Container spaces and functional features for top-down 3D layout design

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Although there have been many advances in computer-aided modelling techniques and representations of mechanical parts, there are areas where exact modelling is a handicap. One of these is 3D layout design. Here, simpler models are useful for initial design sketches to verify kinematic behaviour and organise product structure before the detailed component design phase begins. A commitment to exact, or close approximational geometry too early can imply a commitment to form before functionality has been finalised. This paper describes a system for top-down 3D layout design based on simple conceptual elements which can be used as a basis for visualisation, discussion, definition of product structure and kinematic functionality in the conceptual design phase before the embodiment or detailing begins. This tool forms a bridge between the abstract nature of the conceptual design phase and the geometric nature of the embodiment phase. The 3D layout module uses design spaces with simple geometry and kinematic connections to represent a product. The design spaces act as containers or envelopes within which the final component design is to be realised. The kinematic connections allow the behaviour of the product to be simulated to gain more information (such as overall component dimensions and areas of potential collisions) for the detailed design phase. In addition the paper describes the design process based on the proposed 3D layout design system and contrasts this with the traditional design process. An industrial case study is presented to illustrate the following advantages of the proposed approach: (i) the design process proceeds faster because unnecessary layout parameter and constraint modifications are avoided since kinematic functionality verification precedes the detail design, (ii) the design process can produce better designs since alternative solution principles can be explored early in the design process. Theoretical issues are discussed concerning kinematic constraint inheritance during design space decomposition and concerning computer support for non-rigid design spaces.