Design Functions and Solutions

Christopher Saldana, Ph.D.

Woodruff School of Mechanical Engineering
G e o r g i a I n s t i t u t e o f Te c h n o l o g y
Atlanta, Georgia, USA
Phases of Design
Customer Detail Design
• Understand the Design Process Specification of Production
Specification Development • Process Planning
• Specification of Information Manufacture
Conceptual Design
• Specification of a Principle
• Functional Decomposition
• Generate Concepts
• Concept Evaluation
• Concept Selection
• Preliminary Design/Embodiment
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Concept Generation/Selection
Creating, screening, scoring alternatives

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4
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Alternatives (Project Purple - iPhone)
Apple’s design approach
Pixel-perfect design mockups
10 to 3 to 1 design down-select
Paired design meetings – brainstorming/production
Pony meetings – design review for managers
Integrated business process design
Customer experience focus

Walters, Helen. "Apple's Design Process, Bloomberg Businessweek." (2008).

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Alternatives (Project Purple - iPhone)
Initial Concepts Design Iterations
Alternative 1 - P1 design P2 design prototypes P2 refined designs

Concept Make,
screen, iterate
prototype and
and score ‘Sandwich’ ‘Extrudo’ finalize
Alternative 2 - P2 design

Samsung Electronics Co., Ltd., et al. v. Apple Inc. (2016), SCOTUS Case 15-777.
Kahney, L. (2013). Jony Ive: The Genius Behind Apple's Greatest Products. Penguin.
Kahney, L., ”Birth of the iPhone”, Cult of Mac, June 26, 2017 7
Learning Objectives

Identify design functions and sub-functions (Function Tree)

Identify solutions for different functions/sub-functions
(Morphological Chart)
Combining individual solutions to generate conceptual
alternatives

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Guidelines for Functional Modeling
Consider what not how
• Draw a box
• Identify a verb
• Identify a noun(s) on which the verb acts
Follow flows of energy, material, and information/signals.
Consider interactions with external energy, material
Break the function down as finely as needed
• Fine enough to address customer needs
• Fine enough for a single basic solution principle to satisfy each sub-function.
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Black Box Models
Define overall function
Identify system boundaries
Identify flows of Energy (E), Material (M), and Information (I)
Identify interfacing objects that exchange E, M, or I
Conserve E and M

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Function Block Diagrams
Example: Packing of Carpet Squares

Function Structure
Loose carpet
squares stamped
Overall Carpet squares
packed in lots
out of the length Function

Stamp
Separate Check Count Combine
Material Form Pack Dispatch
Offcuts Quality Squares in lots
Length

Material Flow Main Function System Boundary

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Function Block Diagrams
Example: Material Testing Machine
E load E deformation
Test Specimen Specimen deformed
Specimen (Force I force
Deformation)
I I deformation

Measure
IF
E load Change force
energy into
I force &
movement
Measure
I∆
deformation

Load
E deformation
Specimen specimen
Specimen deformed

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Function Block Diagrams
Example: Material Testing Machine
E auxil.
Measure
IF
I F target Compare target force
Amplify
with actual
I ∆ target measurements
values
Measure
I∆
deformation

E load Change
energy into Adjust
I force & energy flow
movement

E loss

Hold Load E deformation

Specimen specimen specimen Specimen deformed

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Determining Functional Variants
Example: Dough Dough
E Eloss
Shape Dough
Shaping Machine Additives
I
Shaped Dough

Dough Feed in Prepare Dispense Shape Separate Feed Out Shaped

1 2 3 4 5 6 Dough

Return Additives Waste Waste Waste

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1 2 3 4 5 6 1 2 3+4+5 6

7 7

1 2 3+4 5 6 1 2+3 4+5 6

7 7
Overall function and function structure variants of a dough-shaping machine
for the manufacture of biscuits (in respect of the main flow only)

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Function Tree
Function

SF1 SF2 SF3

SF11 SF12 SF13 SF21 SF22 SF23 SF31 SF32 SF33

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Function Tree Example

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Developing Solution Principles
Physical Effect Physical Principle Solution Principle
Sub-Function (Independent (Sub-function (Physical Principle &
of Solution) & Physical Effect) form Design Features)

Friction FN Transfer Friction Surface

T Transfer T Torque by
FF T
Torque Friction T
FF=µFN FT=FF=µFN
V
Lever FA a b FB FA Amplify FB
FA Amplify FB
Muscular
muscular Force by Lever
force bFB=aFA FB=FA(a/b)

Expansion L Close Contact

L
Close L by Expanding L
T contact T Mercury
when T≥Ta ∆L=(α)(L)(∆T)
∆L=(α)(L)(∆T)

