MECHANICAL SYSTEM DESIGN

AN OVER VIEW

D R . N . G OV I N DA R A J U
Content

• Course objectives
• Engineering and System definition
• System life cycle
• Evolution of design process
• Multidisciplinary system design Optimization
• System engineering
• Role system engineering in product development
• Building blocks of system engineering
• Systems engineering heritage
• Modern origins of the systems approach
• Spread of the systems approach

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 Session Outcomes

On completion of this session you should be able to:

• Define a system.
• explain the different phases of system development life cycle.
• enumerate the components of system analysis.
• explain the components of system designing.
• Study of multidisciplinary design optimization.
• Define system engineering
• Role of system engineering in product development.
• Building blocks of system engineering

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Failure Cases of Systems Engineering

• Air bags, safety device appearing in automobiles in the early

1990’s, became the cause of death for a noticeable number of
individuals.
• There were severe flaws in the design, testing and deployment
conditions envisaged.

Fig.1: Air bags in car 4

ARIANE 5 Flight 501 Failure case continued….

• Ariane 5, the launch vehicle developed by European Space

agency, was first launched on June 4 1996, with four satellites.
At 37 seconds into flight, Ariane5 veered off course and
disintegrated shortly thereafter.

• A major flaw in the communication interface resulted into this

catastrophe

Fig.: Arine 5 5
Columbia disaster…..

Fig: Space shuttle Columbia disintegrates on

February 1, 2003 6
 System Engineering

• Systems Engineering is a top-down, life-cycle approach to the design,

development, and deployment of large-scale systems, processes, or operations
to meet the effective needs of users and stakeholders in a cost-effective, high-
quality way.
• An organized and systematic way of design.
• Considers all the factors involved in the design.
• Integrates all the disciplines and specialty groups into a team effort.
• Ensures the business and customer needs of all stakeholders and ensures a
system that meets the user needs

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Fig.5: System engineering bridges the gap between user need to system developer

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What is engineering?
“…engineering is the art of doing something well with 1 dollar which
any bungler can do with 2 dollars”, Arthur Wellington

The process of devising a system, component, or process to meet desired needs.

It is a decision-making process (often iterative) in which the basic sciences,
mathematics, and engineering sciences are applied to convert resources optimally
to meet a stated objective.
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 What is a System?

• A group of interacting, interrelated, or

interdependent elements forming a complex whole.
• A functionally related group of elements, : The
human body regarded as a functional physiological
unit
• An organism as a whole, especially with regard to
its vital processes or functions
• A group of physiologically or anatomically
complementary organs or parts: the nervous system;
the skeletal system
• A group of interacting mechanical or electrical
components
• A network of related computer software, hardware,
and data transmission devices
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Continued…….

• A system is commonly defined to be collection of hardware,

software, people, facilities, and procedures organised to
accomplish some common objectives.
• Basically there are three major components in every system,
namely input, processing and output

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• Definition of a System (Ref: NASA Systems Engineering Handbook)
A system is a set of interrelated components which interact with one
another in an organized fashion toward a common purpose.

• System components may be quite diverse

Persons and Organizations
Software and Data
Equipment and Hardware
Facilities and Materials
Services and Techniques
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The world around us

AIRCRAFT SPACECRAFT AUTOMOBILES BUILDINGS

Aerodynamics Astrodynamics Engines Structure & Seismology

Propulsion Structures Body/chassis Space and Aesthetics

Structures Communications Aerodynamics Aerodynamics/Wind

Controls Payload & Sensor Electronics HVAC

Avionics/Software Optics Hydraulics Networking

Manufacturing Guidance & Control Industrial design Fire & Safety

Others Others Others Others

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 The world within us

SYSTEMS?

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More examples of Mechanical systems

SYSTEMS?

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 Level Specific Name
Continued……. 

System
Subsystem
Launch vehicle
Propulsion
 Element SRM(manual)
 Component Ignition Device
 Part Igniter
Mechanical SYSTEMS?

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Continued…….

Relationships System

Components

 A Component can itself be a SYSTEM.

System .

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System complexity

Analysis codes should reside

with experts ?
System analysis should execute
analysis codes on experts’
Aerodynamics Expert
computers or … ?

Structures Expert System Analysis Controls Expert

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 System life cycle
• System life cycle is an organizational process of developing and maintaining
systems.
• It helps in establishing a system project plan, because it gives overall list of
processes and sub-processes required for developing a system.
• Following are the different phases of mechanical system in product
development life cycle:

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 Preliminary System Study

• problem identification and project initiation

• background analysis

• inference or findings (system proposal)

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 Feasibility Study

• The feasibility study is basically the test of the proposed system in

the light of its workability, meeting user’s requirements,
effective use of resources and of course, the cost effectiveness.

• The main goal of feasibility study is not to solve the problem but to
achieve the scope.

• In the process of feasibility study, the cost and benefits are

estimated with greater accuracy to find the Return on Investment
(ROI).

• A feasibility report submitted to the management.This may be

accepted or accepted with modifications or rejected.
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 Detailed System Study

• Problems and requirements.

• Pros & cons including new areas of interest.
• Data and finding in the shape of DFD’s, data dictionary, logical
data structure and miniature specifications
• What the new system is accomplished based on users
requirements.
• Functional hierarchy by the new system and their relationship
with the other.
• Functional network: for more than one procedure.
• List of attributes in the entities.

