Product Design Cycle Research Articles

Modeling and design of a multidisciplinary simulator of the concept of operations for space mission pre-phase A studies

Nowadays, it is practically impossible to develop a complex project without the assistance of a comprehensive set of modeling and simulation tools. In space engineering, they are used throughout the product design cycle, from component up to the system level. In conceptual, pre-phase A studies of a space mission, these tools are essential to explore more broadly the design space, in the search for suitable candidate system solutions for the mission. They are also of prime importance in helping to reduce the design time in integrated concurrent design environments. Here, a multidisciplinary tool for concept of operation simulation, developed to be used in that kind of environments, is presented. FOrPlan has the main purpose of performing functional simulations of the satellite and associated ground segments, providing a dynamic verification of the mission designed operational concept. Through the use of suitable graphical interfaces, key parameters of the mission functional scenarios can be presented to the design team and other mission stakeholders, allowing them also a better understanding of the mission operational concept. The simulator presents high flexibility such that it can be quickly customized to different mission scenarios. It has been used successfully at the Space Missions Integrated Design Center (CPRIME) of the Brazilian National Institute for Space Research. In this article, the structure of FOrPlan is presented, and its main features highlighted through results of concept of operation simulations performed for a scientific space mission study that was carried out recently at CPRIME.

A study on the collaborative management method of product design cycle knowledge

Because of the ever-increasing market competition and rapidly changing of customers' requirements, the innovation quality and design efficiency of knowledge-intensive product has become the key factors in business success. The traditional knowledge management method which is based on design reuse and the single categories of design knowledge cannot satisfy these demands any more. Therefore, in order to effectively support the innovative design process of enterprises, a design knowledge collaborative management method based on multi-knowledge migration is proposed. According to the characteristics and functions during the product design process, the design knowledge is divided into three categories, design principle knowledge, design domain knowledge and design object knowledge. By extracting the operation attributes, relation attributes and physical attributes of the design knowledge, a unified knowledge representation model is established for different design participants. The ontology concept and knowledge matrix are used to establish the association between various categories of design knowledge. Multifarious knowledge search methods include keyword, function, principle and natural semantics are proposed for different design participants in different design stages. They can not only realize the knowledge reuse in the same domain but also support the cross-domain knowledge migration among different domain. Finally, based on the system analysis modelling, a design knowledge collaborative platform is established for the design process of mechanical products. A case study is also presented to illustrate the implementation of the platform.

Influence of Fluid–Thermal–Structural Interaction on Boundary Layer Flow in Rectangular Supersonic Nozzles

The aim of this work is to highlight the significance of Fluid–Thermal–Structural Interaction (FTSI) as a diagnosis of existing designs, and as a means of preliminary investigation to ensure the feasibility of new designs before conducting experimental and field tests. The novelty of this work lies in the multi-physics simulations, which are, for the first time, performed on rectangular nozzles. An existing experimental supersonic rectangular converging/diverging nozzle geometry is considered for multi-physics 3D simulations. A design that has been improved by eliminating the sharp throat is further investigated to evaluate its structural integrity at design Nozzle Pressure Ratio (NPR 3.67) and off-design (NPR 4.5) conditions. Static structural analysis is performed by unidirectional coupling of pressure loads from steady 3D Computational Fluid Dynamics (CFD) and thermal loads from steady thermal conduction simulations, such that the simulations represent the experimental set up. Structural deformation in the existing design is far less than the boundary layer thickness, because the impact of Shock wave Boundary Layer Interaction (SBLI) is not as severe. FTSI demonstrates that the discharge coefficient of the improved design is 0.99, and its structural integrity remains intact at off-design conditions. This proves the feasibility of the improved design. Although FTSI influence is shown for a nozzle, the approach can be applied to any product design cycle, or as a prelude to building prototypes.

The Roll-Forming Process Analysis of the Situation and Development Trend

Roll – forming is through the allocation of roll the sheets for multiple successive of transverse bending deformation process of the section, to form a specific shape with high energy efficiency, uniform cross section, stable product quality, etc. Since the 19th century began to study the roll-forming process, successively completed the exploration of this kind of technology and promotion from 1938 to 1938.It has entered the rapid development of roll-forming technology at present. Began to roll-forming technology research relatively late in our country, but the trend of development of fast, such as the construction industry, automotive industry, white home appliance industry has been widely used, to specific parts such as highway anti-collision WeiDang, auto parts anticollision beam beams, before and after the threshold of the anticollision beam and a side door production, etc. Roll-forming technology belongs to the nonlinear problem of large plastic deformation, the forming theory of the present domestic scholars have researched, forming a simplified analytical method, energy analysis method, cable original research method and finite element method theory. With the development of computer aided design technology, through the computer simulation of sheet deformation and regional stress analysis, and makes the product design cycle is shortened, the product design quality was improved. At home and abroad, roll-forming equipment have developed highly efficient, the formation of the uncoiled stamping - roll-forming - welding - material such as plastic - cut – code craft route, eventually forming the results approach to the product shape, implementation process highly integrated production mode, cold-formed molding equipment of high automation intelligent design, help to realize planning of ‘Made in China 2025 strategy’ in the industry of roll-forming.

