9 - Design methodology

Based on previous demonstrated success at fabricating 5 and 10 kW scale magnetic gearbox (MGB) prototypes, Emrgy and its partners (the project team) proposed to design and construct a 100 kW scale MGB with a 30:1 gear ratio for the low-head hydro applications. The Statement of Project Objectives included tasks covering: 1) Market Applicability; 2) Technical Metrics; 3) Design (initial); 4) Electromagnetic (EM) Load and Structural Analysis; 5) Modal Analysis; 6) Sealing Design and 7) Final Design during Budget Period 1. Budget Period 2 included tasks covering: 1) Materials Procurement and Test Plan Development; 2) Assembly; and 3) Testing. The Market Applicability study (Task 1) led to a clear conclusion and recommendation toward “Low Head” technologies for maximum market share of both New Stream Reach development as well as powering Non-Powered Dams. The findings of this study also identified the opportunity for a larger scale magnetic gearbox-based drive train as a function of increased torque, as opposed to increased speed. The Technical Metrics Study (Task 2) concluded a horizontal orientation was preferred, examined potential loss mechanisms, concluded that a Halbach Array1 magnetic design was preferred, established a 30:1 gear ratio as optimal, and established a power rating of 100 kW as optimal. The subsequent initial and final detailed design process included electro-magnetic (EM) load and structural analysis (Task 4), a Modal analysis (for vibration) (Task 5), and a sealing design (Task 6) to assure water impermeability. The final design package (Task 7) included 729 individual parts, 117 unique part numbers, and 15 assemblies. In order to facilitate procurement, the full bill of materials was broken down into several sub-components: 1) custom magnetic parts; 2) custom machined parts; 3) custom casted parts; and 4) commercial off the shelf (COTS) parts. The casted parts were fabricated by Oak Ridge National Laboratory (ORNL) via a Cooperative Research and Development Agreement (CRADA) with Emrgy and funded by the Advanced Manufacturing Office (AMO). The procurement effort (Task 8) ultimately covered three time periods based on challenges encountered in meeting the budgeted cost for the prototype. Following the first effort in the early stages of Budget Period 2 in 2017, a no-cost time extension was granted to seek alternative fabrication and procurement options. The project was re-booted in 2020 based on the new ORNL CRADA that would focus on five (5) of the more difficult and expensive parts using their advanced manufacturing expertise. Procurement efforts for the other custom machined parts resulted in quotations that still exceeded the budget by more than $100k. This was, in part, also due to the concurrent COVID-19 pandemic that caused both supply chain disruptions and labor shortages. As the project continued, pricing and availability degraded further. In Q2 FY’22, it was decided to not proceed with the fabrication of the prototype (Task 9) based on budgetary limitations. Outcomes included a full and detailed design of a 100 kW magnetic gearbox and associated indented bill of materials (BOM) and CAD drawings, a full assembly instruction manual with an associated BOM for materials necessary to support assembly, the fabrication of the double Halbach magnetic array for the rotor/stator system, fabrication of five (5) sand-casted/machined parts (via CRADA with ORNL) and an initial draft of a comprehensive testing plan. The most significant non-outcome was the actual fabrication and testing of the prototype gearbox based on budget limitations. Lessons learned included the need for an Application / Design / Cost trade analysis to better elucidate the cost potential of the MGB in the projected volumes anticipated for future demand. This would better establish the efficacy of the original cost target ($0.80/Watt) and/or the need for reconsideration of designs and applications. Likewise, additional consideration of the prototype nature of the gearbox – single use, short lifetime, etc. - either as a separate exercise or in place of the design process completed, to reduce the cost of the demonstration prototype device. Additionally, project continuity was cited as a significant risk based on the loss of the primary design engineering firm after Budget Period 1. A design analysis exercise was conducted at the conclusion of the project to identify potential areas for cost reduction. One concept considered was the removal of the inner ring of magnets (with associated changes in the outer ring magnets) to enable a horizontal collapse of the design. It was estimated this could reduce cost by 10-25% without impacting performance.

