DESKFZG525

MECHANICAL SYSTEM DESIGN

CONCEPT OF SYSTEM DESIGN Lecture 01

Books :

1. Pahl, G.and W.Beitz, Engineering DesignA

Systematic Approach Springer, 2nd Ed., 1996.

1 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

 THE SCOPE OF DESIGN
The task of engineers
1. Apply their scientific and engineering knowledge to the solution of
technical problems,
2. Optimise those solutions within the requirements and constraints set
by material, technological, economic, legal, environmental and
human~related considerations.
3. With clear definition of the problems, solve to create new technical
products

Design is an engineering activity that:

affects almost all areas of human life;
uses the laws and insights of science;
builds upon special experience; and
provides the prerequisites for the physical realisation of
solution ideas

2 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

 THE SCOPE OF DESIGN

The work of engineering designers at the centre of two intersecting

cultural and technical streams
3 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir
 THE SCOPE OF DESIGN
In psychological respects, designing is a creative activity that
calls for a sound grounding in mathematics, physics, chemistry,
mechanics, thermodynamics, hydrodynamics, electrical engineering,
production engineering, materials technology and design theory, as well
as knowledge and experience of the domain of interest. Initiative,
resolution, economic insight, tenacity, optimism and teamwork are
qualities that stand all designers in good stead and are indispensable to
those in responsible positions

In systematic respects, designing is the optimisation of given

objectives within partly conflicting constraints. Requirements change with
time, so that a particular solution can only be optimised for a particular set
of circumstances.

In organisational respects design is an essential part of the

product life cycle.
4 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir
LIFE CYCLE OF A PRODUCT

Life cycle is triggered by a

market need or a new idea. It starts with
product planning and ends, when the
product's useful life is over, with
recycling or environmentally safe
disposal.

Life cycle represents a process

of converting raw materials into
economic products of high added value.

5 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

CHARACTERISTICS OF DESIGN TASK

Classification characteristics of design tasks.

6 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir
CHARACTERISTICS OF DESIGN TASK

Origin of the task: Projects starts by a product planning group after

carrying out a thorough analysis of the market. The requirements
established leaving a large solution space for designers.
In the case of a customised order, tighter quantitative requirements
to fulfil, solutions is based on the existing company know-how that has
been built up from previous developments and orders. Developments will
be in small incremental steps in order to limit the risks involved.
If the development is only part of a product (assembly or module),
the requirements and the design space are even tighter and the need to
interact with other design groups is very high.
In case of the production of a product, there are design tasks related
to production machines, jigs and fixtures, and inspection equipment. For
these tasks, fulfilling the functional requirements and technological
constraints is especially important.
7 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir
CHARACTERISTICS OF DESIGN TASK

Organisation: The organisation of the design and development

process depends in the first instance on the overall organisation of the
company.

In product oriented companies, the product development and

subsequent production is in separate divisions of the company based on
specific product types (eg rotary compressor division, piston compressor
division, accessory equipment division).

Problem-oriented companies split the responsibility according to

the way the task is broken down into partial tasks (eg mechanical
engineering, control system, materials selection, stress analysis). In this
arrangement the project manager must pay particular attention to the co-
ordination of the project as the work passes from group to group.

8 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

CHARACTERISTICS OF DESIGN TASK
Other organisational structures are based on: the particular phase
of the design process (conceptual design, embodiment design, detail
design); the domain (mechanical engineering, electrical engineering,
software development); the stage of the product development process
(research, design, development, pre-production). In large projects with
clearly distinct domains, it is often necessary to develop individual modules
of the product in parallel.

Novelty: Original designs usually proceed through all design

phases; depend on physical and process fundamentals; and require a careful
technical and economic analysis of the task.
In adaptive design the emphasis is on geometrical, analytical (strength,
stiffness etc), production and material issues.
In variant design the sizes and arrangements of parts and assemblies are
varied, design is referred to as "principle design" or "design with fixed
principle").
9 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir
CHARACTERISTICS OF DESIGN TASK

Production: The design of one-off and small batch products requires

careful design of all physical processes and embodiment of details to
minimise risk. Not economic to produce development prototypes. Often
functionality and reliability have a higher priority than economic
optimisation.
Large batch or mass production must have their technical and economic
characteristics fully checked prior to full-scale production. This is achieved
using models and prototypes and often requires several development steps

Branch: Mechanical engineering has to fulfil specific requirements

regarding hygiene; precision and operating speed; power-to-weight ratio
and efficiency; functionality and robustness; ergonomics and noise levels.
Electro-mechanical engineering products for heavy current applications,
work at higher voltages and provide greater power outputs.

