Design Functions and Solutions
Christopher Saldana, Ph.D.
Woodruff School of Mechanical Engineering
G e o r g i a I n s t i t u t e o f Te c h n o l o g y
Atlanta, Georgia, USA
Phases of Design
Customer Detail Design
• Understand the Design Process Specification of Production
Specification Development • Process Planning
• Specification of Information Manufacture
Conceptual Design
• Specification of a Principle
• Functional Decomposition
• Generate Concepts
• Concept Evaluation
• Concept Selection
• Preliminary Design/Embodiment
2
Concept Generation/Selection
Creating, screening, scoring alternatives
3
4
5
Alternatives (Project Purple - iPhone)
Apple’s design approach
Pixel-perfect design mockups
10 to 3 to 1 design down-select
Paired design meetings – brainstorming/production
Pony meetings – design review for managers
Integrated business process design
Customer experience focus
Walters, Helen. "Apple's Design Process, Bloomberg Businessweek." (2008).
6
Alternatives (Project Purple - iPhone)
Initial Concepts Design Iterations
Alternative 1 - P1 design P2 design prototypes P2 refined designs
Concept Make,
screen, iterate
prototype and
and score ‘Sandwich’ ‘Extrudo’ finalize
Alternative 2 - P2 design
Samsung Electronics Co., Ltd., et al. v. Apple Inc. (2016), SCOTUS Case 15-777.
Kahney, L. (2013). Jony Ive: The Genius Behind Apple's Greatest Products. Penguin.
Kahney, L., ”Birth of the iPhone”, Cult of Mac, June 26, 2017 7
Learning Objectives
Identify design functions and sub-functions (Function Tree)
Identify solutions for different functions/sub-functions
(Morphological Chart)
Combining individual solutions to generate conceptual
alternatives
8
Guidelines for Functional Modeling
Consider what not how
• Draw a box
• Identify a verb
• Identify a noun(s) on which the verb acts
Follow flows of energy, material, and information/signals.
Consider interactions with external energy, material
Break the function down as finely as needed
• Fine enough to address customer needs
• Fine enough for a single basic solution principle to satisfy each sub-function.
9
Black Box Models
Define overall function
Identify system boundaries
Identify flows of Energy (E), Material (M), and Information (I)
Identify interfacing objects that exchange E, M, or I
Conserve E and M
10
Function Block Diagrams
Example: Packing of Carpet Squares
Function Structure
Loose carpet
squares stamped
Overall Carpet squares
packed in lots
out of the length Function
Stamp
Separate Check Count Combine
Material Form Pack Dispatch
Offcuts Quality Squares in lots
Length
Material Flow Main Function System Boundary
11
Function Block Diagrams
Example: Material Testing Machine
E load E deformation
Test Specimen Specimen deformed
Specimen (Force I force
Deformation)
I I deformation
Measure
IF
E load Change force
energy into
I force &
movement
Measure
I∆
deformation
Load
E deformation
Specimen specimen
Specimen deformed
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Function Block Diagrams
Example: Material Testing Machine
E auxil.
Measure
IF
I F target Compare target force
Amplify
with actual
I ∆ target measurements
values
Measure
I∆
deformation
E load Change
energy into Adjust
I force & energy flow
movement
E loss
Hold Load E deformation
Specimen specimen specimen Specimen deformed
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Determining Functional Variants
Example: Dough Dough
E Eloss
Shape Dough
Shaping Machine Additives
I
Shaped Dough
Dough Feed in Prepare Dispense Shape Separate Feed Out Shaped
1 2 3 4 5 6 Dough
Return Additives Waste Waste Waste
7
1 2 3 4 5 6 1 2 3+4+5 6
7 7
1 2 3+4 5 6 1 2+3 4+5 6
7 7
Overall function and function structure variants of a dough-shaping machine
for the manufacture of biscuits (in respect of the main flow only)
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Function Tree
Function
SF1 SF2 SF3
SF11 SF12 SF13 SF21 SF22 SF23 SF31 SF32 SF33
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Function Tree Example
16
Developing Solution Principles
Physical Effect Physical Principle Solution Principle
Sub-Function (Independent (Sub-function (Physical Principle &
of Solution) & Physical Effect) form Design Features)
Friction FN Transfer Friction Surface
T Transfer T Torque by
FF T
Torque Friction T
FF=µFN FT=FF=µFN
V
Lever FA a b FB FA Amplify FB
FA Amplify FB
Muscular
muscular Force by Lever
force bFB=aFA FB=FA(a/b)
Expansion L Close Contact
L
Close L by Expanding L
T contact T Mercury
when T≥Ta ∆L=(α)(L)(∆T)
∆L=(α)(L)(∆T)
Fulfilling sub-functions by solution principles built up of physical principles
and form design features
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Solution Principle Matrix
Example: Design of a Pencil
Sub-function 1: Make an Erasable Mark
Sub-function 2: Erase an Erasable Mark
Sub- Solution Principles
func. (Idea/ Source)
Idea: (Mechanical) (Mechanical) (Mechanical) (Chemical)
1 Rub on Material Squirt Material Place Material Change paper composition
(like Letterset)
Source: Standard product Team #2 Letterset Acid etching
(Chemical) (Electrical) (Electrical) (Electrical)
1 Change paper color Burn paper (spark) Electrify Paper (glow Static charge to hold mark
(like Litmus paper) (like old fashioned strip discharge) on
chart recorders) (like Etch-A-Sketch)
Fisher Scientific Team #3 Team #1 Etch-A-Sketch
(Thermal) (Thermal) (Thermal) (Magnetic)
1 Burn paper (flame) Heat paper (glow discharge) Melt on Mark Attach magnetic material
(like refrigerator magnets)
Team #2 Team #2 Wax seals Gift Store
(Biological) (Biological) (Optical) (Optical)
1 Grow bacteria, fungus Modify (digest?) paper Change light properties of Change light (hologram)
paper (reflectance, polarity)
Team #2 BioTech Magazine Team #2 Team #2
(Mechanical) (Mechanical) (Mechanical) (Chemical)
2 Rub off Material Take off material Cover mark Change paper composition
(like white out)
Standard product Team #2 Team #1 Team #2
(Chemical) (Chemical) (Electrical)
2 Change paper color Change mark (e.g., bleach) Burn off mark (spark)
(like dying fabric the same ETC.