Experimental and numerical investigation of heat dissipation from an electronic component in a closed enclosure

Intensifying electronic component power dissipation levels, shortening product design cycle times, and greater than before requirement for more compact and reliable electronic systems with greater functionality, has heightened the need for thermal design tools that enable accurate solutions to be generated and quickly assessed. The present numerical study aims at developing a computational tool in OpenFOAM that can predict the heat dissipation rate and temperature profile of any electronic component in operation. A suitable computational domain with defined aspect ratio is chosen. For analyzing, “buoyant Boussinesq Simple Foam“ solver available with OpenFOAM is used. It was modified for adapting to the investigation with specified initial and boundary conditions. The experimental setup was made with the dimensions taken up for numerical study. Thermocouples were calibrated and placed in specified locations. For different heat input, the temperatures are noted down at steady state and compared with results from the numerical study.

Experimental and numerical investigation of heat dissipation from an electronic component in a closed enclosure

Intensifying electronic component power dissipation levels, shortening product design cycle times, and greater than before requirement for more compact and reliable electronic systems with greater functionality, has heightened the need for thermal design tools that enable accurate solutions to be generated and quickly assessed. The present numerical study aims at developing a computational tool in OpenFOAM that can predict the heat dissipation rate and temperature profile of any electronic component in operation. A suitable computational domain with defined aspect ratio is chosen. For analyzing, “buoyant Boussinesq Simple Foam“ solver available with OpenFOAM is used. It was modified for adapting to the investigation with specified initial and boundary conditions. The experimental setup was made with the dimensions taken up for numerical study. Thermocouples were calibrated and placed in specified locations. For different heat input, the temperatures are noted down at steady state and compared with results from the numerical study.

Use of multidisciplinary analysis programs in the design process and its importance in terms of design education

Product design is a sophisticated cyclical process involving different stages, beginning from the problem state to the product end, nested in the process. Also, in the process of design education, the form created by the designer is subjected to various criticisms and is undergoing a change with function relation. The multidimensional thinking skills have been gained to the students during design education cause unique changes on the product. Depending on the dynamic developments, the self-renewing product forms deem it necessary for the designer to be prompted from different sources. Although the factors such as areas of expertise, user needs, production techniques, material choice, and form concern are effective in determining the product identity, the designer presents innovative ideas and solutions to create a “magic touch.” This magic touch would contribute identity to the product within this framework. These programs, which contribute to the designers' abilities along with the development of design and analysis programs, are positioned at different intersections in the product design cycle. This situation also has a significant impact on design education. In this study, the effects of these programs, used at different stages of the product design education, on the form were investigated. Moreover, strength examination of the design of the table foot and flow simulation on the hair dryer end apparatus were determined. In two separate multidisciplinary analysis studies, the change in characteristics of the product function with physical interactions was shown. Along with the findings of this research, the contributions of analysis programs on the design process, and the effects to product identity are explained through examples.

Dynamic Simulation of a Mobile Manipulator with Joint Friction

Mission criticality in disaster search and rescue robotics highlights the requirement of specialized equipment. Specialized manipulators that can be mounted on existing mobile platforms can improve rescue process. However specialized manipulators capable of lifting heavy loads are not yet available. Moreover, effect of joint friction in these manipulators requires further analysis. To address these issues, concepts of model based design and concurrent engineering are applied to develop a virtual prototype of the manipulator mechanism. Closed loop manipulator mechanism actuated by prismatic actuators is proposed herein. The mechanics model of the manipulator is presented here as a set of equations and as multibody models. Mechanistic simulation of the virtual prototype has been conducted and the results are presented. Combined friction model that comprises Coulomb, viscous and Stribeck friction is used to compute frictional forces and torques generated at each one degree of freedom translational and rotational joints. Multidisciplinary approach employed in this work improves product design cycle time for complex mechanisms. Kinematic and dynamic parameters are presented in this paper. Friction forces and torques from simulation are also presented in addition to the visual representation of the virtual prototype.

