System Design Process Research Articles

Using Concept of Operations to Design Human‐Centric Manufacturing Systems for Novel Products—A Comprehensive Prescriptive Case Study

ABSTRACTEfficient production systems are necessary for the realization of products that fulfill customer needs and delivery requirements. However, the process of designing the production system has received little academic attention, and today's manufacturing system design processes and architecture are still based on traditional engineering methods. This paper covers a case study using the systems engineering method Concept of Operations and Operational Concept for the design of a human‐centric production system for a novel product. A comprehensive prescriptive study was designed, combined with attempts to verify the methods used. The case study applies design methods defined in ISO/IEC/IEEE 15288. A total of six workshops, the development of Concepts of Operations, three levels of Operational Concept, and two validation studies are documented. A total of 166 persons participated, and up to 15 persons participated in the validation workshops. The analysis shows that the design methods addressed gaps identified in literature: (1) the lack of systematic and effective systems engineering design methods in production system design, and (2) the lack of inclusion of human aspects in the production system design. The gaps in the effectiveness of the methods remain to be fully evaluated as the project is still running and will not be concluded until 2025. Recommendations for future work include exploring how ConOps/OpsCon method can be more widely spread and adopted by engineering as a significant artifact for systems understanding for the design of more human‐centric, resilient production systems.

Energy storage materials for phase change heat devices recovering industrial waste heat for heating purposes

The abundance of industrial waste heat resources offers valuable opportunities for the utilization of phase change heat exchangers in clean energy applications. This study focuses on the innovative development of binary phase change material (PCM) composed of paraffin and stearic acid (SA) in various ratios, aimed at optimizing waste heat recovery. Comprehensive analyses of the phase change temperature, latent heat, and thermal conductivity of these mixtures were conducted. The research identified a mixture with a 20 % paraffin and 80 % stearic acid ratio, which exhibits a phase change temperature of 62.73 °C and a latent heat of 205.53 J/g. This mixture stands out due to its minimal subcooling and consistent thermal properties, making it highly effective for low-temperature waste heat recovery. Additionally, a novel process design and simulation system for using these materials in heat exchangers to convert intermittent industrial waste heat into continuous thermal energy for heating were developed.

Design and Manufacture of Intelligent Filter Processing System of Modular Cutting Fluid

For the needs of ecological protection and high-quality development in the Yellow River Basin, the project plans to design and produce the intelligent filtration treatment system of modular cutting fluid, which is caused by the massive application of cutting wastewater and the improper treatment will cause serious damage to the environment. Through the study of the action mechanism of semiconductor inorganic film on cutting liquid, the development and application verification of cutting liquid filtration system and the development of cutting liquid online monitoring system, a complete set of semiconductor inorganic film high strength toughness steel cutting liquid filtration technology and equipment is formed, providing technical support for green, high efficiency, energy saving and environmental protection cutting fluid treatment. To solve the problem of improper treatment of cutting waste liquid after the processing process of deep hole parts of high strength and toughness steel. Keywords: modularization, online detection, semiconductor inorganic film.

Numerical Design Structure Matrix–Genetic Algorithm-Based Optimization Method for Design Process of Complex Civil Aircraft Systems

In the requirement-driven forward design process of civil aircraft, the large number of design tasks of complex systems with varying difficulty and the complex relationships between design tasks lead to unnecessary repetitive design iterations. In order to solve the above problems, the concept of overlap coefficient is proposed to further sort out the forward and backward logical relationships between design tasks and the civil aircraft system design process optimization model based on a numerical design structure matrix. The algorithm NSGA-II is improved and verified with the flight control system design as a case study. The results show that the proposed method can effectively improve the efficiency of complex system design and provide technical support for the optimization of the design process of complex civil aircraft systems.

Sustainable Packaging Solutions: Food Engineering and Biodegradable Materials

In modern, fast-paced lifestyles, food containers have become a popular solution for quick meals; however, they have significantly contributed to the increase in plastic packaging waste, which poses a substantial environmental risk. The prevalent use of non-biodegradable plastic containers exacerbates plastic pollution, contradicting government regulations designed to reduce plastic usage and promote sustainability. To address these issues, this study integrates TRIZ, ergonomics, inherent safety, and universal design methodologies, with an emphasis on sustainability. First, the technical contradiction matrix from TRIZ is applied to identify parameters for improvement without inducing negative side effects. Ergonomics principles ensure the development of user-friendly designs, while inherent safety and universal design approaches aim for accessibility and full biodegradability. Through a systematic innovation design process, this research proposes a biodegradable food container capable of decomposing entirely into particles and water within one month, blending naturally with the soil without compromising functionality. Moreover, the container incorporates a quick-alignment mechanism and an intuitive sealing design that ensures airtightness and spill prevention. As a result, the product not only meets user demands but also addresses pressing environmental concerns, aligning with global sustainability goals.