The design of reactive distillation systems is considerably more complex than that of conventional reactors and distillation columns. It includes several steps (Malone and Doherty, 2000): feasibility analysis, conceptual design, equipment selection and design, operability and control studies. These steps can be corresponded to the stages of the process design model presented in this work — ABstract design (feasibility analysis), Conceptual design, DEtailed design (equipment selection and design) and Final design (operability and control studies). The methodology of case-based design support has been applied to the DE phase of the design of a reactive distillation column.

PurposeThe generic design environment for a flexible printed‐circuit board assemblies (PCBA) remanufacturing cell contains four interrelated complex design domains. Mechanical design domains are really complex and the use of well‐proven mechanical product design methodologies does not help the designer. Hence, this paper aims to develop a generic systematic design methodology for a flexible PCBA remanufacturing cell.Design/methodology/approachThe study investigates the use of conventional mechanical product design techniques for the design of a flexible PCBA rework (remanufacturing) cell. It indicates problems and the weaknesses when conventional product design techniques are used for the development of flexible manufacturing systems (FMS). It then provides a new systematic mechanical design methodology for designing a flexible PCBA rework (remanufacturing) cell. The design methodology is intended to be generic in order to apply successfully to any FMS design.FindingsConventional product design methodology cannot be used directly for the design of a flexible PCBA remanufacturing cell. Hence, two design methodologies were developed: the generic FMS mechanical design methodology and a specific FMS design methodology for a PCBA rework cell. The first one was developed based on the tasks of the conventional product design process integrated with new design tools. The generic design methodology was then extended to obtain the second methodology for a PCBA rework cell design. Both of the methodologies were applied to a flexible PCBA rework cell design problem. Both design methodologies eliminated unusable design solutions at the early design stages of the conceptual design process and made the design process easier.Practical implicationsThe generic and specific design methodologies provide a better design environment, even for less specialized FMS designers.Originality/valueThe design methodologies may help for the commercialization of a flexible PCBA remanufacturing cell that may be used for SM rework and assembly.

With the increasing environmental sophistication of consumers, there is a need to consider environmental factors and sustainability in the design process. This paper proposes a design methodology intended for software implementation called eAD+ to address the following four issues: 1) there are inherent couplings between eco-factors and product design parameters, 2) eco-factors are seldom structured for ready use within all phases of the design process, 3) there is a need for a formal feedback mechanism from the results of eco-analysis to the design process, and 4) it can be difficult to identify which design choice causes the most egregious environmental issue or functional coupling. eAD+ is based primarily on the Axiomatic Design (AD) methodology and addresses these issues as follows. First, AD directly identifies couplings between the functional requirements (FRs) in a design so that efforts, such as TRIZ, can be applied to address them. Second, as common eco-factors do not provide sufficient structure for inclusion in the AD framework, we develop structured eco-FRs and constraints. These are included alongside the product FRs throughout the design process. Third, the subset of the design matrix (DM) relating the eco-FRs to the design parameters explicitly incorporates feedback from eco-analysis into the design process. Here a database containing environmental (or sustainability) information is employed to evaluate the design. Fourth, we employ an augmented DM (drawing inspiration from the House of Quality of QFD) that provides weights highlighting which design parameter has the greatest influence on eco-factors and functional couplings.

Despite a great deal of effort has been made to present systematic models of design process, in practice, a lot of designs still proceed through unsystematic methods. It seems that the reason for this is too much emphasizing on describing the final design (product) and little attention to the design process; such that, there is no clear method so as to research-based design. This led to illustrate a distinct pattern from configuration of "design protocol" in terms of research-based design process. The aim of this study is to develop a model that can be used in the architecture educational system. So at first step, the readers of this research are architecture students, and designers can also benefit from it in the next steps. So that all the readers of this research using this model, in a logical process, can recognize the right information for design and ultimately achieve an optimal architectural design. In this research, our preferred context is architecture, and the focus is on research-oriented design; therefore, any given example would be in the field of architecture. In this paper, the proposed process is the result of experience gained from five years teaching architectural design (2) in master's degree that includes three milestones as follows: 1) Statement of problem 2) The scheme and 3) Design protocol. "Statement of design problem" is obtained from people's concerns about "design subject" integrated in its "bed". The scheme, itself, constitutes the expectations, goals and mission representing two sets of information (cognitive and distinction) about design that finally leads to establish a "spatial-body program" of the project. As proceeding from the onset of diagram into the end, we passed from "analyze" into "synthesize" phase. In fact, in «analyze» phase, designer decides to collect and analyze information; however, as the process goes forward, he/she combines the information from the previous phase in order to achieve novel findings. Finally, we hope that by taking advantage of the proposed process, designers can find the best way to accomplish their design projects within a defined framework.

