Fundamentals of Engineering Design Prof Lachmayer 2011

Institut für Produktentwicklung & Gerätebau

Fundamentals of Enineering design Lecture to Global Poduction Logistic students at JUB

Prof. Dr. Roland J. Lachmayer


Institute for product development and optomechatronic systems engineering


   

Welfengarten 1A, D-30167 Hannover http://www.ipeg.uni-hannover.de [email protected] Phone: +49 511 762 3472


Engineering Design

Course Name 050131 Credits 2,5 Grade 90 min written test on Friday 28 January 2011 9:30-11:30 • Questions and answers (10-20) Need: • Paper A3 • Set square / ruler • 3-4 calculations/drawings •

Lectures: Thursday 13th Jan. 2011 Friday 14th Jan. 2011 Friday 21st Jan. 2011 Friday 28th Jan. 2011 Lecture Hall Research II Prof. Dr. Roland J. Lachmayer

pencil

9:45 - 12:30 and 14:15 - 18:30 8:15 - 12:30 and 14:15 - 18:30 8:15 - 12:30 9:30 – 11:30 (Test of 90 min)

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Course Description


The course will provide a general understanding of innovation and development management and the processes and methods used to develop and design machines with its context to logistics engineering. Basic aspects of development methods will be explained: Development processes including specification, conceptual design and detailed design as well as different types of modular approaches and development levels will be trained. The use and need of design standards DIN/ISO, patents/IP and CAD systems will be shown. An introduction to the general parts and elements of machines such and their function will be given: • Shafts, springs, screws, bearings, gears For selected examples basic methods to dimension these elements and machines with respect to material and tension will be explained. Specific focus will be given to the interrelations between product modularization and logistics as well as the importance of logistic planning during the development process. The course contents lectures and exercises.


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Engineering Design 1. Fundamentals/Introduction Need to innovate Fundamentals of technical systems Products, costs and logistics 2. Product creation Product planning and development processes Clarification and specifications Concepts and modular design 3. Embodiment design Design standards DIN/ISO and drawings Design rules and principles Outlook to CAD use and CAE tools 4. Materials and mechanics Material parameters Fundamentals of mechanic stress calculation 5. Dimensioning of design elements Shafts, springs, screws, bearings Gears 6. Conclusion Strategy and IP Total Quality Management Prof. Dr. Roland J. Lachmayer

Day 1

Day 2

Day 3

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Targets of chapter 1


• Basic understanding of the development of industrial production/products • Product Lifecycle • Innovations due to Software, Photonic and Nanotechnology • Mechatronic Systems / Technical Systems • Product Costs • Link between product design and logistics


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Material – Energy - Signal

Material

Energy


Signal

Quelle: Roth Prof. Dr. Roland J. Lachmayer

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Modell of Long Waves

Chemical Industries Mass Production

Electronic Communication

Telecommunication

Nano Bio Health

Railway steel

Steam engine

Today


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Product Lifecycle


Quelle: Pahl/Beitz Prof. Dr. Roland J. Lachmayer

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Software related Innovations Moore‘s law: • •

2x number of transistors on chips 18 month

Mechatronics, „intelligent machines“ Microsystem- and Nanotechnology Software agents

Networked systems and Mobility Optoelectronics and Photonics

Light engineering Virtual Reality/Augmented Reality


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Virtual Reality



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Technical systems



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Constraints during design



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Structure of Mechatronics Communication system

Information Processing units Digital/analog conversion

Energy feed

Information processing

Operator interface (human-machine interface)

Digital quantities

Human

Digital/analog conversion

Analog/digital conversion

Amplification

Analog quantities Energy feed

Actuator(s)

Energy feed

Sensor(s)

Basic system

Quelle: Gausemeier Prof. Dr. Roland J. Lachmayer

Flow of information

Flow of material

Flow of energy

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„New“ Market-Constellation

Past

Today


 Costs and time to market  Only two reasons to buy a new product: 1. Value added 2. Cheaper drive developments  Vertical integration is a risk


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Costs to Market

• •

Typical picture of project business For mass production design phase is much larger related to building and testing of products, but design costs and may also be much higher than product costs


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Total costs of ownership Manufacturer costs

Product user costs

Production costs

acquisition costs

Costs for: Management, marketing, development, …

non-recurring costs for: Transport, installation, environmental protection, scrapping

Manufacturing costs (Cost of labor, production overhead costs)

Cost of operation (Energy, operating materials, auxiliaries, operation)

Cost of material

Maintenance costs (Maintenance, repairs, Inspection)

Requirements: Funktion, Safety,…

Total cost of product

Quelle: Ehrlenspiel Prof. Dr. Roland J. Lachmayer

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Costs responsibility Cost responsibility and influence Cost generation

Development

Process engineering

Purchasing

Sales and marketing

Quelle: VDI 2235 Prof. Dr. Roland J. Lachmayer

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Cost impact of design



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Impact of Complexity Plant B