10 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

CHARACTERISTICS OF DESIGN TASK
Chemical and process engineering products (plant and machinery) require
the interdisciplinary application of fundamental chemical science and
process technology
Transport engineering include specially developed machine elements and
production processes also to cope with demanding strength and safety
requirements.
Precision engineering the introduction of micro- and opto-electronics. The
impact of these new technologies is large and many new design principles
are involved.
Software engineering products require systematic design steps similar to
those for physical products, but involve only relationships between data
elements.

11 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

CHARACTERISTICS OF
DESIGN TASK

Complexity: When planning the layout of process plant, the

combination of commercially available or specially developed machines,
modules and components, and the design of the control system considered.
Because of the variety of domains and system elements involved, generic
methods are required for designing and optimising from receipt of order to
final commissioning.
When designing machines and devices, tasks of similar complexity
to those in process engineering have to be solved. However, detail design
usually plays a greater role because of its crucial importance in optimising
the performance of this type of product.
The size of components influences the approach adopted and the
embodiment possibilities, because size directly affects production tools,
raw and semi-finished materials, transport, assembly and testing.
When designing repeat parts or bought-in parts, the constraints and
spatial requirements have to be specified
12 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir
CHARACTERISTICS OF DESIGN TASK
Goals: Design tasks to meet the optimisation
goals- taking into account the given restrictions.
Optimisation of function requires the application of computational and
experimental optimisation procedures.
Minimisation of costs within a given framework requires: generation of
alternative solutions; determination of production costs; close co-operation
with purchasing and production planning; and careful attention to detail
To achieve ultimate performance (eg very high precision, critical safety,
extreme performance etc) special design principles and advanced computer-
based analysis methods have to be used.
Aesthetic considerations are important for products that can be seen, and
essential in the case of consumer products.
Ergonomic criteria consider for human-operated production equipment,
office machinery and consumer products.
Minimisation of weight, for example in automobile engineering, requires
special design strategies and machine elements.
13 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir
ACTIVITIES OF DESIGNER
To cope with the wide variety of tasks, designers have to adopt
different approaches; use a wide range of skills and tools; have broad design
knowledge; and consult specialists on specific problems.
This becomes easier if designers master a general working
procedure; understand generation and evaluation methods; and are familiar
with well known technical solutions to existing problems.

The activities of designers can be roughly classified into:

Conceptualising- searching for solution principles. Generally
applicable methods can be used along with the special methods.
Embodying- engineering a solution principle by determining the
general arrangement and preliminary shapes and materials of all
components.
Detailing, - finalising production and operating details.
Computing, drawing and information collecting. These occur during
all phases of the design process.
14 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir
ACTIVITIES OF DESIGNER
Another classification is direct design activities (eg
conceptualising, embodying, detailing, computing),

Indirect design activities (eg collecting and processing information,

attending meetings, co-ordinating staff).

One should aim to keep the proportion of the indirect activities as low as
possible.

In the design process, the required design activities have to be

structured in a purposeful way, that is in a clear sequence of main phases
and individual working steps, so that the flow of work can be planned and
controlled

15 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

 THE POSITION OF THE DESIGN
PROCESS WITHIN A COMPANY
The design department is of a central
importance in any company. Designers
determine the properties of every product in
terms of function, safety, ergonomics,
production, transport, operation, maintenance,
recycling and disposal. In addition, designers
have a large influence on production and
operating costs, on quality and on production
lead times. Because of this heavy
responsibility, designers have to continuously
reappraise the general goals of the task in hand
Production and assembly depend
fundamentally on information from product
planning, design and development. However,
design and development are strongly
influenced by knowledge and experience from
production and assembly.
16 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir
 THE POSITION OF THE DESIGN
PROCESS WITHIN A COMPANY
Because of current market pressures to
increase product performance, lower
prices and reduce time-to-market, product
planning, sales and marketing must draw
increasingly upon specialised engineering
knowledge. Because of their key position
in the product development process, it is
therefore particularly important to make
full use of the theoretical knowledge and
product experience of designers.
Current product liability
legislation demands not only professional
and responsible product development
using the best technology but also the
highest possible production quality.
17 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir
 THE NECESSITY FOR SYSTEMATIC DESIGN
In line with the variety of problems and tasks in the development of
technical products, design activities are many sided. First of all they rely on
basic scientific and engineering knowledge, but also on special experience
in the specific product area. The activities cannot be forced into rigid
organisational or procedural templates.

In view of the central responsibility of designers for the technical

and economic properties of a product, and the commercial importance of
timely and efficient product development, it is important to have a defined
design procedure to find good solutions. This procedure must flexible, and
at the same time be capable of being planned, optimised and verified.

Such a procedure, however, can only be realised if the designers

have the necessary domain knowledge and are required to work in a
systematic way.

