Embodiment Design Phase Research Articles

Novel Computer-Aided Design-Based Collaboration Framework for the Conceptual–Embodiment Design Phase

Novel Computer-Aided Design-Based Collaboration Framework for the Conceptual–Embodiment Design Phase

Integracija tačnosti modela ponašanja u odluke o dizajnu korišćenjem AHP, FMEA i fizičkog prototipa

The embodiment design phase consists of rough selections/arrangements of materials, technologies used, dimensions, and main components. During this phase, many behavior models are used to verify the achievement of design objectives. The lack of confidence in these models due to the assumptions adopted causes designers to realize many prototypes during product development, causing time/cost-consuming loops of the "trial-and-error" procedure. We propose a decision model that integrates the accuracy of behavior models into decision-making. The objective is to limit the use of physical prototypes and improve the quality of decision-making. Each design alternative is evaluated using two indicators. The first is a desirability indicator that measures the level of completion of design objectives. The second indicator assesses the risk associated with the accuracy of behavior models using AHP, FMEA, and experimental tests on a prototype. The proposed approach was applied to the development of a solar collector.

KNOWLEDGE-BASED DATA IDENTIFICATION FOR MACHINE LEARNING USE CASES

AbstractThe number of digital solutions based on machine learning has increased in recent years. In many industrial sectors, they try to enhance automation in manual or repetitive tasks or provide decision support for complex problems. Data plays an essential role in the selection and implementation of ML algorithms, as it determines the quality of the training and the results. As data drive ML models, selecting the correct data with the suitable ML algorithm for a given use case is crucial but challenging. This paper reviews the application of machine learning in the embodiment design phase addressing the challenge. The work focuses on ML applications in conventional product development and non-conventional additive manufacturing processes. Based on the literature review, the required knowledge to implement the ML algorithms has been derived and presented in a systematic approach. This work highlights the importance of an initial analysis of the existing knowledge in the engineering and additive manufacturing processes in order to implement the proper ML algorithms.

Proto-Arch: Guidance Tool for Prototyping of Mechanical Systems at the Embodiment Design Phase

AbstractPrototypes are a critical aid in the product development process, allowing designers translate concepts to reality. However, the execution of prototypes depends heavily on the designer experience, evidenced in research in the need of creating design support tools to establish a standard for a prototyping effort. To improve on these findings, the Proto-Arch is introduced as a partial result of creating a standard for executing prototypes in each product development phase based on the prototyping roles and purposes. Proto-Arch defines the prototyping activities in the embodiment design phase.

VR as a 3D Modelling Tool in Engineering Design Applications

The study aims to explore the usefulness of existing VR 3D modelling tools for use in mechanical engineering. Previous studies have investigated the use of VR 3D modelling tools in conceptual phases of the product development process. Our objective was to find out if VR tools are useful in creating advanced freeform CAD models that are part of the embodiment design phase in the context of mechanical design science. Two studies were conducted. In the preliminary study, the group of participants modelled a 3D part in a standard desktop CAD application, which provided information about the key characteristics that must be satisfied to obtain a solid model from a surface model. In the research study conducted with a focus group of participants, who were firstly trained in the use of VR, the same part was modelled using a VR headset. The results were analysed and the fulfilment of key characteristics in the use of VR was evaluated. It was found that using VR tools provides a fast way to create complex part geometries, however, it has certain drawbacks. Finally, the ease of use and specific features of the VR technology were discussed.

An Optimization Workflow in Design for Additive Manufacturing

Additive Manufacturing (AM) brought a revolution in parts design and production. It enables the possibility to obtain objects with complex geometries and to exploit structural optimization algorithms. Nevertheless, AM is far from being a mature technology and advances are still needed from different perspectives. Among these, the literature highlights the need of improving the frameworks that describe the design process and taking full advantage of the possibilities offered by AM. This work aims to propose a workflow for AM guiding the designer during the embodiment design phase, from the engineering requirements to the production of the final part. The main aspects are the optimization of the dimensions and the topology of the parts, to take into consideration functional and manufacturing requirements, and to validate the geometric model by computer-aided engineering software. Moreover, a case study dealing with the redesign of a piston rod is presented, in which the proposed workflow is adopted. Results show the effectiveness of the workflow when applied to cases in which structural optimization could bring an advantage in the design of a part and the pros and cons of the choices made during the design phases were highlighted.

