Engineering Exploration

Module 3 Engineering Design

Session 1

First Year Engineering (All)

2018-19
Maharashtra Institute of Technology
Aurangabad
 Engineering Design
• Engineering Design Process

• Multidisciplinary facet of design

• Pair wise comparison chart
• Introduction to mechatronics system
• Generation of multiple solution
• Pugh Chart
• Motor, battery sizing concepts
• Introduction to PCB design
 Engineering Design
• Engineering is the creative process of turning abstract ideas
into physical representations (products or systems).
• Producing products or systems that meet human needs. This
creative act is called design.
• Inventions, or designs, do not suddenly appear from nowhere.
They are the result of bringing together technologies to meet
human needs or to solve problems.
• Design activity occurs over a period of time and requires a
step-by-step methodology.
 Engineering Design
• Design problems are open ended in nature, which means they
have more than one correct solution.
• Solving design problems is often an iterative process: As the
solution to a design problem evolves, the design is
continuously refined.
• While implementing the solution to a design problem, it may
be found that the solution developed is unsafe, too expensive,
or will not work.
• Then "go back to the drawing board" and modify the solution
until it meets requirements.
Engineering Design
Engineering Design
 Topic Learning Outcomes
At the end of this module, student will be able to
• Explain engineering design process .
• Formulate problem definition for the need statement .
• Identify multi-disciplinary facet of design.
• Identify sub-systems and functions of a system.

• Select best alternative out of generated design alternatives.

• Construct proposed mechanical / mechatronics system.
• Test the solution/system for the given criteria.
 Key Concepts
• Engineering Design Process

• Objective tree
• Pair-wise comparison chart
• Function tree
• Functional structure

• Morphological chart
• Concept generation
• Concept selection
 Activity 1
Group Activity Team Size:2
Duration : 25 min

• Build a catapult that can launch a projectile to hit the target.

• Constraints
• Materials (8 popsicle sticks, 4 rubber bands)
• Time = 20 minutes
• Rules:
• Must be free standing on a flat surface.
• Team must maintain an accurate count of the sticks and
rubber bands used.
• Only use materials provided.
• Sticks and rubber bands should not be cut.
 Activity 1 continued

• We will calculate success index at the end of this activity

• Success Index= Distance travelled

(No of popsicle sticks + No of rubber bands used)
 Activity 1 continued
• Can you describe the process you followed in a single word?

• Are all the structures similar? (Though there was same need)
 Lets have a look at this
A Dragon lost its one of the wing and not able to fly

Undesirable situation

Desirable situation

Designing a wing that helps it to fly

 Activity 1 continued
• In the video, identify 5 tasks involved in translating
undesirable situation to desirable.

1.
2. Is there any standard
3. process to translate
undesirable situation to
4.
desirable ones?
.
.
.
 Activity 1 continued

There is aWhen?
need/probl AnWho ?
Engineer
em

Design

How? To Whom ?
Follow Engineering Client
Design Process
 Activity 1 continued
• What knowledge and skills should I acquire to solve a problem
and provide engineering solution?
 What is Engineering Design?
• Engineering design is the process of converting an idea or
market need into the detailed information from which a
technical system (product or process) can be produced.

Product
/
Process

Market
need
 What is Engineering Design?
• Engineering design is a systematic, intelligent process in
which designers generate, evaluate, and specify designs for
devices, systems, or processes, whose form(s) & function(s)
achieve client’s objectives and user’s needs while satisfying a
specified set of constraints.
 Engineering
1.Design Design Module
Mechanisms
and PBD
Process of Engg.
Exploration
modules of course
Engg.
Exploration
course

Engineer 3.
2. Design as Professional
Tools problem Skills
solver
Project
Engg. Management
Exploration and Ethics
course Module of Engg.
project Exploration
course
 5.Design 1.Problem
Communication definition

Engineering
Design
Process 2.Conceptual
4.Detailed design
design

3.Product
Architecture
08/20/2021 Engineering Exploration 2017-2018 (Even) 19
 1.Problem definition phase

