| 1. |
- Borgue, Olivia, 1989, et al.
(author)
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Constraint Replacement-Based Design for Additive Manufacturing of Satellite Components: Ensuring Design Manufacturability through Tailored Test Artefacts
- 2019
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In: Aerospace. - : MDPI AG. - 2226-4310. ; 6:11
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Journal article (peer-reviewed)abstract
- Additive manufacturing (AM) is becoming increasingly attractive for aerospace companies due to the fact of its increased ability to allow design freedom and reduce weight. Despite these benefits, AM comes with manufacturing constraints that limit design freedom and reduce the possibility of achieving advanced geometries that can be produced in a cost-efficient manner. To exploit the design freedom offered by AM while ensuring product manufacturability, a model-based design for an additive manufacturing (DfAM) method is presented. The method is based on the premise that lessons learned from testing and prototyping activities can be systematically captured and organized to support early design activities. To enable this outcome, the DfAM method extends a representation often used in early design, a function-means model, with the introduction of a new model construct-manufacturing constraints (Cm). The method was applied to the redesign, manufacturing, and testing of a flow connector for satellite applications. The results of this application-as well as the reflections of industrial practitioners-point to the benefits of the DfAM method in establishing a systematic, cost-efficient way of challenging the general AM design guidelines found in the literature and a means to redefine and update manufacturing constraints for specific design problems.
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| 2. |
- Isaksson, Ola, 1969, et al.
(author)
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Trends, observations and drivers for change in systems engineering design
- 2017
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In: Proceedings of the International Conference on Engineering Design, ICED. - : The Design Society. ; 3, s. 201-210
-
Conference paper (peer-reviewed)abstract
- Manufactures, developing products, need to adapt and improve their practices taking advantage of technology advancements and simultaneously develop products and solutions to fit a new world. This paper discusses how societal and technological trends drive the need for change and evolution in what is called Systems Engineering Design (SED), indicating a systems view on engineering design. Through an analysis and selected examples it is argued that SED capabilities need to better address the width and complexity of design problem, takes advantages of increased computational power and sensing technologies to master future challenges. An important factor for successful deployment and change in industrial context, is the need for interactive and visual AIDS and easily accessible support methods. This can pave the way also for advanced SED support.
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| 3. |
- Bonham, Euan, et al.
(author)
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Designing and Integrating a Digital Thread System for Customized Additive Manufacturing in Multi-Partner Kayak Production
- 2020
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In: Systems. - : MDPI AG. - 2079-8954. ; 8:4
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Journal article (peer-reviewed)abstract
- Additive manufacturing (AM) opens the vision of decentralised and individualised manufacturing, as a tailored product can be manufactured in proximity to the customers with minimal physical infrastructure required. Consequently, the digital infrastructure and systems solution becomes substantially more complex. There is always a need to design the entire digital system so that different partners (or stakeholders) access correct and relevant information and even support design iterations despite the heterogenous digital environments involved. This paper describes how the design and integration of a digital thread for AM can be approached. A system supporting a digital thread for AM kayak production has been designed and integrated in collaboration with a kayak manufacturer and a professional collaborative product lifecycle management (PLM) software and service provider. From the demonstrated system functionality, three key lessons learnt are clarified: (1) The need for developing a process model of the physical and digital flow in the early stages, (2) the separation between the data to be shared and the processing of data to perform each parties' task, and (3) the development of an ad-hoc digital application for the involvement of new stakeholders in the AM digital flow, such as final users. The application of the digital thread system was demonstrated through a test of the overall concept by manufacturing a functional and individually customised kayak, printed remotely using AM (composed of a biocomposite containing 20% wood-based fibre).
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| 4. |
- Borgue, Olivia, 1989, et al.
(author)
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Function modelling and constraints replacement for additive manufacturing in satellite component design
- 2018
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In: Proceedings of NordDesign: Design in the Era of Digitalization, NordDesign 2018.