A preliminary design embodiment analysis through the graph theory implementation

The work presented in this article underlines the embodiment design phase aiming at the determination of different possible architectures of a system according to the energy vision combined with the graph theory. Indeed, the embodiment design phase presents the difficulty of organizing the design alternatives. This difficulty is due to the fact that the various components of the system are not yet fully defined, and there are many arrangement possibilities. In this context, we seek to structure a methodology for the preliminary definition of the technical system architecture, while respecting the TRIZ law of completeness of the system parts. We consider the availability of the transmission elements of the principal energy flow (functional flow). The modeling of the system will concern the flow ensuring the positioning of the system principal component called (contact flow). The modeling of an optimal system composed of the main elements (converter, transmitter, operator, and reference) with a graph ensures the possibility to propose various architectures based on the combinations of these components. The proposed approach consists of three principal phases: appropriate graph-system model association, inappropriate solutions elimination, full system definition, and decision making. An illustration of the methodology is carried out on a wind system example.

A comparison of how novice and experienced design engineers benefit from design guidelines

Though design guidelines' benefit has been shown in the conceptual stage, little is known how novice and experienced design engineers benefit in the embodiment design phase. To address this, a mobile eye tracking study has been developed and carried out with seventeen practitioners from and in industry. Results show differences in how design guidelines impact experts' and novices’ performance, indicate beneficial ways of using them, point out the participants areas of major interest and show the way of representation that attracts the most attention. The study concludes that, especially for novice design engineers, design guidelines with a redefined and clear structure are valuable and needed as input to the embodiment design phase.

A multi-objective sequential method for manufacturing cost and structural optimization of modular steel towers

This paper proposes a methodological approach for the multi-objective optimization of steel towers made from prefabricated cylindrical stacks that are typically used in the oil and gas sector. The goal is to support engineers in designing economical products while meeting structural requirements. The multi-objective optimization approach involves the minimization of the weights and costs related to the manufacturing and assembly phases. The method is based on three optimization levels. The first is used in the preliminary design phase when a company receives a request for proposal. Here, minimal information on the order is available, and the time available to formulate an offer is limited. Thus, parametric cost models and simplified 1-D geometries are used in the optimization loop performed by genetic algorithms. The second phase, the embodiment design phase, starts when an offer becomes an order based on the results of the first stage. Simplified shell geometries and advanced parametric cost models are used in the optimization loop, which present a restricted problem domain. In the last phase involving detailed design, a full 3-D computer-aided design model is generated, and specific finite-element method simulations are performed. The cost estimations, given the high levels of detail considered, are analytic and are performed using dedicated software.

Integrative CAE-Driven Design Process in the Embodiment Design Phase of L7e Vehicle Structures

In the past decade, the mechanical engineering industry has searched for a design methodology that could systematically unify the support of computer-aided engineering (CAE) tools for the design process. More recently, some propositions have been put forward for the CAE-driven design process (CDDP), but the efficiency of these design processes is questionable. We have proposed improvements and new arrangements that result in the integrative CDDP (ICDDP), which makes CDDP more reliable, efficient and predictive. The ICDDP redefines the role of CAE tools and positions the optimization technology as a fundamental driving force behind the whole design process. Consequently, the ICDDP orders design phases as: (1) conceptual design, (2) design crystallization and (3) design sophistication, which steer the design process sequentially. The accurately established linkages between the sequential design steps enhance the smooth recurrence of the ICDDP for new product executions. In addition, this work demonstrates the application of the conceptual design phase to design a new L7e (eQuad) vehicle structure. This phase of the ICDDP illustrates the specific steering methodology for the topology optimization of a new eQuad structure as well as the geometric solution derivation step that reveals the transformation of bionic shapes into rough manufacturable geometry. Additionally, the numerical verification of the simple geometric model is presented for the load cases given. Our results exemplify the fact that the ICDDP allows engineers to design new innovative and lightweight structures.

