Course Reflection
AK47
hacker_ch._23_lecture.pptxInformed Design & Application
Chapter 2&3 Hacker
ETSC 101 CHAPTER 2&3 HACKER
All of Ch. 2, 3.1, 3.3, 3.2, 3.4
1
Sect. 1: Critical Components to Design
Creativity
Willing to take risks
Visual Thinking
Knowledge of Subject Matter
Determination
Research
Specifications
Constraints
Brainstorming
Analyzing the Design
Using mathematical and physical models to assess function.
Constructing, Testing, and Evaluating a Prototype
Does actual performance and function line up with model performance and function?
ETSC 101 CHAPTER 2&3 HACKER
You learn a lot more when you fail, learn from mistakes, then succeed, than when you succeed the first time.
Visual thinking causes you to make connections between perspectives and between things that would usually not be connected.
Knowledge of subject matter offers the danger of fixed and rigid thinking, but also allows foundation for ideas and strengthens intuition in the creative process.
Determination is required to overcome hurdles and resistance that are inevitable in the design process.
Research must be done to determine what the designed solution should be, the nature of the problem must be fully understood.
Specifications are statements of what the product will actually do. These are quantitative and can be measured. These are gathered from assessing customer needs that are assessed by customer surveys and feedback, etc.
Constraints are the things that you are not able to do because they are imposed on you. Cost, time, resources, government regulations, material availability.
Brainstorming because you can’t just come up with one, often times you need multiple possible solutions to determine which is the best.
Design becomes more than just art when engineering analyses come in. This is the predictions of loads, when things will fail, how much a bridge can hold, etc.
2
Sect. 2: The Design Process
Describe the design problem clearly and fully.
Research and investigate the problem.
Generate alternative designs.
Choose and justify your optimal design.
Develop a prototype.
Test and evaluate the design solution.
Redesign the solution with modifications.
Communicate your achievements.
ETSC 101 CHAPTER 2&3 HACKER
Most all engineers follow this process when designing solutions for customer problems and needs. And these apply to artifacts, systems, and processes/infrastructures.
3
Phase 1: Describe the Design Problem Clearly and Fully
Finding the nature of the problem, its environment.
Finding the specifications (goals) and constraints (limitations).
Safety considerations
ETSC 101 CHAPTER 2&3 HACKER
Let’s consider the problem that humans need to sit.
Why do people need to sit? What drives the human desire to do that? Where and when? Do they need to bring their sitting device with them?
How much does the person weigh sitting in it? What is the typical geometry of a person? Do we need to consider safety? What could happen in event of a failure?
With design solutions involving human safety, it’s important for safety factors to be included in design. For example, your chairs are probably designed to carry 600 pounds and your bridge is definitely designed to hold at least 8X its expected max weight.
4
Phase 2: Research and Investigate the Problem
This involves…
Scanning solutions to similar problems (Benchmarking)
Scanning current and emerging technologies currently available
Doing small experiments and making small prototypes to search for possible solutions.
ETSC 101 CHAPTER 2&3 HACKER
Chair example: At some point in history someone acknowledged the problem that chairs weren’t mobile. Before solving this problem, that person or group scanned and looked at every still chair their ever was and also looked at other pieces of furniture or small bodied products that were mobile.
They also scanned all the different technologies available for “moving things” such as air propulsion, wheels, bearings, rollers like we see on mobile chairs today.
They may of also tested different wheels and rollers for which would work best in homes and offices, on hard floor and carpet.
5
Phase 3: Generate Alternative Designs
Brainstorming and Creativity
Developing Design Concepts
Sketches, 3D Models, etc.
Screening down to a select few and developing further.
ETSC 101 CHAPTER 2&3 HACKER
Here is where brainstorming and creativity come in. Looking at what is currently able to accomplish similar tasks and applying them to design concepts.
Screening methodologies can be voting, authoritative decision, least risk decision, or just choosing by opinion. Decision matrices can also be used at this stage.
6
Initial Screening
ETSC 101 CHAPTER 2&3 HACKER
Further Developed Superior Concepts
ETSC 101 CHAPTER 2&3 HACKER
Phase 4: Choose and Justify Your Optimal Design
Alternatives are weighed in terms of…
Make a Decision
Further Development
Performance predictions, analyses, material selection, manufacturing plan
Safety, Risk
Design for Environment (DFE), Design for Manufacturing (DFM), Design for Assembly (DFA)
Industrial Design, Robust Design
ETSC 101 CHAPTER 2&3 HACKER
Tradeoffs, cultural/environmental/economic effects, performance, costs, profit potential
Testing is often done with low-level prototypes to test functionality
Risk assessment for company and the potential customer
When weighing these alternatives, its important to ensure the quality of the information you are using.
Also when assessing the effects these alternatives might have, appropriate forecasting techniques and trend analyses should be used. These forecasts and trend analyses are done in more detail when the optimal design is chosen.
Decision matrix, economic analyses, done in teams, not one person making the decision
Safety: In art you might want to reconsider using materials that aren’t toxic. When designing an ad that says “This lift can handle any load!” You might want to consider safety concerns that entails.
DFE: Looking for ways to employ conservation, regeneration, and stewardship into the design process. Ecological design: designing to be more inline with natural processes.
DFA: Figuring out how to make assembly easier so that its safer, faster, and less expensive for either customers or the manufacturer.
DFM: Figuring out how to make manufacturing as cost-effective as possible, taking into account the manufacturing process into the design.
Robust Design: Is the design going to hold up under unknown and uncontrollable variables (earthquakes, improper use, etc.)
Industrial Design: The looks and feels of the design.
