Function, Structure and Morph Charts

ME – 2110Creative Decisions and Design

Thomas R. Kurfess, Ph.D., P.E.HUSCO/Ramirez Distinguished Chair in Fluid Power and Motion Control

Woodruff School of Mechanical EngineeringGeorgia Institute of Technology

Atlanta, Georgia USA

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Packing of Carpet Squares

Material Flow Main Function System Boundary

Stamp Form

Length

Separate Offcuts

Check Quality

Count Squares

Combine in lots Pack DispatchMaterial

Overall Function

Loose carpet squares stamped out of the length

Carpet squares packed in lots

Function Structure

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Packing of Carpet Squares

Function Structure with Auxiliary Functions

Material Flow Main Function System Boundary

Signal Flow Auxiliary Function

Stamp Form

Length

Separate Offcuts

Check Quality

Count Squares

Combine in lots Pack DispatchMaterial

Send Signal to combine squares into

one lot

Supply packing material

Remove rejects

Remove offcuts

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Formulations for Feed DistributionFo

rmul

atio

n 2

Form

ulat

ion

3Fo

rmul

atio

n 6

Form

ulat

ion

8

State A

Feedmixing bin

State A

Feedmixing bin

State A

Feedmixing bin

State A

Feed atsource

State B

Stacked bags of feedin warehouse

State B

Bag of feed ondelivery truck

State B

Feed in customer’sstorage bin

State B

Feed in customer’sstorage bin

A = Initial State B = Final State

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Functions & Sub-Functions for a Testing Machine

Test Specimen

(Force Deformation)

E load

Specimen

E deformation

Specimen deformedI force

I deformationI

Change energy into

force & movement

Measure force

Measure deformation

Load specimen

I F

I

E load

I

Specimen E deformation

Specimen deformed

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Complete Function Structure for Testing Machine

Change energy into

force & movement

Measure force

Measure deformation

Load specimen

I F

I

E load

I

SpecimenE deformation

Specimen deformed

Hold specimen

Adjust energy

flow

Compare target with

actual values

Amplify measurements

E auxil.

I F target

I target

E loss

6

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Functional Variants for Dough Shaping

Shape DoughShaped Dough

ElossDoughAdditives

I

E

1 2 3 54 6

7

1 2 3+4 5 6

7

Feed in1

Prepare2

Dispense3

Shape4

Separate5

Feed Out6

Return7

Dough ShapedDough

Waste Waste WasteAdditives

1 2 3+4+5 6

7

1 2+3 4+5 6

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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Functions & Sub-Functions

Function

SF1 SF2 SF3

SF11 SF12 SF13 SF21 SF22 SF23 SF31 SF32 SF33

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Function Table

Sub-Function \ Solution1 2 ... j ... m

1 SF1 S11 S12 S1j S1m

2 SF2 S21 S22 S2j S2m

...i SFi Si1 Si2 Sij Sim

...n SFn Sn1 Sn2 Snj Snm

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Functions & Sub-Functions

Function

SF1 SF2 SF3

SF11 SF12 SF13 SF21 SF22 SF23 SF31 SF32 SF33

Sub-Function \ Solution1 2 ... j ... m

1 SF1 S11 S12 S1j S1m

2 SF2 S21 S22 S2j S2m

...i SFi Si1 Si2 Sij Sim

...n SFn Sn1 Sn2 Snj Snm

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Solution Principles

Sub-FunctionPhysical Effect

(Independentof Solution)

Physical Principle(Sub-function

& Physical Effect)

Solution Principle(Physical Principle &

form Design Features)

TransferTorque

TT

Amplifymuscular

force

FA FB

Closecontact

when TTa

LL

T

TransferTorque byFriction

FT=FF=FN

TT

AmplifyMuscular

Force by LeverFB=FA(a/b)

FA FB

Close Contactby Expanding

MercuryL=()(L)(T)

LL

T

FF=FN

Friction

bFB=aFA

Lever

L=()(L)(T)

Expansion

Fulfilling sub-functions by solution principles built up of physical principlesand form design features

FF

FN

VFBFA ba

Friction Surface

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Systems & Functions

Paper withErasable Mark

Paper withErasable Mark

Paper withoutErasable Mark

Paper withoutErasable Mark

Systems

Functions

Erases Erasable

MarkE Person

E Waste

Needs New Eraser

Waste Material

Makes & Erases Erasable Marks

EMI

E WasteMark on PaperNeeds Sharpening

Makes Erasable

MarkE Person

E Waste

Needs Sharpening

Mark on Paper

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Solution Principle Matrix

Sub-func.