Quality criteria for process design in the design process — industrial case studies and an expert panel

An examination of designer and user perceptions of JAD and the traditional IS design methodology

Design methodology and the nature of technical artefacts

Product design is an innovative process that, through the stages of problem statement, concept, and initial and detailed design, meets the needs of customers, the requirements of companies, and their limitations. In the current process of product design and development, formulating design objectives plays a crucial role in objective setting, project implementation, product needs and requirements specification, and performing activities validation. Currently, the role of the design and development stages in the sustainability of products, identifying strategies for improving this stage is of particular significance, and paying attention to the product planning and definition process group and focusing on establishing sustainability principles in the target book and defining new attributes can be regarded as one of the sustainable product development strategies. Consequently, this research is a case study in the field of applying the sustainability principles in the target book as one of the deliverables at the stage of product planning. The present study proposes strategies towards developing the attributes of the target book as a tool for exerting sustainability pillars in the process of design and development by means of surveying automotive industry experts, applying the DEMATEL and Fuzzy ANP combined method, and evaluating and determining new attributes.

The effectiveness of system analysis and design methodologies plays a pivotal role in the success of software development projects. This research conducts a comparative analysis of various methodologies, including the Waterfall Model, Spiral Model, Prototyping Model, Iterative Model, Unified Process, Object-Oriented Analysis and Design, Joint Application Design, Computer Aided Software Engineering Tools, Rapid Application Development / Rapid Systems Development, Feature- Driven Development, Extreme Programming, Agile Method, and DevOps, to explore their respective strengths and considerations. The study examines key aspects such as flexibility, documentation, risk management, complexity, and suitability across these methodologies. Findings reveal that each methodology offers unique advantages and challenges, influencing their applicability in different project contexts. The research underscores the importance of aligning methodology choices with project-specific requirements, organizational culture, and environmental factors to optimize software development outcomes. Moreover, it suggests that hybrid approaches, combining elements from multiple methodologies, may offer a balanced approach to address diverse project needs and maximize effectiveness. By providing insights into the comparative effectiveness of system analysis and design methodologies, this research contributes to informed decision- making and improved project success in software development endeavors.

This paper describes the experience of Petrobras in the design, installation and operation of deepwater mooring systems incorporating high efficiency polyester fiber ropes. These ropes have been used now for more than 12 years in catenary and taut configurations to moor drilling and production units as well as storage and offloading facilities. The paper provides a history of the development of this technology, highlighting the key issues involved in introducing in mooring systems a component that has non-linear visco-elastic behavior. Differences to all steel systems in terms of: behavior, failure modes and design criteria and procedures are discussed. The paper presents the life cycle management strategy adopted by Petrobras in the early years of the use of this technology and its evolution that have guaranteed that the only failure mode observed over all these years was mechanical damage. It is expected that this paper shows that the use of polyester (polyethylene terephthalate) ropes in deepwater moorings is a mature technology. Introduction In the mid 80's Petrobras was drilling in Campos Basin in water depths around 600m and producing in depths around 400m. Mooring systems were all based on chain, wire rope and drag embedment anchors. Increasing water depths indicated that all steel systems would become anti-economical due to the reduction in restoring efficiency. Initial studies were based in using synthetic fiber ropes as extension wires in the mid-catenary. Since compliance to wave induced motions would be given by the geometry of the steel components the fiber rope should have stiffness similar to a steel wire rope. Therefore aramid ropes were the first to be considered (Riewald, 1986). Cost considerations led Petrobras and the US Navy (Karnosky & Liu, 1988) to start studying the use of polyester fiber ropes for moorings. It was also devised that, in deepwater, the axial compliance of polyester ropes could provide enough compliance so that a long catenary might not be required (Baxter, 1987). The use of polyester ropes in permanent moorings was a big challenge for several reasons, the most obvious one being establishing design methodologies and criteria for all possible failure modes. Since most large diameter fiber ropes were not optimized for tension and axial fatigue performance (Parsey, 1983)), it was also necessary to further develop rope constructions and generate enough data on the performance of these ropes. Results of a comprehensive study on the use of fiber ropes for deepwater moorings were presented in 1992 (Chaplin & Del Vecchio, 1992). Full details of the study, including assessment of failure modes, load-elongation behavior, design methodologies and criteria were produced (Del Vecchio, 1992). Since the study was partially based in model ropes, confirmation of load-elongation behavior in full scale and additional data on fatigue performance were obtained in the following years and incorporated in the type approval process of the ropes. Field trials were conducted in 1995 to assess installation procedures.