color as a stain)
Team #1 Team #2 Team #2
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Different Principles to Store Energy
Type of Energy
Working Principle
Mechanical Hydraulic Electrical Thermal
m Pot. Liquid Battery Mass
1 h Energy h Res. M, s, T
Pot. E. +V-
v Moving Capacitor
Flowing (Electric Field) Heated
2 m Mass
C
Liquid Liquid
Flywheel
ω Superheated
3
J Steam
Wheel
ω v on
4 incline
J Plane
Spring Other Springs
5 Comp. Gas
F F
Hydraulic
6 reservoir
e.g, Piston
Different working principles to satisfy the function “store energy” by varying the type of energy.
19
An Old Competition
20 ft
12.5 ft
Start Line
6.25 ft
20
Function Tree Diagram
Place Mass
on Target
Generate Transmit Hit Brake on
Power Power Target Target
Move Navigate
to to
Target Target
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Morphological Chart
Going from concept to physical reality
Generate
Power
Gravity Mouse Traps
Transmit
Power
Car Hit by Trap Rip Cord Effect Ramp Catapult
Brake on
Target
Friction String Break Anchor Rubber Stopper Weighted Skid
Move to
Target
Rolling Sliding Projectile Launch
Navigate to
Target
Equal Size Wheels Larger Front Wheels
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Combining Solution Principles
Sub- \Solutions
1 2 j m
Functions
1 F1 S11 S12 S1j S1m
2 F2 S21 S22 S2j S2m
i Fi Si2 Sij Sim
n Fn Sn1 Sn2 Snj Snm
1 2 Combination of Principles
Combination 1: S11 + S21 + … + Sn1
Combination 1: S11 + S22 + … + Sn2
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Summary – Function Tree
Elements
• List critical functions and sub-functions
• Sub-branches from a function or sub-function must
number 2 or greater
• Do not specify specifications that are dependent on
design decisions, design choices come later!
Describing this figure in text
• Describe the contents, not the tool itself! See Ch. 3 in book
• What are critical functions? for detail
24
Summary – Morphological Chart
Elements
• Mechanisms for lowest level elements of
FT, match one-to-one
• Diagrams to depict mechanisms
• Labels to briefly name mechanisms
Describing this figure in text
• Highlight key mechanisms/functions
• Use a selection matrix to identify
mechanisms used in different designs See Ch. 5 in book for detail
• Use different mechanisms in designs
25
Learning Objectives
Identify design functions and sub-functions (Function Tree)
Identify solutions for different functions/sub-functions
(Morphological Chart)
Combining individual solutions to generate conceptual
alternatives
26
Other Morphological Chart Examples
27
Function Block Diagrams
Example: Packing of Carpet Squares
Function Structure with Auxiliary Functions
Send Signal to
combine Supply
squares into packing
one lot material
Stamp
Separate Check Count Combine
Material Form Pack Dispatch
Offcuts Quality Squares in lots
Length
Remove Remove
offcuts rejects
Material Flow Main Function System Boundary
Signal Flow Auxiliary Function
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Example: Harvest Potatoes
Potatoes
E
Potatoes in Reject Potatoes
Harvest Potatoes
the ground Leaves
I
Soil, etc.
E2 Change
E2 Change
E2 Change
E1
Potatoes in
the ground Lift Sift Separate Separate Sort Collect Potatoes
I Reject Potatoes
Course Particles
Leaves
Fine Particles
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Example: Harvest Potatoes
30
Example: Additive Manufacturing
Williams, C.B., Mistree, F. and Rosen, D.W. (2011), “A Functional Classification Framework for the Conceptual Design of Additive
Manufacturing Technologies”, Journal of Mechanical Design, Vol. 133 No. 12, p. 121002.
31
Example: Additive Manufacturing
Williams, C.B., Mistree, F. and Rosen, D.W. (2011), “A Functional Classification Framework for the Conceptual Design of Additive
Manufacturing Technologies”, Journal of Mechanical Design, Vol. 133 No. 12, p. 121002.
32
Example: Additive Manufacturing
Williams, C.B., Mistree, F. and Rosen, D.W. (2011), “A Functional Classification Framework for the Conceptual Design of Additive
Manufacturing Technologies”, Journal of Mechanical Design, Vol. 133 No. 12, p. 121002.
33
Example: Additive Manufacturing
Williams, C.B., Mistree, F. and Rosen, D.W. (2011), “A Functional Classification Framework for the Conceptual Design of Additive Manufacturing 34
Technologies”, Journal of Mechanical Design, Vol. 133 No. 12, p. 121002.
