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Product Design > Lectures 1-5 > Flashcards

Lectures 1-5 Flashcards

1
Q

What is the Technology readiness level of a product

A

defines the maturity of the product

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2
Q

What does TRL stand for

A

technology readiness level

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3
Q

What is the form of a product

A

The shape of the product

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4
Q

What is the function of a product

A

The function of the product

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5
Q

What is ergonomics

A

The design for human use and interface

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6
Q

What is aethetics

A

Design for beautiful appeal

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7
Q

What is product design a combination of?

A

Engineering design and industrial design

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8
Q

What does industrial design include

A

Aesthetics, ergonomic, safety and reliability

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9
Q

How many technology readiness levels are there

A

9 with TRL0 being the idea and TRL9 being a commercially applicable product

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10
Q

What describes the different stages a product goes through from an idea to a product with a fully commercial application

A

Technology readiness levels

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11
Q

When a new product uses new technology, what TRLs should it go through

A

all of them

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12
Q

When a product uses existing technology, which TRLs should it go through

A

From TRL4 (small scale prototype)

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13
Q

Does a product have to sequentially go through the TRL levels

A

No, level 2 may start before level 1

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14
Q

What TRL levels do universities deal with

A

TRL 0-4

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15
Q

What TRL levels do industry tend to deal with

A

TRL 2-9

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16
Q

Why is it important for products to go through systematic methods and procedures?

A

So that decisions can be made efficiently and effectively

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17
Q

How many parts may a car contain

A

10,000 parts

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18
Q

Why is a product so complex

A

because a product has thousands of parts and each part involves a lot of precise design information. Also each part may also represent a complex technology itself

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19
Q

Give an example of a known unknown

A

true safety margins (some safety margins may be less than thought)

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20
Q

Give an example of an unknown unknown

A

load cases that cannot be predicted

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21
Q

Explain the complexity of organisations that may occur when producing a car

A

Designing a car involves multiple companies with diverse multi-disciplinary design teams consisting of thousands of people. A car may contain parts from 100s of different suppliers in a hierarchical structure

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22
Q

Why must each part have a paper trail

A

so that it can be shown where a part has come from and that the original supplier has quality control methods and has carried out necessary test verification. This is to help give proof if a company is prosecuted for false claims

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23
Q

Describe the complexity of documentation

A

The fact that commercial products need verification and documentation

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24
Q

What are the 8 major objectives of a car

A 
Technical performance
Cost
Environment
Ergonomics
Aesthetics
Reliability and Safety
Manufacturing
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25
Q

What work is done and method used by mechanical engineers for Technical performance

A

Vibration analysis
Strength design
Through material selection

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26
Q

What work is done and method used by mechanical engineers for Cost

A

materials selection and life cycle costing through life cycle costing

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27
Q

What work is done and method used by mechanical engineers for Environment

A

life cycle analysis and material selection through life cycle analysis

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28
Q

What work is done and method used by mechanical engineers for Ergonomics

A

Ergonomic design and modelling. Beneficial to liaise with an industrial engineer

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29
Q

What work is done and method used by mechanical engineers for Aesthetics

A

industrial design through colour selection and following aesthetic guidelines. Beneficial to liaise with an industrial designer

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30
Q

What work is done and method used by mechanical engineers for Reliability and safety

A

reliability modelling. beneficial to liaise with a reliability engineer

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31
Q

What work is done and method used by mechanical engineers for Manufacturing

A

Complete manufacturing design with tolerance analysis. Beneficial to liaise with a manufacturing engineer

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32
Q

What objectives come under Technical performance for a car

A
  1. Drive: speed, acceleration, range, stability, turning circle
  2. Size: cabin space, number of seats, boot space
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33
Q

What objectives come under Cost for a car

A
  1. Purchase cost
  2. Maintenance (MOT, servicing)
  3. Running cost (Tax, insurance, fuel consumption)
  4. Depreciation (resale value)
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34
Q

What objectives come under ergonomics for a car

A
  1. Space
  2. Forces
  3. Comfort
  4. Man machine interface
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35
Q

What objectives come under safety for a car

A
  1. Crumple zones
  2. Warning lights
  3. Braking systems
  4. Driver’s view
  5. Fail safe (bolts facing up not down)
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36
Q

