Configuration Design
Abstract embodiment
Physical principles
Material
Geometry
Configuration
Design
Architecture
Special Purpose Parts:
Features
Arrangements
Relative dimensions
Attribute list (variables)
Standard Parts:
Type
Attribute list (variables)
Product or Part
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Product configuration = “architecture”
Part configuration
Start with the big
picture....
i.e. Product architecture
Iterate
Best
concept(s)
Configuration design
Configure
Product
Product architecture
Integral / modular
Standard / special purpose
Configure
Part(s)
Re-examine EDS
Research sources
Configuration requirements sketch
Analyze
and
Refine
Design for Function
Design for Assembly
Design for Manufacture
Evaluate
Pugh’s Method
Weighted Rating Method
Best
configuration(s)
Product First… Use component decomposition diagrams
penlight
bulb
glass lens
filament
base
battery
anode
cathode
electrolyte
plastic cover
body
screw cap
switch
case
spring
elements are arranged into “physical building blocks”
Generalized component decomposition
Product
Standard Special purpose
Part
Part
Subassembly A
Subassembly B
Special purpose part
Special purpose part
Standard part
a. type, number, arrangement of components
b. standard or special purpose (make or buy)
Subassembly B1
Standard part
Special purpose part
Product architecture …like house architecture
Architecture style
colonial
ranch
Scheme
dining, living rooms 1st floor
bedrooms on 2nd floor
all rooms on ground floor
Rooms are arranged according to a logical “scheme.”
Before the details of all the house are designed we determine
the general layout or “architecture.”
Product Architecture (Ullrich & Eppinger)
def – the scheme by which the

functional elements of a product are arranged

into physical building blocks (components,
subsystems or subassemblies)

that interact with each other

to perform the overall function of the product.
Product architectures can be “modular” or “integral”
Modular architecture
Product examples
Flashlight
Refrigerator
Automobile
Personal computer
Modular components
Batteries, bulbs
Motors, compressor, switches
Tires, radios, seats, pumps engines
Drives, keyboards, mice, modems
• chunks implement one or a few functions,
• interactions between chunks are well defined
(standard interfaces / connections)
Integral Architecture
Product examples
BMW Motorcycle engine
Printer case
Shaft
Beverage cup
Integrating aspects
engine/frame
integral snap-fasteners
machined bearing race
integrated handle
• a single chunk implements many functions
• interaction is ill defined
• physical element “shares” functions
Printer Example
Cluster elements into logical chunks
Sketch rough geometric layout
Sketch interaction diagram
Iterate
Best
concept(s)
Part configuration design
Configure
Product
Product architecture
Integral / modular
Standard / special purpose
Configure
Part(s)
Re-examine EDS
Research sources
Configuration requirements sketch
Analyze
and
Refine
Design for Function
Design for Assembly
Design for Manufacture
Evaluate
Pugh’s Method
Weighted Rating Method
Best
configuration(s)
What is a part configuration?
For example:
Design problem: support vertical load ---- Concept: wall bracket
Physical principle
Force Equilibriu m
geometry & material
F  0
What are some possible “configurations” for a wall bracket?
Part configuration design
geometric features include:
walls
rounds
cubes
notches
ribs
bosses
spheres
chamfers
projections cylinders
holes
grooves
fillets
slots
tubes
How can we “generate” alternative part
configurations?
Recall bracket
configurations
Abstract
embodiment
different
features
alternative
arrangements
different
relative dimensions
Configuration decisions
How do we create different configurations?
Change one or more of these…
Obtaining the “best” configuration
To choose the “best” alternative….
Implies that we have a number of feasible alternatives!
To be selective, we need a selection!
Iterate
Best
concept(s)
Configuration design - analysis
Configure
Product
Product architecture
Integral / modular
Standard / special purpose
Configure
Part(s)
Re-examine EDS
Research sources
Configuration requirements sketch
Analyze
and
Refine
Design for Function
Design for Assembly
Design for Manufacture
Evaluate
Pugh’s Method
Weighted Rating Method
Best
configuration(s)
Continue on Tuesday
To analyze configurations, we ask…
Will it likely function?
Will it likely assemble?
Will it be likely manufacturable?
Design for function
Will the part or product perform its function(s)?
1. Strong
2. Stiff or flexible
3. Buckle
4. Thermal expansion
5. Vibrate
6. Quiet / Noise
7. Heat transfer
8. Fluids transport / storage
9. Energy efficient
10. Stable
11. Reliable
12. Human factors/ergonomics
13. Safe
14. Easy to use
15. Maintain
16. Repairable
17. Durable (wear, corrosion)
18. Life-cycle costs
19. Styling/aesthetics
Use knowledge from math, eng’g and sciences…
Will it assemble?
What do we mean by assemble?
Assembly - a process of handling
components
to bring them together (inserting) and then
fastening them.
DFA
Design for Assembly - a set of design practices which
reduce the manpower time required to handle, insert and
fasten components of a product.
1. Design Guidelines (written and graphical)
2. Cost estimating methods
DFA Graphical 1
Design for Assembly Guidelines from SME
• minimize part count
• minimize levels of assembly (number of assemblies)
• encourage modular assembly
• use standard parts
• stack sub-assemblies from the bottom up
• design parts with self-fastening features (snap-fits,
press-fits)
• facilitate parts handling (grasp, orient, move)
• design parts with self-locating features (e.g. chamfers,
aligning recesses/dimples)
• eliminate reorientation (i.e. insertion from 2 or more
directions)
• eliminate (electric) cables
DFM
Deign for Manufacture (manufacturability) - A set of
practices that aim to improve the fabrication of
individual parts
1. Design Guidelines (written and graphical)
2. Cost estimating methods
DFM – Injection molding / casting
• avoid designing parts with thick walls or heavy sections
• design parts without undercuts
• choose polymer for minimum total part cost
(i.e. tooling, processing, material)
• design external threads to lie on parting plane/surface
• add ribs for stiffening
DFM – Sheet metalworking

