DEBRECENI EGYETEM

MŰSZAKI KAR
GÉPÉSZMÉRNÖKI TANSZÉK

Machine and product design

Dr. Czégé Levente
Machine and product design 2
Machine and product design 3
Generating variatons of the function structure
• On the basis of the general valid fuction structure it is easily possible
to generate variations already in this design phase.
• However at this high level of abstraction it is still not possible to chose
an optimal solution, becouse of lack of evaluation criteria.
• Variants must be checked focusing on logical compatibility.
• It is easy to eliminate variations, which can’t fulfill the requirements.
• This step is suitable mainly to determine the fundamental
possibilities.

Machine and product design 4

A funkcióstruktúra-változatok kidolgozása
• Possibilities:
• Defining system boundary, changing the boundary
• Dividing the function structure into subsystems (clarity, simplicity, low level of
restrictions due to minimal connections to other subsystems)
• Varying the sequence of the finctions
• Dividing the function further to subfunctions
• Merging functions
• Eliminating or extending functions
• Changing input and output points
• Etc.

Machine and product design 5

Searching for Working Principles
• Goal: to find working principles for the various subfunctions, and
these principles must eventually be combined into a working
structure.
• Working principle: reflects the physical effect needed for the
fulfilment of a given function and also its geometric and material
characteristic.
• physical process-> working interrelationship-> working location->
working geometry (working surfaces, working motions) -> working
principle (working surfaces, working motions and materials)

Machine and product design 6

Conventional methodes
1. Information Gathering
2. Analysis of Natural Systems
3. Analysis of Existing Technical Systems
4. Analogies
5. Measurements and Model Tests

Machine and product design 7

Conventional methodes
1. Information Gathering
• access to state-of-the-art information is essential.
• Active search and passive discovery of solutions.
• Sources:
• searching the literature
• analysing trade publications
• surveying the presentations from exhibitions and fairs
• assessing catalogues of competitors
• exploring patents, etc.

Machine and product design 8

Conventional methodes
2. Analysis of Natural Systems
• The study of natural forms, structures, organisms and processes can lead to
very useful and novel technical solutions.
• Nature can stimulate the creative imagination of designers

Searching for Analysis of

Problem Elaborating
analogies in organic
definition own solution
natural systems solutions

Machine and product design 9

Machine and product design 10
Machine and product design 11
Machine and product design 12
Conventional methodes
3. Analysis of Existing Technical Systems
• one of the most important means of generating new or improved solution
variants in a step-by-step manner. Reverse engineering.
• involves the mental or even physical dissection of finished products, with
the aim of the discovery of related logical, physical and embodiment design
features.
• Sources:
• products or production methods from competing companies
• older products and production methods from own company
• similar products or assemblies with corresponding subfunctions or parts of the
function structure
• It carries the danger of causing designers to stick with known solutions
instead of pursuing new paths.
Machine and product design 13
Conventional methodes
4. Analogies
• It is often useful to substitute an analogous problem (or system) for the
one under consideration, and to treat it as a model.
• E.g.: electric system – hydraulic system
• helpful in the study of the behaviour of a system during the early stages of
its development (simulation and model techniques)

Machine and product design 14

Conventional methodes
5. Measurements and Model Tests
• Measurements on existing systems, model tests supported by
similarity analyses and other experimental studies are among the
most important sources of information.
• In the precision engineering and mass production industries
experimental investigations are an important and established means
of arriving at solutions.

Machine and product design 15

Intuitive Methods
• There are several methods of encouraging intuition and opening new paths
by the association of ideas.
• Methodes involve group dynamics that are used to generate the widest
possible range of ideas. -> uninhibited exchange of associated ideas
between the members.
• Módszerek:
• Brainstorming
• Method 635
• Gallery Method
• Delphi Method
• Synectics
• Six thinking hats

Machine and product design 16

Intuitive Methods
1. Brainstorming
• A group of open-minded people from as many different spheres of life as possible bring
up, without prejudice, any thoughts that occur to them and thus trigger off new ideas in
the minds of the other participants.
• The group should have a leader and consist of 5-15 people. The involvement of
nontechnical members add a rich new dimension.
• The group should not be hierarchically structured but made up of equals in order to
prevent the censoring of such thoughts as might give offence to superiors or
subordinates.
• Rules:
• All participants should avoid rejecting as absurd, false, embarrassing, stupid, well-known or
redundant any ideas expressed spontaneously by themselves or by other members of the group.
• No participant should criticise any ideas, and everyone must refrain from using killer phrases.
• All ideas should be written down, sketched out, or recorded. The practicability of the suggestions
should be ignored at first.

