-
What is TRL 0?
Idea - Unproven Concept, no testing
-
TRL 1?
Basic Research - Principles postulated and observed but no experimental proof
-
TRL 2?
Technology Formulation - Concept and application have been forumlated
-
TRL 3?
Applied Research - First lab tests; proof of concept
-
TRL 4?
Small Scale Prototype - Built in a lab and "ugly"
-
TRL 5?
Large Scale Prototype - tested in intended environment
-
TRL 6?
Prototype System - tested in intended environment close to expected performance
-
TRL 7?
Demonstration system - operating in operational environment at pre-commercial scale
-
TRL 8?
First of a kind commercial system - Manufacturing issues solved
-
TRL 9?
Full commercial application - Tech available for consumers
-
Which TRL levels do universities deal with? Industry?
- Universities - 0-4
- Industry - 2-9
-
Brand new technologies start at which TRL? Which level do products based on exisiting technologies start at?
- Brand new - TRL 0
- Existing - TRL 4
-
One design challenge is that products are complicated. What is complex about them?
- The product itself - Vast amounts of information required
- Organisations - A product may involve multiple suppliers in a hierarchical structure
- Documentation - Must have a paper trail for each part showing tests have been performed, can be prosecuted otherwise
-
What are the 8 major objectives in (car) design?
- Cost
- Environmental Performance
- Reliability
- Aesthetics
- Luxury
- Technical Performance
- Safety
- Ergonomics
-
What factors are a part of the Technical Performance objective for a car? What work can be done to improve this?
- Drive performance and size of car
- Conduct vibration analysis and strength design
-
What factors are a part of the Cost objective for a car? What work can be done to improve this?
- Purchase cost, Maintenance, Running costs, Depreciation
- Materials Selection and lifecycle costing
-
What factors are a part of the Environment objective for a car? What work can be done to improve this?
- Emissions, Waste, Fuel consumption
- Lifecycle analysis, Material selection
-
What factors are a part of the Ergonomics objective for a car? What work can be done to improve this?
- Space, Forces, Comfort, Man-machine-interface
- Ergonomics design/modelling (normal distribution analysis)
-
What factors are a part of the Aesthetics objective for a car? What work can be done to improve this?
- External, Internal, General
- Industrial design - Aesthetics guidelines and colour selection
-
What factors are a part of the Reliability & Safty objective for a car? What work can be done to improve this?
- Reliability- Redundancy, Failsafes
- Safety - Warning lights, Braking systems, driver's view, Failsafes, Crumple zones
- Reliability modelling (exponential distribution)
-
What factors are a part of the Luxury objective for a car?
Comfort, Convenience, Entertainment
-
The Honda Accord, made in 1976, is an example of a design that has a 'heritage' and has become 'dominant' in the market. How many generations has it got and what does 'dominant design' mean?
- 9 generations
- Dominant design means it has become the industry standard and other designs should at least implement the features it presents as a minimum.
-
Give two examples where form conflicted with function.
- Audi TT rear wheel slip
- Millennium bridge vibration
-
What is the current EU instated target for CO2 emissions per car?
95g/km CO2 average
-
Toyota announced a recall for 4m vehicles in the US over which fault? What date was this? How much did it cost for the recall/redesign?
- Accelerator pedals being stuck down
- September 2009
- $2 billion
-
September 2017 - Dyson intends to invest £2 billion in what industry?
Electric Cars - incorporating tech from the company's other products
-
5th September 2018 - What was the ratio of electric cars bought in the UK compared to fuel cars?
One in every 12 bought were electric
-
5th September 2018- The Society of Motor Manufacturers and Traders said hybrid/electric cars made up how much of the overall market?
8%
-
Which country has the highest market share of electric cars? How much is it?
-
Name four examples of key future developments in engineering.
- Electric Cars
- Robotics
- Renewable Energy
- Domestic Products (Dyson stuff)
-
Automotive is the largest industry in the UK. What is its turnover and how many people does it employ indirectly? What percent of exports are automotive related?
- £77.5 billion with 814,000 employed
- 12% of all exports
-
Which products showcase why its necessary to have a systemic design process?
- Dyson supersonic hairdryer
- Dyson electric car
- Airbus 380
-
Dyson Supersonic Hairdryer - 2016
How much invested?
How many engineers?
How many prototypes?
How many patents pending?
- $100 million invested
- 100 engineers
- 600 prototypes
- 100 patents pending
-
Dyson electric car - 2020
How many engineers?
When did the project start?
- 400 engineers
- Started 2014
-
Airbus A380
How many parts?
How many design engineers?
How many companies produce parts?