Plant A

No. of variants

Revenue

Stock

No. of variants

Revenue

Stock

Variants cause a lot of stock but do not increase revenue significantly Options for action:

Constriction to core business Co-operation with „refiners“ for specific market niches Prof. Dr. Roland J. Lachmayer

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Segments of Products


Intensity of technology is responsible for complexity of production and process development in R&D. Intensity of labor provides information on amount of manual labor in production. Radius of market indicates reasonable transportation of product from manufacturing plant to customer Prof. Dr. Roland J. Lachmayer

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Function of a Company



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Engineering Design


1. Fundamentals/Introduction Need to innovate Fundamentals of technical systems Products, costs and logistics 2. Product creation Product planning and development processes Clarification and specifications Concepts and modular design 3. Embodiment design Design standards DIN/ISO and drawings Design rules and principles Outlook to CAD use and CAE tools 4. Materials and mechanics Material parameters Fundamentals of mechanic stress calculation 5. Dimensioning of design elements Shafts, springs, screws, bearings Gears 6. Conclusion Strategy and IP Total Quality Management Prof. Dr. Roland J. Lachmayer

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Targets of chapter 2 • • • •


Basic understanding of development process Specification Technologies Development of concepts Use of building blocks and modular design


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Innovation drivers Market driven innovation

Technology driven innovation Research Advanced development Design

Planning

Production Life cycle of a product Quelle: Pahl/Beitz


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General approach to design


Types of designs: • New design • Modification design • Adaptation design


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Development for mass production



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Product Requirements List



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Specification Technologies • • • • •


Product checklist Brainstorming Analysis of Product Lifecycle Analysis of Product Use and Environment Market survey / User Clinic


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Example of a specification list •

• • •

Quality of requirements • Fixed • Targeted • Wishes Date changes Responsabilities Concrete and measurable


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Introduction to the examples



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Checklist for specification


Performance Geometry Materials Energy Time

Cost Manufacture Standards Safety Transport Ergonomics


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Conceptual design



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Establish functional structure



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Example car lifter


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Search for working principles



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Different working principles that satisfy the function “store energy“ obtained by varying the type of energy Quelle: Pahl/Beitz Prof. Dr. Roland J. Lachmayer

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Combination of principals



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Evaluation of concepts



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Parameter design



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Modularity / Building Blocks



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Modularity / Building Blocks



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Types of construction

Composite construction


Product

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Engineering Design



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Targets of chapter 3 - Drawings

• • • • • • •


Basic understanding of technical drawing standards Ability to read and understand technical drawings Ability to draw technical scratches Basic understanding of tolerances and surface parameters Understanding of basic design values and principals Use and need of technical documents Basic understanding of computer aided engineering


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CNC Machining Centre


Quelle: Hüller Hille GmbH Prof. Dr. Roland J. Lachmayer

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Component drawing



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Assembly drawing

Bill of material DIN 6771 Form A


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Design drawing



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Exploded assembly drawing



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Important Standards for Drawings Top view

Front view

Side view

2

(7) (8)

4

3

Front view

35 Top view


15

1

Front view

50

(6)

(5)

Side view

Side view

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Projection

Bottom view

Side view from right

Front view

Side view from left

Rear view

Top view


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Dimensioning

Arrow head Extension line Measure

Examples for Dimensioning of angles

Dimendion line Linear dimension

Dimension arrow head


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Dimensioning



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General tolerances



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Types of sectional drawings

Full section

Half section

Partial sections


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Cutting lines



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Screw threads


External screw thread: hexagon head screw ISO 4014

Internal screw thread: tapped blind hole


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Tolerances

Ao = Go – N Au = Gu – N T = Go - Gu = Ao - Au


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Tolerances



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Often used tolerance classes



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Surfaces

Rz: Mean Roughness Depth

Ra: Roughness Average


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Surface symbols



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Surface specifications

unmachined


Roughed down

smoothed

finished

Very fine machined

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Reuse norm parts and solutions



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Reuse norm parts and solutions • • •



Database of norm part as well in DIN/ISO but also from suppliers Today geometries of norm parts can automatically be copied into CAD programs Different types of export systems are in use

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Design catalogue


Quelle: Roth Prof. Dr. Roland J. Lachmayer

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Influences on Notch Effect



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Influences on Notch Effect



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Bearing arrangements

a. b. c.