What objectives come under reliability for a car

A
  1. Redundancy (Manual and central locking, extra bolts on engine head)
  2. fail safe
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37
Q

What objectives come under luxury for a car

A
  1. Comfort extras (air con, seat adjustment and quality)
  2. Convenience
  3. entertainment
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38
Q

What objective come under Environment for a car

A
  1. Emissions
  2. Waste
  3. Full consumption
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39
Q

What objectives come under aesthetics

A
  1. External (character line, borders, curves)
  2. Internal (textures, colours, blending)
  3. General (biomimetics)
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40
Q

Give the case study of Toyota accelerator pedal problem and what it is an example of

A
  • Illustrates how a company can experience problems due to unknown unknowns (a scenario they didnt know they didnt know about)
  • Cars had to be recalled due to the accelerator pedal being able to get caught on the floor mats which could have been very dangerous
  • cost of the recall was $2 billion
  • They solved the problem by reducing the size of the pedal and introducing a new design of floor mat
  • A brake override system was implemented that would cut of the engine if the break and accelerator are both detected as being pressed
  • They made a million correct decisions throughout the design of the car, but a single incorrect decision can have massive implications
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41
Q

What are the 7 challenges of product design?

A
  • Fast changing environmental conditions
  • Conflicts between form and function
  • retaining information
  • High reliability
  • Products have multiple objectives
  • Products are complicated
  • Many stages are required to develop products
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42
Q

What are the three main areas of complexity for products

A
  • Complexity of the product
  • Complexity of organisations
  • Complexity of documentations
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43
Q

What does it mean to have a vast ‘design heritage’

A

When a product has gone through multiple life cycles and knowledge has been retained throughout the process

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44
Q

What is meant by a dominant design

A

Through adaptive design, a design is gradually modified and improved to become a design that is commonly seen among products within the same market as it has been recognised through the adaptive process as being the most successful design

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45
Q

Give an example of a car that has gone through many generations of design cycles

A

Honda accord

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46
Q

What is meant by the conflicts between form and function

A

When a particular form might effect the product in being able to complete its desired function.

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47
Q

Give an example of where there has been a conflict between form and function

A

The millennium bridge

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48
Q

What are the key changes around environmental conditions which may effect future products.

A
  1. Push to remove diesel cars and replace with electric (air quality, taxing etc)
  2. Publicity about amounts of plastic waste
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49
Q

What is the current challenge for the car industry due to fast changing environmental conditions

A

The EU has given a target for the amount of CO2 emissions, therefore the industry invested in diesel technology (as it is more efficient at using fuel compared to petrol) in order to meet these targets However the government have started taxing diesels and the media have been badly publicising them therefore sales of diesels have reduced making it highly unlikely for the industry to meet the targets

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50
Q

Give 4 examples of key area for future development in engineering and product design

A
  1. Electric cars
  2. Robotics
  3. Renewable energy
  4. Domestic products
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51
Q

What is the biggest industry in the UK

A

Automotive

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52
Q

Why is a design process needed

A

A design process is needed to systematically co-ordinate the efforts of large multi-disciplinary design teams

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53
Q

Give an example of a multi-objective design

A 
Aircraft seat with
• Technical requirements
• ergonomic requirements
• aesthetic requirements
• Entertainment systems
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54
Q

According to Pahl and Beitz, what are the 3 modes of design

A
  1. Incremental design
  2. Adaptive design
  3. Original design
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55
Q

Explain incremental design, why and when it is used

A

Minor changes/improvements to an existing product

very common because it presents low-risk design. Common in industries with mature products such as high volume products (cars, domestic appliances)

Incremental design is enable by new elements of technology such as new materials and new manufacturing processes

It also occurs when a fault has been detected

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56
Q

Give an example of incremental design

A

Improve the windscreen material in a car

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57
Q

Explain Adaptive design

A

When significant changes/improvements are made to whole sub systems

It is common when significant new technologies come along such as airbags/crumple zones

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58
Q

Give an example of adaptive design

A

The implementation of airbags/crumple zones

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59
Q

Explain Original design

A

This is when major changes or improvement are made to whole sub systems.

