Introduction to

Engineering Design
Embodiment Design

Dr. Kıvanç Azgın

Middle East Technical University
Department of Mechanical Engineering
Ankara 06531, TURKEY
1956
The Design Steps

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 Embodiment Design
• The bridge between conceptual design
and detailed design
• It is the effort of turning your
“Frankenstein” best concept to a design
as “operational” and “handsome” as
possible.

• Also referred to as:

– Analytical Design
– Preliminary Design 3
Steps in Embodiment Design

• Product Architecture
• Configuration Design
• Parametric Design
• Detail Design

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 Product Architecture
• Arrangement of the physical elements to carry
out its required functions (system level design)
– Create a schematic diagram of the product
– Cluster the elements of the schematic
– Create a rough geometric layout
– Identify the fundamental and incidental
interactions

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 Terminology
• Component: includes special-purpose parts, standard parts,
and standard assemblies / modules

• Part: a designed object that has no assembly operations in its

manufacture

• Standard Part: generic function and manufactured routinely

without regard to a particular product

• Special-Purpose Part: designed and manufactured for a

specific purpose in a specific product line

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 Terminology2
• Assembly: collection of two or more parts

• Subassembly: assembly that is included within

another assembly or subassembly

• Standard Assembly / Module: assembly or

subassembly that has a generic function and is
manufactured routinely (ex: electric motors,
gearboxes)

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 Product Architecture Styles
• Two opposite approaches to product
architecture:

– Modular Architecture
• Designed of maintainability, expandability

– Integral Architecture
• Designed for performance, compactness

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 Product Architecture Steps

• STEP 1: Create a schematic diagram of the product

• STEP 2: Cluster the elements of the schematic

• STEP 3: Create a rough geometric layout

• STEP 4: Identify the fundamental and incidental

interactions

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Example: Laser Fusing Rapid Prototyping Machine

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 Schematic Diagram of a Laser Fusing Rapid
Prototyping Machine

• The functional
relationship
among the blocks.

• The blocks are

loosely arranged
according to their
geometric
configurations.

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Cluster Elements of Schematic

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Rough Geometric Layout

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 Configuration Design
• Establishing shape and general dimensions of components
– Standard parts
– Special purpose parts
– Assembly / standard assembly / standard module
– Sub-assembly
• Preliminary selection of materials and manufacturing process

Use CAD!!
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 Step by Step
• Establish spatial constraints

• Create / refine the interface or connections between

components

• Maintain functional independence in design of an assembly or

component

• Question the design

– Parts can be eliminated / combined?
– Standard module / part ?

• Iteratively fefine and patch

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 Parametric Design
• Objective of parametric design is to set values for
design variables such that they will produce the
best possible design considering the performance
and manufacturing.

• Attributes identified in configuration design

becomes design variables in parametric design.
Some such variables are dimensions, tolerances,
material, surface finish, heat treatment, etc.

• Set dimensions and tolerances so as to maximize

quality & performance and minimize cost!
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 Aspects of Parametric Design
• Failure modes and effects analysis (FMEA)
• Design for reliability
• Robust design
• Tolerance design

• By the end of the parametric design, a

prototype of the product should be
developed.
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 Detailed Design

• Last phase of your Detail Design work.

– Preparation of detailed technical drawings.

– All dimensions, tolerances and surface finish information
should be completed.
– Material information (Bill of Materials).
– Deciding on manufacturing operations.

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Other Aspects of Emb. and Detailed Design
– Industrial Design (Ch.6 Sec.6)
– Human factors in design (Ch.6 Sec.7)
– Design for the Enviroment (Ch.1 Sec.13, Ch.6 Sec.8, Ch.8
Sec.14)
– Design for …
• Cost (Ch.9 and Ch.14)
• Assembly (Ch.9)
• Manufacture (Ch.9)
• Quality (Ch.12 Sec.1-3)
• Reliability (Ch.11)
• Safety (Ch.11)
• Serviceability (Ch.6 Sec.7)

Considering all these aspects in the design process

requires the use of concurrent engineering approach. 19
 Concurrent Engineering
• Started as Simultaneous engineering
– Integration of manufacturing process development into the
early design phases.

