
Design for Product Evolution
(DFPE)
• Extends product life cycle.
• Reduces program life cycle cost.
• Enables low cost future product feature
enhancements.
• Helps to achieve commonality across
product lines.
• Enables quick response to change to ever
changing market demand.
Design for Product Evolution
(DFPE)
• What’s DFPE?
• Why DFPE?
• Examples
• Conclusions
Design for Product Evolution
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•
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Design for Automatic Transmission Evolution
Design for Automotive Safety
Design for Alternator Evolution
Design for Die casting Evolution
Design for Computer Evolution
Design for Machine Tool Evolution
Design for Vehicle Freshening Evolution
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Instrument Clusters
Seats
Switches
Badging
Design For Transmission
Evolution
• Minimum design consideration for future
transmissions updates.
• Drive to meet target specifications.
• Drive to cut cost.
• No common strategy – each transmission has
many unique parts requiring unique manufacturing
process, strategy and calibration.
Design For Transmission
Evolution - AXOD
• Original AXOD design targeted for maximum
2.8L normally aspirated engine application.
• Engine torque truncation is required for
transmission to operate in current applications
with 3.8L or 4.6L engine.
• Demonstrates clever engineering, but a lack of
foresight in terms of product evolution.
Design For Transmission
Evolution - AXOD
• AXOD design considered non-synchronous shift
originally, but the concept was rejected.
• AX4N design upgrade (a non-sync design) was
required to improve shift quality, durability and
torque capacity concerns that could have been
addressed in the initial AXOD design.
Design For Transmission
Evolution
• However, some subsystems exhibit consideration of future
needs.
• Examples:
• Bulkhead connection on E4OD transmission
designed with extra pins for future added
functionality, a lesson learned from previous
designs.
• New Black Oak processor for Powertrain control is
currently faster and more powerful than required.
• Projections of future software complexity are
considered in the design of calibration tools.
3-speed to “5”-speed
Transmission Design Evolution
•
•
•
•
•
•
•
C3 -> A4LD -> 5R55.
3 to 4 speed - added O/D gear set.
4-speed closed architecture.
A 5-speed is really 4-speed with 2nd gear OD.
Same gear span for 4 and 5-speed.
Minimum fuel benefit.
Marketing catch?
A4LD and 5R Same Transmission
Architecture Gear Span
A4LDE 4-speed
5R55E 5-speed
1
2.47
2.47
2
1.47
1.86
3
1.00
1.47
4
0.75
1.00
5
R
Gear Span
0.75
2.11
2.11
3.29
3.29
4R and 6R Same Transmission
Architecture Gear Span
Gear
4R100
6R110
1
2.71
3.09
2
1.54
2.2
3
1.0
1.54
4
0.71
1.096
5
1.0
6
.71
R
2.18
2.88
Gear Span
3.82
4.34
ZF Good Design Practice For Future Updates
From 5 to 6 speeds
with open type
architecture enables adding
additional gears
without major
transmission tearup
and offers
opportunity to reuse
majority of
components.
ZF 5 and 6-speed Transmissions
Gear
5HP 5-speed
6HP/6R 6-speed
1
3.55
4.17
2
2.23
2.34
3
1.56
1.52
4
1.0
1.14
5
0.79
0.87
6
0.69
R
3.78
3.4
Gear Span
4.49
6.035
Good Design Practice For Future
Updates Example
Extra space left for
future torque
converter changes (Kfactor, stall speed,
input torque);
possibility to increase
the pump output and
input shaft diameter
for higher torque
applications.
Transmission Case With Transfer
Case Casting Attachments
This transmission
is used in both 2
and 4- wheel drive
applications using
the same
transmission case.
Transmission Case W/O Transfer
Case Casting Attachments
Good Design Habits For Automatic
Transmission Evolution
• Leave space for both axial and radial torque
converter updates.
• Leave space for converter damper/isolator
updates.
• Leave space for pump capacity updates.