O.K Specific Dangerous

 Allow thermal expansion! Prof. Dr. Roland J. Lachmayer

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Avoiding double fits



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Self-reinforcing seals

Self-reinforcing seals: a self-sealing washer b tubeless tyre c radial shaft seal d sleeve seal e sliding ring seal


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Reduce stiffness


 To avoid breaking Seite 79

Ensure guidance



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Parameters of embodiment design


Variant Characteristic

Shape Position Size Quantity


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Rules for moulding



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Design rules for manufacturing



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Bill of material/drawings

Production planning and control Process planning Accounting


Construction

Bill of material

After sales service

Production/ Assembly Purchasing/ Storage Distribution

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Design Defense



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Computer aided design


Virtual prototype Digital Mock-up

Element design

Product structure


Kinematics, dynamics, stability

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Visualisation



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Virtual Prototyping



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Computer Aided Planning


Analysis of assembly line ergonomics (Source: Siemens PLM Software)

3D-model of factory building (Source: Siemens PLM Software) Prof. Dr. Roland J. Lachmayer

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Computer Aided Planning


Model components

SPS code of production system Gantt-chart with necessary states of manufacturing steps


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Engineering Design



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• • • • •


Basic understanding of Hooke’s law Understanding of fracture behavior of steel Dynamic influence on material strength Hardness Fundamentals of stress and strain


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Material



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Material

Material


Design

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Stress and Strain



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Fracture Behaviour Elastic / plastic

brittle

Tensile strength Elastic strength Elastic limit Elastic Modulus Ultimate strain


Rm Re Rp 0.2 E A

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Dynamic Fatigue Test



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Stress



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Stress



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Comparison stress


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Dynamic Fatigue Strength



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Engineering Design



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• Basic understanding of design elements  Springs  Bolted connections  Roller bearings


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Design Elements

Axes: stagnant


Shaft: revolving

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Design Elements

(1) Bearing seat

(2) Shaft-hub joint


(3) Axial fixation

(4) Shaft seal Seite 105


Springs Steel springs


Rubber springs

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Springs

F, Mt

progressive

linear

degressive

Stored work W

f, φ


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Examples of Springs



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Springs

Series Parallel


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Bolted Connections

Embodiment of bolted connections:


a)

Bolt and nut

b)

Stud bolt

c)

Headed screw

d)

Extension bolt

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Bolted Connections



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Bolted Connections

F

1 1 f g  FV     cS cP 

FS

FP  FV  FPB

FSB

FV FB cS

FPB

FS  FV  FSB FP

cS FSB  FB cS  cP

cP fs

fp fg


f

cP FPB  FB cS  cP

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+σzdw

Fatigue Strength

-σzdw

Construction steel: e.g. E295, σm = 200 N/mm2 ⇒ σAzul = ± 95 N/mm2 Bolt: e.g. property class 5.6 ( ≙ E295) ⇒ σAzul = ± 50 N/mm2 Prof. Dr. Roland J. Lachmayer

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Bolted Connections



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Roller Bearings – DIN 625



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Roller Bearings – DIN 625



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Bearings – Design

Shaft nut with lock washer Possibilities of axial fixation

Retaining rings for shafts and bore holes


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Bearings – Design


Fixed and floating bearing arrangement

Semi-locating bearing arrangement


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Gears


Normal efficiency ~ 97%


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Gears – Example



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Gears – Example



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Engineering Design



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• • • • • 


Basic understanding of quality FMEA Total quality and balanced Scorecards Strategy and innovation Patents Integrated innovation


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Errors

Discovery of errors

Prevention of errors

Buy and produce

Error Costs

Develop and plan


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Errors

Error rate

Errors fixed

Error cause

Phases in product lifecycle


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Failure Mode and Effect Analysis



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Total Quality Management Elements of TQM

Targets of TQM

Quality of products

Quality of processes

Optimal satisfaction of external customers Optimal satisfaction of internal customers

Quality of work

Minimal costs

Quality of contact with customers and suppliers

Increase of productivity Increase of market share

Implementing TQM in stages DIN ISO 9001 certification as standard

TQM expresses overall success


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Balanced Scorecard Strategic goals


Indicator

Oper. goals

Activities

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Competitive Ability Competitive capability

Future orientation


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Strategy



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Impact on Strategy

Differentiation

Take advantage of synergistic effects

Efficiency

Take advantage of environmental chances

Timing

Concentration of power

Balance of ressources and goals

Unité de doctrine

Build upon strengths


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Innovation



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Patents



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Integrated innovation

Scenarios

Strategies

Processes

Systems Prof. Dr. Roland J. Lachmayer

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Literature


G. Pahl, u.a.: Engineering design, 3rd edition Springer Verlag, Berlin, 2007, ISBN 978-1-84628-318-5 P. Kosky, u.a.: Exploring engineering, 2nd edition Academic press, San Diego, 2010, ISBN 978-0-12-374723-5 J. Gausemeier, u.a.: Zukunftsorientierte Unternehmensgestaltung Carl Hanser Verlag, München, 2009, ISBN 978-3-446-41055-8 W. Steinhilper, u.a.: Konstruktionselemente des Maschinenbaus 1 u.2, 6st edition Springer Verlag, Berlin, 2008, ISBN 978-3-540-76646-9 K. Roth: Konstruieren mit Konstruktionskatalogen 1 u.2, 3rd edition Springer Verlag, Berlin, 1994, ISBN 3-540-09815-1


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Fundamentals of Engineering Design Prof Lachmayer 2011

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