Machine and product design 17

Intuitive Methods
2. 6-3-5 method
• Process
• six participants write down three rough solutions in the form of keywords.
• the solutions are handed to each participant’s neighbour who, after reading
the previous suggestions, enters three further solutions or developments.
• This process is continued until each original set of three solutions has been
completed or developed through association by the five other participants
• A good idea can be developed more systematically, than by
brainstorming.
• Reduced creativity by the individual participants owing to isolation,
and lack of stimulation in the absence of overt group activity.

Machine and product design 18

Intuitive Methods
3. Gallery Method
• Combines individual work with group work, and is particularly suitable for any
stage of the design process where solution proposals can be expressed in the
form of sketches or drawings.
• Process:
• Introduction Step: The group leader presents the problem and explains the context.
• Idea Generation Step 1: group members create solutions intuitively using sketches.
• Association Step: The results are hung on a wall as in an art gallery to discuss them, to find
new ideas or to identify complementary proposals through negation.
• Idea Generation Step 2: The ideas are further developed individually by each of the group
members.
• Selection Step: All ideas generated are reviewed, classified and finalised. Promising solutions
are then selected.
• Intuitive group working, without lengthy discussions. An effective exchange of
ideas using sketches is possible.
Machine and product design 19
Intuitive Methods
4. Delphi Method
• Experts in a particular field are asked for written opinions.
• Individual problem solving, group activity is not necessary.
• Process:
• First Round:What starting points for solving the given problem do you suggest?
• Second Round: Please go through the list of various starting points and make what
further suggestions occur to you.
• Third Round: Please go through the list of the final evaluation and write down what
suggestions you consider most practicable.
• The procedure must be planned very carefully and is usually confined to
general problems bearing on fundamental questions or on company policy.
• Suitable for fundamental studies of long-term developments.

Machine and product design 20

Intuitive Methods
5. Synectics
• Aim is to trigger off fruitful ideas with the help of analogies from
nontechnical or semi-technical fields.
• A group of no more than seven members supported by a leader.
• Steps:
• Presentation of the problem.
• Familiarisation with the problem (analysis).
• Grasping the problem.
• Rejection of familiar assumptions with the help of analogies drawn from other spheres.
• Analysis of one of the analogies.
• Comparison of the analogy with the existing problem.
• Development of a new idea from that comparison.
• Development of a possible solution.

Machine and product design 21

 Intuitive Methods módszerek

• Question: How can the umbrella analogy be applied?

• Possible answer 1: By (b) drilling through the stone, pushing the umbrella through the hole and
opening it up. Not very feasible.
• Possible answer 2: By (c) pushing a tube through the hole and blowing it up (balloon) behind the
stone. Drilling of hole not feasible.
• Possible answer 3: By (d) pushing the tube past the stone. When the tube is withdrawn the resistance
may seriously damage the urethra.
• Possible answer 4:By (e) adding a second balloon as a guide and by (f)embedding the stone in a gel
between the two balloons and then pulling it out? This was found to be the best solution.
Machine and product design 22
 Intuitive Methods
Synectics recognizes four types of analogy:
• Direct analogy: The designer searches for the closest physical analogy to the situation at hand.
A direct analogy may take the form of a similarity in physical, similarity in geometrical
configuration, or in function.
• Fantasy analogy: The designer disregards all problem limitations and laws of nature, physics, or
reason. Instead, the designer imagines or wishes for the perfect solution to a problem.
• Personal analogy: The designer imagines that he or she is the device being designed,
associating his or her body with the device or the process under consideration.
• Symbolic analogy: This is perhaps the least intuitive of the approaches. Using symbolic analogy
the designer replaces the specifics of the problem with symbols and then uses manipulation of
the symbols to discover solutions to the original problem. (LaPlace transforms, structural
synthesis of mechanisms that requires drawing a graph representing the joints and linkages of
the mechanism and then converting the graph into a set of equations for solution)

Machine and product design 23

Intuitive Methods
6. Six Thinking Hats
• De Bono identifies six distinct directions in which the brain can be challenged.
In each of these directions the brain will identify and bring into conscious
thought certain aspects of issues being considered (e.g. gut instinct,
pessimistic judgement, neutral facts).
• Switching to a direction is symbolized by the act of putting on a coloured hat,
either literally or metaphorically. This allows for a more complete and
elaborate segregation of the thinking directions.
• The hats aid individuals in addressing problems from a variety of angles, and
focus individuals on deficiencies in the way that they approach problem
solving.
• Because everyone is focused on a particular approach at any one time, the
group tends to be more collaborative.

