Nick Matthews

The Warwick Manufacturing Group University of Warwick

Nick Matthews

The Warwick Manufacturing Group University of Warwick

The Importance of Designing in the Real

World, Where is our future in

Manufacturing?

NAAIDT CONFERENCE 2006

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The value of DesignThe value of Design

The most expensive Toyota Yaris is (at least list price) £13,260 with maximum extras it goes up to about £15,500.

A Mini Cooper S Convertible is listed at £17,960 and can easily go to £22,000 with extras.

So the value of design then in this case is about Six and a half grand.

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DigitalisationDigitalisation

For many of us in manufacturing the holy grail of systems integration is now possible.

We see the emergence of a world platform, a degree of connectivity previous generations of engineers could only dream of.

The digitalisation of content and the ubiquity of the internet seamlessly connect people; so that people can manipulate digitalised content like never before.

Knowledge that would once have taken years to cross the world now travels at the click of a mouse.

For many of us in manufacturing the holy grail of systems integration is now possible.

We see the emergence of a world platform, a degree of connectivity previous generations of engineers could only dream of.

The digitalisation of content and the ubiquity of the internet seamlessly connect people; so that people can manipulate digitalised content like never before.

Knowledge that would once have taken years to cross the world now travels at the click of a mouse.

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LeanerLeaner

I believe digitalisation can still bring significant cost and time savings to the whole processes of product inception, product design and product development.

The whole new product introduction process can have major time savings from concurrent digital engineering processes.

Now if this is true in automotive who are many ways leading in this area just think of time and cost savings in light rail and aerospace applications.

I believe digitalisation can still bring significant cost and time savings to the whole processes of product inception, product design and product development.

The whole new product introduction process can have major time savings from concurrent digital engineering processes.

Now if this is true in automotive who are many ways leading in this area just think of time and cost savings in light rail and aerospace applications.

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CleanerCleaner

There is no doubt that there will be extra issues that designers will have to take into account when it comes to product design.As well as design for manufacture I will have to design for disassembly and be able to trace where everything has come from and gone to.Only by the intensive use of digital technologies will I be able to manage this huge explosion in the data required to manage in this new environment.

There is no doubt that there will be extra issues that designers will have to take into account when it comes to product design.As well as design for manufacture I will have to design for disassembly and be able to trace where everything has come from and gone to.Only by the intensive use of digital technologies will I be able to manage this huge explosion in the data required to manage in this new environment.

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SmarterSmarter

The degree of intelligence in all products will mean that the number of things that where only able to be done in certain locations will be vastly reduced.

Further blurring the difference between home and office or being on the move.

The embedded intelligence in the products we use will “learn” about us and modify themselves to meet our changing needs.

The degree of intelligence in all products will mean that the number of things that where only able to be done in certain locations will be vastly reduced.

Further blurring the difference between home and office or being on the move.

The embedded intelligence in the products we use will “learn” about us and modify themselves to meet our changing needs.

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FasterFaster

Digital manufacturing will ensure that products get to market more quickly.

No longer will it be necessary to produce physical prototypes in all cases.

Products will be designed, marketed prototyped and tested in ‘silico’.

That is inside computers using increasingly sophisticated 3D visualisation.

Customers will be more intimately involved in ‘concept to delivery’.

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GlobalisationGlobalisation

This is the Tata plant at Poona. Not a human being in sight.

The new generation of global manufacturing facilities are state of the art. For example employment in the textiles sector in China is falling as new plant replaces older facilities.

This is the Tata plant at Poona. Not a human being in sight.

The new generation of global manufacturing facilities are state of the art. For example employment in the textiles sector in China is falling as new plant replaces older facilities.

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PersonalisedPersonalised

For lower volume higher cost products, there will be a demand for an ongoing sophistication of automation to increase the capability of variety.

This will require the productionisation of what we currently refer to as rapid prototyping techniques.

For lower volume higher cost products, there will be a demand for an ongoing sophistication of automation to increase the capability of variety.

This will require the productionisation of what we currently refer to as rapid prototyping techniques.

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Sound Quality Target

VehicleDesign

Vehicle Customer

Sound Quality EngineeringSound Quality Engineering

( Objective Measures )( Subjective Measures )

WARWICK

( Engineering Targets )

sound &vibration

technology ltd

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Jury EvaluationsJury Evaluations

Comfortable, controlled and repeatable environment.

Database of results assembled from WMG and Jaguar

Warwick Listening Room

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Brand D

Brand F

Brand GBrand E

Brand B

Brand C

Brand A

Powerful Factor

Ref

ined

F

acto

r

Target

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& Visualisation & Visualisation

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The Future….The Future….

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•Monophonic•Very Simple•No Character - just a tune

Single NotesSingle Notes

“Close Encounters of the Third Kind”

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• Chords (i.e. polyphonic)

• Regular beat

• Individual, regularlyspaced harmonics can be clearly identified

Classical MusicClassical Music

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• Simpler Harmonic Content

• Regular beat i.e. simple temporal structure

• Lots of distortion, i.e no longer pure tones

Rock MusicRock Music

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• Complex, time varying harmonic patterns

• Continuously changing

• Varies with engine speed, load, gear, road surface, wind conditions, weather …

• Lots of broad band (wind/road)

Interior Noise of Accelerating CarInterior Noise of Accelerating Car

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Traditional NVH EvaluationTraditional NVH Evaluation

Drive an existing vehicle on the road or track Not back-to back Current cars only

No Targets No New Designs

Listen to fixed sounds in a room / experiencing vibration on a rig

Look at objective data (Test or CAE) Graphical

Metrics

Drive an existing vehicle on the road or track Not back-to back Current cars only

No Targets No New Designs

Listen to fixed sounds in a room / experiencing vibration on a rig

Look at objective data (Test or CAE) Graphical

Metrics

We need a better way to perform NVH assessments

Increasing difficulty for the non-expert

Increasing time & difficulty in data

interpretation

Limited number of Driving Conditions

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The WMG InteractiveNVH Simulator

The WMG InteractiveNVH Simulator

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Cascade Model – Complete Vehicle LevelCascade Model – Complete Vehicle Level

Masking Engine

Total VehicleL1

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Cascade Model – Vehicle Source LevelCascade Model – Vehicle Source Level

Masking

RoadStructure-

Borne

RoadAir-borne

Wind Powertrain Intake Exhaust

Engine

Total VehicleL1L2

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Cascade Model – Vehicle Path LevelCascade Model – Vehicle Path Level

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Services Or ManufacturingServices Or Manufacturing

The modern mobile phone comes almost entirely out of Britain.

The liquid crystal display comes from the RSRE. The camera is detector technology from astronomy and originally developed at University College London.

The design and manufacture of the nipple antennas come from Sarantel in Northampton.

The electronic design software behind the huge amount of embedded intelligence comes from ARM in Cambridge.

OK they may be manufactured in the Far East, but the largest mobile phone company is British - Vodaphone - a service business which spends £200million a year on R&D.

The modern mobile phone comes almost entirely out of Britain.

The liquid crystal display comes from the RSRE. The camera is detector technology from astronomy and originally developed at University College London.

The design and manufacture of the nipple antennas come from Sarantel in Northampton.

The electronic design software behind the huge amount of embedded intelligence comes from ARM in Cambridge.

OK they may be manufactured in the Far East, but the largest mobile phone company is British - Vodaphone - a service business which spends £200million a year on R&D.