I nstitute for I nnovation & D esign in E ngineering T exas A & M U niversity ASME Houston Sept. 23...

ASME Houston Sept. 23 2004. 1

Institute for Innovation &

Design in EngineeringTexas A & M

University




University

How do we think?How do we think?

Configurationally – most often analogically.Evolutionary - Can we do this analog better?

Within our comfort zone.

Our thoughts are constraint driven. We have tunnel vision – We go for the answer.For the sake of efficiency and sufficiency.

There is nothing wrong with thisExcept

There are better ways of thinking!




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Why is the Natural Thought Pattern soWhy is the Natural Thought Pattern so Configurational?Configurational?

Why is the Natural Thought Pattern soWhy is the Natural Thought Pattern so Configurational?Configurational?

• Less cognitive effort is required to identify an event by comparing it with prior knowledge rather than interpreting it by its properties.

• Convenient to modify previous solutions.

• Less cognitive effort is required to identify an event by comparing it with prior knowledge rather than interpreting it by its properties.

• Convenient to modify previous solutions.




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Natural Thought Process -Its Implication to InnovationNatural Thought Process -

Its Implication to Innovation

• A configurational solution is conceived almost immediately after the problem presentation.

• This solution is invariably not innovative.

• Once conceived, it causes design fixation. It prevents the consideration of alternatives.

• Thus, the designer is prematurely locked into a common solution.

• This hampers innovation.




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How to Improve the Natural Thought Process?

How to Improve the Natural Thought Process?

• Making a conscious effort to evoke the informational core by:– Identifying Conceptual properties

– Identifying the critical parameter

– Questioning every decision

• Considering several alternative solutions.




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Let us enable innovation by:Let us enable innovation by:

By also thinking:

• Conceptually

• Revolutionary

• Outside our comfort zone

With:

• Funnel vision

• Concept-Configuration Looping

• Skillful Questioning and

• Critical Parameter Identification




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Engineering Design ProcessEngineering Design ProcessStages in Design

Activity Output

Function StructureDevelopment &

Order of MagnitudeCalculations

Simulation &Rapid Prototyping

Parameter Analysis &Concept Selection

FunctionalDesign Principles

ManufacturingDesign Principles

Design Methodologies &Techniques

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Need

Product Prototype

Engineering Drawings

Design Layout

Design Concept

Design Requirements

Need Analysis

Prototype Creation

Detail Design

Embodiment Design

Conceptual Design

I T E R A T I O N

C Y C L E




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Example: Car BrakesExample: Car Brakes

Evolution of Need Statement (Abstraction)Colloquial

Abstract

Stopping distance

Evolution of Critical Parameter

Stopping distance (Qualitative)

• Reduce the speed of a car from 60 mph to 0 mph in less than 120 ft

Deceleration• Decelerate a car at a controlled rate

Energy dissipationrate

• Dissipate the kinetic energy of a car at a required rate

• To stop a car

Reduce the speed of a car as fast as possible

Rate of energytransformation

• Transform the translational kinetic energy of a car at the highest acceptable rate




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Discover the REAL NEED!Discover the REAL NEED!

Through:Abstraction,

Good Conceptual Thinking and

Precise identification of critical parameters

Discover the:REAL NEED expressed as an active noun-verb pair

Plus the Critical Functional Constraint

In 10 words or fewer.

(You may ad an adjective and/or adverb - or phrase.)

IF YOU ARE UNABLE TO DO THIS

THEN YOU DO NOT KNOW YOUR NEED!




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If you do not know the NEEDIf you do not know the NEED

You will be:• unable to quantify the magnitude of the design task.

• unable to justify the sufficiency of your solution.

• unable to effectively, efficiently and innovatively execute an effective, efficient and innovative design.

You will:– Do many extensive ( read “expensive”) iterations.

– Go through extensive development.

– END UP WITH A SUB-OPTIMAL DESIGN.




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Abstraction is:Abstraction is:Abstraction is:Abstraction is:

The Process by which a perceived need is

progressively transformed, from a colloquially

expressed statement of a design task into a

functionally precise definition of a need, expressed in

technically fundamental and quantifiable terms

The Process by which a perceived need is

progressively transformed, from a colloquially

expressed statement of a design task into a

functionally precise definition of a need, expressed in

technically fundamental and quantifiable terms




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Critical Parameter IdentificationCritical Parameter IdentificationCritical Parameter IdentificationCritical Parameter Identification

Critical Parameter Critical Parameter Make or Break Issue Make or Break Issue Critical Parameter Identification(CPI): Identify the key issue:

Embedded in the design need Associated with a concept Associated with a specific configuration

Pointers toward a Critical Parameter frequently are:– Gradients (in time or space)– Interfaces (Functional or Configurational)

Critical Parameter Critical Parameter Make or Break Issue Make or Break Issue Critical Parameter Identification(CPI): Identify the key issue:

Embedded in the design need Associated with a concept Associated with a specific configuration

Pointers toward a Critical Parameter frequently are:– Gradients (in time or space)– Interfaces (Functional or Configurational)




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Loom Example: Reduce the noise of the shuttle

Loom Example: Reduce the noise of the shuttle




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Loom Example : The Design TaskLoom Example : The Design Task

• For higher production rates, it is necessary to increase the velocity of the shuttle.

• The shuttle should be stopped at each end and restarted in the opposite direction.

• This involves noise.

• The NEED is to reduce noise without lowering the speed.




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Example: Design the brakes for a car.Example: Design the brakes for a car.