Modeling and dynamic characteristics analysis of concentrating-receiver-heat exchanger system of sCO2 solar thermal power plant

In a supercritical carbon dioxide (sCO2) solar thermal power plant system using solid particle as the heat absorption and transfer medium, the concentrating-receiver-heat exchange coupled system composed of a heliostat field, solar particle receiver, and particle/sCO2 heat exchanger is one of the most important subsystems in the power plant system, and its dynamic characteristics directly affect the performance of the whole system. In this paper, taking the 200kWe sCO2 solar thermal power plant as the research objective, firstly, a discretized lumped parameter model of the coupled system was established to study the dynamic performance and operational characteristics based on the TRNSYS platform, and the following characteristics of some key parameters such as particle and sCO2 outlet temperature to the DNI variation were deeply studied without taking any control measures. The results indicate that the particle and sCO2 outlet temperature are positively correlated with the DNI variation and are highly sensitive, and the efficiency of the particle receiver is basically maintained at around 0.7 whether it is sunny or cloudy; Secondly, in order to achieve the rated outlet design parameters, the dynamic characteristics on June 13 and 15, 2023 with a PID control strategy were also studied. The results show that the particle outlet temperature can be maintained at 800 °C by controlling the particle inlet mass flowrate in the particle receiver, while the sCO2 outlet temperature can be guaranteed at 550 °C by adjusting the sCO2 inlet mass flowrate in the heat exchanger with the condition of mild DNI variation. Besides, it is also found that, the PID control is unlikely to be effective under severe DNI changes. Therefore, the addition of buffer particle tanks is essential to compensate for the intermittency of the DNI in the system design process.

DESIGN & DEVELOPMENT OF DIFFERENTIAL DIAGNOSIS SOFTWARE FOR SALIVARY GLANDS DISEASE AND COMPARISON WITH CLINICIAN'S RESULTS

Introduction: Due to increase of population, increasing number of less-experienced dentists more associated information and consequent updates of such information; the need for design of information processing systems to help in better diagnosis of patients with oral disorders becomes more evident. Among other factors, some factors such as age, clinical symptoms, location and shape of lesion could influence the decision to treat salivary gland disorders and determine of their possibility. Up to now, there is no software for differential diagnosis of salivary gland diseases. Objectives: The objective of present study is to design and develop a software so as to help to differential diagnosis of salivary gland diseases and determine the accuracy and effectiveness of its results. Methods: Software based on Bayes' theorem was designed with the help of editor application into which the information of 60 salivary gland diseases was inserted. Then, the information of 40reports of salivary gland diseases was added to the software. In the next stage, the information of the chosen cases given to two expert clinicians so as to develop a differential diagnosis. The result was analyzed using menemar and Wilcoxon test. Results: The results were compared with results of the reports. Almost 60 percent of generated answers by the software and two clinicians included absolute diagnosis of statistically insignificant difference (P-value=0.96). Conclusion: The results showed the acceptable performance of the software. Although the software cannot act instead of a clinician due to the fact that the software user should be quite familiar with salivary gland diseases and methods of examination, this software can be used to help the clinicians in differential diagnosis and training objectives.

Sign Language Translator via Smartphone Image Analysis using Convolutional Neural Network

This study presents the design and implementation of a smartphone-based image processing system aimed at translating sign language gestures into text in real-time. The primary objective was to create a platform that enhances communication between deaf individuals and non-sign language users through the accurate recognition of sign language gestures. Using Kotlin programming and MediaPipe, the system captures and processes gestures, converting them into readable text. The results demonstrated that the system is capable of recognizing and translating various sign language gestures with a high degree of accuracy and efficiency. The successful deployment of this system highlights its potential to break down communication barriers and offers a foundation for future improvements, including expanded sign language support and performance optimization for real-world applications.