The original design is not common because it is high risk. It tends to happen when there is an acute need as with pollution and energy concerns with motor cars

It is risky due to the need for the entire design to be error free. Changing all design details make it more likely for something to go wrong in comparison to incremental design

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60
Q

Give an example of original design

A

The change from IC engine to hybrid drive train in a car

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61
Q

What are the high level stages in a product life cycle

A
  1. Motivation
  2. Creation
  3. Operation
  4. Disposal
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62
Q

What are the low level stages of the product life cycle

A
  1. Trigger
  2. Product planning
  3. Feasibility study
  4. Design
  5. Development
  6. Production
  7. Distribution
  8. Operation
  9. Disposal
63
Q

What are the 4 main design process models

A
  1. The Pahl and Beitz model
  2. The double diamond process model
  3. The V model
  4. The stage gate model
64
Q

Describe the Pahl and Beitz model

A

The design process if broken doen into distinct stages.

The Pahl and Beitz model is one of the msot used. By having stages the process is more manageable.

The process is divided into 4 main phases: Task clarification, Conceptual design, embodiment design and detail design

It is a top down process starting with abstract ideas and finishing with complete details

Stages of design can sometimes be overlapped to reduce time (concurrent engineering). Concurrent design is more suitable and feasible for incremental design

65
Q

What are the 4 main stages of the double diamond process model

A
  1. Discover
  2. Define
  3. Develop
  4. Deliver
66
Q

Describe the double diamond design process and the 4 main stages within it

A

The double diamond process model encourages designer to see task clarification as a major task involving significant research

  1. Discover: a divergent stage in which users and markets are researched in order to understand the task.
  2. Define: a convergent stage in which market and user information is aligned with business objectives to define project goals
  3. Develop: a divergent stage in which a wide range of design solutions are developed and iterated
  4. Deliver: a convergent approach is used to complete the product definition
67
Q

What are the benefits of the double diamond process model

A

1 Breaks the tasks into stages with outputs

2. it encourages the designers to clarify the specification

68
Q

Describe the V-model of the design process

A

The V model shows that the product life cycle goes from top-down during the design phase to bottom up during the verification and delivery phase

69
Q

What is the advantage of top-down design as presented by the V model design process

A

• You have to plan the system before you can decide on the details
(its best to start with the systems design before carrying out the detailed design of individual parts)

70
Q

What is the advantage of the bottom up testing as presented by the V model design process

A

Helpful because these is no use testing the system if individual components are not right/do not work

71
Q

What part of the design process if top down and what is bottom up in the V model

A

Project definition and design: top down

Project testing and integration: bottom up

72
Q

Describe the stage gate model and which company uses it

A

Airbus uses this process and it splits the design process into 2 key phases: Definition phase and development phase, which are then followed by the production and in-service phases.

There are meeting points/design reviews between each phase so that it is checked by people high up. This ensures that teams are granted the go ahead and their design work has been checked through and authorised

73
Q

What are the advantages of the stage gate model design process

A
  • It emphasises that certain achievements are required before progress in the design process can be made
  • Regular design reviews can be performed at set dates
  • The performance of the design can be defined and recorded at set milestones
  • Key senior managers can sign-off that they approve of the progress being made
74
Q

What are prototypes and why are they important

A

Prototypes are a physical model/representation of a product that is produced before it is manufactured and is used to evaluate the design.

It is important because computer models always have some limitations. If a designer is unaware of weaknesses in a design, it is unlikely that it will be modelled by the software that is produced. (because they dont understand the unknown unknowns)

75
Q

What are the series of prototype models that are designed and tested for a high cost system (such as a spacecraft)

A
  1. Breadboard model
  2. Engineering model
  3. Qualification model
  4. The delivered model
76
Q

What is a breadboard model (prototype)

A

checking the broad feasibility of a technology such as hybrid cars

77
Q

What is a engineering model (prototype)

A

Physically verifying the main performance aspects of a design solution

78
Q

What is a qualification model (prototype)

A

Checking the entire performance of a product compared to requirements. Often loads will go beyond performance to demonstrate safety margins

79
Q

What is the delivered model (prototype)

A

The model to check the actual product performance before delivery

80
Q

Why are design reviews useful?