18 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

 THE NECESSITY FOR SYSTEMATIC DESIGN

Design Science - Uses scientific methods to analyse the structure of

technical systems and their relationships with the environment.
The aim is to derive rules for the development of these systems from the
system elements and their relationships

Design methodology - is a concrete course of action for the design of

technical systems that derives its knowledge from design science and
cognitive psychology, and from practical experience in different domains.
It includes: plans of action to link working steps and design phases
according to content and organisation; strategies, rules and principles to
achieve general and specific goals; and methods to solve individual design
problems or partial tasks

19 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

 THE NECESSITY FOR SYSTEMATIC DESIGN
A design methodology, therefore, must:
Encourage a problem-directed approach; ie it must be applicable
to every type of design activity, no matter in what specialist field;
Foster inventiveness and understanding; ie facilitate the search
for optimum solutions;
Be compatible with the concepts, methods and findings of other
disciplines;
Not rely on finding solutions by chance;
Facilitate the application of known solutions to related tasks;
Be compatible with electronic data processing;
Be easily taught and learned; and
Reflect the findings of cognitive psychology and modern
ergonomics; ie reduce workload, save time, prevent human error,
and help to maintain active interest.
Such an approach will lead designers to possible solutions more quickly
and directly than any other.

20 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

 THE NECESSITY FOR SYSTEMATIC DESIGN
The use of systematic procedures can only serve to increase the
output and inventiveness of talented designers. Design methodology
should therefore foster and guide the abilities of designers, encourage
creativity, and at the same time drive home the need for objective
evaluation of the results.

Systematic procedures merely try to steer the efforts of designers

from unconscious into conscious and more purposeful paths.

Systematic design provides an effective way to rationalise the design

and production processes.

The approach of developing size ranges and modular products is an

important start to rationalisation in the design area but especially
important for the production process.

21 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

 THE NECESSITY FOR SYSTEMATIC DESIGN
A design methodology is also a prerequisite for flexible and
continuous computer support of the design process using product
models stored in the computer. It is difficult to: develop knowledge-
based systems; model using features; use stored data and methods; link
separate programs, especially geometric modellers with analysis
programs; ensure the continuity of data flow; and link data from
different company divisions (CIM). Systematic procedures also make
it easier to divide the work between designers and computers in a
meaningful way.

A rational approach must also cover cost and quality considerations.

More accurate and speedy preliminary calculations with the help of
better data are a necessity in the design field, as is the early
recognition of weak points in a solution. All this calls for systematic
processing of the design documentation.

22 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

 THE NECESSITY FOR SYSTEMATIC DESIGN
In the theory of form design there are five overlying principles:
the principle of minimum production costs;
the principle of minimum space requirement;
the principle of minimum weight;
the principle of minimum losses; and
the principle of optimum handling.

The design and optimisation of individual parts and simple

technical artefacts is the object of the theory of form design. It is
characterised by the simultaneous application of physical and economic
laws, and leads to a determination of the shape and dimensions of
components and an appropriate choice of materials, production methods
etc. If selected optimisation characteristics are taken into account, the best
solution can be found with the help of mathematical methods.
Four fundamental design factors, namely working principle,
material, form and size. And if the cost aspect is unsatisfactory, all four
factors have to be re-examined in an iterative manner.
23 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir
 CURRENT METHODS - 1 Design Methods
Design methodology is characterised by a set of integrated and
logically structured design catalogues. A particular goal is the partitioning of the
design process into small steps that can be described by algorithms. It should then
be possible to process these steps completely and continuously using the
computer. To that end "product representing models" are defined that can be
described unambiguously by "product defining data"
The design process divided as Corresponding to this defines three
product representing models:
1. Problem formulation phase, 1.problem-representing models",
2. Functional phase 2.function-representing models",
3. Embodiment phase. 3.embodiment-representing models".
The smaller steps of phases .
1.A requirements list identifying the main tasks and requirements.
2.Logical function structures; cybernetic function structures (general function
structures) with material, energy and information functions; physical function
structures with physical, chemical and other effects; and principle solutions.
3. Geometrical working structures; embodied principle solutions; modular
structures based on pre-designed modules and functional elements
24 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir
 CURRENT METHODS - 2 System Theory
In socio-economic-technical processes, procedures and
methods of systems theory are increasingly important. Systems theory as
an inter-disciplinary science uses special methods, procedures and aids for
the analysis, planning, selection and optimum design of complex systems
Technical artefacts, including the products of light and heavy
engineering industry, are artificial, concrete and mostly dynamic systems
consisting of sets of ordered elements, interrelated by virtue of their
properties.

From the idea that technical artefacts can be represented as

systems, it was a short step to the application of systems theory to the
design process, the more so as the objectives of systems theory correspond
very largely to the expectations we have of a good design method.