-
Conference paper (peer-reviewed)abstract
- Additive Manufacturing is increasingly attracting interest among manufacturers of space components, mainly due to its high design freedom, capability for achieving weight reduction and for being cost-efficiently produced in low volumes. However, AM is a less mature technology compared to established manufacturing methods. This lack of maturity concerns especially the area of AM manufacturing constraints as the knowledge about them is limited and because they mature over time, as the technology evolves. The lack of knowledge hinders designers to fully take advantage of AM, fearing that the technology will affect product reliability. This situation is particularly emphasized in space components, since they are subject to high reliability requirements. In this paper, a methodology based on function decomposition and constraint modelling is proposed as a basis for re-design of products using AM. In the methodology, the original functions, design solutions and manufacturing constraints of a product are identified. Then, the original manufacturing constraints are removed and replaced with manufacturing constraints for AM. Afterwards, functions and design solutions on the function model are modified and a new part geometry is designed and eventually realised in CAD. This methodology has been applied on a case study featuring a satellite sub-component.
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| 5. |
- Borgue, Olivia, 1989, et al.
(author)
-
Function modelling and constraints replacement to support design for additive manufacturing of satellite components
- 2018
-
In: Proceedings of NordDesign: Design in the Era of Digitalization, NordDesign 2018.
-
Conference paper (peer-reviewed)abstract
- © Proceedings of NordDesign: Design in the Era of Digitalization, NordDesign 2018. All rights reserved. Additive Manufacturing is increasingly attracting interest among manufacturers of space components, mainly due to its high design freedom, capability for achieving weight reduction and for being cost-efficiently produced in low volumes. However, AM is a less mature technology compared to established manufacturing methods. This lack of maturity concerns especially the area of AM manufacturing constraints as the knowledge about them is limited and because they mature over time, as the technology evolves. The lack of knowledge hinders designers to fully take advantage of AM, fearing that the technology will affect product reliability. This situation is particularly emphasized in space components, since they are subject to high reliability requirements. In this paper, a methodology based on function decomposition and constraint modelling is proposed as a basis for re-design of products using AM. In the methodology, the original functions, design solutions and manufacturing constraints of a product are identified. Then, the original manufacturing constraints are removed and replaced with manufacturing constraints for AM. Afterwards, functions and design solutions on the function model are modified and a new part geometry is designed and eventually realised in CAD. This methodology has been applied on a case study featuring a satellite sub-component.
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| 6. |
- Isaksson, Ola, 1969, et al.
(author)
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Virtual Contextual Validation of technologies and methods for Product Development
- 2016
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In: 14th International Design Conference, DESIGN 2016, Cavtat, Dubrovnik, Croatia, 16-19 May 2016. - 1847-9073. ; DS 84, s. 669-678
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Conference paper (peer-reviewed)abstract
- In this paper the use of virtual demonstrators as means to contextually validate both design methods and novel Technologies in advance of industrial Product development. Since maturity requirements are high, and pure technology and methods development Projects typically result in promising, but not validated, methods and Technologies and full scale hardware demonstration initiatives are costly, there is a gap to fill.Functional Modeling and Value Driven design methods are used with Ceramic Metallic Composites technologies in a virtual demonstrator.
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| 7. |
- Levandowski, Christoffer E, 1984, et al.
(author)
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Modularization in Concept Development Using Functional Modeling
- 2016
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In: Advances in transdisciplinary engineering. - 2352-751X .- 2352-7528. - 9781614997030 ; 4, s. 117-126
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Conference paper (peer-reviewed)abstract
- This paper presents a set-based approach to use functional models for platform concept development to identify feasible modules at early design stages. The concepts are defined using functional requirements, design solutions and their interconnections. These models are then encapsulated into functional modules through clustering of Design Structure Matrixes. A metric is introduced to quantify the ability to modularize a certain concept, which may be used to assess and eliminate inferior concepts. The approach is illustrated using a case study from the aerospace industry. The result shows that modules can be identified by clustering of the functional structure. This has an integral effect on early division of work, possibility to design reuse, etc. The ability to modularize a specific concept The case study also shows that, despite of the traditionally integrated character of the product studied, it is possible to identify functional modules for reuse in a platform.