A

Because they mean that designers are forced to declare the design status at milestone points and senior managers are forced to confirm if they approve of progress or whether corrective action is required

81
Q

What are the 4 different types of design review

A
  1. Preliminary
  2. Engineering
  3. Qualification
  4. Final
82
Q

What does a preliminary design review involve

A

Review of concept design and bradboard model results

83
Q

What does a engineering design review involve

A

Review of detailed design and engineering model results

84
Q

What does a qualification design review involve

A

Review of qualification model performance

85
Q

What does a final design review involve

A

Review of delivered model performance

86
Q

Describe the case study of the hubble space telescope in terms of presenting the importance of test verification

A

The hubble space telescope had a problem due to wobble of the solar array caused by inadequate thermal blankets during orbital sunrise and sunset

The was not modelled because the designers did not know it was an issue

If they have had physically tested the system more thoroughly it may have been spotted

87
Q

What is a constraint

A

An aspect that must be achieved. Such as safety performance or level of emissions

88
Q

What is the difference between hard requirements and soft requirements

A

hard requirements: non negotiable

soft requirements: are desirable but not essential

89
Q

Give examples of hard requirements for a car

A
  • must meet safety standards
  • must meet pollution standards
  • must be a hybrid
90
Q

Give examples of soft requirements for a car

A
  • Should have a range greater than 500 miles
  • should have a top-of-the-range music system
  • should have the best gear shift performance
91
Q

What is the man machine interface

A

It is the interface between a human operator and a machine. The man machine interface is a critical part of a system and must be designed with care

92
Q

Why is a solution-neutral problem statement important

A

Because by stating a particular solution or implying a solution through the problem statement can course discouragement of innovative solutions

93
Q

Which is better?
• Design a faster lift for this high-rise building.
• Modify the lift so that people feel satisfied with the speed of the lift.

A

• Modify the lift so that people feel satisfied with the speed of the lift.

94
Q

Which is better?
• Design a chassis for this car.
• Design a structural platform for this car

A

Design a structural platform for this car

95
Q

What does MHRA stand for and what are they?

A

Medicines and healthcare product regulatory agency - provide regulations for general medical devices and vitro diagnostic medical devices

96
Q

What are the 3 key regulatory authorities for aircraft deign

A

FAA: the federal aviation administration (USA)
CAA: Civil aviation authority
ICAO: The international civil aviation organisation (UN specialised agency)

97
Q

What is the Euro NCAP

A

The european car safety regulation authority

98
Q

What are the regularity documents that are used for structural design

A

The eurocodes 1-9

99
Q

What is the regulation document for electrical equipment

A

Must comply with the electrical equipment (safety) regualtions 1994

100
Q

What is the regulation used for racing bicycles and what does it specify

A

Union Cycliste Internationale (UCI)

1, minimum mass

  1. diamond frame concept
  2. max section sizes
  3. pedal floor clearance
101
Q

Describe a function mean tree and what its used for

A

Function mean trees help to convert abstract function (or objective) into specific sub-function and eventually into concrete features

They help to identify requirements and can be used for conceptual design

102
Q

How should worst case loading be calculated

A

Using worse case possible rather than worst case normally expected

103
Q

Describe the case study of the bristol rovers main stand to describe the importance of clarifying information

A

The customer stated that they wanted a covered stand with a function hall underneath.
The outcome was than 50% of spectators got wet because they were not protect from the rain due to the prevailing wind and the near touchline could not be seen

The designers were found guilt of incompetence and fined £1 million. The stand was modified to increase the terrace angle and extended the roof

104
Q

Describe the case study of the Challenger disaster in 1986 in terms of the importance to clarify information

A

The Challenger disaster was caused by failure int eh joint between the two lower segments of the right solid rocket motor - due to failure (destruction) of the seals that are intended to prevent hot gases from leaking through the joint during the propellant burn of the rocket motor. A combustion gas leaked through and weakened the external tank initiating vehicle structural breakup and loss of the space shuttle

This was due to the ambient temperature at launch being lower than previous launches and the O rings were not rated for this kind of temperature. Therefore the failure could have been avoided by stating that launch should not go ahead for temperatures less than a certain value

105
Q

How are do engineers contrast with industrial designers in terms off being able to be inventive

A

Engineers are trained to be cautious and to follow rules in design which can inhibit creativity and adventure.

Where as industrial designers are trained to be creative. with their training tending to be more project based.