Enhancing Payroll Systems for Accountability and User Experience: A Case Study at Kanindo Cooperative, Malang

The research aims are to evaluate and develop a payroll accounting information system for the Cooperative Agro Niaga Indonesia Syariah Malang, East Java, which functions as the research object. The analytical approach employs the Business Process Management (BPM) framework, while the system design process employs the ADDIE model. The researcher selected the BPM framework to evaluate the integration of information technology in the accounting information system process more thoroughly. Research is done in five stages. The problem analysis step comes first. At this stage, the information on company issues taken through interviews, documentation, and observational data collection. The second stage involves designing the system using the Business Process Management Notation (BPMN) model and matrix. The third step involves developing a web-based employee payroll accounting information system. The company develops this system to improve the quality of its commercial operations. The implementation stage, which includes evaluation, comes last. This study distinguishes itself by integrating the BPMN framework and ADDIE model to address the complex requirements of payroll accounting systems in a sharia-based cooperative context. Unlike prior studies, this research offers a dual-methodological approach that combines detailed business process visualization with iterative system refinement, ensuring a higher degree of standardization, automation, and user-friendliness. The application in Cooperative Agro Niaga Indonesia Syariah Malang represents a novel contribution by tailoring IT solutions to the unique needs of a rapidly growing sharia financial institution, demonstrating scalability and adaptability for similar organizations.

Designing with words: Writing as design

Writing for design has, over the past few decades, seen steady appreciation. Literature on design writing refers to it as a mostly technical vocation centred on the craft of writing in and of itself. Moreover, the suggestion seems to be that while writing is beneficial to, it is also distinct from the practice of communication design. Elsewhere, writing in the context of communication design is viewed as a specialisation - a skill that is typically reserved for a specialist writer who helps craft a tone to complement a predominantly visual design. In this article, we argue that writing for design is a far more complex and foundational skill for communication designers. In doing so, we explore the interdependence of narrative and writing, as a systematic design process and so highlight the importance of creative writing as design in an educational context and emphasise how integral writing is to the designer as a storyteller. To demonstrate this, we explore a selection of student work from an editorial project that has, for the past 21 years, been delivered to fourth-year Information Design students at the University of Pretoria (and which formed part of the 2023 Stories Worth Telling retrospective exhibition).

Heat Transfer Investigation Inside Heated Pipes of Different Cross-sections

This research examines the thermal transfer efficiency in pipes including various cross-sectional geometries, such as circular, square, and triangular shapes. A computational fluid dynamics (CFD) methodology was used to model flow conditions and examine heat transfer and turbulence intensities under consistent boundary conditions. The results indicate substantial variations in thermal and flow characteristics across the geometries. Circular pipes provide greater convective heat transfer efficiency and minimum temperature gradients, but square and triangular pipes show more turbulence accompanied by a higher pressure drop. These insights may guide the design of efficient piping systems for many technical applications, including HVAC, chemical processing, and renewable energy systems.

BLE Bluetooth remote-controlled car based on ESP32

Abstract. With the rapid advancement of information technology, Bluetooth technology has been widely used in the field of short-range wireless communication, playing an important role in information exchange. As one of the main technologies for short-range wireless communication, Bluetooth technology has broad application prospects, especially in robotic applications such as remote-controlled cars. This paper provides a detailed introduction to the design and implementation process of a Bluetooth remote-controlled car system based on the ESP32. It covers the classic Bluetooth and Bluetooth Low Energy (BLE) functionalities of the ESP32, the hardware design and assembly of the car (including the DC motor drive module, Bluetooth module, and speed measurement module), and methods for establishing a connection between the ESP32 and Bluetooth module, data transmission, and remote control of the car's movement. The paper also evaluates the system's performance through experiments, discusses the application and parameter adjustment of the PID control algorithm in enhancing speed control, and finally summarizes the research findings and suggests directions for future work.

An automated AI-powered IoT algorithm with data processing and noise elimination for plant monitoring and actuating.

This article aims to develop a novel Artificial Intelligence-powered Internet of Things (AI-powered IoT) system that can automatically monitor the conditions of the plant (crop) and apply the necessary action without human interaction. The system can remotely send a report on the plant conditions to the farmers through IoT, enabling them for tracking the healthiness of plants. Chili plant has been selected to test the proposed AI-powered IoT monitoring and actuating system as it is so sensitive to the soil moisture, weather changes and can be attacked by several types of diseases. The structure of the proposed system is passed through five main stages, namely, AI-powered IoT system design, prototype fabrication, signal and image processing, noise elimination and proposed system testing. The prototype for monitoring is equipped with multiple sensors, namely, soil moisture, carbon dioxide (CO2) detector, temperature, and camera sensors, which are utilized to continuously monitor the conditions of the plant. Several signal and image processing operations have been applied on the acquired sensors data to prepare them for further post-processing stage. In the post processing step, a new AI based noise elimination algorithm has been introduced to eliminate the noise in the images and take the right actions which are performed using actuators such as pumps, fans to make the necessary actions. The experimental results show that the prototype is functioning well with the proposed AI-powered IoT algorithm, where the water pump, exhausted fan and pesticide pump are actuated when the sensors detect a low moisture level, high CO2 concentration level, and video processing-based pests' detection, respectively. The results also show that the algorithm is capable to detect the pests on the leaves with 75% successful rate.

