Eliminate Costly “Test And Fix” Design By Developing A Design “Science Base”

Many product developments rely on experimental or “test and fix” procedures involving costly and time-consuming hardware iterations. This type of development process is usually necessary when the product technology is not well understood. Often, it is possible to develop a “science base” for such product technologies. A design science base provides a concise mathematical understanding of the product technology together with an easy to use design methodology. Once an appropriate science base is available, computer simulations and other computational techniques can be used to more quickly explore the feasible design region and to better optimize the design with respect to performance, cost, and ease of manufacture. An effective design science base takes the mystery out of design and makes it possible for the engineer to understand exactly why a given design behaves the way it does and what changes are needed to make it better. This consultant has developed an appropriate science base for several mechanical product technologies. Typically, a science base will consist of different elements depending on the needs and preferences of the client. In almost all cases, a basic analysis is performed in which the physics of the product technology is modeled mathematically. Often this includes the development of a computer program using readily available, easy to use high-level software such as Excel, TK Solver, MathCad, etc. In addition, this associate is frequently asked to develop a “design methodology” for using the science base to systematize the design process. This expert associate also trains employees in the use of the science base and participates in follow-on projects that involve application of the science base and design methodology to solving specific design problems.

In one circuit breaker design application, this associate developed a design science base that accounted for the effect of mechanism configuration, linkage dimensions, tolerance specifications, and bimetal material property variation. Using a computer simulation based on this analysis together with robust design (i.e., Taguchi method) techniques, this associate was able to identify a circuit breaker design that did not require adjustment or calibration during manufacture. This greatly simplified the manufacturing process and eventually resulted in significant quality improvement and cost savings. In another example, this associate developed a design science base for a certain type of tape dispenser. In this product, a differential clutch mechanism is used that involves complex relationships between moving parts that depend on frictional behavior. As a result, costly test and fix design procedures that often offer little hope of success needed to be used to improve mechanism performance. With the development of a comprehensive science base, it is now possible to quickly develop highly optimized designs that far outperform the competition.

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