106
Q

How can design methods encourage creativity

A

by giving a structured step by step process to generating ideas

107
Q

What are the 7 main drivers for innovation

A
  1. Legislation
  2. Customer wishes
  3. Technology breakthroughs
  4. Innovators/entrepreneurs
  5. Elite activities
  6. Affluence
  7. Competition
108
Q

Give an example where legislation has drived innovation

A

Limits in emissions

109
Q

Give an example where customer wishes are driving innovation

A

Reduce environmental impact

110
Q

Give an example technology breakthroughs are driving innovation

A

Artificial intelligence for driverless cars

111
Q

Give an example where innovators are driving innovation

A

Elon Musk: tesla cars, spaceX

James Dyson: appliances

112
Q

Give an example where elite activities are driving innovation

A

F1

olympics/sporting events

113
Q

What does affluence mean and how is it driving innovation

A

Affluence means that people will pay for higher performance products and allow nte markets to open up

114
Q

What are the 12 key conceptual design methods

A
  • Sketching
  • Technology opportunities
  • Inversion
  • Structured questioning
  • Brainstorming
  • Prototyping
  • backwards design
  • functional decomposition
  • technology transfer
  • bio inspiration
  • insight
  • study the competition
115
Q

Describe the conceptual design method of studying the competition

A

Analyse the best designs of competitors and draw inspiration from them

There are legal and ethical restriction in copying designs which have to be taken into account (iphone vs samsung case study)

116
Q

Describe the conceptual design method of insight

A

understanding the physics of a problem helps to produce effective ideas

117
Q

Give an example of where insight has been used for conceptual design

A

Large ships: Brunel pioneered large iron hulled ships. He notices that drag is proportional to the frontal area whilst fuel capacity is proportional to volume. Therefore meaning that range can be increased through scaling up the size of the ship

118
Q

Describe the conceptual design method of bio inspiration

A

being inspired by solution in the natural world.

119
Q

What are the advantages of bio inspiration

A
  • Concepts that are proven to work efficiently in harsh environments
  • Very large range of concepts
120
Q

What are the disadvantages of bio inspiration

A
  • Often extremely complex at micro level and difficult to copy in detail
  • Not necessarily designed for long life
  • Some strategies in nature are brutal
121
Q

What is the difference by bioinspiration and biomimetics

A

Bio inspiration is why the design is inspired by nature where as biomimetic is where the method is attempted to be mimiced exactly. Bioinspiration is better than biomimetics

122
Q

Give some examples of biomimetics

A
  • Velcro
  • self cleaning glass
  • painless medical needle
  • helmet design inspired by brain fluid
123
Q

Describe the conceptual design method of technology transfer

A

This is where you transfer the elements of one technology from a product to another very different product

124
Q

Give an example of where technology transfer has been used

A

Cyclone vacuum cleaner: James dyson transferred cyclone technology (from removal of sawdust at a local sawmill using large industrial cyclones) for a factory application to vacuum cleaner

125
Q

Describe the conceptual design method of functional decomposition

A

Identify the individual sub-functions of the product and then consider feasible/ideal combinations of sub solutions

126
Q

What is a morphological chart and what type of conceptual design method does it promote

A

When sub function and sub solutions are put in a table/ it support functional decompostion

127
Q

Describe the conceptual design method of Backwards design

A

identifying an idealistic solution and them working backwards to make it work

128
Q

What is the case stuy for backwards design

A

Double action worm gear set for spacecraft

This gearbox can act like a rack and pinion gear to absorb launch vibrations as well as a normal worm gearbox for deployment of the solar array

The device was invented by imagining a gearbox that could absorb enforced displacements and then working out how that could be achieved.

129
Q

What are the advantages of prototyping

A
  1. Gives feedback on form and function very quickly
  2. Good for 3D visualisations
  3. can be cheaper than computer modelling
  4. You can learn things that computer models dont tell you as you can only model what you understand
  5. There may be no off the shelf computer models for novel products
  6. Aids team work
  7. Aids selling to investors
130
Q

Describe the conceptual design method of brianstorming

A

Brainstorming is the uninhibited idea creation by a team of people bouncing ideas off each other.