Electrical Explosion-Proof design of Low-Temperature condensation oil and gas recovery machine

Abstract The condensation oil and gas recovery machine is a highly efficient device specifically designed to recover oil and gas using condensation principles. This equipment is primarily used in flammable and explosive environments; thus, its electrical control system must meet explosion-proof requirements. This paper takes the oil and gas recovery machine as an example to introduce the design process of an explosion-proof electrical control system. The control system is composed of PLC and HMI as the core. The appropriate explosion-proof type is chosen based on the structural and performance characteristics of the recovery machine. The key points and considerations for designing the explosion-proof control box are elaborated on. The experimental results indicate that after undergoing triple-stage refrigeration, the oil and gas recovery machine can reduce the temperature of the oil and gas to −80°C. The electrical control system meets the explosion-proof safety and control function requirements of the oil and gas recovery machine.

Selecting sustainable packaging materials and strategies: A holistic approach considering whole life cycle and customer preferences

With the increasing public awareness of packaging and the environmental impact caused by it, companies are driving their businesses to introduce and promote practices that help ease the negative impact of packaging on the environment. Studies done on consumer behaviour show that decisions nowadays are influenced by sustainability. Yet, companies struggle with changing practices and justifying adopting environmentally friendly packaging materials. The current paper presents a holistic approach, addressing the need for identifying, assessing, and selecting sustainable materials for packaging applications. The Kano model prioritises features that are then used with Ashby plots for identifying alternative materials. Life cycle assessment, as well as life cycle costing, are used for assessing the environmental and financial impact of the use of such materials. Automatically weighted Multi-Criteria Decision-Making Analysis (MCDA) is used to select the most appropriate packaging material. This methodology provides a combinatorial ranking for each criterion set by four pre-defined weight distributions for Technique for Order Preference by Similarity to the Ideal Solution (TOPSIS). The proposed methodology allows for a systematic and holistic design process when deciding on packaging materials for any product. The methodology is validated for the case of packaging weather-sensitive cast stone products and carbonated drinks. In cast stone, three packaging materials are ranked for pallets based on their attributes. Similarly, for carbonated drinks, three packaging materials are recommended at the end of the study.

Design and Implementation of a 7-Person Voting Device based on Quartus

As the complexity of digital system design continues to increase, efficient and precise decision support systems have become increasingly important. This paper presents the design and implementation of a 7-voter decision system based on Altera’s Quartus software. The voter is applied in the core decision-making process to ensure the accuracy and efficiency of decisions. The study begins by outlining the design principles of the 7-voter decision system, using a design philosophy that minimizes timing delays and optimizes hardware resource utilization. A complex majority voting logic circuit is implemented using high-level hardware description languages (VHDL/Verilog), ensuring the advanced nature and applicability of the voting circuit. In terms of the logical implementation of the voting circuit, the paper conducts an in-depth analysis of the optimization of combinational and sequential logic and standardizes the input and output to enhance the signal stability and the system’s resistance to interference. On the Quartus platform, the design process of the voting system is elaborated in detail, with careful consideration given to boundary conditions and hardware compatibility. The implementation of the voter has undergone rigorous simulation and testing. Strict parameter setting for simulations and waveform analysis confirm the correctness of the circuit, and fault simulation tests further confirm its reliability. Performance indicators such as response time and percentage of resource utilization have been quantitatively analyzed and meet the design objectives set beforehand. Overall, this research not only realizes a highperformance 7-voter decision system but also provides an effective case study for applications on the high-performance Quartus design platform. Future research can build on the current work to further optimize algorithms and hardware, explore the potential for the application of the voter in a broader range of fields, and adapt to the new features of the Quartus platform to achieve more powerful decision support functions.

