MECH4240: Step in the Mechanical Design Process

Step 1.  Understand and Define the Problem.  Communicate with sponsor.
Step 2.  Document Objectives, Constraints and Specifications. Sponsor will have an objective in mind ( e.g. a mousetrap that doesn’t kill the mouse).  Design constraints will limit your choices of designs (e.g. it must cost less that 20 cents to make, must fit in a 3”x3”x3” box).   They can come from the sponsor (e.g. must be biodegradable).  Sometimes a product must adhere to industrial standards (e.g. UL standards, professional society standards).   The sponsor may have their own specifications or requirements of the design - negotiate here with sponsor so you there are no unreasonable demands.  Craft a carefully-worded contract that both you and sponsor agree on.
Step 3.  Innovate – Propose Ideas through Brainstorming.   Aka lateral thinking or thinking “outside the box”.   Lateral thinking versus vertical thinking (mathematical “if – then – if – then” logic, or step-by-step procedures like most analytical engineering course homework problems).   Handsketch it and put in your design notebook.  Mousetrap that doesn’t kill the mouse – how many ideas would this class have?  Example idea of mousetrap – door with hinge, tines pointed inward, tube.
Step 4.  Create a Concept(s) from Best Ideas.   Concepts are ideas that you have developed and expanded.  Downselect from many ideas to 1 or 2.  Ways to develop/expand an idea toward a concept: 1) Add some details, draw parts and assemble in Solid Edge making 3-D concept drawings for review by engineering managers, 2) Select and size components that are critical to performance such as motors, heat exchanges, control valves, linkages, sensors, actuators, etc..  Browse catalogs and supplier websites, talk to sales engineers, 3) Proof-of-concept physical testing to prove concept feasibility (vacuum system example), build a small-scale model, 4) Perform simple engineering calculations (such as sizing linkages, cylinders for expected loads, heat exchanger sizing, motor horsepower requirements (tines), 5) use software to simulate and assist in engineering analysis (e.g. Working Model, FE software, Virtual Prototyping software, Motion in Solid Edge).  Time for “Concepts Presentation/Report”
Step 5. Finish the Design.  Incorporate industrial sponsors comments.  Add dimension to Solid Edge Drawings.  Create drafts (3 view dimensioned orthographic projections).  Complete the Bill of Materials and economic analysis.  Complete engineering analysis so parts and components can be accurately dimensioned and sized.  Present Design Presentation/Report.   

A note on instructor/student responsibility regarding innovation.