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[email protected] ENGR-11_Small_Volume_Design.pptx1
Bruce Mayer, PE Engineering-11: Engineering Design
Bruce Mayer, PELicensed Electrical & Mechanical Engineer
Engineering 11
Engineering Designfor Small-Volume
Electro-Mechanical Systems
[email protected] ENGR-11_Small_Volume_Design.pptx2
Bruce Mayer, PE Engineering-11: Engineering Design
To Build a Designed Object
Say you were Asked to BUILD or CONSTRUCT something using basic hand tools
You would need (at a minimum)• A list of Parts with P/N’s and Qtys• Parts FABRICATED specially for this Object• Parts PURCHASED from Catalogs for this
Object (a.k.a. “Standard Parts”)• Instructions on how ASSEMBLE the Object
[email protected] ENGR-11_Small_Volume_Design.pptx3
Bruce Mayer, PE Engineering-11: Engineering Design
Small-Volume Object DesignRaw-Material in
Basic-Shapes (chosen by the
Engineer)
Parts Fabricated
per Specialized
designs (your
BluePrints)
Parts Purchased from Technical
Catalogs (Selected by the Engineer)
Assembly Documentation
(Parts-List, BluePrints,
Instructions, etc.) Written by the
Engineer
[email protected] ENGR-11_Small_Volume_Design.pptx4
Bruce Mayer, PE Engineering-11: Engineering Design
When Designing Something…
Think About CRITICAL Issues• Will It WORK• Will it Meet the SCHEDULE &
BUDGET• Can it be BUILT from MY
Design Documentation?– Ask Yourself: “If I were Building this
object What Info would I need?”
[email protected] ENGR-11_Small_Volume_Design.pptx5
Bruce Mayer, PE Engineering-11: Engineering Design
Discussion Scope
We Examine what it takes to BUILD small quantities (dozens to hundreds per year)of Engineering-Designed ElectroMechanical Systems for Sale
This Discussion Does NOT Address the FUNCTIONAL PERFORMANCE of the design; only what it takes to actually BUILD IT, regardless of how Well it works
[email protected] ENGR-11_Small_Volume_Design.pptx6
Bruce Mayer, PE Engineering-11: Engineering Design
BUILDING SomeThing is HARD
Designing on Paper is MUCH EASIER than Designing Something that must be BUILT and Ultimately Sold
The Build-Process exposes• Incomplete Design Documents
– Wrong Parts Purchased Incorrect Order Number
– Part-Purchase Delayed Incorrect Supplier Phone Number
– $-Costs much higher than estimated
[email protected] ENGR-11_Small_Volume_Design.pptx7
Bruce Mayer, PE Engineering-11: Engineering Design
BUILDING SomeThing is HARD
The Build-Process exposes• Incomplete Design Documents
– Not Sufficient Information to ConstructBluePrints Missing/Incorrect Dimensions
or Notes; e.g., Inconsistent Material CallOut Missing/Confusing Lines Missing Surface Finish
Schematics or Assembly Drawing Missing/Incorrect ID-Information; e.g., Missing Balloon CallOut for O-Ring, Bolt,
Valve, etc. Missing Value for Resistor or Capacitor
[email protected] ENGR-11_Small_Volume_Design.pptx8
Bruce Mayer, PE Engineering-11: Engineering Design
BUILDING SomeThing is HARD
The Build-Process exposes• Design Errors
– Mechanical Elements do NOT FIT– Electrical Elements SHORT or do not PowerUp– Can Not be Fabricated or Assembled as
Designed– Mechanical Structures are NonRigid
“Floppy” or “Doingy” or “Cheesy” of “Wobbly”
– Electrical or Fluid Systems are UnderPowered or Noisy or Unstable “Whimpy” or “Flakey” or “Glitchy”