- 4 million parts
- 5000 design engineers
- 1500 companies
-
Aircraft seats are an example of multi-objective design. Which objectives are those and give an example for each.
- Technical Performance - crash load, static loads, mass constraints
- Ergonomic - Seat width, seat height, adjustment, comfort
- Aesthetics - colour, patterns, shape, texture
- Entertainment - TV screen, music
-
What are the three modes of design?
- Incremental design
- Adaptive design
- Original design
-
Incremental design means what? Where/why is it common?
- Minor changes/improvements to an existing product
- Common as it is low-risk design and good for mature industries that produce high volumes of units. (automotive/domestic/aero) Happens when new materials/manufacturing techniques discovered
-
Adaptive design means what? When is it implemented?
- Significant changes/improvements to whole sub-systems
- Common when new technologies invented (airbags/crumple zones)
-
Original design means what? Why is it risky?
- Major changes/improvements to whole sub-systems or systems
- Hard to specify the millions pieces of information required correctly so hard to complete error free.
-
Give two examples of original design in the automotive industry.
Although a source of high-risk, why are they possible?
- 2013 Hybrid Honda accord
- Tesla fully-electric car
- Possible because of government legislation and incentives
-
What are the 4 steps in the double diamond process model?
- Discover - Markets researched
- Define - User info aligned with company objectivs
- Develop - Multiple design solutions iterated
- Deliver - Convergent design to final solution
-
What are the design stages in the Pahl-Beitz model?
- Task
- Specification
- Concept
- Preliminary Layout
- Definitive Layout
- Documentation
- Solution
-
What are the stages of a product lifecycle as given by the BS 7000-2:1997 handbook?
- Trigger
- Product Planning
- Feasibility Study
- Design
- Development
- Production
- Distribution
- Operation
- Disposal
-
What are the stages of the V-model?
- Concept of operations
- Requirements and Architecture
- Detailed Design
- Implementation
- Integration, Test and Verification
- System Verification and Validation
- Operations and Maintenance
-
Benefits of the Pahl-Beitz model?
- Stages can be done concurrently to reduce time in incremental design
- Top-down process starting with abstract ideas
-
Benefits of the double diamond process?
- Breaks the tasks into stages with outputs
- Encourages designers to clarify the specification
-
Benefits of the V-model?
Top-down to component level and bottom-up to system level. Have to plan system before you can work on specific details then specify component details before testing a system
-
Benefits of identifying stage gates?
- Emphasises that certain achievements are required to be completed
- Regular design reviews set at milestones
- Performance of the design can be defined and recorded at milestones
- Senior managers can 'sign-off' when in approval of progress
- Workers get used to the routine
-
What are the prototype models before release? Their purpose?
- Breadboard model - Broad feasibility of tech
- Engineering model - verifying main performance aspects
- Qualification model - go beyond normal operation to demonstrate safety margins
- Delivered model - checking performance of final product
-
What case study can be used to show the importance of test verification?
- Hubble telescope solar panel array wobble
- Caused by irregular thermal blankets in orbital sunrise/sunset
- Would have been found in physical verification rather than modelled behaviour
-
What is the difference between Metrics, Constraints, Soft Requirements and Hard Requirements?
- Metrics are used to monitor performance during design. They quantify how good a design is.
- Constraints must be fulfilled. Usually not self-imposed (e.g. safety)
- Soft requirements are desirable but not necessary
- Hard requirements are self-imposed constraints
-
What are the benefits of a solution-neutral problem statement?
Does not lead the designer in a particular way. No solution is implied within the problem. Encourages innovation.
-
"Design a chassis for a car"
How can this be made into a solution-neutral problem statement?
"Design a structural platform for a car"
-
What design authorities exist for aircraft design?
- FAA - Federal Aviation Administration
- CAA - Civil Aviation Administration
- ICAO - International Civil Aviation Organisation
-
Which design authority is in charge of medical products?
What are the two types of medical device?
- MHRA - Medicines and Healthcare products Regulatory Agency
- General medical devices and in vitro diagnostic medical devices (IVDs)
-
Which regulation should all electrical equipment comply with?
Electrical Equipment (Safety) Regulations 1994
-
What could come under a function-means tree for a high performance vacuum cleaner?
-
What could come under a function-means tree for good safety performance in a car?
-
"Worst-case loading" means what?
The absolute worst case conceivable, not just worst case in normal operation
-
A waterslide is limited to two people, what is its worst-case loading?
What case study is tied to this?
- It should be calculated at ~50 people at 80kg
- Napa High Waterslide collapse - 1997
-
Bristol Rovers stand - 1992
What was wrong with the stand designed?
What was the designer's defence?