Output
Input Tasks

1. List of
objectives
1. Identify design 2. List of
Clients objectives constraints
Need 2. Identify constraints 3. List of
statement 3. Establish functions functions
4. Revised
Problem
statement
 1.Problem definition phase

Input

Clients Example: Build a catapult that can launch

Need a projectile to hit the target
statement
 1.Problem definition phase

Output
Input Tasks

1. List of
objectives
1. Identify design 2. List of
Clients objectives constraints
Need 2. Identify constraints 3. List of
statement 3. Establish functions functions
4. Revised
Problem
statement
Example: Build a catapult
that can launch a projectile
to hit the target
 1.1. Design objectives
• Something toward which effort is directed ; an aim or end of
action.
• A feature or behaviour that we wish the design to have or
exhibit
• It defining the requirements of a design Objectives, or design
goals, are the desired attributes of the design, what the design
will "be“ and what qualities it will have.
 1.1 Design objectives
• Objectives are normally expressed as adjectives that capture
what the design should be, as opposed to what the design
should do.
• For example, saying that a ladder should be portable or
lightweight expresses an attribute that the client wants the
ladder to have.
• These features and behaviours, expressed in the natural
languages of the client and of potential users, make the object
“look good” in the eyes of the client or user.
 1.2 Identify constraints
• A limit or restriction on the design’s behaviour.
 1.2 Identify constraints
• Constraints are typically framed as a binary yes-or-no choice.

• Constraints are important to the design process because they

limit the size of a design space by forcing the designer to meet
a well defined set of requirements.
• Constraints enable us to reject unacceptable alternatives, while
objectives enable us to select among design alternatives that
are at least acceptable.
• Constrains are fixed under the consideration of factor of safety
(FOS), Standardization, Customer requirements, Cost, Market
etc.
 1.3 Establish functions

• A specific action that a designed device or system is expected

to do.
• Functions should consider ‘what’ the product does (the
problem) and not ‘how’ it does it (solution).
• A function involves the following two components.

• An action verb
• A noun representing the object on which the action verb
takes place
 1.3 Establish functions

• A design should perform certain functions for convert given

input to required output.
• Functions are often expressed as verb-object pairs.
• They describe what the design (or, more likely, an object
within the design) will "do" or accomplish, with an emphasis
on input-output transformations
• The statement of a function typically couples an action verb to
a noun or object:
• Eg: lift a book, support a shelf, transmit a current, measure a
temperature, or switch on a light
 Objectives vs. Functions
• Objectives
– Objectives tend to characterize what products are
– Objectives are usually expressed in the language of the client or users.

• Functions
– Functions describe what products do
– Functions express the actions that the designed product must perform
to successfully accomplish the designer’s intention.
– Functions are often expressed in the language of engineers or
scientists, in the form of verb-object pairs.
 Types of Functions
• Basic functions - the specific work that the designed product
is intended to accomplish
• Secondary functions - any other function, or those that result
from the basic function
• Required secondary functions - those secondary
• functions that are needed for the basic function to be
accomplished
• Unwanted secondary functions - functions related to
undesired byproducts of either basic or secondary functions
Example
 How to start?

• Interact with client to understand their need.

• Do brain storming and basic survey to arrive at pruned list.

 Interact with client to understand their
need by asking questions like
• What do you want the catapult to do?

• What features would you like to have in the catapult?

• Where do you want to use this catapult?
• Who are going to use this catapult?
Example: Build a
catapult that can
launch a projectile
to hit the target
Need : Build a catapult that can launch a
projectile to hit the target
• Compile the answers
• Launch the projectile to hit the target.
• a)Must be freely standing on a surface.

• b) Easy to use
• In a recreation centre of a hotel.
• People belonging to various age group use it.
 Further the customer adds

• Only use the materials provided to build the catapult. ( 8

popsicle sticks and 4 rubber bands)
• Each unit of catapult should not cost more than Rs 40/-
• Materials used to build must be reusable.