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| 8. |
- Lithgow, Drew, et al.
(author)
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DESIGN AUTOMATION FOR CUSTOMISED AND LARGE-SCALE ADDITIVE MANUFACTURING: A CASE STUDY ON CUSTOM KAYAKS
- 2019
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In: Proceedings of the International Conference on Engineering Design, ICED. - : Cambridge University Press (CUP). - 2220-4334 .- 2220-4342.
-
Conference paper (peer-reviewed)abstract
- Additive Manufacturing (AM) offers the potential to increase the ability to customise large-scale plastic components. However, a substantial amount of manual work is still required during the customisation process, both in design and manufacturing. This paper looks into how the additive manufacturing of mass customised large-scale products can be supported. Data was collected through interaction with industrial partners and potential customers in a case study regarding the customisation of kayaks. As a result, the paper proposes a model-based methodology which combines design automation with a user interface. The results point to the benefit of the proposed methodology in terms of design efficiency, as well as in terms of displaying results to the end user in an understandable format.
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| 9. |
- Müller, Jakob, 1987, et al.
(author)
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Connecting functional and geometrical representations to support the evaluation of design alternatives for aerospace components
- 2019
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In: Proceedings of the International Conference on Engineering Design, ICED. - : Cambridge University Press (CUP). - 2220-4334 .- 2220-4342. ; 2019-August, s. 1423-1432
-
Conference paper (peer-reviewed)abstract
- Novel product concepts are often down-selected in favour of the incremental development of available designs. This can be attributed to the fact that for the development of a new product, simulations and analysis based on high-fidelity CAD models are required, which are expensive to create. To solve this problem, the use of a function model (FM) as intermediate step between ideation and embodiment is suggested. The approach has been examined in a case study with an aerospace company for the development of a turbine rear assembly, using multiple workshops and interviews with practitioners from the company. A multitude of novel solutions, even extending the functionality of the legacy design, were captured. The FM approach proved to support the representation, analysis, and configuration of 102 different concepts. Although supported by the FM model, the embodiment still showed to be a bottle neck for further development. The subsequent interviews with practitioners showed that the benefits of the approach were seen, but experienced as too complex. Further work will concern a more systematic connection between the FM and CAD model, in order to automate of the embodiment process.
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| 10. |
- Müller, Jakob, 1987, et al.
(author)
-
Design space exploration of a jet engine component using a combined object model for function and geometry
- 2020
-
In: Aerospace. - : MDPI AG. - 2226-4310. ; 7:12, s. 1-18
-
Journal article (peer-reviewed)abstract
- The design of aircraft and engine components hinges on the use of computer aided design (CAD) models and the subsequent geometry-based analyses for evaluation of the quality of a concept. However, the generation (and variation) of CAD models to include radical or novel design solutions is a resource intense modelling effort. While approaches to automate the generation and variation of CAD models exist, they neglect the capture and representation of the product’s design rationale—what the product is supposed to do. The design space exploration approach Function and Geometry Exploration (FGE) aims to support the exploration of more functionally and geometrically different product concepts under consideration of not only geometrical, but also teleological aspects. The FGE approach has been presented and verified in a previous presentation. However, in order to contribute to engineering design practice, a design method needs to be validated through application in industrial practice. Hence, this publication reports from a study where the FGE approach has been applied by a design team of a Swedish aerospace manufacturers in a conceptual product development project. Conceptually different alternatives were identified in order to meet the expected functionality of a guide vane (GV). The FGE was introduced and applied in a series of workshops. Data was collected through participatory observation in the design teams by the researchers, as well as interviews and questionnaires. The results reveal the potential of the FGE approach as a design support to: (1) Represent and capture the design rationale and the design space; (2) capture, integrate and model novel solutions; and (3) provide support for the embodiment of novel concepts that would otherwise remain unexplored. In conclusion, the FGE method supports designers to articulate and link the design rationale, including functional requirements and alternative solutions, to geometrical features of the product concepts. The method supports the exploration of alternative solutions as well as functions. However, scalability and robustness of the generated CAD models remain subject to further research.
