Function, Structure and Morph Charts. ME 2110 Creative Decisions and Design

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Gerald Clyde Gaines
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HUSCO/Ramirez Distinguished Chair in Fluid Power and Motion

1 Function, Structure and Morph Charts ME 2110 Creative Decisions and Design Thomas R. Kurfess, Ph.D., P.E. HUSCO/Ramirez Distinguished Chair in Fluid Power and Motion Control Woodruff School of Mechanical Engineering Georgia Institute of Technology Atlanta, Georgia USA

2 Packing of Carpet Squares Function Structure Loose carpet squares stamped out of the length Overall Function Carpet squares packed in lots Material Stamp Form Length Separate Offcuts Check Quality Count Squares Combine in lots Pack Dispatch Material Flow Main Function System Boundary 2 / 21

3 Packing of Carpet Squares Function Structure with Auxiliary Functions Send Signal to combine squares into one lot Supply packing material Material Stamp Form Length Separate Offcuts Check Quality Count Squares Combine in lots Pack Dispatch Remove offcuts Remove rejects Material Flow Main Function System Boundary Signal Flow Auxiliary Function 3 / 21

4 Formulations for Feed Distribution A = Initial State B = Final State Formulation 2 Formulation 3 State A Feed mixing bin State A Feed mixing bin State B Stacked bags of feed in warehouse State B Bag of feed on delivery truck Formulation 6 State A Feed mixing bin State B Feed in customer s storage bin Formulation 8 State A Feed at source State B Feed in customer s storage bin 4 / 21

5 Functions & Sub-Functions for a Testing Machine E load Specimen I Test Specimen (Force Deformation) E deformation Specimen deformed I force I deformation E load I Change energy into force & movement Measure force Measure deformation I F I Specimen Load specimen E deformation Specimen deformed 5 / 21

6 Complete Function Structure for Testing Machine E auxil. I F target I target Compare target with actual values Amplify measurements Measure force Measure deformation I F I E load I Change energy into force & movement Adjust energy flow E loss Specimen Hold specimen Load specimen E deformation Specimen deformed 6 / 21

7 Functional Variants for Dough Shaping E Dough Additives I Shape Dough E loss Shaped Dough Dough Feed in 1 Prepare 2 Dispense 3 Shape 4 Separate 5 Feed Out 6 Shaped Dough Return 7 Additives Waste Waste Waste Overall function and function structure variants of a dough-shaping machine for the manufacture of biscuits (in respect of the main flow only) 7 7 / 21

8 Functions & Sub-Functions Function SF 1 SF 2 SF 3 SF 11 SF 12 SF 13 SF 21 SF 22 SF 23 SF 31 SF 32 SF 33 8 / 21

9 Function Table Sub-Function \ Solution j... m 1 SF 1 S 11 S 12 S 1j S 1m 2 SF 2 S 21 S 22 S 2j S 2m... i SF i S i1 S i2 S ij S im... n SF n S n1 S n2 S nj S nm 9 / 21

10 Functions & Sub-Functions Function SF 1 SF 2 SF 3 SF 11 SF 12 SF 13 SF 21 SF 22 SF 23 SF 31 SF 32 SF 33 Sub-Function \ Solution j... m 1 SF 1 S 11 S 12 S 1j S 1m 2 SF 2 S 21 S 22 S 2j S 2m... i SF i S i1 S i2 S ij S im... n SF n S n1 S n2 S nj S nm 10 / 21

11 Solution Principles Sub-Function Physical Effect (Independent of Solution) Physical Principle (Sub-function & Physical Effect) Solution Principle (Physical Principle & form Design Features) T F A Transfer Torque Amplify muscular force T F B Friction F F = F N Lever bf B= af A F A F N a V b F F F B T F A Transfer Torque by Friction F T =F F = F N T Amplify Muscular Force by Lever F B =F A (a/b) F B Friction Surface L T Close contact when T T a L Expansion L=( )(L)( T) L T Close Contact by Expanding Mercury L=( )(L)( T) L Fulfilling sub-functions by solution principles built up of physical principles and form design features 11 / 21

