Mechanical 

system design
Dr. Arun Kumar Jalan
BITS Pilani Mechanical Engineering Department
Pilani Campus
 BITS Pilani
Pilani Campus

DE ZG525
MECHANICAL SYSTEM DESIGN
LECTURE NO: 4
Ref: Pahl, G.and W.Beitz, Engineering Design–A Systematic Approach – Springer, 3rd Ed.
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Discuss on last lecture

• Fundamentals of systematic approach

 Problem solving process
 Characteristics of good problem solver
Information processing
 Working methodology
 Applicable methods
 Role of computer support

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Discuss on last lecture:

Process Planning : product planning
1. Degree of novelty of a product
2. Product life cycle
3. Company Goals and their effect
4. Product Planning procedures

Product development process

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Topic: Process Planning

• Product Planning
• Solution finding
• Selection and Evaluation

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Topic: Process Planning

• Product Planning
• Solution finding
• Selection and Evaluation

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Solution Finding Methods

An optimal solution:
• fulfils all demands in the requirements list as well as most
of the wishes
• can be realised by the company within the constraints of
budget, time-to-market, production facilities, etc.
Steps required to realise such a solution are and not limited to
 First step, a range of possible solutions for the given task
has to be generated. (The basis for this is the function
structure)
 In a second step, one or more possible physical effects are
assigned to each of these solution-neutral sub functions in
order to realise them. (This is done in accordance with the
task-specific requirements)

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Solution Finding Methods

Conventional Intuitive Discursive Methods for
Methods Methods Methods Combining
Solutions
Information Brainstorming Systematic Study Systematic
Gathering of Physical Combination
Analysis of Method 635 Processes
Natural Systems
Analysis of Gallery Method Systematic
Existing Technical Delphi Method Search with the Combining
Systems Help of With the Help of
Classification Mathematical
Schemes Methods
Analogies Synectics Use of Design
Measurements Combination of Catalogues
and Model Test Methods
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Conventional Methods
1. Information Gathering
2. Analysis of Natural Systems
3. Analysis of Existing Technical Systems
4. Analogies
5. Measurements and Model Test

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Information Gathering
• Searching the literature
• Analysing trade publications
• Surveying the presentations from exhibitions and fairs
• Assessing catalogues of competitors
• Exploring patents, etc.

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Analysis of Natural Systems

 The study of natural forms, structures, organisms and
processes can lead to very useful and novel technical
solutions
 The connections between biology and technology are
investigated by bionics and biomechanics
 Nature can stimulate the creative imagination of designers
in a host of different ways

EXAMPLES

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Mercedes bionic concept car is designed based on the body shape of

a boxfish. The car has hexagonal shaped body which has less weight
and all its parts are also lighter weight. This car can travel 60 km.
within eight seconds only

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Velcro is the famous brand of the hook-and-loop fasteners that

were designed by Swiss Engineer George de Mestral in 1940.
He designed it after the observation of how the hooks of the
plant burrs stuck in the fur of his dog and his pants

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The Eastgate Complex located in Harare, Zimbabwe was designed by the

Engineers of Arup led by Mick Pearce. This complex is designed with the
inspiration from the ventilation design from termite mounds. Termites
require their home to remain at an exact temperature of 30.5°C
throughout the day even when the temperature ranges from 1°C (during
the night) to 40°C (during the day). This complex has natural cooling
ventilation process with specially designed hooded windows, variable
thickness wall and light colored paints to reduce heat absorption

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Analysis of Existing Technical Systems

 involves the mental or even physical dissection of finished
products
 May be considered a form of structure analysis aimed at the
discovery of related logical, physical and embodiment
design features
 Here, subfunctions were derived from the existing
configuration.
 Existing systems used for analysis might include:
• Products or production methods from competing companies
• Older products and production methods from one’s own
company
• Similar products or assemblies in which some subfunctions
or parts of the function structure correspond to those for
which a solution is being sought
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Analogies
 In the search for solutions and in the analysis of system
properties, it is often useful to substitute an analogous
problem (or system) for the one under consideration, and
to treat it as a model
 In technical systems, analogies may be obtained, for
instance, by changing the type of energy used
 Analogies chosen from the non technical sphere may
prove very useful as well
 Analogies are also helpful in the study of the behaviour
of a system during the early stages of its development by
means of simulation and model techniques, and in the
subsequent identification of essential new sub solutions
and the introduction of early optimisations