• The size and weight of launching items vary

 Further the customer adds

• Automatically sense the projectile and start its launching.

• Launch 4 projectiles consecutively.
• Alert the operator once operation is complete.

• Allow user to select the mode of operation (Manual /Auto)

 Do brain storming , basic survey to
understand concepts and also to arrive
at pruned requirement list

Observations and inputs from Survey Requirements

Shooting range depends on shooting Shooting angle should
speed (v), gravity (g) and shooting angle be at 45 degrees for
(Ө) maximum range.
Look at existing products and their
features to understand the requirements
 1.1 Design objectives

• Something toward which effort is directed ; an aim or end of

action.
 1.1 Identifying objectives

• Step 1: Prepare a list of design objectives from the compiled

list
• Launch the projectile to hit the target.
• Must be freely standing on a surface and stable

• Easy to use
• In a recreation centre of a hotel Rugged.
 1.1 Design objectives

• Step 2. Order the list into sets.

Catapult

1.Performance 2.User friendly

Hit the target exactly Easy to use

Stable and freely Rugged

standing
 Objective tree
• Is a ordered list of desired attributes of a design
• The highest level is the top-level design goal
• It describes dimensions of quality of a proposed design
• Performance (operating characteristics)
• Features (functions)
• Reliability (product failing)
• Durability (product life)
• Serviceability (during breakdown)
• Conformance (rules & regulations)
• Aesthetics (ergonomics)
• Perceived quality (reputation/branding)
 1.1 Design objectives
• Step 3. Draw objective tree

Catapult

Performance User friendly

Hit the Stable and

target freely Easy to use Rugged
exactly standing
 Decision Making
• Making decisions requires comparing alternatives with respect
to a set of criteria.
• If there are more than two criteria, determining which criteria
are more important can itself be a serious problem.
• One would like to be able to rank the criteria in order of
importance, and to assign to the criteria some relative ranking
indicating the degree of importance of each criterion with
respect to the other criteria.
 Decision Making
• Planning a Vacation
• Choosing a Job Offer
• Designing a project

• Pair wise comparison is a kind of divide-and-conquer

problem-solving method. It allows one to determine the
relative order (ranking) of a group of items.
• This is often used as part of a process of assigning weights to
criteria in design.
 Pair-wise Comparison Chart
• Let us consider a problem of designing a portable ladder. The
objectives for the problem are
– Cost
– Portability

– Usefulness
– Durability
 Pair-wise Comparison Chart
• Place each of the key objectives in a row across the top of the
chart and in a column down the left-hand side.
• For each row, compare the row objective to each column
objective.

• If the row objective is more important than the column

objective, place a “1” in the cell.
• If the column objective is more important than the row
objective, place a “0” in the cell.
 Pair-wise Comparison Chart
• Add up the value in each row to determine the total score for
that row objective. The higher the total, the higher priority that
objective has.
 • Cost is less important than portability 0
• Cost is less important than usefulness 0
• Cost is more important than durability 1
Goals Cost Portabilit Usefulness Durabilit Score
y y
Cost *** 0 0 1 1

Portability

Usefulness

Durability
 • Portability is more important than cost 1
• Portability is more important than usefulness 1
• Portability is more important than durability 1
Goals Cost Portabilit Usefulness Durabilit Score
y y
Cost *** 0 0 1 1

Portability 1 *** 1 1 3

Usefulness

Durability
 • Usefulness is more important than cost 1
• Usefulness is less important than portability 0
• Usefulness is more important than durability 1
Goals Cost Portabilit Usefulness Durabilit Score
y y
Cost *** 0 0 1 1

Portability 1 *** 1 1 3

Usefulness 1 0 *** 1 2

Durability
 • Durability is less important than cost 0
• Durability is less important than portability 0
• Durability is less important than usefulness 0
Goals Cost Portabilit Usefulness Durabilit Score
y y
Cost *** 0 0 1 1

