ENGINEERING DESIGN

DAM 21503
Chapter 1

Prepared by : Noraniah binti Kassim

June 13, 2021 Lecture 1b 1

 Engineering Design Process

How does a design occur ?

How does it start ?
Does an engineer sits on a desk and start
drawing ?
What happen next ?
What factors influence a design decision ?
How does a design ends ?

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Engineering Design Process

There are various models of the design process which

has been proposed by several authors.
Among the notable ones are by Pugh, French, Pahl &
Beitz, N.P.Suh, Shigley

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Pugh’s Design
Process Model

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 French’s Design
Process Model

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Pahl and Beitz Design
Process Model

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 Suh’s Design Process Model

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 Stages of the Design Process
Primary Goal
Product Design Specifications
Identification of Need • Product Functions
• Design Requirements
• Design Criteria
Gathering information
Ergonomic & Anthropometrics
Design Codes Background Research
Patent Search

Concept Generation
• Brainstorm
Conceptual Design Concept Evaluation
• Matrix Evaluation
Design Review
Dimensional Modeling
Material Selection
Analysis / Calculations Embodiment Design
Initial / Basic Testing
Design Review
Detail Drawings
Manufacturing Process
Final Design Evaluate Cost
Prototype & Testing
Design Review

Lecture 1b 9
June 13, 2021 Lecture 1b 10
 Identification of Need
• clearly articulate the primary goals of the need before
beginning the design process.

• then, develop the product design specification (PDS).

• sometimes the designer has to do the background research

first to get some information to complete the PDS

• this PDS is a document listing the problem in detail.

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 Background Research
• The most important phase in the process, and is unfortunately often the
most neglected
• Gathering background information on the relevant aspects of the problem
• To find out if this, or a similar problem, has been solved before. There is
no point in reinventing things e.g. wheel.  more economical to purchase
it than to built your own.
• Information  Patent literature, Technical publications, magazines,
books, market survey, interview, lead users and experts & etc.
• Design that are related to human use, need to consider
Ergonomic & Anthropometrics

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 Conceptual Design
• Using the PDS as the basis, the designer attempts to produce an outline of
a solution. A conceptual design is a usually an outline of key components
and their arrangement with the details of the design left for a later stage.
• This stage of the design involves drawing up a number of different viable
concept designs which satisfy the requirements of the product outlined in
the PDS and then evaluating them to decide on the most suitable to
develop further. Hence, concept design can be seen as a two-stage
process:-
– concept generation
– concept evaluation

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 Embodiment Design
The principal purposes for embodiment design is:

• Narrowing of the design concept. Obtain a clear picture of the selected

concept and establish its dimensions until its become a
dimensional modeling
• Prepare material selection to all components / parts in the product
• Perform supporting analyses / calculation (including analyses at each
critical point in each component)
• Perform some initial / basic test to ensure the design get it right first time

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 Final Design

In this phase, we deal with individual components of

the product and the product as a whole:

– Prepare component detail drawings

– Select manufacturing process
– Evaluate cost
– Prototype & testing

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Product Design Specification (PDS)
The product design specification (PDS) is a very important
document in the design process as it contains all the
information necessary for a design team to successfully
produce a solution to the design problem.
A PDS splits the problem up into smaller categories to make
it easier to consider the problem. The final document
should fully document as unambiguously as possible all
the requirements that a product must fulfill together with
any constraints that may affect the product.
The actual or intended customer should be consulted as fully
as possible while the PDS is being drawn up as their
requirements are of paramount importance.

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 PDS Importance

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 Typical PDS Categories
Various aspects relating to the product must be considered. The actual
categories can vary, but a typical PDS may consist of the following
categories:

Appearance Materials
Customer Packaging and transport
Documentation Performance
Ergonomics Product cost
Environment Product dimensions
Installation Product life
Product disposal Quality
Lead times Quantity
Legal and safety implication Standards
s Testing
Legislation, patents and cop
yright
Maintenance

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 PDS - example
 Portable Winch
 Design Brief
 From internal market research, it has been decided that IWC need to design a general purpose winch
to sell to the cable and pipe laying market sector. The winch should be portable but have mounting
points for the end user. It is important that the winch sits within out current range of 'Excel General
Purpose winches'.
 1.0 Performance
 1.1 Lift / lower a load of 2.5 tonnes (+/- 10%).
 1.2 Draw in cable in at a rate of 0.2 m/s.
 1.3 The winch drive should cut out when the load exceeds 10% of the specified load.
 1.4 Drive to stop lowering load when only 1.5 metres of cable remains on winch drum.
 1.5 Winch should operate with forward, reverse, stop and inch facility.
 1.6 Any braking system employed, should produce a braking torque of 150% the full load torque.
 1.7 Winch should have a manual device to control the brake release and load descent in the event of
a power failure.
 1.8 In the event of the winch 'overrunning', a manual safety relay/braking device should operate
within 1 second or before the load exceeds a speed of 3m/s.
 1.9 The product should be portable but with the option for permanent mounting.
 1.10 The product must use a portable power source, preferably a diesel engine.
 1.11 The weight of the product must be sufficient to aid the stability of the product.
 1.12 Efficiency of the unit should be high, preferably in the area of 20 - 30%.
 1.13 The drum should hold 50m of cable.