[email protected] ENGR-11_Small_Volume_Design.pptx9
Bruce Mayer, PE Engineering-11: Engineering Design
To BUILD an Engineered Design
CORRECT & COMPLETE information on PURCHASED-Parts Given to the “Purchasing Department”• NAMES & PHONE-NUMBERS
of ALL Suppliers• Correct Part-Numbers for ALL
Purchased Parts• Correct Order-Quantities
and Estimated $-Costs
[email protected] ENGR-11_Small_Volume_Design.pptx10
Bruce Mayer, PE Engineering-11: Engineering Design
To BUILD an Engineered Design Dot “i’s” & Cross “t’s” on
All FABRICATION Drawings (the “BluePrints”)• A single Missing-Dimension or Superfluous
Line or Missing Feature-Callout Brings Production to a HALT
• OMISSIONS result in ReWork or Scrap; e.g.;– Forgetting a needed Removed-Feature (Hole or
Slot or Notch or Groove)– Superfluous Removed-Feature (‘extra” hole)
[email protected] ENGR-11_Small_Volume_Design.pptx11
Bruce Mayer, PE Engineering-11: Engineering Design
Designed Part (Piece Part)
[email protected] ENGR-11_Small_Volume_Design.pptx12
Bruce Mayer, PE Engineering-11: Engineering Design
To BUILD an Engineered Design
COMPLETE Bill of Materials (“BoM”, also called the “Parts List”)• EVERY Nut, Bolt, Washer, Wire-Connector,
Plumbing-Fitting, etc.,Listed on the BoM Table
• Complete CallOuts ALL parts shown with “Balloons” containing part ID-number
Clearly UNDERSTOOD Assy Dwgs• Don’t Confuse
the Assemblers
[email protected] ENGR-11_Small_Volume_Design.pptx13
Bruce Mayer, PE Engineering-11: Engineering Design
Typical Assembly Drawing
On-Dwg BoMBalloon CallOut
[email protected] ENGR-11_Small_Volume_Design.pptx14
Bruce Mayer, PE Engineering-11: Engineering Design
Tools at the Engineer’s Disposal
INGENUITY & CREATIVITY• MOST Important
Knowledge of SCIENCE and MATHEMATICS
Technical CATALOGS “BluePrint” Making Software Standard Fabrication Methods
• Machining, Welding, Injection-Molding, etc.
[email protected] ENGR-11_Small_Volume_Design.pptx15
Bruce Mayer, PE Engineering-11: Engineering Design
Summary: Design Docs Include
Purchased Part Information• What Mfr-PN, Who Supplies, How Much $
Fabricated Parts Drawings (BluePrints)• 100% Accurate; generate NO Questions
from Fabricators
BoM or Parts List• 100% Accurate as it is used to “Pull Parts
from Stock” to Make an “Assembly Kit”
NonConfusing Assembly Drawings
[email protected] ENGR-11_Small_Volume_Design.pptx16
Bruce Mayer, PE Engineering-11: Engineering Design
Small Volume Design FlowChartSupplier
Contact InfoPurchased Part
Catalog No.
PurchasedParts
Physical Design to Scale (LayOut)
MaterialSelection
Fabrication Notes
Formal “BluePrints”(Use Std TitleBlock)
To FabricatorMachine Shop, etc.
Fabricatorcontact Info
FabricatedPiece-Parts
Assy Parts List(Bill of Materials)
Order & ReceivePurchased Parts
Assembly Drawing & Documentation
Physical Assembly and/or Construction
[email protected] ENGR-11_Small_Volume_Design.pptx17
Bruce Mayer, PE Engineering-11: Engineering Design
All Done for Today
EngineeringDesign
Pyramid
[email protected] ENGR-11_Small_Volume_Design.pptx18
Bruce Mayer, PE Engineering-11: Engineering Design
Bruce Mayer, PERegistered Electrical & Mechanical Engineer
Engineering 11
Appendix
[email protected] ENGR-11_Small_Volume_Design.pptx19
Bruce Mayer, PE Engineering-11: Engineering Design