Design Analysis 2015
Design Analysis 2015
Applications
in
Industry & Senior Design
kTH
TCLAD GLCORE,TEMP xCORE
Optimize
+
X CORE
Parameters
+
Clad Torch
LCORE + - Pull Speed
(Constant)
L
LO xCLAD
X CLAD LCORE
DANGER!
Inaccurate /over simplified models
Results may have convergence error
Model input may not be correct, or correctly applied
Boundary conditions, assumptions, etc.
Physical world differences from model
Misapplied analysis and assumptions
Analysis limitations (linear, non-linear)
FEA makes a good engineer better
..but makes a bad engineer dangerous
Understand Implement
& Define Problems Solution
Assess
Situation for new design
or improvement
Case Study in Design
for Optical Fiber Production
Optical fiber produced in 2004 was over
55,000,000,000 meters.
(Enough to go around the world over 1300 times!)
Production machines generally produce on the order of 1
million meters of optical fiber per day.
Cost improvements on the order of 0.1% are significant
in terms of dollars (millions of dollars per year).
Designs changes for tightening specifications, yield and
productivity are done continuously.
Fiber Manufacturing Process
Many design opportunitities.
Problem: Customers Require More
Uniform Lengths of Fiber on
Spools, so short length sell for less.
Customers purchase specific lengths of fiber
(12.5km, 25km, 37.5km, 50km)
The probability of breaks in the fiber during
fabrication is somewhat random (lengths vary).
Longer in-process lengths will reduce the
manufactured breaks in the fiber.
Action from feasibility study: Design and
deploy machines and process with greater
spooling capacity greater than 500 km per spool
instead of 100 km.
Longer Lengths of Fiber on a Spool?
Solution Seems Simple: Get Larger Spools!..but
New machinery required for processing larger spools
New materials handling equipment required
New process procedures required
New test equipment required
In-process lag on quality feedback
REPEAT if needed
Generations of Development
Latest Design
First Prototype
Summary:
Obtain Successful New Design through
Planned Design, Analysis & Testing :
Understand current situation: systems and opportunities
Thorough design and analysis
Changing/Designing as a system.
Not just a collection of well-designed parts
Effective exchange of information to all groups affected
by a proposed change
Extensive testing and evaluation still needed
?