The systems approach reflects the general appreciation that

complex problems are best tackled in fixed steps, each involving analysis
and synthesis
25 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir
 CURRENT METHODS - 2 System Theory
A system is also
characterised by the fact
that it has a boundary
which cuts across its
links with the
environment. These
links determine the
external behaviour of
the system, so that it is
possible to define a
function expressing the
relationship between Structure of a system.
inputs and outputs, and S: system boundary;
hence changes in the S1,-S5 : sub-systems of S;
magnitudes of the S21,,-S24,.: sub-systems or elements of S2,;
system variables. I1,-I3: inputs; 01,-02 : outputs.

26 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

 CURRENT METHODS -
2 System Theory
First Step (Problem Analysis) -
Gathering of information about the
system under consideration by means
of market analyses, trend studies or
specific tasks. The aim is formulation
of the problem (or sub-problem) to be
solved, which is the actual starting
point for the development of the
system.
Second step (Problem Formulation)-
A programme is drawn up to give
formal expression to the goals of the
system. Such goals provide important
criteria for the subsequent evaluation
of solution variants and hence for the
discovery of the optimum solution.
27 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir
 CURRENT METHODS - 2 System Theory
Third step ( System synthesis) Several solution variants are then
synthesised on the basis of the information acquired during the first two
steps.
Fourth step ( System Analysis) - The performance of each must be
analysed for its properties and behaviour.
Fifth step ( System Evaluation) - In the evaluation, the performance of
each variant is compared with the original goals.
Sixth step ( System decision) - a decision is made and the optimum system
selected.
Finally, information is given out in the form of system implementation
plans.

The steps do not always lead straight to the final goal, so iterative
procedures may be needed. Built-in decision steps facilitate this
optimisation process, which constitutes a transformation of information.

28 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

 CURRENT METHODS - 2 System Theory
In a systems theory process model the steps repeat themselves in
so-called life cycle phases of the system in which the chronological
progression of a system goes from abstract to concrete.

29 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

 CURRENT METHODS - 2 System Theory

An important sphere of application of the systems approach is

function-oriented synthesis.
On the basis of a known or a developed solution concept it is
possible to produce a function model (function structure, function chain)
whose inputs and outputs, together with their links, can be subjected to
mathematical variation and optimised to satisfy the demands of the
problem.
A necessary requirement for the use of such mathematical
statements about the quantitative behaviour of solution concepts is the
availability of mathematical relations expressing the static and dynamic
behaviour of the elements, for instance in the form of transfer functions,
and the formulation of a goal function.
Such mathematical laws for the description of systems models
have been established, above all, for signal-processing equipment.

30 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

CURRENT METHODS - 3 Value Analysis
The main aim of Value Analysis described in
DIN 69910 is to reduce cost . To that end a
systematic overall approach is proposed
which is applicable, in particular, to the
further development of existing products.

The basic working steps of Value Analysis. In

general a start is made with an existing
design, which is analysed with respect to the
required functions and costs. Solution ideas
are then proposed to meet the new targets.
Because of its emphasis on functions and the
stepwise search for better solutions, Value
Analysis has much in common with
systematic design.

31 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

 CURRENT METHODS - 4. VDI Guidelines
VDI Guideline defines an overall approach and individual methods for the
conceptual design of technical products and is therefore particularly
suitable for the development of new products.

The VDI Guideline proposes a systematic approach to the design of

technical systems and products and emphasises the general applicability of
the approach in the fields of mechanical, precision, control, software and
process engineering.

The approach includes seven basic working steps that accord with the
fundamentals of technical systems and company strategy.

The aim is for general applicability, the design process has been only
roughly structured thus permitting product-specific and company-specific
variations.

32 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir

The General approach to
design is regarded as a
guideline to which detailed
working procedures can be
assigned. Special emphasis
is on the iterative nature of
the approach and the
sequence of the steps must
not be considered rigid.
Some steps might be
omitted, and others
repeated frequently. Such
flexibility is in accordance
with practical design
experience and is very
important for the
application of all design
methods.
33 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir
 CONCLUSION
The proposals of individual methodologists and schools of
systematic design, however, have different emphases according to the
different contexts and requirements of the product groups they represent.
For example, precision engineering products are characterised by electronic
and software issues, and a focus on function; heavy engineering products
by strength, stiffness and production issues; automobile engineering by
tuning individual components within the overall system, by mass
production issues, by light-weight engineering and by external shape; and
process plant engineering by the combination of devices developed
elsewhere.

Theory of design still does not claim to be the final word on the
subject-it simply tries to combine various methods in a coherent and
practicable way.

34 WILP BITS PILANI , PUNE CENTER Prof Milind Ramgir