Research on variant design based on topological entity compression algorithm

In order to improve the efficiency of product design and shorten the design cycle of product, the research progress in recent years is introduced. The basics of variant design such as the entities of topology, the equation’s structure and the compression/decompression are analyzed. An algorithm, which can compress redundant parts, based on the conditions of algebraic equations completely is put forward. A variant design system of volumetric heat exchanger is designed by using VB and SolidWorks API (Application Programing Interface). The results show that the variant design system based on algebraic equations can be quickly and accurately modeled according to different process parameters, which can improve the efficiency of product design and shorten the design period.

Analysis of the Wrinkle of an Automobile Weather-Strip Seal in Bending

ABSTRACTWeather-strip seals in automotive door systems play a major role in determining the door closing effort, isolating the passenger compartment from water and reducing the wind noise inside the vehicle. The phenomenon of a wrinkle often occurs in weather-strips when they are assembled on the door surfaces which have bent or twisted profiles. Wrinkles in automobile weather-strip seals will affect the closing effort and noise isolation characteristics of the automotive door system. The wrinkle of anethylene-propylene-diene (EPDM) automobile weather-strip seals when bent and the critical conditions for a wrinkle to develop were characterized in this study. The hyperelastic material behavior of the EPDM sponge and EPDM dense rubber in the seal were modeled using the Foam model and Mooney–Rivlin model, respectively. Then a finite element analysis (FEA) model of the automobile weather-strip seal in assembly was developed and analyzed using then on linear FEA software Marc. The deformation of the seal and the thickness decrease in the critical region where it was prone to wrinkle were obtained by this FEA method. Finally the critical criterion of wrinkling was determined by analysis of the reaction forces in the critical region. The proposed analysis method can shorten the product design cycle and decrease the design and trial-product cost considerably.

"Product Development" - a New Learning in Open Ended Experiment

Nowadays many educational institutions are adopting outcome based education system, wherein active participation and learning of students is involved. This paper reports OBE based learning experience as a part of laboratory experiments in the field of analog electronics at 3rd semester. Theory of analog electronic circuits will be well understood only if students conduct series of experiments from simple to complex circuits using various analog components. Also, if students are taught to develop small products at primitive level, it will help them to carry projects till product realization in higher semesters. This motivated us to keep product development exercise as a part of open ended category along with generating a datasheet for the said product, which requires active learning and involvement of the students throughout the development life cycle of a product. This paper presents the experiential learning in developing 5V power supply as a part of open ended experiment. This helped students not only to understand the product design cycle and also helped to improve their circuit debugging skills as well as in designing PCB's along with generating data sheet for a given specifications at 3 rd semester level.

Fostering selection of sustainable manufacturing technologies – a case study involving product design, supply chain and life cycle performance

The main objective of this paper is to compare an emergent technology of manufacturing three-dimensional contoured thermoplastic sandwich structures with two technologies commonly used to produce similar components. The Life Cycle Engineering principles are applied to this case aiming at basing the selection on the economic and environmental life cycle performance of the alternatives. The approach integrates those two dimensions with an engineering perspective on technical and functional performance allowing to relate the product design and involved technology with the required resources and impacts generated. The analysis framework takes advantage of the use of process-based models endorsing sensitivity analysis of crucial technological, production and supply-chain parameters. The integration of functional, environmental and economic performance on a life cycle perspective in a single best-solutions space, for a specific business scenario, is a contribution to the methodology of life cycle engineering that fosters the adoption of more informed approaches in the manufacturing technologies selection.

Hierarchy definition of UAV conceptual design parameters based on a diachronic process matrix

Achieving competitive advantages in product development may lead to significant efforts to identify and minimize product design and development cycles time and cost while improving product quality.

Integrated Ontologies in Support of Factory Systems Design

Digital factory modelling based on virtual design and simulation has emerged as part of the mainstream activities geared towards reducing product design cycle. Some basic industrial systems are currently integrated via semantic modelling technologies so that products matching processes and resource requirements are integrated to fulfil customer demands. Despite these achievements, product design is still dependent on the knowledge of designers and do not benefit from existing process and resource knowledge, which are in separate domains. This paper therefore presents an integration method based on semantic technologies and PPR ontologies to enable the reuse of known and unknown knowledge. The method relies on the use of cloud manufacturing to improve the efficiency of responsesgenerated by querying the PPR ontology.