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Measurements and Model Tests

 Measurements on existing systems, model tests supported
by similarity analyses and other experimental studies are
among the most important sources of information
 design can be interpreted as the reversal of physical
experiment
 experimental development is often incorporated within the
design activity
 In the precision engineering and mass production
industries, including those where micromechanisms and
electronic products are developed, experimental
investigations are an important and established means of
arriving at solutions
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II. Intuitive Methods

• Intuitive -Solutions come in a flash after a period of search
and reflection
• These solutions suddenly appear as conscious thoughts
and often their origins cannot be traced
• “The good idea is not discovered or undiscovered; it comes,
it happens” It is then developed, modified and amended,
until such time as it leads to the solution of the problem
• Purely intuitive methods have the following disadvantages:
 The right idea does not always come at the right time, since it
cannot be forced
 Current conventions and personal prejudices may inhibit
original developments
 Because of inadequate information, new technologies or
procedures may fail to reach the consciousness of the
designer

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Intuitive Methods

Methods with an intuitive bias:

1. Brainstorming
2. Method 635
3. Gallery Method
4. Delphi Method
5. Synectics
6. Combination of Methods

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Brainstorming

 A method of generating a flood of

new ideas, suggested by Osborn

Provides conditions in which a group of open-minded

people from as many different spheres of life as possible
bring up, without prejudice, any thoughts that occur to
them and thus trigger off new ideas in the minds of the
other participants

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Brainstorming : Composition of the Group

 The group should have a leader and consist of a

minimum of 5 and a maximum of 15 people.
 Fewer than 5 constitute a spectrum of opinion and
experience that is too small, and hence produce too few
stimuli. With more than 15, close collaboration may
decline because of individual passivity and withdrawal.
 The group must not be confined to experts. It is
important that as many fields and activities as possible
are represented, the involvement of non technical
members adding a rich new dimension.
 The group should not be hierarchically structured but, if
possible, made up of equals in order to prevent the
censoring of such thoughts as might give offence to
superiors or subordinates.
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Brainstorming: Leadership of the Group

 The leader of the group should only take the initiative when
dealing with organisational problems (invitation,
composition, duration and evaluation)
 Before the actual brainstorming session, the leader must
outline the problem and, during the session, must see that
the rules are observed and atmosphere remains free and
easy
 To that end the leader should start the session by
expressing a few absurd ideas, or mentioning an example
from another brainstorming session, but should never lead
in the expression of ideas
 On the other hand, the flow of new ideas should be
encouraged whenever the productivity of the group slackens
 The leader must ensure that no one criticizes the ideas of
other participants, and should appoint one or two members
to take minutes
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Brainstorming Procedure
 All participants must try to shed their intellectual
inhibitions; that is, they should avoid rejecting as absurd,
false, embarrassing, stupid, well-known or redundant
any ideas expressed spontaneously by themselves or by
other members of the group.
 No participant should criticize any ideas that are brought
up, and every one must refrain from using such killer
phrases as “we’ve heard it all before”, “it can’t be done”,
“it will never work” and “this has nothing to do with the
problem”.
 New ideas will be taken up by the other participants, who
may change and develop them at will. It is also useful to
combine several ideas into new proposals.

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Brainstorming Procedure contd…

 All ideas should be written down, sketched out, or recorded.

 All suggestions should be concrete enough to allow the
emergence of specific solution ideas. The practicability of
the suggestions should be ignored at first.
 A session should not generally last for more than 30 to 45
minutes. Experience has shown that longer sessions
produce nothing new and lead to unnecessary repetitions.
 The first 10 minutes are typically devoted to the problem
description and familiarity.
 The next 20-25 minutes will see the sharp increase of ideas
, followed by a flat region, followed by sharp decrease.
 During the final 10 minutes , a trickling of ideas will occur,
which should be encouraged, but stagnation will also
happen quickly
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Brainstorming Evaluation
 The results should be reviewed by experts to find potential
solution elements. If possible, these should be classified
and graded in order of feasibility and then developed
further.
 The final result should be reviewed with the entire group to
avoid possible misunderstandings or one-sided
interpretations on the part of the experts. New and more
advanced ideas may well be expressed or developed
during such a review session.
 Brainstorming is indicated whenever:
• No practical solution principle has been discovered.
• The physical process underlying a possible solution has not yet been
identified.
• There is a general feeling that deadlock has been reached.
• A radical departure from the conventional approach is required