• Allow for clutches, shafts, and bearings updates.
• Make provisions for easy 4x4 transfer case
attachments.
• Design for “open” type architecture.
Transmission Design Recap
• Adding gears to current transmissions nearly
impossible (“closed” type architecture).
• Difficult to update for higher torque capacity and
higher speeds (shafts, clutches, pump) w/o
complete transmission tear up.
• ZF open type transmission architecture allows for
more updates with less changes to current parts.
Automobile Safety Solutions
• The innovative use of materials plays a significant
role in making automobiles safer.
• New materials are applied mainly to the interior.
• The focal point are airbags and inflatable side
curtains – there are more of them, deploying at
variable speeds, and staying inflated longer.
New Materials For Safety
• Airbags coated with the special sealant compound that
forces air to escape through pinholes in the fabric instead
of the seams; airbags inflation time increased up to 7 sec.
• New resins used for I/P and the the door panels to prevent
material disintegration when airbags are deployed.
• Long-Glass Fiber Polypropylene material made by JCI
ensures that once the hidden airbag deploys there won’t be
parts breaking off from the I/P and flying toward the
occupants.
• Visteon Laminate Injection Molding (VLIM) material is
able simultaneously create hard and soft surface through
one injection molding of I/P.
New Materials For Safety – cont.
• Floor
Use of “sandwiform” composite material – consists of
honeycombed cellular core placed between two
thermoplastic skins reinforced with glass; material is light,
strong, can be recycled, and is easy to manufacture.
• Bodyshell
“Betaform” Structural Foam material is made with a waterblown polyurethane; fills closed body cavities such as
rails, pillars, and rocker panels; improves body stiffness
and increases safety by improving the load transfer path
during a crash.
New Materials For Safety – cont.
• Door Panel
Eco-Cor material by JCI is a 50-50 blend of natural and
polypropylene fibers which is cheaper, lighter, has
improved acoustics, and is stronger compared to
conventional steel panels.
• B-Pillar
Sequal 2321 material is an impact resistant material that
does not splinter when the side airbag deploys during a
collision; this material is used on both covers for the Bpillar to simplify the manufacturing process.
New Materials For Safety – cont.
• Ride and Handling
“Vibracoustic Microcellular Urethane” – more
pliable form of rubber that reduces noise,
vibration, and harshness; the material is used to
integrate body mounts and jounce bumpers (the
jounce bumpers reduce the impact harshness of
moderate to large impact event such as driving
through potholes); the system provides more
consistent ride over a variety of road inputs.
Design for Alternator Evolution
• The alternator has a
modular assembly
with defined
components: rotor,
stator/rectifier, voltage
regulator, front
housing, rear housing
and pulley.
Modularity facilitates
Product Evolution.
Design for Alternator Evolution
• These components can easily evolve with the
broadening of technology. Special attention must
be paid to the architecture and engineering of the
system to ensure compatibility.
Design for Alternator Evolution
• The rotor produces the
magnetic field that
supplies voltage.
There are five distinct
parts: slip ring, rotor
shaft, rotor assembly,
rotor coil assembly
and rotor halves.
Design for Alternator Evolution
• All of the parts in the rotor can be optimized,
individually if needed, as innovations become
available in the marketplace (ex. stronger shafts,
more conductive wire coils and slip rings, etc).
Design for Alternator Evolution
• The fan blades can be
redesigned to improve
air circulation in the
interior of the
alternator to keep it
cool.
Design for Alternator Evolution
• The stator produces
the alternator’s output.
Product evolution
could involve changes
in stator to alleviate
inaccuracies in
construction which
can cause variability in
performance.
Design for Alternator Evolution
• The voltage regulator
controls alternator
output.
• Modularity of the
design of this
component allows
redesign to be done
without affecting the
rest of the unit.
Design for Die casting Evolution
• In die casting, dies are
made so they can be
upgraded or changed
to make a different
detail on a casting or a
totally new part.