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| 11. |
- Müller, Jakob, 1987
(author)
-
Does Form follow Function? Connecting Function Modelling and Geometry Modelling for Design Space Exploration
- 2020
-
Doctoral thesis (other academic/artistic)abstract
- The aerospace industry, representative of industries developing complex products, faces challenges from changes in user behaviour, legislation, environmental policy. Meeting these challenges will require the development of radically new products. Radically new technologies and solutions need to be explored, investigated, and integrated into existing aerospace component architectures. The currently available design space exploration (DSE) methods, mainly based around computer-aided design (CAD) modelling, do not provide sufficient support for this exploration. These methods often lack a representation of the product’s architecture in relation to its design rationale (DR)—they do not illustrate how form follows function. Hence, relations between different functions and solutions, as well as how novel ideas relate to the legacy design, are not captured. In particular, the connection between a product’s function and the embodiment of its solution is not captured in the applied product modelling approaches, and can therefore not be used in the product development process. To alleviate this situation, this thesis presents a combined function and geometry-modelling approach with automated generation of CAD models for variant concepts. The approach builds on enhanced function means (EF-M) modelling for representation of the design space and the legacy design’s position in it. EF-M is also used to capture novel design solutions and reference them to the legacy design’s architecture. A design automation (DA) approach based on modularisation of the CAD model, which in turn is based on the functional decomposition of the product concepts, is used to capture geometric product information. A combined function-geometry object model captures the relations between functions, solutions, and geometry. This allows for CAD models of concepts based on alternative solutions to be generated. The function- and geometry-exploration (FGE) approach has been developed and tested in collaboration with an aerospace manufacturing company. A proof-of-concept tool implementing the approach has been realised. The approach has been validated for decomposition, innovation, and embodiment of new concepts in multiple studies involving three different aerospace suppliers. Application of FGE provides knowledge capture and representation, connecting the teleological and geometric aspects of the product. Furthermore, it supports the exploration of increasingly novel solutions, enabling the coverage of a wider area of the design space. The connection between the modelling domains addresses a research gap for the “integration of function architectures with CAD models”. While the FGE approach has been tested in laboratory environments as well as in applied product development projects, further development is needed to refine CAD integration and user experience and integrate additional modelling domains.
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| 12. |
- Müller, Jakob, 1987, et al.
(author)
-
Enhanced function-means modeling supporting design space exploration
- 2019
-
In: Artificial intelligence for engineering design, analysis and manufacturing. - : Cambridge University Press. - 0890-0604 .- 1469-1760. ; 33:4, s. 502-516
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Journal article (peer-reviewed)abstract
- One problem in incremental product development is that geometric models are limited in their ability to explore radical alternative design variants. In this publication, a function modeling approach is suggested to increase the amount and variety of explored alternatives, since function models (FM) provide greater model flexibility. An enhanced function-means (EF-M) model capable of representing the constraints of the design space as well as alternative designs is created through a reverse engineering process. This model is then used as a basis for the development of a new product variant. This work describes the EF-M model's capabilities for representing the design space and integrating novel solutions into the existing product structure and explains how these capabilities support the exploration of alternative design variants. First-order analyses are executed, and the EF-M model is used to capture and represent already existing design information for further analyses. Based on these findings, a design space exploration approach is developed. It positions the FM as a connection between legacy and novel designs and, through this, allows for the exploration of more diverse product concepts. This approach is based on three steps-decomposition, design, and embodiment-A nd builds on the capabilities of EF-M to model alternative solutions for different requirements. While the embodiment step of creating the novel product's geometry is still a topic for future research, the design space exploration concept can be used to enable wider, more methodological, and potentially automated design space exploration.
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| 13. |
- Müller, Jakob, 1987, et al.