To support designers considering human value in their design process, the HuValue tool was developed. This tool is instanciated as a tangible, card-based design toolkit including a value wheel, 45 value words, and 207 picture cards, grounded in a comprehensive value framework. Using this toolkit can enable designers to be aware and sensitive to human values and consider various value aspects of their design challenge through different types of values, even if they personally do not value them. To know whether our tool is useful in a design process, we conducted a quasi-experimental study with 64 first year bachelor students in the context of a project based course of an industrial design program. We supported randomly selected students in 12 group projects with four students each, to use our tool during their whole design process (phases: vision, ideation, conceptualization, realization, and validation). Six project groups received the toolkit, an introduction and also guidance during the semester about how to use it in different design phases (Trained Groups). The remaining six of these 12 project groups received the toolkit and an introduction to its usage (Introduction Groups). Additionally, four project groups without any support for human values were used as benchmark (Control Groups). It was up to the students in all 16 groups if at all, and if so when and how to use our tool. We evaluated all the 16 project groups’ final designs whether they used the HuValue tool in their design process, if so, how and in which part they used our tool. This setting gave us the opportunity in gaining insights how to propose relevant usage of our tool. The results showed that nine out of the 16 in total (=56%) and eight out of the 12 tool-based (=67%) project groups reported using our tool during their design process for different purposes. Even one of the control groups got - beyond our control - access to our toolkit and used it. The project groups which used the tool applied it in the following phases: vision, ideation, conceptualization and validation, but not realization.

This paper describes the results of an agenda-setting panel session that took place at the 2021 International Design Engineering Technical Conferences organized by the Design Theory and Methodology (DTM) research community. While the state of design research in engineering design has advanced tremendously in the last thirty-five years since the formation of the DTM community, reflecting on the successes and challenges faced by this community revealed several key directions and opportunities that this community is well positioned to take. Namely, panelists and audience members in the session identified five new agenda items that have the potential to further strengthen research on Design Theory and Methodology: 1) Ethics, Equity, and Justice-focused design research, 2) Design for Sustainability research programs, and 3) Research on Computational Agents as team members in the design process,4) Building new theories from research conducted on Design Theory and Methodology, and 5) Focus on inclusive excellence in the review process of new and cross-disciplinary research. These agenda items as well as reflections on the history and legacy of the Design Theory and Methodology research community on the evolution of design research more broadly are discussed in this paper. The results of the panel session provide directions for next-generation design theory and methodology research that is effective, inclusive, and impactful.

This paper deals with problems involving the incorporation of safety into the design process of large marine and offshore engineering products from the initial stages. In this paper, the characteristics of large marine and offshore products are described and their design process is studied together with a proposed design framework. After investigating the current design for safety status of large marine and offshore products, a design for safety methodology is proposed in a generic sense and discussed in the context of the design process. The phases in the proposed design for safety methodology are studied together with their objectives and requirements. Finally, concluding remarks are given.

<p>This design led research advocates for mutually beneficial architecture indicative of its context; that balances the needs of the individual equally with those of the community. Developed through shifting scales and media, the thesis explores how urban architecture can best respond to context. Milieu, addresses issues of spatial, social and cultural context across four research phases intertwined under the design criteria of domain and sanctuary, a contemporary take on the public and private realm. Through a process of design and critique a design evolves which breaks the mould of traditional apartment models by contributing to its context as well as responding to it. The final design outcome is the result of a correlational design methodology. The design methodology examines the techniques of precedent extracting those successful and applying them to the subject site.</p>