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Method 635
 Brainstorming has been developed into Method 635 by
Rohrbach
 After familiarizing themselves with the task, and after
careful analysis, each of six participants is asked to write
down three rough solutions in the form of keywords
 After some time, the solutions are handed to each
participant’s neighbor who, after reading the previous
suggestions, enters three further solutions or
developments
 This process is continued until each original set of three
solutions has been completed or developed through
association by the five other participants

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Method 635
Advantages over brainstorming
• A good idea can be developed more systematically.
• It is possible to follow the development of an idea and to
determine more or less reliably who originated the
successful solution principle, which might prove advisable
for legal reasons.
• The problem of group leadership rarely arises.
disadvantage:
• Reduced creativity by the individual participants owing to
isolation, and lack of stimulation in the absence of overt
group activity

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Gallery Method
 The Gallery Method developed by Hellfritz
 Combines individual work with group work, and is
particularly suitable for any stage of the design process
where solution proposals can be expressed in the form
of sketches or drawings
 The organization and team building are similar to
Brainstorming

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Gallery Method : Steps

 Introduction Step: The group leader presents the problem and
explains the context.
 Idea Generation Step 1: For 15 minutes the individual group
members create solutions intuitively and without prejudice using
sketches supported, where necessary, by text.
 Association Step: The results from idea generation step 1 are
hung on a wall as in an art gallery so that all group members
can see and discuss them. The purpose of this 15-minute
association step is to find new ideas or to identify
complementary or improved proposals through negation and
reappraisal.
 Idea Generation Step 2: The ideas and insights from the
association step are further developed individually by each of
the group members.
 Selection Step: All ideas generated are reviewed, classified and,
if necessary, finalized. Promising solutions are then selected. It
is also possible to identify potential solution characteristics that
can be developed later using a discursive method
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Gallery method : Advantages

 Intuitive group working takes place without unduly
lengthy discussions.
 An effective exchange of ideas using sketches is
possible.
 Individual contributions can be identified.
 Documentary records are easily assessed and stored.

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Delphi Method
 In this method, experts in a particular field are asked for
written opinions
 The requests take the following form:
• First Round: What starting points for solving the given problem
do you suggest? Please make spontaneous suggestions.
• Second Round: Here is a list of various starting points for
solving the given problem. Please go through this list and make
what further suggestions occur to you.
• Third Round: Here is the final evaluation of the first two rounds.
Please go through the list and write down what suggestions you
consider most practicable.
• This elaborate procedure must be planned very carefully and is
usually confined to general problems bearing on fundamental
questions or on company policy.
• In the field of engineering design, the Delphi Method should be
reserved for fundamental studies of long-term developments
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Synectics
 Synectics (Greek) refers to the activity of combining various
and apparently independent concepts
 Synectics is comparable to Brainstorming, the difference is
trigger off fruitful ideas with the help of analogies from non-
technical or semi-technical fields
 The method proposed by Gordon, is more systematic than
Brainstorming, with its arbitrary flow of ideas
 A synectics group should consist of no more than seven
members, otherwise the ideas expressed will run away with
themselves
 The leader of the group has the additional task of helping
the group to develop the proposed analogies by guiding
them through the different steps

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Synectics : Steps
• Presentation of the problem.
• Familiarization with the problem (analysis).
• Grasping the problem.
• Rejection of familiar assumptions with the help of
analogies drawn from other spheres.
• Analysis of one of the analogies.
• Comparison of the analogy with the existing problem.
• Development of a new idea from that comparison.
• Development of a possible solution.

If the result is unsatisfactory, the process may have to be

repeated with a different analogy

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Synectics - Example
Question: discovering the best method of
removing urinary calculi from the human body

several mechanical devices for gripping, holding

and extracting these stones were mentioned . The
device would have to stretch and open up inside the
urethra.