(author)
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Function model-based generation of CAD model variants
- 2021
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In: Computer-Aided Design and Applications. - : CAD Solutions, LLC. - 1686-4360. ; 18:5, s. 970-989
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Journal article (peer-reviewed)abstract
- A product is an artefact which fulfils a specific function. However, most design automation (DA) approaches wich are used to generate multiple alternative design concepts focus on the generation of CAD models. These neglect to represent the functional aspects of the product, and are furthermore deemed too rigid for the introductino of novel solutions. Pure function modellingappraoches on the other hand provides methods such as design rationale representation, introduction of novel solutions or instantiation of combinatorial alternative concepts, but the resulting models are insufficient for analysis. To alleviate this, a design space exploration (DSE) approach which couples function modelling and CAD is presented. The approachlinks the product’s design rationale modelled in enhanced functionmeans (EF-M) to a DA approach via the here introduced object model for function and geometry (OMFG). The resulting method is able to automatically generate CAD models of alternative concepts based on combinations of alternative design solutions defined in the function model. The approach is presented through a case study of an aircraft engine component. Sixteen different concepts are generated based on four functions with alternative solutions. In an initial computation of the effort to generate all alternative concepts, the DA aspect of the approach’s effort pays off as soon as five functions have two or more alternative solutions. Beyond the benefit of efficient instantiation of CAD models of alternative product concepts, the approach promises to provide the design rationale behind each concept, and thereby a more systematic way of exploring and evaluating alternative design concepts.
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| 14. |
- Müller, Jakob, 1987, et al.
(author)
-
Lessons learned from the application of enhanced Function-Means modelling
- 2020
-
In: Proceedings of the Design Society: DESIGN Conference. - : Cambridge University Press (CUP). - 2633-7762. ; , s. 1325-1334
-
Conference paper (peer-reviewed)abstract
- Although well researched and praised in academic publications, function modelling (FM) does not have gained much traction in industrial application. To investigate into possible reasons for this, this publication researches literature of nine different projects where enhanced function-means modelling has been applied. The projects are analysed for their purpose of FM-use, applied benefits and discovered challenges of the FM approach. From this, the main challenges for FM application are the abstraction level of the modelling language as well as the lack of an interface to CAD modelling.
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| 15. |
- Müller, Jakob, 1987, et al.
(author)
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Lifecycle design and management of additive manufacturing technologies
- 2018
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In: Procedia Manufacturing. - : Elsevier BV. - 2351-9789. ; 19, s. 135-142
-
Journal article (peer-reviewed)abstract
- Additive manufacturing (AM) is being proposed as a revolutionary manufacturing technology, promising significant advantages both from a design and production perspective. One challenge is the disruptive nature of AM and its impact on all life cycle phases. This paper reports from a demonstrator project highlighting digitalization and process implications. A demonstrator tool was developed able to collectively capture and visualize different life cycle implications of AM products. Market expectations, technology characteristics and life cycle constraints were met in the demonstrator tool. Each individual part collected its own traceable data set, from design over manufacturing up to postproduction services. Key aspects demonstrated were 1) the need to represent any manufacturing and life cycle constraint already in design, 2) the need to integrate unique identifiers that build a digital twin and 3) the need to automate links between life cycle engineering steps.
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| 16. |
- Müller, Jakob, 1987, et al.
(author)
-
Mapping the design space in function and geometry models supporting redesign for additive manufacturing
- 2020
-
In: Journal of Design Research. - 1569-1551 .- 1748-3050. ; 18:1-2, s. 37-56
-
Journal article (peer-reviewed)abstract
- The advent of additive manufacturing (AM) brings many benefits in terms of lightweight design. However, there is no established design for additive manufacturing (DfAM) method available, nor are all the impacts and constraints on the product and development process known. Therefore, a method to redesign existing products for AM is proposed. It consists of functional decomposition enhanced by constraints identification, and analyses of the impact on the design space. Furthermore, the approach defines a coupling of function and geometry models to support an inter-domain redesign process. The approach has been successfully applied in an industrial collaboration project with three aerospace companies, where the support of the method for design space exploration has been recognised. Future work sees the use of this method for design space exploration even outside the AM domain, but a more methodical definition of the relationship between the functional and geometrical domain is required to do so.