Integrated design-oriented framework for Resource Selection in Additive Manufacturing

Resource selection (RS) is one of the prime phases of product design that have substantiating impact on the manufacturing of products. Material and manufacturing process selection are considered an important ingredient of RS and must be dealt with in early stages of design. Since, emerging technologies such as Additive Manufacturing (AM) have re-defined the potentials of manufacturing by re-orienting market drivers such as high part-complexity needs, individualization, shorter product development cycles, abundant materials and manufacturing processes, diverse streams of applications, etc., it is imperative to select the right compromise of materials, manufacturing processes and associated machines in early stages of design considering the Design for Additive Manufacturing guidelines. As several criteria, material attributes and process functionality requirements are involved for decision making in the industries today, an integrated design-oriented framework is proposed in this paper for RS in AM to structure design knowledge pertaining to each stage of design process; conceptual, embodiment and detail designs. However, more focus will be kept on the conceptual and embodiment design phases. Moreover, axioms are defined to aid in decision making and help in extracting the rules associated with each of the design criteria. The framework is aimed to act as a guideline for designers in the AM industry to provide design oriented and feasible material-machine-process combinations.

Exact Constraint Design and its Potential for Robust Embodiment

The design of exact, also referred to as minimal, constraints means applying just enough constraints between the various components of a mechanical assembly, in order to unambiguously define their positions in six degrees of freedom (3 translations, 3 rotations), their desired motions respectively. To ensure a predictable and reliable product performance, a systematic design of the corresponding elementary mechanical interfaces between components is of utmost importance. Over constraints, i. e. part-to-part connections with redundant interfaces which constrain one single degree of freedom, are largely susceptible to variation and therefore result in design solutions which frequently experience production/ assembly issues, reduced performance, excessive and non-predictable wear-rates, etc.Being a basic rule of embodiment design, literature provides various well-know and widely applied approaches for Exact Constraint Design. Examples are the calculation of a mechanisms’ mobility using the Grübler-Kutzbach criterion, the analysis of statically determinate assemblies by means of the screw theory or so called Schlussartenmatrizen, as well as the analysis of engaging surfaces in terms of location schemes or interface ambiguity. However, despite the various existing approaches, workshops with practitioners and academics have shown that the systematic design of optimal constraints appears to be cumbersome for many engineers. Based on an overview of the most relevant approaches for Exact Constraint design, this contribution therefore reviews the challenges experienced by the workshop participants, discusses the necessity of kinematically correct constraints for robustness, and derives an initial prescriptive procedure for a coherent design of constraints throughout the embodiment design phase, which, despite a variety of available approaches, seems to be still missing.

A decision support methodology for embodiment design and process chain selection for hybrid manufacturing platforms

This paper presents a methodology for the transformation of a product concept into a detailed design and manufacturing process chain for hybrid manufacturing platforms. Hybrid platforms offer new capabilities and opportunities for product design. However, they require high levels of process expertise for effective design and effective process selection. Design for hybrid manufacture is challenging as there is a requirement to understand a number of technologies, which may be highly varied. To address this challenge, a knowledge-based decision support system developed in this paper enables manufacturing expertise to be integrated into procedures for product design and process chain selection. This formalised numerical methodology is able to consider a wider range of varied manufacturing processes than any previous study. A feature-based design method is developed, which guides the designer towards an optimised product design during the embodiment design phase, and a process chain selection program is utilised to enable the effective analysis of a product design based on product evaluation criteria. The methodology has been successfully applied to the design of an LED product with internal geometries and electronics.

Ergonomic analysis in conceptual design stage using a gesture-based modelling tool

Commonly, ergonomic analysis of the products’ assembly processes starts in the embodiment design phase, when the information of the parts and their interaction are clearly defined. This may imply iterations during the design process for making improvements associated with ergonomic issues. We asked whether it is possible to infer possible ergonomic issues related to the manual assembly process during product conceptualisation. So, we integrated an AR-based modelling tool, in which the user creates and places virtual parts over the context in a top-down design strategy using his/her hands as interface, with an Ergonomic Assessment Module for continuous evaluation of the user postures, movements and forces related to the created parts. In that way, the spectrum of the potential solutions during the conceptualisation phase, when the information about the problem is vague enough, can be delimited and the convergence to the near-optimal solution may be more effective.