Fatigue Life Estimation of an Elastomeric Pad by ε-N Curve and FEA

Failure analysis and fatigue life prediction are very important in the design procedure to assure the safety and reliability of rubber components. The fatigue life of a railway elastomeric pad is predicted by combining the test of material properties and finite element analysis (FEA). The specially developed chloroprene rubber material’s fatigue life equation is acquired based on uniaxial tensile test and fatigue life tests performed on the dumbbell specimens of the chloroprene rubber. The same chloroprene rubber was developed at Indian Rubber Manufacturer’s Research Association, Thane. The strain distribution contours and the maximum total principal strains of the elastomeric pad at different compressive loads are obtained using finite element analysis method. The software used for the FEA was ANSYS. The three parameter nonlinear hyperelastic Mooney-Rivlin Model and plane 182 elements were used for finite element analysis. The critical region cracks prone to arise are obtained and analysed. Then the maximum first principal elastic strain was used as the fatigue damage parameter, which is substituted in the chloroprene rubber’s fatigue life equation, to predict the fatigue life of an elastomeric pad in the number of cycles at different compressive loads. The results were compared with the technical requirements given by Indian Railway’s Research Designs and Standards Organization. These requirements were achieved up to certain extents. The results were also compared with the data available in the literature and a similarity was observed between the results acquired and literature data. In short, the proposed fatigue life prediction method can shorten the product design cycle, decrease the design and product cost remarkably and improve the quality of an elastomeric pad.

Durability Reliability Demonstration Test Methods

A complete product design cycle should include the following three stages: target setting, product design and development, and product validation. In the first target setting stage, it is required to understand the voice of customers (VOC), define the extreme customer usage conditions, acquire the duty cycle or customer usage data for the target, and cascade the top-down VOC targets from vehicle to system and component levels. In the second stage of product design and development, the multi-objective design optimization in the virtual analysis domain needs to be performed, where the analytical tools to design the products for various design criteria should have been developed and in place for analyses. In the final product validation stage, the test methods with a limited sample size are required to demonstrate the reliability of the product population for meeting the specific design functional and performance requirements. Since the test results exhibit significant statistical variations, these test methods (named the reliability demonstration test methods) are the most important mechanism to ensure a successful product launch for durability, reliability and quality. Again, due to the limited sample size for testing, a specific reliability and confidence target should be predetermined to be demonstrated by these test methods.The focus of this paper is to review the theoretical background and discuss the pros and cons of commonly used reliability demonstration test methods. Depending on the failure criterion in product validation testing, these reliability demonstration test methods can be categorized into the methods for non-repairable and repairable systems. For a non-repairable system, the test is considered complete, censored or suspended as the system fails, while a repairable system allows the actions required to restore/renew a failed system to operational status. The methods of interest for non-repairable systems include the test-to-failure method, the test-to-bogey method, the extended life test bogey method, and the step-stress accelerated life test method. Repairable systems are often modeled with the non-homogeneous Poisson process which includes the Duane and the Crow reliability growth models.

Human Factors Methods in a Design Cycle Framework

Understanding when, why, where, and how to use human factors methods is a key skill for human factors practitioners. Experienced professionals are very skilled at selecting methods appropriate to the task at hand, but the skill is a result of years of exposure. The current study examines the value of organizing human factors methods into a framework that relates and integrates information in meaningful ways to aid non-experts in selecting appropriate methods. The product design cycle is proposed as a viable framework for addressing this issue, though it is only one of many possible frameworks. Recommendations for future work include the development of additional frameworks targeting other audiences.

Parametric Modeling and Analysis of Self-Loading Container Vehicle Based on ANSYS

For the technical requirements of a domestic enterprise to develop a new generation of self-loading container truck products, this paper creatively puts forward a set of suitable reduction standards for special structure. Based on ANSYS and Visual Studio 2008 platform, the parametric modeling and automatic analysis of side loader container structure are achieved independently. Several operating conditions, such as stacking, self-loading and unloading etc. can be analyzed rapidly and automatically. The research achievement can be not only used for the conceptual design stage of forward design process, but also applied in the modification of the original structure, thus effectively shortening the product design cycle, reducing design cost, providing useful guidance for independent research of domestic enterprise.

Multi-Objective Optimal Design of a Double Circular Gear Based on the Differential Evolution Algorithm

In order to improve the comprehensive technical and economic indicators of a double circular gear, based on the conjugate principle and design method of the double circular gear, by use of the modified differential evolution multi-objective optimization technique and MATLAB computer simulation technology, constrained multi-objective optimization design of a double circular gear was done. According to the research process and results, by use of the improved differential evolutionary multi-objective optimization technique, the design cycle of product can be shorten effectively, the design quality of product can be improved.

Application of Reverse Engineering based on Computer in Product Design

This paper described the application of reverse engineering in product design and development; effectively solved the design and subsequent engineering design, manufacturing link disjoint problems; put forward a kind of using computer software Pro/Designer, Pro/ Engineer and SolidWorks seamless connection method in the process of product design; industrial product modeling design and the engineering and manufacturing of coherence have opened up a new way; the design process will provide effective measures for the product design system, so as to shorten the product design and development cycle and realize the product design system.