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 • 2.0 Environment
• 2.1 The winch drive and power unit should be power unit.
• 2.2 The unit will be mainly used in European weather conditions. But we could expect sales of about
2% unit volume to the Far East.
• 2.3 Temperature ranges:
• -28 degree C - European
12 - 44 degree C - Far East
• 2.4 The product may experience humid conditions.
• 2.5 Corrosion resistance may be considered by the use of special materials or surface protection
methods.
• 2.6 Any noise from the equipment should not exceed 95 dB at a distance of 1.0m.
• 2.7 The winch will be stored in suppliers warehouses before sales.
• 3.0 Product Life Span
• 3.1 Product will be on the market for 10 years.
• 3.2 Spare parts will be available for a further 5 years after that.
• 4.0 Life in Service
• 4.1 Should withstand an operating period of 1 hr uninterrupted use per day for 5 years.
• 4.2 Life in service should be assessed against the criteria outlined in the Performance and
Environment categories.
• 5.0 Shelf Life
• 5.1 The product will be stored on-site for up to 1 month before dispatched.
• 5.2 Our Far East distributor may store the product for several months.

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  6.0 Target Costs
 6.1 The product should have an end-user cost of £5500 within Britain.
 6.2 The cost of manufacture should be less than £2750.
 6.3 The cost of packaging and shipping should be no more than 15% of the manufacturing cost.
 7.0 Quantity
 7.1 150 units in the first year, increasing to 800 within four years.
 8.0 Maintenance
 8.1 To be maintenance free except for light lubrication once a month and a recommended service
every two years.
 8.2 Parts requiring lubrication should be accessible within 15 minutes without the use of special tools
or equipment.
 8.3 All fasteners used should comply with BS6105.
 8.4 Spares should be available for 5 years after the product is replaced with a new model.
 8.5 No special tools should be required for maintenance.
 9.0 Packaging
 9.1 Packaging / transport cost should be kept to a minimum and preferably below 5% of the unit
cost.
 10.0 Size and Weight Restrictions
 10.1 Weight should not exceed 500 kg.
 10.2 Length not to exceed 2500 mm.
 10.3 Width not to exceed 2000mm.
 10.4 Height not to exceed 2000mm.

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  11.0 Shipping
 11.1 Product will be shipped by road within Europe.
 11.2 Product will be shipped by sea to Far Eastern markets.
 12.0 Manufacturing Processes
 12.1 Capacity is available for current market demand within scope to increase production to 200 per
year without investment / expansion.
 12.2 Motors, transmissions, bearing and ropes are bought in from the following suppliers:
 Drives:
 Electric Motors - Brook Compton
 Diesel Engines - Gardener
 Hydraulic Motors - Hydrostatic Transmission Ltd
 Bearings:
 RHP Bearings
 Transmissions:
 Couplings - Wellman Bibby
 Worm Gears - Reynold
 Planetary Gears - David Brown (PPG Divisions)
 In-Line Gears - David Brown Radicon Ltd
 V-belts - Fenner
 Ropes:
 Bridon
 12.3 Castings and injection moulds produced by external suppliers.
 13.0 Aesthetics
 13.1 The form can follow function.
 13.2 If cost dictates, the winch should look attractive to improve our perception within the market.

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  15.0 Ergonomics
 15.1 Controls to be mounted in an accessible position, relative to the operator i.e. waist height -
around 1m, to accommodate 95% of the working population.
 15.2 All controls should be hand operated, requiring one-hand operation with a maximum force of
1.5 N/m2
 15.3 One man should be able to operate the product.
 16.0 Customer Requirements
 See Marketing
 17.0 Competition
 17.1 The winch will be operating against equivalent models which include the following companies:
 Swansom - England
 Oholom - Sweden
 Winderhock - Germany
 18.0 Quality and Reliability
 18.1 Quality should be such that winches should not generally fail within a period of three years and
only 1 in 50 should fail within the first year.
 18.2 No winch should fail in the area of the safety overload device.
 19.0 Standards and Specifications
 19.1 Standards to be adhered to:
 BS 5000 part 99 Motor Performance
 BS 6105 and BSEN 20898(1) Bolts
 BS 6322(2) & BS 4320 Nuts and washers
 BS 7676 and BS 4517 Gears
 BS 3019 Welding
 BS 5989 Bearings
 BS 2754 Electrical Insulation
 BS 5646 pt4 Bearing Housing
 BS 4235 Keys and Keyways

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 • 20.0 Company Constraints
• 20.1 None - except those outlines in Manufacturing and Processes.
• 21.0 Processes
• 21.1 All components to be of metric form and comply with ISO 4900 for limits and fits.
• 22.0 Safety
• 22.1 No winch should fail in the area of the safety overload device.
• 22.2 Winch should not operate when maintenance is being carried out.
• 23.0 Testing
• 23.1 Testing is to be carried out on 5% of units.
• 23.2 All cables should be tested to BS3621.
• 24.0 Legal
• 24.0 Possible litigation lies in the user injuring themselves by having access to moving parts during
winch operation.
• 25.0 Installation
• N/A
• 26.0 Documentation
• 26.1 Product should be supplied with a user manual covering winch operation and maintenance.
• 26.2 Suppliers require maintenance and repair manual.
• 27.0 Disposal
• 27.1 Plastic parts should be separable and marked to aid disposal.

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Ergonomics and Anthropometrics
Anthropometrics
Anthropometrics is the study and recording of the
physical properties of the human body

Ergonomics
Ergonomics investigates how we use our environment
and the design of environments which enable users to
use the environment easily and comfortably

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 Anthropometric data
Anthropometrics has proven a very useful
science to help designers and engineers
produce products that the general public
can use.

Most data tables show the average and

the two extreme's, of human size. These
are the 50%ile, and the 5th and 95th%ile
respectively. Male and female sizes are
generally separate since there are big
differences in the sizes of males and
females.

This graph shows how the distribution of

sizes for an average population varies.
The 50%'ile, is the 'average' person. In
most population's, people are around the
'average' size

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 Anthropometrics of an average person

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 Ergonomics Data

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 Examples of Ergonomic Design

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 A problem well put
is a problem half solved

Old English Proverb

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 Questions ??

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