Portability 1 *** 1 1 3

Usefulness 1 0 *** 1 2

Durability 0 0 0 *** 0
 Pair-wise Comparison Chart
• Of the objectives listed, the prioritized list is

1. Portability

2. Usefulness
3. Cost
4. Durability
• The fact that durability scored a “0” on the PCC does not
mean that we can drop durability from the list of objectives. It
just means that of the four objectives listed, durability is the
least important.
 Pair-wise Comparison Chart
Goals Hit the Stable Easy to Rugged Score
target and freely use
standing
Hit the **** 0 1 1 2
target
Stable and 1 **** 1 1 3
freely
standing
Easy to 0 0 **** 1 1
use
Rugged 0 0 0 **** 0
Problem Statement

• V1.1 Design a stable and freely standing catapult structure that

aims to hit the target. The structure should be rugged in nature
and easy to use.
 Activity 2
Group Activity Team Size:4
Duration : 20 min
• 1.Assume the role of designer and prepare a set of questions that
you can ask for a client (for the need mentioned in template)
• 2. Prepare a list of design objectives from the compiled answer
list.
• 3. Order the list into sets

• 4. Prepare objective tree

• 5. Prioritize the objectives using PCC chart
• 6. Write Problem statement version1.1
 1.2. Identify constraints
• Only use the materials provided to build the catapult. ( 8
popsicle sticks and 4 rubber bands)
• Each unit of catapult should not cost more than Rs 40/-
 Add constraints to the problem
statement
• V1.1 Design a stable and freely standing catapult structure that
aims to hit the target. The structure should be rugged in nature
and easy to use.
• V1.2 Design a stable and freely standing catapult structure that
aims to hit the target. The structure should be rugged in nature
and easy to use. Building the catapult should be done using the
given materials and cost should not exceed 40/- per unit.
 Activity 3
Group Activity Team Size:4
Duration : 10 min
• Add constraints to Problem statement version1.1
• Write Problem statement version1.2
 1.3 Establish functions

• A specific action that a designed device or system is expected

to do (perform). Functions should consider ‘what’ the product
does (the problem) and not ‘how’ it does it (solution).
• A function involves the following two components.

• An action verb
• A noun representing the object on which the action verb
takes place
 1.3 Establish functions
• Consider catapult example
• Launch the projectile to hit the target.
• Components must be in a condition to reuse.

• Handle projectile of sizes varying from 1 to 4 cm diameter.

• Automatically sense the projectile and start its launching.
• Launch 4 projectiles consecutively.

• Alert the operator once operation is complete.

• Allow user to select the mode of operation (Manual /Auto)
Add Functions to the problem statement

• V1.2 Design a stable and freely standing catapult structure that

aims to hit the target. The structure should be rugged in nature
and easy to use. Building the catapult should be done using the
given materials and cost should not exceed 40/- per unit.
 After adding Functions to the problem
statement
• V1.3 Design a stable and freely standing catapult structure that
aims to hit the target. The structure should be rugged in nature
and easy to use. Building the catapult should be done using the
given materials and cost should not exceed 40/- per unit.
Catapult should be able handle projectile of sizes varying from
1 to 4 cm diameter. Components used for construction should
be in a condition to reuse. It should be able to sense and
launch projectile automatically. It should launch 4 projectiles
consecutively. It should allow user to make choice of mode.
 Activity 4
Group Activity Team Size:4
Duration : 10 min
• Complete Problem definition phase for the need statement given
in the worksheet by adding functions and prepare Problem
statement version1.3
 Key Concepts Learned today are
• Engineering Design Process

• Objective tree
• Pair-wise comparison chart
• Function tree
• Functional structure

• Morphological chart
• Concept generation
• Concept selection
 Topic Learning Outcomes
At the end of this module, student will be able to
• Explain engineering design process .
• Formulate problem definition for the need statement .
• Identify multi-disciplinary facet of design.
• Identify sub-systems and functions of a system.

• Select best alternative out of generated design alternatives.

• Construct proposed mechanical / mechatronics system.
• Test the solution/system for the given criteria.