Evolution of Need Statement (Abstraction)Colloquial

Abstract

Stopping distance

Evolution of Critical Parameter

Stopping time (Qualitative)

• Reduce the speed of a car from 60 mph to 0 mph in less than 120 ft

Deceleration• Decelerate a car at a controlled rate

Energy dissipationrate

• Dissipate the kinetic energy of a car at a required rate

• To stop a car

Reduce the speed of a car as fast as possible

Rate of energytransformation

• Transform the translational kinetic energy of a car at the highest acceptable rate




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ConstraintConstraint

• Constraint is a condition imposed by the stated design requirements.

• It defines the envelope within which a function must be satisfied.

• Constraints often determine the difficulty of the design task.

• Some constraints are “Must be”.

• Some constraints are “Would like to be”.

• Identifying the critical functional constraint in a manner that is quantifiable is the task.




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How to Question?How to Question?

NEED

What?

Why? When?

Who? Where?

How?

NEED

Whatnot?

Whynot?

Whennot?

Whonot?

Wherenot?

How not?

Five “WH’s” and “HOW”




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Some Important QuestionsSome Important Questions

• “What” is required?

• “When” is it required?

• “Where” is it required?

• “Who” requires it?

• “Why” is it required?

• “How” is the solution constrained?

• IS IT REQUIRED AT ALL?

•What is not required?

•When is it not required?

•Where is it not required?

•Who does not require it?




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Constraining the Solution spaceConstraining the Solution space

Constraints

Unacceptablesolutions

SolutionSpace • Each constraint eliminates

possible solutions.

• To foster innovation, it is important to identify only the real constraints and eliminate fictitious constraints.




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Technological EvolutionTechnological Evolution

DevelopmentBarrier

(Adapted from Linde, 1995)




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Comfort ZonesComfort Zones

1

2

3

1. Zone of confidence1. Zone of confidence

3. Zone of rejection3. Zone of rejection

2. Zone of discomfort2. Zone of discomfort




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Funneling of Concept Solution Space Funneling of Concept Solution Space

Sample big – Converge rapidly

•Sample many different concepts

•Converge rapidly

•To one optimal conceptual solution




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Two Spaces Model: Knowledge BaseTwo Spaces Model: Knowledge Base

• Concepts– Provides the theoretical or

scientific foundation

ConceptSpace

ConfigurationSpace

F = ma

Damping occurs

at the interfaces.

F = kxV

= IR F

Fk

• Configurations– Based on the practical or

engineering basis




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Two Spaces Model: The Design ProcessTwo Spaces Model: The Design Process

ConceptSpace

ConfigurationSpace

F = ma

Damping occurs

at the interfaces.

F = kx

V =

IR F

Fk

Particularization

Generalization

Design can be viewed as an iterative movementbetween the two knowledge domains achieved through

the use of the two distinct thinking modes.




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ConceptConcept

• Any natural law, physical principle (or effect) or mathematical relationship that can be applied to address the design need.

• Concepts represent ideas for meeting the design need.

• The governing equation for a concept represent the interrelationship between various parameters.




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ConfigurationConfiguration

• Configuration is the physical realization or embodiment of a concept.

• A configuration originates as a preliminary sketch and is developed into detail drawings as the design process progresses.




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Concept-Configuration ModelConcept-Configuration ModelConcept-Configuration ModelConcept-Configuration Model

Concept SpaceGeneralization

– Abstraction of specific information to fundamental concepts

– Fosters divergent thinking

Example

– Overheated drum brake requires removal of heat from the interface

Concept SpaceGeneralization

– Abstraction of specific information to fundamental concepts

– Fosters divergent thinking

Example

– Overheated drum brake requires removal of heat from the interface

Configuration SpaceParticularization

– Configuration of abstract principles/ concepts

– Fosters convergent thinking

Example– Mechanical removal of

heat from interface is realized in the form of disc brakes

Configuration SpaceParticularization

– Configuration of abstract principles/ concepts

– Fosters convergent thinking

Example– Mechanical removal of

heat from interface is realized in the form of disc brakes




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Concept-Configuration ModelConcept-Configuration Model

Concept Generation Using Various Techniques

Creative Synthesis

Critical Parameter Identification

Config-uration

Space

Concept Space

Original Need

Eva

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Evaluation against design requirements

Rede-fined Need

Rede-fined Need

• Requires 3 successful cycles to validate a concept

• Three conceptually different conceptual solutions




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Conceptual DifferenceConceptual Difference

• The ideas or concepts are conceptually different when:– the underlying scientific principle or

governing effect for each concept is different.

– The concepts do not share the same critical design parameter.




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Are these designs conceptually different?Are these designs conceptually different?

• Orifice plate, nozzle and venturi share the same concept: Bernoulli’s principle. Therefore, they are conceptually similar.

Orifice plate Nozzle Venturi




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Conceptually Different Solutions: Flow Measurement

Conceptually Different Solutions: Flow Measurement

Concepts:– Bernoulli’s principle, Change in resistance with temperature.,

Aerodynamic lift & Aerodynamic drag.

OrificePlate

Hot wire PropellerDeflecting

Vane

T T1 2




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TAMU- IIDE Engineering Design MethodologyTAMU- IIDE Engineering Design Methodology

Need Statement

Design Specifications

3 Design Concepts

Design Layout

Engineering Drawings

Product Prototype

Detailed Design & Product Creation

Embodiment Design

Conceptual Design

Need Analysis Function Structure

Selected Concept

Design Stages & Design Outputs

Function Structure Development &

Constraint Analysis

Concept-Configuration Model Concept Generation

& Selection

Design Principles & Optimization

Manufacturing Design Principles

Design Methods

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Con

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Object-Function Method

Concept Generation Techniques

Design Techniques

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