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
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avoid designing parts with narrow cutouts or
projections
minimize manufactured scrap (cut-off versus
blanking)
reduce number of bend planes
keep side-action features to a minimum or avoid
completely
DFM – Machining
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employ standard features
(e.g. holes, slots, chamfers, fillets, rounds)
use raw material available in standard forms
(e.g. sheet, roll, bar, plate)
avoid sharp internal corners on turned parts
specify liberal tolerances and surface finishes
Iterate
Best
concept(s)
Configuration design evaluation
Configure
Product
Product architecture
Integral / modular
Standard / special purpose
Configure
Part(s)
Re-examine EDS
Research sources
Configuration requirements sketch
Analyze
and
Refine
Design for Function
Design for Assembly
Design for Manufacture
Evaluate
Pugh’s Method
Weighted Rating Method
Best
configuration(s)
Graphics during Configuration Design
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Sketches are used a lot in configuration design
Sketches assist creativity
Sketches are not typically used to “document” the
“design”

CAD Drawings need sizes (e.g. H, W, L, D)
CAD Takes time

But, some CAD may be useful

Iterate
Best
concept(s)
Configuration design
summary
Configure
Product
Product architecture
Integral / modular
Standard / special purpose
Configure
Part(s)
Re-examine EDS
Research sources
Configuration requirements sketch
Analyze
and
Refine
Design for Function
Design for Assembly
Design for Manufacture
Evaluate
Pugh’s Method
Weighted Rating Method
Best
configuration(s)
Configuration Design
Abstract embodiment
Physical principles
Material
Geometry
Configuration
Design
Architecture
Special Purpose Parts:
Features
Arrangements
Relative dimensions
Attribute list (variables)
Standard Parts:
Type
Attribute list (variables)