Solution Principles(Idea/ Source)

1Idea: (Mechanical)Rub on Material

(Mechanical)Squirt Material

(Mechanical)Place Material(like Letterset)

(Chemical)Change paper composition

Source: Standard product Team #2 Letterset Acid etching

1(Chemical)

Change paper color(like Litmus paper)

(Electrical)Burn paper (spark)

(like old fashioned stripchart recorders)

(Electrical)Electrify Paper (glow

discharge)

(Electrical)Static charge to hold mark

on(like Etch-A-Sketch)

Fisher Scientific Team #3 Team #1 Etch-A-Sketch

1(Thermal)

Burn paper (flame)(Thermal)

Heat paper (glow discharge)(Thermal)

Melt on Mark(Magnetic)

Attach magnetic material(like refrigerator magnets)

Team #2 Team #2 Wax seals Gift Store

1(Biological)

Grow bacteria, fungus(Biological)

Modify (digest?) paper(Optical)

Change light properties ofpaper (reflectance, polarity)

(Optical)Change light (hologram)

Team #2 BioTech Magazine Team #2 Team #2

2(Mechanical)

Rub off Material(Mechanical)

Take off material(Mechanical)Cover mark

(like white out)

(Chemical)Change paper composition

Standard product Team #2 Team #1 Team #2

2(Chemical)

Change paper color(like dying fabric the same

color as a stain)

(Chemical)Change mark (e.g., bleach)

(Electrical)Burn off mark (spark)

ETC.

Team #1 Team #2 Team #2

Example: Design of a PencilSub-function 1: Make an Erasable MarkSub-function 2: Erase an Erasable Mark

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Different Principles to Store Energy

Different working principles to satisfy the function “store energy” by varying the type of energy.

1

2

3

4

5

6

Mechanical Hydraulic Electrical Thermal

FlowingLiquid

HeatedLiquid

SuperheatedSteam

Type of EnergyWorking Principle

Battery

Capacitor(Electric Field)

C

Pot. Energy

mh

Hydraulic reservoire.g, Piston

Moving Massm

v

MassM, s, T

Flywheel

J

+V-

J

v WheeloninclinePlane

Liquid Res. Pot. E.

h

F

Spring Other SpringsComp. GasF

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An Old Competition

20 ft

Sta

rt Li

ne

6.25 ft

12.5 ft

15

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Function Tree Diagram

Place Masson Target

Moveto

Target

Navigateto

Target

Brake onTarget

GeneratePower

TransmitPower

HitTarget

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The Morphological Chart

Going from concept to physical reality

Generate Power

Transmit Power

Brake on Target

Move to Target

Navigate to Target

Gravity Mouse Traps

Car Hit by Trap Rip Cord Effect Ramp Catapult

Friction String Break Anchor Rubber Stopper Weighted Skid

Equal Size Wheels Larger Front Wheels

Rolling Sliding Projectile Launch

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Example Harvest Potatoes

Potatoes

Reject Potatoes

Leaves

Course Particles

Lift Sift Separate Separate Sort Collect

Change

Change

Change

Fine Particles

Potatoes inthe ground

E2

E1

E2

E2

I

Harvest PotatoesPotatoes inthe ground

Potatoes

Reject PotatoesLeavesSoil, etc.

I

E

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The Potato Harvester

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Combining Solution Principles

Sub-Functions

\Solutions 1 2 j m

1 F1 S11 S12 S1j S1m

2 F2 S21 S22 S2j S2m

i Fi Si2 Sij Sim

n Fn Sn1 Sn2 Snj Snm

Combination of Principles1 2

Combination 1: S11 + S21 + … + Sn1Combination 1: S11 + S22 + … + Sn2

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The Morph Chart

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