Machine and product design 24

Intuitive Methods

Machine and product design 25

Discursive Methods
1. Systematic Study of Physical Processes
2. Classification Schemes
3. Use of Design Catalogues
4. TRIZ

Machine and product design 26

Discursive Methods
1. Systematic Study of Physical Processes
• If the solution of a problem involves a known physical effect
represented by an equation, various solutions can be derived from
the analysis of their interrelationships.
• Analyzing the relationship between a dependent and an independent
variable, all other quantities being kept constant.
• E.g.: if we have an equation: y=f(u,v,w);
we investigate solution variants for the relationships
y1 = f (u, v, w), y2 = f (u, v, w), y3 = f (u, v, w),
the underlined quantities being kept constant.

Machine and product design 27

 Discursive Methods
1. Systematic Study of Physical Processes
Example: capillary viscometer
1. the differential pressure Δp serves as a
Hagen–Poiseuille-törvény:
measure
qV , r , l = constant

2. changes in radius of the capillary tube (r)

qV , Δp , l = constant
qV volume flow rate,
Δp pressure,
3. changes in the length of the capillary tube (l)
l length,
qV , Δp , r = constant
r radius
η viscosity
4. on changes in the volume flow rate (qV)
l , Δp , r = constant
Machine and product design 28
Discursive Methods
2. Classification Schemes
• the systematic presentation of information and data is helpful
• it stimulates the search for further solutions in various directions
• it facilitates the identification and combination of essential solution characteristics
• They can serve as design catalogues and they can also help in the
combination of subsolutions into overall solutions.
• The choice of classifying criteria or their parameters is of crucial importance.
• Procedure:
Step 1: Solution proposals are entered in the rows in random order.
Step 2: These proposals are analysed in the light of the main characteristics, such as type of
energy, working geometry, working motion, etc.
Step 3: They are classified in accordance with these headings.

Machine and product design 29

Discursive Methods
2. Classification Schemes

Different working
principles that satisfy the
function “store energy”
obtained by varying the
type of energy

Machine and product design 30

Means of coating the backs of carpets by combining the
motions of the carpet (strip) and those of the applicator

Machine and product design

31
 Variations in the
working geometry for
shaft–hub
connections
Machine and product design 32
Machine and product design 33
Discursive Methods
3. Design catalogues
• Design catalogues are collections of known and proven solutions to
design problems. They may cover physical effects, working principles,
principle solutions, machine elements, standard parts, materials, etc.
• Types of design catalogues:
• Object catalogue: cover fundamental physical, geometrical, technological
knowledge.
• Operation catalogue: cover operations, sequences of operations, processes
and their conditions of application.
• Solution catalogue: assign functions to tasks, effects to functions, working
surfaces and geometries to effects, and finally production processes to
geometry.
Machine and product design 34
Machine and product design 35
Machine and product design 36
Discursive Methods
4. TRIZ
• TRIZ relies on the study of the patterns of problems and solutions, not on
the spontaneous and intuitive creativity of individuals or groups.
• More than three million patents have been analyzed to discover the
patterns that predict breakthrough solutions to problems.
• The principal TRIZ tools direct us to find all the ways of solving a problem,
to find new concepts and the routes for developing new products.

Machine and product design 37

Altshuller – TRIZ method
• The confirmed hypothesis behind is that similar problems lead to similar
solutions so the research of patents can reveal underlying solution
patterns.
• It was found that each of these solution patterns, which are named
Inventive Principles, can be viewed as overcoming of an engineering
contradiction. I.e., a moving object has to be of low weight but of high
strength.
• Such contradictions were collected and systematically processed in the
contradiction matrix, which is one of the most established TRIZ tools.
Depending on the version of the matrix, 40 or more Innovative Principles
are assigned to multiple parameters that have to be improved on the one
side, but that also worse another parameter on the other side.

Machine and product design 38

Altshuller – TRIZ method
• In the crossing field of the matrix, each number codes one of the
Inventive Principles, which is applicable in that situation.
• A designer has to translate these solution patterns to his actual
design problem. The quality of the results strongly depends on
expertise and experience of the designer since the principles are
formulated in an abstract way to meet a large variety of applications.

Machine and product design 39

Machine and product design 40