The keywords “stretch” and “open up” suggested

the idea of an umbrella to one of the participants

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Ref: Engineering
Design: Pahl. G
and others
Possible answer 1: By (b) drilling through the stone, pushing
the umbrella through the hole and opening it up. Not very
feasible.
Possible answer 2: By (c) pushing a tube through the hole and
blowing it up (balloon) behind the stone. Drilling of hole not
feasible.
Possible answer 3: By (d) pushing the tube past the stone.
When the tube is withdrawn the resistance may seriously
damage the urethra.
Possible answer 4:By (e) adding a second balloon as a guide
and by (f) embedding the stone in a gel between the two
balloons and then pulling it out 35
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Combination of Methods
 The group leader of, or another participant introduce
synectic to release a new flood of ideas
 A new idea or an analogy may radically change the
approach and ideas of the group.
 A summary of what has been agreed so far may lead to
new ideas.
 The explicit use of the methods of negation and
reappraisal and of forward steps can enrich and extend
the variety of ideas.
 The different methods should be combined so as to best
address particular cases. A pragmatic approach ensures
the best results

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3. Discursive Methods
I. Systematic Study of Physical Processes
II. Systematic Search with the Help of Classification
Schemes
III. Use of Design Catalogues

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(i) Systematic Study of Physical Processes

 If the solution of a problem involves a known physical

(chemical, biological) effect represented by an equation,
when several physical variables are involved, various
solutions can be derived from the analysis of their
interrelationships
 Interrelationship is the relationship between a dependent
and an independent variable, all other quantities being
kept constant
 For equation y = f (u, v, w), the solution variants are y1 =
f (u, v, w), y2 = f (u, v, w) and y3 = f (u, v, w) (underlined
quantities being kept constant)

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Example: development of a capillary viscometer

suggested by Rodenacker
Four solution variants can be derived from the well-known law of capillary
action η ~ Δp ꞏ r4/ ( ˙V ꞏ l)

differential pressure Δp ~ η (˙V , r and l = constant

changes in the volume flow rate: Δ˙V ~ η (Δp, r and l = constant)

Changes in the length of the capillary tube: Δl ~ η (Δp, ˙V and r = constant)

changes in radius of the capillary tube: Δr ~ η (˙V , Δp and l = constant)

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Another example:
Another way of obtaining new or improved solutions by the
analysis of physical equations is the resolution of known
physical effects into their individual components

Example: Development of a frictional thread locking device,

based on the analysis of the equation governing the torque
needed to release a threaded fastener:

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• To discover solution principles for the improvement of the

locking properties of a threaded fastener, we must analyze
the physical relationships further so as to identify the physical
effects involved
• The individual effects involved in Equations:

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(ii) Systematic Search with the Help of Classification Schemes

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Classification scheme with further subdivision of parameters

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Modified classification scheme with only the row parameters are retained,
and the columns are merely numbered
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Classification scheme contd….

 The choice of classifying criteria or their parameters is of
crucial importance
 Step-by-step procedure in establishing a classification
scheme :
• Step 1: Solution proposals are entered in the rows in
random order.
• Step 2: These proposals are analyzed in the light of the
main headings (characteristics), such as type of energy,
working geometry, working motion, etc.
• Step 3: They are classified in accordance with these
headings.
 The criteria and their parameters can also be obtained
from an earlier use of intuitive methods to analyze known
solutions or solution ideas
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Classification scheme contd….

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Classification scheme contd….

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Ex: varying the type of energy against a number of working principles

Ref: Engineering
Design: Pahl. G
and others
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Ex: variation based on working motions

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Ex:
variation in the working geometry (shaft hub connections)

Ref:
Engineering
Design:
Pahl. G and
others

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Recommendations for classification scheme

• Classification schemes should be built up step-by-step

and as comprehensively as possible.
• Incompatibilities should be discarded, and only the most
promising solution proposals pursued.
• The most promising solutions should be labelled using a
special selection procedure
• If possible, the most comprehensive classification
schemes should be drawn up (those schemes intended
for repeated use), but systems should never be built for
the sake of systematics alone.

