Engineering
product development is essential for the comfort of man and
development of nations. All the major economies of the world, like
US, Germany, Japan, Korea, China have companies that make engineering
products that are sold across the world. New products, efficient
process are the key wealth of the nations.
New
product development is not just about things that appear in news like
cars or computers, they make news because they are sold directly to
consumers. Better products and process are introduced in industries
and lead to huge gains for the society.
I will
try the explain the process of Engineering product development using
an example of a electric wheel chair. Lets say a group of engineers
want to develop a electric wheel chair. Its not a rocket science or a
cutting edge R&D, its a product that requires engineering.
User
Requirement: At each stage it is extremely important to
understand the users requirement and review it repeatedly. It is
usually seen that there is a big gap between engineers and their end
users. This affects the product development negatively. This is an
iterative process.
Multidisciplinary:
This product (and many others) is a combination of, mechanical,
electrical, electronics/controls and computer science engineering. It
is always good to have friends from other branches of engineering.
One should be capable of appreciating and understanding the subjects
from other branches also. Never have this attitude, “I am a xyz
Engg, so I have no idea of other engg.”
Gross
BoM: Then make a gross Bill of Materials or list of important
parts. The wheels, the structure of the chair, the bearings, motors,
battery, control stick, PCB, display or indicators. Once you have the
gross BoM, find out which parts can be made lighter, cheaper, or more
efficient. Here are a few examples, the battery can be same as a car
or 40 mobile batterys in series. Can the PCB be same as used in toy
cars? Can the bearing be same as used in cycle, scooter, motorbike?
What are the advantages/disadvantages of each options. Example, if
you use mobile battery, they can be replaces one by one, while a car
battery change will cost more? Or the charging time of each?
Gross
calculations: Make a gross calculation of the major components.
The wheel chair is for patients till 50kg or till 80 Kg. Then
calculate the required torque for plain surface, or for inclined
surface of 15deg. On the basis of torque required, you will calculate
the power of the motor required, then the battery required to run the
motor for a few hours. All this, will give you an idea of the control
system required to maneuver the wheel chair. Make control algorithm,
and a drawing showing what the product may look like.
References:
Why not Google it, ya sure!!. Find out what others have done,
mistakes they made and learn from them.
Detail
Calculations: After a few iterations of gross BoM and gross
calculations, you have to do the detailed calculations and show it on
paper that the wheel chair with the selected components, like chair,
wheels, bearing, motors, battery will work under the given
environmental conditions. At this stage you will also finalize, where
each of this components is kept, and the control algorithms.
Detail
Drawings: Now is the stage of detail drawing, preparing final
Bill of Material and making assembly drawing, work instructions and
sourcing the components.
Design
Standards: Most of the engineering products, from a door knob to
aeroplane, have to adhere to certain design standard,. There are
Indian standards (ISI) , German standards (DIN), international
standards (ISO). There are standards for the components, drawings
symbols and every smallest of the details, even the nut bolts that
you use. If you want to make a product that is of high quality and is
acceptable world wide, then you choose the appropriate standard and
make sure your calculations and drawings fulfill those standards. For
example, bolts and nuts are as per ISO 4016 or 4018 depending on
application and there are separate standards for washers.
Documentation:
At each stage, it is extremely important to have a good
documentation. Make tables, charts, of the requirements, calculations
etc. This is extremely important when making decisions or reviewing
decisions.
Further
development: Always document further advancement that are
possible in this product. For example, the wheel chair can be made
using a direct drive motor or can have a regenerative braking, i.e.
Which generates electricity on braking.
The
future needs of humanity asks for more efficient products that have
longer life spans, are more reliable, have less impact on environment
in their production or operation. Great companies have begun with
small products and new ones continue to be build on strong
engineering foundations. A example is DEHN, a German company
dedicated to lightning protection only or SVENDBORG that makes brakes
only.. They make high quality engineering products and test
these products to high standards. Good engineering teams are an asset
to the nation.
Abhinav
Bhatnagar
2000
Electrical
Mar 2011
for SRIJAN , MNNIT College Magazine