Tolerance optimisation considering economic and environmental sustainability

Sustainability is becoming increasingly important in the development of new product and production solutions, and the eco-design movement stresses the importance of environmental considerations in all design phases and activities. One such design activity in the embodiment design phase of product development is the specification of dimensional tolerances, where designers seek to ensure high functionality at low costs. A traditional approach to this decision-making process is to minimise economic losses to the manufacturer and the consumer through a process known as tolerance optimisation. This paper presents a new approach for tolerance optimisation that considers sustainability not only in the context of economic costs but also environmental impacts, which are shown to be significantly affected by manufacturing and product quality. This new framework is formulated as a bi-objective optimisation problem to minimise economic and environmental costs, and important modelling considerations for these two types of costs are outlined and discussed. The proposed approach is explored using two example cases of design assemblies, which demonstrate the trade-offs between economic and environmental design objectives as a result of tolerances and other quality-related design decisions.

Using Functional Requirements Formulation in Fault Tree Analysis Construction - A Way to Improve Product's Design

In a technological system, the design has to be thought so that all the possible faults to be mitigated or avoided both in conceptual design and embodiment design phases. This is an ideal point of view because in reality the faults are present and sometimes it is a cumbersome task to find all the possible events and their causes. As a way to help these this paper presents the possibility to use the axiomatic design FR-DP decomposition in order to define the events from a Fault Tree Analyze, its construction, a combination of these two giving results that can be interesting for both methods.

A Typical Approach in Conceptual and Embodiment Design of Foldable Bicycle

The Conceptual design and Embodiment design are two of the important stages in a typical product design and development process. This study aims at generating different concepts for a foldable bicycle product using a systematic concept generation method and the best generated concepts have been selected using various concept selection methods. It also describes a systemic approach to material selection and FEA justify during embodiment design phase. Various design concepts have been generated from a range of available possible solutions to each product function by morphological matrix which was developed based on functions tree. The Pugh chart and numerical concept selection methods have been employed to select the best concepts that have been generated based on a set of criteria. In the Embodiment design phase, the Ashby method has been used for material selection for the selected design concept. The human comfort has been checked by Digital Human Modeling (DHM) Technology. In addition to the material selection process, the proposed design of the foldable bicycle has also been analyzed for its safety by FEA and Fatigue analysis.

A model of application system for man-machine-environment system engineering in vessels based on IDEF0

Applying man-machine-environment system engineering (MMESE) in vessels is a method to improve the effectiveness of the interaction between equipment, environment, and humans for the purpose of advancing operating efficiency, performance, safety, and habitability of a vessel and its subsystems. In the following research, the life cycle of vessels was divided into 9 phases, and 15 research subjects were also identified from among these phases. The 15 subjects were systemized, and then the man-machine-environment engineering system application model for vessels was developed using the ICAM definition method 0 (IDEF0), which is a systematical modeling method. This system model bridges the gap between the data and information flow of every two associated subjects with the major basic research methods and approaches included, which brings the formerly relatively independent subjects together as a whole. The application of this systematic model should facilitate the application of man-machine-environment system engineering in vessels, especially at the conceptual and embodiment design phases. The managers and designers can deal with detailed tasks quickly and efficiently while reducing repetitive work.

COMPARATIVE STUDY OF THE STUDENT'S DESIGN PROCESS: IMPLICATIONS FOR THE TEACHING OF LATER PHASES OF THE MECHANICAL ENGINEERING DESIGN PROCESS

Most methods that guide the designer through the later phases of the design process are general in nature, and it is up to the designer to organize the design work using the tools and techniques available. This process also relies greatly on experience, which is quite a challenge for students, who are mostly novices in the area. In a comparative study, the evolution of the experience and skills acquired by the students in performing design tasks during the embodiment design and detail design phases has been analyzed. The re-sults indicate the main directions for improvement in teaching the later phases of the mechanical engineer-ing design process.

A DESCRIPTIVE MODEL OF THE DESIGNER'S PROBLEM-SOLVING ACTIVITY DURING THE LATER PHASES OF THE MECHANICAL ENGINEERING DESIGN PROCESS

Many specific and precise methods that support the mechanical engineering designer’s work during the conceptual design phase exist, while only a few general methods address the embodiment design and detail design phases. Our study presents the pattern of the designer’s problem-solving activity during the later phases of the design process. This model is in-tended to serve as a basis for further development of tools and methods directly oriented towards the de-signer at work in these stages of the design process. The descriptive model presented here is developed through observations of six designers at work in con-trolled experiments, and follows a previous study published elsewhere.