9
Further Development of Optimal Design
ETSC 101 CHAPTER 2&3 HACKER
Phase 5: Develop a Prototype
Prototype: A working model for testing the design.
Model: A representation of the function(s) of a design.
Purpose:
ID possible modifications
Minimize potential for costly errors
Types:
Scale models, functional models, appearance models.
Computer graphic, simulator, analytical, physical.
Methods:
3D print, stereo-lithography, small-scale manufacturing methods
Mathematical models and simulators/programs
Finite Element Analysis, Computational Fluid Dynamics
ETSC 101 CHAPTER 2&3 HACKER
Not just one prototype is made. Usually development teams will begin making prototypes as early as the first phase of the design process. They start out really simple and increase in complexity.
So the reason for prototypes is that companies and development teams don’t want to have “Oh crap” moments.
More and more prototypes and models are moving to the computer and less and less being actually constructed.
Scale models allow you to see individual parts of a very small assembly or allows you to see the entire design in an overall view in large assemblies.
Functional models will be built to test individual or multiple functions. Tests are large parts of function models.
Appearance models are to assess the industrial design of the products and see how customers will respond to the product.
11
Prototypes
ETSC 101 CHAPTER 2&3 HACKER
3D Printed Appearance Prototype Model
Manufactured Scale Model
Functional Prototype
Prototypes
ETSC 101 CHAPTER 2&3 HACKER
Stereo-lithography
Dynamic Test in Simulator
Creep Test of Wheel to IRobot
Phase 6: Test and Evaluate the Design Solution
This is where testing meets the prototype(s).
Design tests to test the design solution.
Collect data
Analyze data to show how well the design satisfies the constraints and specifications.
ETSC 101 CHAPTER 2&3 HACKER
Tests are associated with all kinds of prototypes. Tests are most detailed and extensive with the pre-production prototype (Closest model of the actual product; may even be the actual product that will reach customers).
Example:
Scale: Does everything fit and go together properly?
Appearance: Customer response surveys
Function: Strength test, mobility test.
14
Sect. 3: Model and Actual Performance
ETSC 101 CHAPTER 2&3 HACKER
Physical/Math Model of System
Mathematical Analysis
Model Performance
Actual System
Experimental Analysis
Actual Performance
COMPARE!
Its important to test the mathematical model against the experimental model to make sure the results line up.
15
Phase 7: Redesign the Solution with Modifications
Take everything you’ve learned from testing and evaluating the design and make the necessary changes.
ETSC 101 CHAPTER 2&3 HACKER
Phase 8: Communicate you Achievements
Design report or portfolio. Everything must be documented.
Present your design solution to whoever is making the call to go forward with production.
IMPORTANT: Communicate how your design solution meets the final specifications and constraints.
Describe the process you went through. How can the process be improved? What did you learned from the project? What will be done differently next time?
ETSC 101 CHAPTER 2&3 HACKER
White board for specifications to final design solution.
17
Another Approach to Solving Problems
Large problems are often broken down into a bunch of small problems.
Given: Gather all relevant information.
Find: State the problem.
Sketch: Illustrate the problem.
Assume: State all assumptions.
Method: State the method applied to solve the problem.
Solution: Lay out the processes and steps taken to apply the method.
Answer: State the solution.
Tolerance: Define limitations/constraints/tolerances on solution.
ETSC 101 CHAPTER 2&3 HACKER
Example:
Qualitative: How to get across a gap.
Given: Gap is 20 feet wide. Gap is very high (Impractical to climb down). Weather conditions
Find: A way across the gap.
Sketch: Picture of gap/dimensions etc.
Assume: There is no way across gap currently. Land masses on both sides are sturdy.
Method: Bridge technology.
Solution: Design bridge, construct bridge on site, test bridge, open for service, cross bridge.
Answer: 25’ span bridge made of wood by the so-so company. Budget: $20,000, Time Frame: 6 months.
Tolerance: 50 year life, max load=1000 lbs.,
Quantitative: Simple bridge problem to solve for forces.
18
From Functional to Project Organizations
Many organizations that provide solutions to the problem filled world are switching from a functional structure to a project structure.
Why?
Global enterprise and competition.
Faster pace of development of design solutions.
More constraints.
What does it mean?
Personnel operates in terms of project teams rather than functional departments.
Requires teamwork, cross-functional cooperation, leadership, and motivation.
It’s not just about developing new technology, but creating cost-effective, timely, and very high quality and high performing solutions that meet customer needs.
ETSC 101 CHAPTER 2&3 HACKER
From cubicles to up close and personal.
Competition is coming from more directions than can be counted at rapid rates.
Organization personnel therefore need teamwork to work on cross-functional teams, leadership to lead projects when asked, and motivation to operate and convince others to operate in the high risk, fast-paced, and mind demanding work of planning and organizing, implementing, and monitoring projects that will make the organization money.
This also means that developing new tech. isn’t good enough anymore. There is so much competition in every field from all over the world that everybody is developing new tech. all the time. So to be competitive, companies have to aim to satisfy the demanding customer needs that change way to often, most the time before you’re even finished with the project that was meant to satisfy their most recent needs.
19
Skills in Project Organizations
Teamwork
Respect
Ability to listen carefully
Having a common goal/purpose
Participation by all/accountability by all
Leadership
Ensure accomplishment of tasks by team
Nurture the growth of the team’s abilities and skills
Take care of the team and assume responsibility for them
ETSC 101 CHAPTER 2&3 HACKER
Projects
Plan and Organize
Project schedules and budgets
Mission statement and goals; concept development
Management of stakeholder needs
Implement
Get it done!
Monitor and Control
Ensure schedules and budgets are met
Assess and fix all deviations from the plan
ETSC 101 CHAPTER 2&3 HACKER