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| 17. |
- Müller, Jakob, 1987
(author)
-
Towards automated conceptual design space exploration
- 2018
-
Licentiate thesis (other academic/artistic)abstract
- In mature and safety-concerned industries, such as the aerospace industry, product development is often incremental and design solutions are limited to improvements of an existing design. Radical changes to the known product architecture are avoided, for reasons of reliability, lack of technology or lack of design space exploration (DSE) methods. This thesis aims to investigate into the challenges for DSE, and how it can be improved to be faster, wider and more systematic. This research has been undertaken in four different research projects, addressing the challenges of the aerospace industry. The process of exploring the design space, the set of all possible designs, can be divided into three phases: to define the design space boundaries, to populate this design space with concepts, and lastly, to analyse the different concepts to find the one which provides the highest value. A deficiency in the description of functions and constraints which constitute the design space dimensions and boundaries, rooted in the lack of methods, has been identified to reduce the available search space already in the beginning. To populate this search space, developers need to generate representations of their new designs. These representations, commonly 3D geometries in the form of CAD models, are too rigid in the form they are used today. Therefore, it is expensive to create many variants, which differ in solutions and shape. This reduces the design space population to only a few concepts, derived from the legacy design. The analysis of alternative concepts is challenged through different maturities and variety of concepts. The coverage of multiple hierarchical search spaces, from geometry over solutions to value, has been identified as a driver for wider DSE. Furthermore, the need for a product development approach that is capable to bridge the levels of modelling abstraction. Enhanced Function-Means (EF-M) modelling, a function model applied in all studies referenced in this thesis, bridges the abstraction from a verbal description to a teleological graph, while enabling a more systematic capture of the design space boundaries. However, a subsequent gap towards geometry models could be observed in all studies. This hindered a faster design space exploration, since extensive manual labour is required to bridge these abstraction levels. For further work, the closing of the abstraction gap in the product modelling methods is seen as the primary goal for further work, either by extending the already applied function- and geometry modelling methods, or by including other frameworks.
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| 18. |
- Raudberget, Dag, et al.
(author)
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Bridging the gap between functions and physical components through a structured functional mapping chart
- 2016
-
In: Proceedings of the 2016 ISPE International Conference on Transdisciplinary Engineering, 4-6 October, Curitiba, 2016.. - : International Society for Productivity Enhancement. ; 4, s. 107-116
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Conference paper (peer-reviewed)abstract
- Functional modelling can be challenging to integrate with physical CAD-modelling, since the natures of these representations are quite different. This paper presents a methodology seeking to bridge these representations in a product platform context. The contribution of this work is a pragmatic way to improve the connections between Functional Requirements and CAD models. It does so by structuring functions, features and components and by linking these through tags in CAD-models. The methodology thereby associates the CAD models to the functional knowledge used when creating them. The result is the functional mapping chart, which is illustrated by an example from the automotive industry.
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| 19. |
- Raudberget, Dag, 1967, et al.
(author)
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Supporting design platforms by identifying flexible modules
- 2017
-
In: Proceedings of the International Conference on Engineering Design, ICED. - : The Design Society. - 2220-4334 .- 2220-4342. ; 3:DS87-3, s. 191-200, s. 191-200
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Conference paper (peer-reviewed)abstract
- One way for firms to stay competitive is to adapt a platform approach. In product platforms, modules are used as exchangeable design blocks to create a variety in product performance. This is a proven way to get advantages of scale in production by reusing physical parts and investments in manufacturing. To ensure exchangeability between modules, interfaces between modules must be well defined. Hence, from this point of view, there is no such thing as flexible modules. In this research, flexibility refers to the idea of identifying strategic portions of the platform where flexibility is needed and to create the modular division in a way that the assigned modules are de-coupled in theses areas. The presented approach shows how the Design platform concept can be extended by the introduction of flexible modules. These support the Design Platforms by allowing areas of strategic importance to be more flexible and thereby enable room for uncertainties such as fluctuating requirements and future technical development.
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