Fulfilling sub-functions by solution principles built up of physical principles

and form design features

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Solution Principle Matrix
Example: Design of a Pencil
Sub-function 1: Make an Erasable Mark
Sub-function 2: Erase an Erasable Mark
Sub- Solution Principles
func. (Idea/ Source)
Idea: (Mechanical) (Mechanical) (Mechanical) (Chemical)
1 Rub on Material Squirt Material Place Material Change paper composition
(like Letterset)
Source: Standard product Team #2 Letterset Acid etching
(Chemical) (Electrical) (Electrical) (Electrical)
1 Change paper color Burn paper (spark) Electrify Paper (glow Static charge to hold mark
(like Litmus paper) (like old fashioned strip discharge) on
chart recorders) (like Etch-A-Sketch)
Fisher Scientific Team #3 Team #1 Etch-A-Sketch
(Thermal) (Thermal) (Thermal) (Magnetic)
1 Burn paper (flame) Heat paper (glow discharge) Melt on Mark Attach magnetic material
(like refrigerator magnets)
Team #2 Team #2 Wax seals Gift Store
(Biological) (Biological) (Optical) (Optical)
1 Grow bacteria, fungus Modify (digest?) paper Change light properties of Change light (hologram)
paper (reflectance, polarity)
Team #2 BioTech Magazine Team #2 Team #2
(Mechanical) (Mechanical) (Mechanical) (Chemical)
2 Rub off Material Take off material Cover mark Change paper composition
(like white out)
Standard product Team #2 Team #1 Team #2
(Chemical) (Chemical) (Electrical)
2 Change paper color Change mark (e.g., bleach) Burn off mark (spark)
(like dying fabric the same ETC.
color as a stain)
Team #1 Team #2 Team #2

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Different Principles to Store Energy
Type of Energy
Working Principle
Mechanical Hydraulic Electrical Thermal
m Pot. Liquid Battery Mass
1 h Energy h Res. M, s, T
Pot. E. +V-
v Moving Capacitor
Flowing (Electric Field) Heated
2 m Mass
C
Liquid Liquid
Flywheel
ω Superheated
3
J Steam
Wheel
ω v on
4 incline
J Plane

Spring Other Springs

5 Comp. Gas
F F
Hydraulic
6 reservoir
e.g, Piston

Different working principles to satisfy the function “store energy” by varying the type of energy.
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An Old Competition

20 ft
12.5 ft
Start Line

6.25 ft

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Function Tree Diagram

Place Mass
on Target

Generate Transmit Hit Brake on

Power Power Target Target

Move Navigate
to to
Target Target

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Morphological Chart
Going from concept to physical reality
Generate
Power
Gravity Mouse Traps

Transmit
Power
Car Hit by Trap Rip Cord Effect Ramp Catapult

Brake on
Target
Friction String Break Anchor Rubber Stopper Weighted Skid

Move to
Target
Rolling Sliding Projectile Launch

Navigate to
Target
Equal Size Wheels Larger Front Wheels

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Combining Solution Principles

Sub- \Solutions
1 2  j  m
Functions
1 F1 S11 S12 S1j S1m
2 F2 S21 S22 S2j S2m
     
i Fi Si2 Sij Sim
     
n Fn Sn1 Sn2 Snj Snm

1 2 Combination of Principles
Combination 1: S11 + S21 + … + Sn1
Combination 1: S11 + S22 + … + Sn2

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Summary – Function Tree

Elements
• List critical functions and sub-functions
• Sub-branches from a function or sub-function must
number 2 or greater
• Do not specify specifications that are dependent on
design decisions, design choices come later!

Describing this figure in text

• Describe the contents, not the tool itself! See Ch. 3 in book
• What are critical functions? for detail

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Summary – Morphological Chart
Elements
• Mechanisms for lowest level elements of
FT, match one-to-one
• Diagrams to depict mechanisms
• Labels to briefly name mechanisms

Describing this figure in text

• Highlight key mechanisms/functions
• Use a selection matrix to identify
mechanisms used in different designs See Ch. 5 in book for detail
• Use different mechanisms in designs
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Learning Objectives

Identify design functions and sub-functions (Function Tree)

Identify solutions for different functions/sub-functions
(Morphological Chart)
Combining individual solutions to generate conceptual
alternatives

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Other Morphological Chart Examples

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Function Block Diagrams
Example: Packing of Carpet Squares
Function Structure with Auxiliary Functions
Send Signal to
combine Supply
squares into packing
one lot material

Stamp
Separate Check Count Combine
Material Form Pack Dispatch
Offcuts Quality Squares in lots
Length

Remove Remove
offcuts rejects

Material Flow Main Function System Boundary

Signal Flow Auxiliary Function
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Example: Harvest Potatoes
Potatoes
E
Potatoes in Reject Potatoes
Harvest Potatoes
the ground Leaves
I
Soil, etc.

E2 Change

E2 Change

E2 Change

E1
Potatoes in
the ground Lift Sift Separate Separate Sort Collect Potatoes

I Reject Potatoes
Course Particles
Leaves
Fine Particles

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Example: Harvest Potatoes

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Example: Additive Manufacturing

Williams, C.B., Mistree, F. and Rosen, D.W. (2011), “A Functional Classification Framework for the Conceptual Design of Additive
Manufacturing Technologies”, Journal of Mechanical Design, Vol. 133 No. 12, p. 121002.

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Example: Additive Manufacturing

Williams, C.B., Mistree, F. and Rosen, D.W. (2011), “A Functional Classification Framework for the Conceptual Design of Additive
Manufacturing Technologies”, Journal of Mechanical Design, Vol. 133 No. 12, p. 121002.
32
Example: Additive Manufacturing

Williams, C.B., Mistree, F. and Rosen, D.W. (2011), “A Functional Classification Framework for the Conceptual Design of Additive
Manufacturing Technologies”, Journal of Mechanical Design, Vol. 133 No. 12, p. 121002.
33
Example: Additive Manufacturing

Williams, C.B., Mistree, F. and Rosen, D.W. (2011), “A Functional Classification Framework for the Conceptual Design of Additive Manufacturing 34
Technologies”, Journal of Mechanical Design, Vol. 133 No. 12, p. 121002.