• Instead of purchasing
a complete new die the
inserts can be altered
or replaced.
Design for Die casting Evolution
Design for Computer Evolution
• Due to the high rate of product innovation in the
consumer PC markets, design for product
evolution is imperative.
• Modular designs are the norm for personal
desktop computers.
• Even laptops exhibit modularity within their
restrictive size, weight and power consumption
constraints.
Design for Computer Evolution
Standard slots for CD
and disk drives allow
upgrades without a
complete redesign.
Design for Computer Evolution
Industry standard pin outs
on peripheral connections
facilitate easy evolution
and capability upgrades,
inside and outside of the
machine.
Design for Computer Evolution
Memory Expansion slots
allow upgrades in capability
without complete system
changes.
Design for Computer Evolution
• Modularity has become a necessary attribute for
participation in the PC market because of the rapid
rate of product evolution.
• Modularity must be supported by the underlying
electrical and software operating system
architecture.
• “Plug and Play” has been an industry objective
since the introduction of the Pentium chip.
Design for Machine Tool
Evolution
• Consideration for Design Evolution in machine
tools usually means easy retrofit to add
components for additional functions.
• Additional hydraulic and pneumatic control
components are often necessary for added
functions.
• Higher performance components are not normally
substituted as is done on PC’s.
Design for Machine Tool
Evolution
Machine Tool control
design always provides
spare space and wiring
for added functionality.
Design for Machine Tool
Evolution
These pneumatic solenoids are
plugged onto a manifold that
provides both control signals and
air pressure. Porting is
to the right side. Note the closure
plates for unused positions.
Design for Machine Tool
Evolution
Some Design evolutions lead to improved (read: less expensive)
manufacturing methods, i.e. plastic hose vs. formed steel tubing.
Design For Vehicle Freshening
Evolution
• Develop all the radios to fit within the same
package. When technology progresses, we have
the ability to adapt it into the radios
• The message center on the instrument cluster can
be reconfigured to work with new information or
technology.
Design For Vehicle Freshening
Evolution
Example of IP Clustering to show White-lighting and Message Center
Design For Vehicle Freshening
Evolution
Example of Common radio packaging with integrated technology:
In-Dash CD Changer, Navigation System, RDS features
Design For Vehicle Freshening
Evolution
• Door and seat bolsters are designed so that fabrics
can be changed.
• Buttons, switches and knobs use the same housing
bodies, so we can change the visible "caps" to
freshen the appearance.
• Eliminate locator holes on exterior badging, so
that the vehicle can be freshened by relocating the
badges without having to change the metal
stamping dies.
Design For Vehicle Freshening
Evolution
Common seat frames and cushions example
Design For Vehicle Freshening
Evolution
Example of seat freshening with integrated head rest
Design For Vehicle Freshening
Evolution
Example of seat freshening with head rest separate
Design For Vehicle Freshening
Evolution
Example of common housing body for freshening
Design For Vehicle Freshening
Evolution
Examples of switch freshening using common housing
Design For Vehicle Freshening
Evolution
Example of old badging tooling holes
Design For Vehicle Freshening
Evolution
Example of freshening without tooling holes
Design for Product Evolution
(DFPE)
• What s DFPE?
• Why DFPE?
• Examples
• Conclusions
Conclusions
• No planning for future updates = paying
more later on.
• Avoid closed-end type designs.
• Customers prefer small-step product
evolution.
• Changes necessary to maintain competitive
position.
Conclusions – cont.
• Good design:
– Meets current and also future anticipated
customer needs.
– Allows for technology advances to be
incorporated in an existing product without a
redesign.
– Consideration for evolution is most important
in product chunks that are undergoing rapid
technological change.
– Consideration for evolution is also especially
important in product areas with a “fashion”
function.
Conclusions – cont.
• Modularity facilitates design evolution.
• Design team must have a vision for the
future.
• Design team has to have knowledge of
future trends in technology, as well as in
industrial design.