An innovative dynamic observer for nonlinear interconnected systems with uncertainties

In this paper, an innovative dynamic observer is applied to complex nonlinear interconnected systems with matched and mismatched uncertainties. This dynamic observer can estimate system states, which cannot be achieved during the design process for nonlinear interconnected systems with uncertainties. The proposed method has great identification ability with small estimated errors for the states of nonlinear interconnected systems with matched and mismatched uncertainties. It should be pointed out that the considered uncertainties of nonlinear interconnected systems have general forms, which means that the proposed method can be effectively used in more generalised nonlinear interconnected systems. Finally, simulation results for the lateral flight control system are presented to ensure the effectiveness of this strategy.

Model predictive control for space robot manipulator modeled by switched systems: A data‐driven approach

AbstractThis article investigates the data‐driven based model predictive control (MPC) problem for a class of space robot manipulator (SRM). First, the SRM system is modeled as a class of discrete‐time switched system to reflect more system characteristics. Second, only the input‐state data are used for end‐to‐end controller design, and the system identification process is avoided. In order to meet the real‐time requirements of the manipulator arm angles, a kind of constrained predictive control method is designed to prevent the overheating or damage of SRM motor, optimizing the cost function for each decision cycle under the safe control input constraints. Then, based on the average dwell time method, the asymptotic stability is assured for the presented SRM system. The design conditions for data‐driven based MPC are provided in the form of linear matrix inequalities. Finally, the effectiveness and advantage for the developed data‐driven based MPC strategy are validated via a case study of SRM system.

Cyber Resilience Limitations in Space Systems Design Process: Insights from Space Designers

Space technology is integral to modern critical systems, including navigation, communication, weather, financial services, and defence. Despite its significance, space infrastructure faces unique cyber resilience challenges exacerbated by the size, isolation, cost, persistence of legacy systems, and lack of comprehensive cyber resilience engineering standards. This paper examines the engineering challenges associated with incorporating cyber resilience into space design, drawing on insights and experiences from industry experts. Through qualitative interviews with engineers, cybersecurity specialists, project managers, and testers, we identified key themes in engineering methodologies, cybersecurity awareness, and the challenges of integrating cyber resilience into space projects. Participants emphasised the importance of incorporating cybersecurity considerations from the earliest stages of design, advocating for principles such as zero-trust architecture and security by design. Our findings reveal that experts favour Model-Based Systems Engineering (MBSE) and Agile methodologies, highlighting their synergy in developing flexible and resilient systems. The study also underscores the tension between principles-based standards, which offer flexibility but can lead to inconsistent implementation, and compliance-based approaches, which provide clear measures but may struggle to adapt to evolving threats. Additionally, the research recognises significant barriers to achieving cyber resilience, including insider threats, the complexity of testing and validation, and budget constraints. Effective stakeholder engagement and innovative funding models are crucial for fostering a culture of cybersecurity awareness and investment in necessary technologies. This study highlights the need for a comprehensive cyber resilience framework that integrates diverse engineering methodologies and proactive security measures, ensuring the resilience of space infrastructure against emerging cyber threats.

Molecular simulation of gas entrapment near a nanoscale cavity: The interplay of surface wettability, cavity shape, and gas type

Surface cavities play a crucial role in trapping and stabilizing gases, a phenomenon that can be used to facilitate applications in separation and drying processes. Understanding surface characteristics in relation to fluid-surface interactions is essential for designing interfacial properties that enable effective processes. In this work, we adopt a molecular simulation approach to investigate gas adsorption and entrapment in surface defects (cavities), focusing on the influence of surface wettability, cavity shape, and gas type. For this purpose, two types of silica-based surfaces with different levels of wettability (methylated and hydroxylated, with the former having lower water wettability), two cavity shapes with identical opening width and depth (V-shaped and square-shaped), and two types of gas (carbon dioxide and nitrogen) are considered. Our observations indicate that a stable gas nanobubble forms when a methylated surface combines with a square-shaped cavity, regardless of the gas type. In contrast, for hydroxylated surface, gas type becomes important; in a square-shaped cavity, nitrogen forms a stable nanobubble while CO2 is trapped in a monolayer fashion. The interfacial forces between the gas and surface which affects gas configuration near the surface, along with the gas molecules’ self-interaction manifested by solubility, are key to the different entrapment modes for N2 and CO2. Moreover, the square-shaped cavity exhibits better capability in trapping gas compared to the V-shaped cavity due to its higher surface area and smaller opening-to-interior ratio. The results of our molecular simulations can guide the design of surface features and processing systems to modify gas entrapment modes and stabilize nanoscale gas bubbles without altering thermodynamic conditions or fluid properties.