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Bruce Mayer, PELicensed Electrical & Mechanical EngineerBMayer@ChabotCollege.eduEngineering 11Engineering Designfor Small-Volume Electro-Mechanical Systems

BMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignTechnical Product CreationEvery Technological Product Has To Be Designed and its Fabrication Overseen, and this is what Engineers DOSamuel Florman, The Civilized Engineer

BMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignTo Build a Designed ObjectSay you were Asked to BUILD or CONSTRUCT From-Scratch Something using Basic Hand ToolsYou would need (at a minimum)A list of Parts with P/Ns and QtysParts FABRICATED specially for this ObjectParts PURCHASED from Catalogs for this Object (a.k.a. Standard Parts)Instructions on how ASSEMBLE the ObjectBMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignSmall-Volume Object DesignRaw-Material in Basic-Shapes (chosen by the Engineer)Parts Fabricated per Specialized Designs (your BluePrints)Parts Purchased from Technical Catalogs (Selected by the Engineer)Assembly Documentation (Parts-List, BluePrints, Instructions, etc.) Written/Drawn by the EngineerBMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignWhen Designing SomethingThink About CRITICAL IssuesWill It WORKWill it Meet the SCHEDULE & BUDGETCan it be BUILT from MY Design Documentation? Ask Yourself: If I were Building this object What Info would I need?

BMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignDiscussion ScopeWe Examine what it takes to BUILD small quantities (dozens to hundreds per year)of Engineering-Designed ElectroMechanical Systems for SaleThis Discussion Does NOT Address the FUNCTIONAL PERFORMANCE of the design; only what it takes to actually BUILD IT, regardless of how Well it works

BMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignBUILDING SomeThing is HARDDesigning on Paper is MUCH EASIER than Designing Something that must be BUILT and Ultimately SoldThe Build-Process exposesIncomplete Design DocumentsWrong Parts PurchasedIncorrect Order NumberPart-Purchase Delayed Incorrect Supplier Phone Number$-Costs much higher than estimated

BMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignBUILDING SomeThing is HARDThe Build-Process exposesIncomplete Design DocumentsNot Sufficient Information to ConstructBluePrints Missing/Incorrect Dimensions or Notes; e.g.,Inconsistent Material CallOutMissing/Confusing LinesMissing Surface FinishSchematics or Assembly Drawing Missing/Incorrect ID-Information; e.g.,Missing Balloon CallOut for O-Ring, Bolt, Valve, etc.Missing Value for Resistor or Capacitor

BMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignBUILDING SomeThing is HARDThe Build-Process exposesDesign ErrorsMechanical Elements do NOT FITElectrical Elements SHORT or do not PowerUpCan Not be Fabricated or Assembled as DesignedMechanical Structures are NonRigid Floppy or Doingy or Cheesy of WobblyElectrical or Fluid Systems are UnderPowered or Noisy or UnstableWhimpy or Flakey or Glitchy BMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignTo BUILD an Engineered DesignCORRECT & COMPLETE information on PURCHASED-Parts Given to the Purchasing DepartmentNAMES & PHONE-NUMBERS of ALL SuppliersCorrect Catalog-Numbers for ALL Purchased PartsCorrect Order-Quantities and Estimated $-Costs

BMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignTo BUILD an Engineered DesignDot is & Cross ts on All FABRICATION Drawings (the BluePrints)A single Missing-Dimension or Superfluous Line or Missing Feature-Callout Brings Production to a HALTOMISSIONS result in ReWork or Scrap; e.g.;Forgetting a needed Removed-Feature (Hole or Slot or Notch or Groove)Superfluous Removed-Feature (extra hole)

BMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignDesigned Part (Piece Part)

BMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignEVERY dim & CallOut MUST be correct. MUST have a material Callout (should be more specific; 1018 Cold Rolled Steel Plate for example)To BUILD an Engineered DesignCOMPLETE Bill of Materials (BoM, also called the Parts List)EVERY Nut, Bolt, Washer, Wire-Connector, Plumbing-Fitting, etc.,Listed on the BoM TableComplete CallOuts ALL parts shown with Balloons containing part ID-numberClearly UNDERSTOOD Assy DwgsDont Confuse the Assemblers

BMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignTypical Assembly Drawing

On-Dwg BoMBalloon CallOutBMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignThe Balllon CallOut can be found on the BoM * Part ID balloons are often called BallTagsTools at the Engineers DisposalINGENUITY & CREATIVITYMOST ImportantKnowledge of SCIENCE and MATHEMATICSTechnical CATALOGSBluePrint Making SoftwareStandard Fabrication MethodsMachining, Welding, Injection-Molding, etc.

BMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignFor a DESIGN EngineerSummary: Design Docs IncludePurchased Part InformationWhat Mfr-PN, Who Supplies, How Much $Fabricated Parts Drawings (BluePrints)100% Accurate; generate NO Questions from FabricatorsBoM or Parts List100% Accurate as it is used to Pull Parts from Stock to Make an Assembly KitNonConfusing Assembly Drawings

BMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignSmall Volume Design FlowChartSupplierContact InfoPurchased Part Catalog No.PurchasedPartsPhysical Design to Scale (LayOut)MaterialSelectionFabrication NotesFormal BluePrints(Use Std TitleBlock)To FabricatorMachine Shop, etc.Fabricatorcontact InfoFabricatedPiece-PartsAssy Parts List(Bill of Materials)Order & ReceivePurchased PartsAssembly Drawing & DocumentationPhysical Assembly and/or ConstructionBMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignAll Done for Today

EngineeringDesignPyramid

BMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering DesignBruce Mayer, PERegistered Electrical & Mechanical EngineerBMayer@ChabotCollege.eduEngineering 11Appendix

BMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering Design

BMayer@ChabotCollege.edu ENGR-11_Small_Volume_Design.pptx#Bruce Mayer, PE Engineering-11: Engineering Design