Often a team is made up of people with different backgrounds such as design engineer, manufacturing engineers and materials scientists to stimulate a diverse range of ideas

To encourage creativity, criticism is not allowed

131
Q

Describe the conceptual design method of structured questioning

A

A set of questions are created that consider what can and cannot be done to solve a problem

132
Q

Give some examples of structured questioning for conceptual design

A
  1. Trains: Is it allowable to have much longer trains or multi-deck trains?
  2. Lorries: is it ok to join several lorries on a motorway?
  3. LED lights: how do they fail? is it possible to overcome this failure?
  4. Bikes: is it possible to fold bikes in a convenient way?
  5. Tube transport: is it possible to have super high speed transport inside a low pressure tube with such a tube buried under ground
133
Q

Describe the conceptual design process of inversion

A

Investigate whether an existing design can be done another way round as sometimes a new design can be generated by inverting some part of an existing design

134
Q

What is the advantages of inversion as a conceptual design process?

A

it starts with a working design

135
Q

Give some examples of where inversion has been used in product design

A
  1. helicopters - rotating wings instead of static
  2. see through covers instead of coloured covers (vacuums)
  3. caterpillar tracks instead of wheels
  4. power from overhead power line instead of coming from the train
136
Q

Describe using technology opportunities as a method for conceptual design

A

Use the latest technological breakthroughs to design new products.

Technological breakthroughs can create great scope for invention

137
Q

Give examples of where technology breakthroughs have been used to generate design

A
  1. Artificial intelligence: driver less cars
  2. Magnetic levitation - trains
  3. smart materials
  4. sensors - smart buildings
  5. more powerful batteries in cars and phones
  6. CFRP for bikes and aircraft
138
Q

What are the advantages of using sketching for conceptual design

A
  1. Easy to focus on the essential parts
  2. quick to produce
  3. Good for 3D visualisation
  4. can record notes
  5. good for team work
  6. impressionist (not exact)
  7. can record design options
139
Q

What is 3 point perception good for

A

tall buildings

140
Q

What is 2 point perspective good for

A

realistic views of cars

141
Q

What are the 4 key methods of sketching

A
  1. 3 point perspective
  2. 2 point perspective
  3. isometric
  4. oblique
142
Q

Which is the easiest form of sketching

A

Oblique

143
Q

Give the case study of James Dyson as an innovator

A

James Dyson is a graduate of 2 of the UK’s most prestigious design schools

He is a graduate of industrial design

Dyson has successfully used analogies and prototyping in concept design

He first designed a wheel barrow that used a fibre glass ball instead of a wheel so that it didnt sink in the mud

144
Q

Give the case study of Elon Musk as an innovator

A

Uses new technologies to leap frog current technologies (such as aiming to replace IC engine cars with electric cars)

He studied business and physics, graduated in economics and completed a second bachelors in physics

He founded paypal, spaceX and tesla motors

145
Q

What is SpaceX, founded by Elon Musk

A

To launch the first commercial vehicle to the international space station

146
Q

What is Solar City, bought by Elon Musk

A

SolarCity corporation is a subsidiary of Tesla that specialises in solar energy services and is headquartered in California. It markets, manufactures and installs residential and commercial solar panels

147
Q

What is Tesla Cars, founded by Elon Musk

A

company dedicated to producing affordable, mass market electric cars as well as battery products and solar roofs.

Musk oversees the product development, engineering and design of the company’s products

148
Q

What is the Hyperloop concept developed by Elon Musk

A

a concept for a new form of transportation called the Hyperloop, an invention that would foster commuting between major cities while severely cutting travel time.

Ideally resistant to weather and powered by renewable energy, the hyperloop would propel riders in pods through a network of low pressure tubes at speeds more than 700 mph.

149
Q

Describe TRIZ

A

created by Genrich Altshuller

Developed around the key concept of ideality - the ideal state of the system is where all its functions are achieved without causing any problems. Having knowledge of the ideal system helps improve the existing system

Features are improved gradually to achieve the best design

TRIZ combines several concept design methods into one

150
Q

What is the TRIZ method

A

There is a contradiction checklist of 39 features that can be improved

Contradictions are improved by using a list of 40 design principles

A contradiction matrix is created with improving and worsening features which contain numbers from the solution principle matrix

151
Q

What different concept design methods does TRIZ combine

A
  1. Backwards design - similar to ideality
  2. structured questioning - similar to checklists
  3. inversion - ‘the other way round’ principle for improvement
  4. prototyping - many principles for improvement encourage physical insight
152
Q

What is a (weighted) pugh matrix

A

assist with decision making

153
Q

Sketch how a bio inspired knee joint works

A

SKETCH

154
Q

Sketch how a self-healing composite works

A

SKETCH

Product Design (5 decks)

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