- More than 50% spectators got wet
- Near touchline could not be seen
- Defence was that the problem statement did not explicitly demand for these requirements
-
Bristol Rovers stand - 1992
What was the fine for the designers?
How was the stand modified?
- Designers fined £1 million for incompetence
- Stand was modified with increased terrace angle and an extended roof
-
Challenger Disaster - 1986
What caused the problems?
What could have been specified about the launch to stop the issue?
- Cold (2 degrees Celsius) O rings were not flexible enough to seal a gap closed between hot gases and the propellant.
- If the launch was specified to never happen before 10 degrees Celsius, the disaster wouldn't have happened
-
What factors are considered "Drivers of Innovation"?
- New legislation
- Customer Wishes/Trends
- Technology Breakthroughs
- Innovators/entrepreneurs
- Elite activities
- Affluence
- Competition
-
Studying the competition is a conceptual design method. Give an example of a product(s) that have used this.
- Common in automotive industry where cars look increasingly similar. (Nissan QASHQAI, Ford Edge, Renault Captur)
- Phone design - Starting in 2011, Apple sued Samsung for patent violations after their designs were too similar.
-
What is 'Insight' in terms of conceptual design methods? Give an example of a product that has used this.
- Using an understanding of physics to innovate around the problem.
- Large iron-hulled ships pioneered by Brunel when he noticed larger ships could carry more fuel and that drag is propotional to frontal area only, meaning longer ships could go further.
-
What is Bio-inspiration? Pros/Cons?
- Studying designs in nature to find best solutions to problems.
- Pros: solutions efficient in harsh environments, very large range of concepts
- Cons: Complex at micro level, not necessarily design for long lives, some strategies in nature are brutal (offspring mortality rate)
-
What products are examples of biomimetics? What was their inspiration?
- Velcro - burrs of the burr plant
- Self-cleaning glass - Lotus leaf
- Painless medical needle - Mosquito bite
- Self-healing composites - Vascular system
-
What is 'Technology Transfer' in terms of conceptual design methods? Give an example of a product that has used this.
- Taking a tech from one application and using it in another
- Dyson cyclone vacuum cleaner. Tech noticed at a sawmill to collect sawdust - was condensed to a smaller scale
-
What is 'Functional Decomposition' in terms of conceptual design methods?
- Identifying sub-functions of the product and then considering combinations of all those sub-solutions.
- Use for a morphological chart
-
What is 'Backwards Design' in terms of conceptual design methods? Give an example of a product that has used this.
- Identify an idealistic solution then work backwards to make it work.
- Double-action worm gear-set for spacecraft - acts as both suspension and deployment method for solar array.
-
What are the benefits of Prototyping in conceptual design?
- Feedback on form/function quickly
- 3-D visuals
- Can be cheaper than PC modelling
- You lean things that computer models don't tell you
- May not be available software to test something if it is a novel product
- Aids team work
- Aids selling to investors
-
What is brainstorming?
Uninhibited idea creation from a team of people. Encourages creativity by forbidding criticism of ideas
-
What is 'Inversion' in terms of conceptual design methods? Give an example of a product that has used this.
- Investigate whether an existing design can be done another way around physically or in its intention.
- Helicopters - rotating wings
- Power overhead powerline instead of within train
- Push rod suspension horizontal instead of vertical
-
Technological opportunities provide opportunity for new designs. What are some recent examples of new technologies and their products?
- AI - driverless cars
- Magnetic levitation - trains
- Graphene - soft robotics
- CFRP - bikes/planes
-
How is sketching beneficial to a conceptual design process?
- Easy to focus on the essential parts
- Quick to produce
- Good for 3D visualisation
- Record Notes
- Team work
- Impressionist not exact
- Can record design options
-
Name four different types of sketching and what they're used to sketch.
- 3-point perspective - tall buildings
- 2-point perspective - realistic cars
- Isometric - generic
- Oblique - easiest sketch form
-
James Dyson
What concept design methods does he employ?
What was his first notable design - when?
- Analogies & prototyping
- Wheelbarrow with a ball - 1974
-
Dyson Company
2015 revenue/profit?
Employees?
- £1.74 billion revenue
- $448 million profit
- 7000 employees
-
Elon Musk
What are his four notable companies/projects? What do they do?
- SpaceX - Sends cars into space I guess
- SolarCity - installs solar panels residential and commercial
- Tesla - affordable electric cars
- Hyperloop - large scale public transport between major cities
-
TRIZ is russian and stands for "Theory of Inventive Problem Solving". What is the core concept?
Ideality - the ideal state of the system where all functions are achieved without causing problems
-
Name two matrices used for decision making.
- Pugh matrix
- Weighted matrix
|
|