Configuration Design

Abstract embodiment
Physical principles
Material Configuration
Configuration Architecture
Geometry Design
Design
Special Purpose Parts:
Features
Arrangements
Relative dimensions
Attribute list (variables)
Standard Parts:
Type
Attribute list (variables)
 Product or Part

 Product configuration = “architecture”

 Part configuration

Start with the big

picture....
i.e. Product
architecture
 Best
concept(s)
Configuration design
Product architecture
Configure Integral / modular
Product Standard / special purpose
Re-examine EDS
Configure Research sources
Part(s) Configuration requirements sketch
Iterate

Analyze Design for Function

and Design for Assembly
Refine Design for Manufacture

Pugh’s Method
Evaluate
Weighted Rating Method

Best
configuration(s)
 Product First… Use component decomposition
diagrams

penlight

bulb battery body screw cap

glass lens anode switch

filament cathode case
base electrolyte
spring
plastic cover

elements are arranged into “physical building blocks”

 Generalized component decomposition

Product

Standard Special purpose Subassembly A Subassembly B

Part Part
Special purpose part Special purpose part

Standard part Subassembly B1

Standard part
a. type, number, arrangement of components
b. standard or special purpose (make or buy) Special purpose part
 Product architecture …like house
architecture

Architecture style Scheme

dining, living rooms 1st
colonial floor
bedrooms on 2nd floor
ranch all rooms on ground floor

Rooms are arranged according to a logical “scheme.”

Before the details of all the house are designed we
determine the general layout or “architecture.”
 Product Architecture (Ullrich & Eppinger)

def – the scheme by which the

 functional elements of a product are arranged

 into physical building blocks (components,

subsystems or subassemblies)
 that interact with each other

 to perform the overall function of the product.

Product architectures can be “modular” or

“integral”
 Modular architecture

Product examples Modular components

Flashlight Batteries, bulbs
Refrigerator Motors, compressor, switches
Automobile Tires, radios, seats, pumps
Personal engines
computer Drives, keyboards, mice,
modems
• chunks implement one or a few functions,
• interactions between chunks are well
defined
(standard interfaces / connections)
Integral Architecture

Product examples Integrating aspects

BMW Motorcycle engine/frame
engine integral snap-fasteners
Printer case machined bearing race
Shaft integrated handle
Beverage cup
• a single chunk implements many
functions
• interaction is ill defined
• physical element “shares” functions
Printer Example
Cluster elements into logical chunks
Sketch rough geometric layout
Sketch interaction diagram
 Best
concept(s) Part configuration
design
Product architecture
Configure Integral / modular
Product Standard / special purpose
Re-examine EDS
Configure Research sources
Part(s) Configuration requirements sketch
Iterate

Analyze Design for Function

and Design for Assembly
Refine Design for Manufacture

Pugh’s Method
Evaluate
Weighted Rating Method

Best
configuration(s)
 What is a part configuration?
For example:
Design problem: support vertical load ---- Concept: wall bracket

Physical principle geometry & material

Force Equilibrium
 F 0

What are some possible “configurations” for a wall bracket?

 Part configuration design

geometric features include:

walls rounds cubes notches

ribs bosses spheres chamfers
projection cylinders holes grooves
s
fillets tubes slots
 How can we “generate” alternative part
configurations?

Recall bracket
configurations
Abstract
embodiment

different alternative different

features arrangements relative dimensions
 Configuration decisions

How do we create different configurations?

Change one or more of these…
 Obtaining the “best”
configuration

To choose the “best” alternative….

Implies that we have a number of feasible
alternatives!
To be selective, we need a
selection!
 Best
concept(s) Configuration design -
analysis
Product architecture
Configure Integral / modular
Product Standard / special purpose
Re-examine EDS
Configure Research sources
Part(s) Configuration requirements sketch
Iterate

Analyze Design for Function

and Design for Assembly
Refine Design for Manufacture

Pugh’s Method
Evaluate
Weighted Rating Method

Best Continue on Tuesday

configuration(s)
To analyze configurations, we ask…

Will it likely function?

Will it likely assemble?
Will it be likely
manufacturable?
 Design for function

Will the part or product perform its

1. Strong function(s)?
11. Reliable
2. Stiff or flexible 12. Human
3. Buckle factors/ergonomics
4. Thermal expansion 13. Safe
5. Vibrate 14. Easy to use
6. Quiet / Noise 15. Maintain
7. Heat transfer 16. Repairable
8. Fluids transport / 17. Durable (wear,
storage corrosion)
9. Energy efficient 18. Life-cycle costs
10. Stable 19. Styling/aesthetics
Use knowledge from math, eng’g and
sciences…
Will it assemble?

What do we mean by assemble?

Assembly - a process of handling

components
to bring them together (inserting)
and then
fastening them.
 DFA

Design for Assembly - a set of design practices

which reduce the manpower time required to
handle, insert and fasten components of a product.

1. Design Guidelines (written and

graphical)
2. Cost estimating methods
DFA Graphical 1
Design for Assembly Guidelines from SME

• minimize part count

• minimize levels of assembly (number of
assemblies)
• encourage modular assembly
• use standard parts
• stack sub-assemblies from the bottom up
• design parts with self-fastening features (snap-
fits, press-fits)
• facilitate parts handling (grasp, orient, move)
• design parts with self-locating features (e.g.
chamfers, aligning recesses/dimples)
• eliminate reorientation (i.e. insertion from 2 or
more directions)
• eliminate (electric) cables
 DFM

Deign for Manufacture (manufacturability) - A

set of practices that aim to improve the
fabrication of individual parts

1. Design Guidelines (written and

graphical)
2. Cost estimating methods
 DFM – Injection molding / casting

• avoid designing parts with thick walls or heavy

sections
• design parts without undercuts
• choose polymer for minimum total part cost
(i.e. tooling, processing, material)
• design external threads to lie on parting
plane/surface
• add ribs for stiffening
 DFM – Sheet metalworking

 avoid designing parts with narrow cutouts or

projections
 minimize manufactured scrap (cut-off versus blanking)
 reduce number of bend planes
 keep side-action features to a minimum or avoid
completely
DFM – Machining

 employ standard features

(e.g. holes, slots, chamfers, fillets, rounds)
 use raw material available in standard forms
(e.g. sheet, roll, bar, plate)
 avoid sharp internal corners on turned parts
 specify liberal tolerances and surface
finishes
 Best
concept(s) Configuration design -
evaluation
Product architecture
Configure Integral / modular
Product Standard / special purpose
Re-examine EDS
Configure Research sources
Part(s) Configuration requirements sketch
Iterate

Analyze Design for Function

and Design for Assembly
Refine Design for Manufacture

Pugh’s Method
Evaluate
Weighted Rating Method

Best
configuration(s)
 Graphics during Configuration Design

 Sketches are used a lot in configuration design

 Sketches assist creativity
 Sketches are not typically used to “document”
the “design”

 CAD Drawings need sizes (e.g. H, W, L, D)

 CAD Takes time

 But, some CAD may be useful

 Best
concept(s) Configuration design
summary
Product architecture
Configure Integral / modular
Product Standard / special purpose
Re-examine EDS
Configure Research sources
Part(s) Configuration requirements sketch
Iterate

Analyze Design for Function

and Design for Assembly
Refine Design for Manufacture

Pugh’s Method
Evaluate
Weighted Rating Method

Best
configuration(s)
 Configuration Design

Abstract embodiment
Physical principles
Material Configuration
Configuration Architecture
Geometry Design
Design
Special Purpose Parts:
Features
Arrangements
Relative dimensions
Attribute list (variables)
Standard Parts:
Type
Attribute list (variables)