12 Systems & Functions Systems Paper with Erasable Mark Paper without Erasable Mark Paper without Erasable Mark Paper with Erasable Mark Functions E M I Makes & Erases Erasable Marks E Waste Mark on Paper Needs Sharpening E Person Makes Erasable Mark E Waste Mark on Paper Needs Sharpening E Person Erases Erasable Mark E Waste Waste Material Needs New Eraser 12 / 21

13 Solution Principle Matrix Example: Design of a Pencil Sub-function 1: Make an Erasable Mark Sub-function 2: Erase an Erasable Mark Subfunc Idea: (Mechanical) Rub on Material Solution Principles (Idea/ Source) (Mechanical) Squirt Material (Mechanical) Place Material (like Letterset) (Chemical) Change paper composition Source: Standard product Team #2 Letterset Acid etching (Chemical) Change paper color (like Litmus paper) (Electrical) Burn paper (spark) (like old fashioned strip chart 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 (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 (Biological) Grow bacteria, fungus (Biological) Modify (digest?) paper (Optical) Change light properties of paper (reflectance, polarity) (Optical) Change light (hologram) Team #2 BioTech Magazine Team #2 Team #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 (Chemical) Change paper color (like dying fabric the same color as a stain) (Chemical) Change mark (e.g., bleach) (Electrical) Burn off mark (spark) Team #1 Team #2 Team #2 ETC. 13 / 21

14 Different Principles to Store Energy Type of Energy Working Principle 1 2 Mechanical Hydraulic Electrical Thermal m m h v Pot. Energy Moving Mass h Liquid Res. Pot. E. Flowing Liquid Battery +V- Capacitor (Electric Field) C Mass M, s, T Heated Liquid 3 Flywheel J Superheated Steam 4 5 J F v Spring Wheel on incline Plane Other Springs Comp. Gas F 6 Hydraulic reservoir e.g, Piston Different working principles to satisfy the function store energy by varying the type of energy. 14 / 21

15 An Old Competition 20 ft 12.5 ft Start Line 6.25 ft 15 / 21

16 Function Tree Diagram Place Mass on Target Generate Power Transmit Power Hit Target Brake on Target Move to Target Navigate to Target 16 / 21

17 The Morphological Chart Going from concept to physical reality Generate Power Gravity Mouse Traps Transmit Power Brake on Target Move to Target Car Hit by Trap Rip Cord Effect Ramp Catapult Friction String Break Anchor Rubber Stopper Weighted Skid Rolling Sliding Projectile Launch Navigate to Target Equal Size Wheels Larger Front Wheels 17 / 21

18 Example Harvest Potatoes Potatoes in the ground E I Harvest Potatoes Potatoes Reject Potatoes Leaves Soil, etc. E 2 Change E 2 Change E 2 Change E 1 Potatoes in the ground I Lift Sift Separate Separate Sort Collect Potatoes Reject Potatoes Course Particles Leaves Fine Particles 18 / 21

19 The Potato Harvester 19 / 21

20 Combining Solution Principles Sub- Functions \Solutions 1 2 j m 1 F 1 S 11 S 12 S 1j S 1m 2 F 2 S 21 S 22 S 2j S 2m i F i S i2 S ij S im n F n S n1 S n2 S nj S nm 1 2 Combination of Principles Combination 1: S 11 + S S n1 Combination 1: S 11 + S S n2 20 / 21

21 The Morph Chart 21 / 21

ME2110. Module 7 : Conceptual Design

ME2110. Module 7 : Conceptual Design ME2110 Module 7 : Conceptual Design Key Concepts Structured Concept Generation processes Functional Decomposition Solution Principle Matrices Morphological Charts Objective Concept Evaluation GIT 2 Outline