• Key aspect of Concurrent Engineering

– Cross-functional teams
• Project members having varying specialties.
– Parallel design
• Development of product and manufacturing process simultaneously.
– Vendor partnering
• Involving the vendors in the design process

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 Important Tools Used in Detail Design
• Modeling
– Representation of the design.
• Simulation
– Representation of the performance of the design.
• Optimization
– Deciding on the design variables that will give the optimum
performance for the design.
• Computer aided design (CAD)
– Combination of modeling, simulation and optimization tasks in
computer environment.
• Computer aided manufacturing (CAM)
– Realization of the design using computer controlled machines.
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 Modeling (in a nutshell)
• There are different model classes:
– Descriptive vs. Predictive
– Static vs. Dynamic
– Deterministic vs. Probabilistic
– Iconic (or physical)
– Mathematical
– Geometrical modeling on the computer

• Levels of Physical Models

– Proof-of-concept model (Minimally operative, “String and chewing gum”
model)
– Scale model (Non-operating model, for visual communication and visualization
of space interferences and conflicts)
– Experimental Model (Functioning model but incomplete in appereance and
can be subject to extensive testing.)
– Prototype model (Technically and visually complete full scale working model)

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 Design Guidelines
• Avoid arbitrary decisions
• Search for alternatives
• Effectively use CAD tools
• Analyze problem at different depths of abstraction
• Develop competing design concepts
• Push some of the design concepts to its physical and
economical limits and then back off
• Clarify functions
• Exploit materails and manufacturing technology to the
fullest!
• Develop a logical chain of reasoning for design

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An Embodiment Example: “Beetle”

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An Embodiment Example: “Beetle”

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An Embodiment Example: “Beetle”

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An Embodiment Example: “Beetle”

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Another Example: “Subaru”

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Another Example: “Porsche”

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One More Example: “Hammer”

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Soyuz FG vs. Saturn V

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Soyuz FG vs. Saturn V
RD-107A (3.7m Dia)

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Soyuz FG vs. Saturn V
RD-107A (2m Dia)

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An ME-407 Project Embodiment:
Automatic Vacuum Cleaner
Vaccum Clean a
Given Area

Make sure
Move to a Manage
Create Vacuum everywhere is
location Available Power
cleaned

Translate the Monitor Power

Chasis Source

Rotate the Decide time to

Chasis recharge

Avoid Collisions

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 An ME-407 Project Embodiment:
Automatic Vacuum Cleaner: Elements

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An ME-407 Project Embodiment:
Automatic Vacuum Cleaner - Base

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An ME-407 Project Embodiment:
Automatic Vacuum Cleaner - Base

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An ME-407 Project Embodiment:
Automatic Vacuum Cleaner:
Transmission

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An ME-407 Project Embodiment:
Automatic Vacuum Cleaner:
Transmission

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 An ME-407 Project Embodiment:
Automatic Vacuum Cleaner: Propeller

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An ME-407 Project Embodiment:
Automatic Vacuum Cleaner

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An ME-407 Project Embodiment:
Automatic Vacuum Cleaner

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An ME-407 Project Embodiment:
Automatic Vacuum Cleaner

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An ME-407 Project Embodiment:
Automatic Vacuum Cleaner

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An ME-407 Project Embodiment:
Automatic Vacuum Cleaner: Calc.

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An ME-407 Project Embodiment:
Automatic Vacuum Cleaner: Calc.

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An ME-407 Project Embodiment:
Automatic Vacuum Cleaner: Calc.

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An ME-407 Project Embodiment:
Automatic Vacuum Cleaner: Calc.

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An ME-407 Project Embodiment:
Automatic Vacuum Cleaner: Calc.

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 An ME-407 Project Embodiment:
Automatic Vacuum Cleaner: Revisions and
Optimization

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 An ME-407 Project Embodiment:
Automatic Vacuum Cleaner: Control
Architecture

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An ME-407 Project Embodiment:
Automatic Vacuum Cleaner:
Manufacturing and Assembly

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