Chapter 10: Concept Prototypes
Proof of process
Production methods and material that can result in desired products
Fault Tree Analysis
symbols used, identify undesirable event (top event) and how it occurs Repeat with occurrence data
Four presentation techniques
Mock up Model Prototype Virtual Prototype
Conceptual Design
Outlines scheme of product, viability of product
Design for X (DFX)
manufacturability, assembly, environment, safety, etc
Design for Manufacturing (DFM)
minimizing cost of production, lower time, and high quality Selection of materials and processes (piece-part and tooling-cost estimates)
Model
physical behavior of system, proof of product prototype
Proof of product
physical embodiment and production feasibility
High Fidelity Prototype
present final product with full functionality and interaction
Virtual prototyping
CAD, feature-based modeling (easy design changes)
Proof of Production
Complete manufacturing process is effective
Four prototype (functional)
1. Proof of concept: initial design 2. Proof of Product: physical embodiment and production feasibility 3. Proof of Process: production methods and materials 4. Proof of Production: complete/effective manufacturing process
FMEA (Failure Mode and Effects Analysis) Steps
1. boundaries and requirements 2. list items 3. identify component and failure modes 4. probability or failure rate for failure modes 5. List effects of failure mode 6. Remarks for failure mode 7. Review/initiate appropriate corrective measures
Focus/outcome of prototype questions
1. who? 2. what features? 3. Dimensions of prototypes 4. horizontal or vertical? 5. low or high fidelity? 6. Resources available?
Design for Environment (DFE)
Disassembly, end of useful life (pollution, energy, resource, quality, recycle)
Categories of prototypes
Domain, Low/High Fidelity, horizontal/vertical
Design for Assembly (DFA)
Ease of assembling final product (low part #, ease of assembly, reduce cost)
Parametric Modeling
FEA, presentation of dimensions as parameters, MANUFACTURING and ANALYSIS stages
FMEA
Failure Mode and Effects Analysis: identify potential failures before they result
Prototype domains
Features Functionality Interaction Design SIMILARITY BETWEEN PROTOTYPE AND PRODUCT
proof of concept
Initial design for future approach
Dimensions of Prototypes
Role Look and Feel Implementation
Types of Models
True: exact geometric responsibility Adequate: test specific characteristics Distorted: violates design condition due to time, $, etc, without result issues
Concurrent Engineering
bringing engineering design and manufacturing personnel together early in the design phase
Low Fidelity Prototypes
built from available or waste resources limited functionality/features/interaction
Prototype
comprehensive prototype (beta)
Mock-up
feel for design, proof of concept prototype
Horizontal Prototype
includes all features with limited functionality
Vertical Prototype
includes limited features with all functionality