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(iii) Use of Design Catalogues

 Design catalogues should provide:
– quicker, more problem-oriented access to the
accumulated solutions or data
– the most comprehensive range of solutions possible, or,
at the very least, the most essential ones, which can be
extended later
– the greatest possible range of interdisciplinary
applications
– data for conventional design procedures as well as for
computer aided methods.

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Use of Design Catalogues

Basic structure of a design catalogue (Roth)

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Available design catalogues

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Example:

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Example: catalogue for shaft-hub connection

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Methods for Combining Solutions

I. Systematic Combination

II. Combining With the Help of Mathematical

Methods

• The main problem with combinations is ensuring

the physical and geometrical compatibility of the
solution principles to be combined, which in turn
ensures the smooth flow of energy, material and
signals, and avoids geometrical interference in
mechanical systems

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I. Systematic Combination
 “morphological matrix” is particularly useful, where, the
subfunctions, usually limited to the main functions, and
appropriate solutions (solution principles) are entered in
the rows of the scheme
 If this scheme is to be used for the elaboration of overall
solutions, then at least one solution principle must be
chosen for every subfunction

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Morphological matrix

Example:
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Morphological matrix: Example

Q) In design of a mini bike, three subfunctions are

identified as Transmit, Brake and Steer. During
concept generation three alternatives Chain,
Gear and Belt for subfunction Transmit, two
alternatives Disk and Drum for subfunction
Brake and three alternatives Handle bar, control
stick and Fly-by-Wire for subfunction Steer are
identified for further refinement. Construct
Morphological matrix and list at least five
technically possible systematic combination

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Morphological matrix: Example

Solution
Sub 1 2 3
Function
Transmit Chain Gear Belt 3 X 2 X 3=
18 No. of
Brake Disk Drum -
Sol
Steer Handle bar Control stick Fly by Wire

chain –disk –handle bar; chain- disk-control stick; chain-disk –fly by wire;
chain-drum-handle bar; chain-drum-control stick; chain –drum - fly by wire;

gear –disk –handle bar; gear - disk-control stick; gear -disk –fly by wire;
gear -drum-handle bar; gear -drum-control stick; gear –drum - fly by wire;

belt –disk –handle bar; belt - disk-control stick; belt -disk –fly by wire;
belt -drum-handle bar; belt -drum-control stick; belt –drum - fly by wire;
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Systematic Combination contd…

 The main problem is to decide which solution principles
are compatible; i.e to narrow down the theoretically
possible search field to the practically possible search
field
 The identification of compatible sub solutions is
facilitated if:
– the subfunctions are listed in the order in which they occur
in the function structure, if necessary separated according
to flow of energy, material and signals
– the solution principles are suitably arranged with the help of
additional column parameters, for example the types of
energy
– the solution principles are not merely expressed in words
but also in rough sketches
– the most important characteristics and properties of the
solution principles are recorded as well.
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Systematic Combination contd…

To sum up:
 Combine only compatible subfunctions
 Pursue only such solutions as meet the demands of the
requirements list and fall within the available resources
 Concentrate on promising combinations and establish
why these should be preferred above the rest

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II. Combining With the Help of Mathematical Methods

 The combination of sub solutions into overall solutions

with the help of mathematical methods calls for
knowledge of the characteristics or properties
(unambiguous and quantifiable) of the sub solutions that
are expected to correspond with the relevant properties
of the neighboring sub solutions.
 In the formation of principle solutions (for example
working structures), data about the physical relationships
may be insufficient, since the geometrical relationships
may have a limiting effect and hence may, in certain
circumstances, lead to incompatibilities
 With increasing physical realization or embodiment of a
solution, it becomes simpler to establish quantitative
combination rules.

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DE  ZG525 Mechanical System Design

Topic: Process Planning

• Product Planning
• Solution finding
• Selection and Evaluation

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Solution Selection
 This selection procedure involves two steps, namely
elimination and preference.
 All totally unsuitable proposals are eliminated. If too
many possible solutions still remain, those that are
patently better than the rest must be given preference.
 Only these solutions are evaluated at the end of the
conceptual design phase.
 If faced with a large number of solution proposals, the
designer should compile a selection chart

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Systematic selection chart

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DE  ZG525 Mechanical System Design

Questions?
Contact : [email protected]

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