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 System Analysis

• Fact finding
• Understanding the current system
• Product data flow diagrams
• Identify the user requirements
• Interpret the user requirements
• Agree the objectives with the user
• Collect data from the current system

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Mechanical System design evaluation

• System design is the process of defining the architecture, modules,

interfaces and data for a system to satisfied requirements
• Based on user requirements and the detailed analysis of the
existing system, the new system must be designed. This is the
phase of system designing
• The system design involves:
i. Defining precisely the required system output
ii. Determining the data requirement for producing the output
iii. Determining the medium and format of files and databases

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Continued…….

iv. Devising processing methods and use of software to

produce output
v. Determine the methods of data capture and data input
vi. Designing Input forms
vii. Designing Codification Schemes
viii. Detailed manual procedures
ix. Documenting the Design

• Normally design proceeds into 2 stages,

1) Preliminary or General design
2) Structured or detailed design
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Continued…….

• In the preliminary or general design, the features of the new system

are specified. The costs of implementing these features and the
benefits to be derived are estimated. If the project is still considered
to be feasible, we move to the detailed design stage.
• In the detailed design stage, computer oriented work begins in
earnest. At this stage, the design of the system becomes more
structured.
• Tools used in detailed design are,
1) Flowchart
2) Data flow diagram (DFD)
3) Data dictionary
4) Structured English
5) Decision table
6) Decision tree 26
Multidisciplinary design and optimization
(MDO)

• The design of any system involves several diverse disciplines with strong
interaction between each other.
• The overall activity is therefore a typical Multidisciplinary Design and
Optimization (MDO) process.
• MDO problems typically involve a large number of design constraints and
variables. The analysis required to compute the objective and constraint
functions are usually highly complex, coupled and imprecise.
• In such problems, traditional optimization techniques based on principles of
mathematical programming have shown to be inadequate.
 Continued…….

Trial & Error Empirical Mathematical Probabilistic

Deterministic Stochastic
(Factors of Safety) (Risk Quantified)

Random
Experimentation
``
Experience-based Graphical Approaches Computer models Computer
based on system Simulations based on
Systematic physics system physics
Experimentation
Point estimates Robust Solutions

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Continued…….

CONCEPTUAL PRELIMINARY
DESIGN DESIGN DETAIL
DESIGN
PRODUCT
ATTRIBUTES
100:1
10:1
1:1

Conceptual design is crucial to the success of the overall design process and
resulting system. It has been estimated that “at least 80% of a Mission’s life-
cycle cost is locked in by the concept that is chosen” and “conceptual design
decision have a 100:1 leverage on end product quality and cost”
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Continued…….

• CONVENTIONAL • OPTIMAL
1. Specification 1. Specification
2. Baseline design 2. Baseline design
3. Analysis (or experiment) 3. Analysis
4. Check performance or failure criteria 4. Check constraints
5. Is design satisfactory? 5. Does design satisfy the optimality
conditions? (If yes, then stop)
(If yes, then stop)
6. Change design parameters using an
6. Change design parameters based on optimization strategy, return to 3.
intuition and experience, return to 3.

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Continued…….

WHAT IS OPTIMIZATION?

“The determination of values for design variables which minimize

(maximize) the objective, while satisfying all constraints”

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 Optimization

Design Space: The space of working (Hill in this case)

Objective: Find the Highest Point.
Design Variables: Longitude and latitude.
Constraints: Stay inside the fences.

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Continued…….

Objective Function
Constraints
Bounds

Design Variables

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 Solving optimization problems

• Optimization problems are typically solved using an

iterative algorithm:
Design variables Responses
Model f , g, h

Derivatives of
responses
Optimizer (design sensitivities)
f g h
, ,
xi xi xi

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 Local and global optima

LOCAL maxima
OPTIMA

Local Local
maxima minima
minima
GLOBAL
MINIMA

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 Optimization problems

Global Local

Single-Objective
Multi-Objective

Constrained Un-Constrained

Gradient Based Non-Gradient

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Optimization problems

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 MDO: Overview

• Multidisciplinary design optimization (MDO) deals with the optimization of

several engineering disciplines simultaneously.

• MDO gives the engineer the opportunity to find the optimal solution of some
system accounting for the interactions between the different disciplines.

• It should be noted that the multidisciplinary solution might not be the solution
for any one discipline analyzed separate from the other disciplines, but is the
best solution accounting for the interactions.

• The MDO field has become vital in design environments in the past decades as
designs are becoming more and more complex.
 MDO: Overview

• Most modern engineering systems are multidisciplinary and their analysis is

often very complex, involving hundreds computer programs, many people in
different locations. This makes it difficult for companies to manage the design
process.

• In the early days, design teams tended to be small an were managed by a single
chief designer who knew most about the design details and could make all the
important decisions.

• Modern design projects are more complex and problem has to be decomposed
and each part tackled by a different team. The way these teams should interact is
still being debated by managers, engineers and researchers
MDO: Framework
 MDO: Overview

AIRCRAFT DESIGN

• Aircraft design can start with very

rough sketches, as did the human
powered airplane, the Gossamer
Condor, or Wright Flyer.
 MDO: Overview

AIRCRAFT DESIGN

• Practical development often

proceeds without detailed
simulation.
 MDO: Overview

AIRCRAFT DESIGN

• Modern aircraft design is strongly

dependent on computational
simulation: computation-based
design.

• Significant challenge: integration

of high-fidelity modeling in
multiple disciplines.
 MDO: Overview

AIRCRAFT DESIGN

• Problem formulation is not

obvious and requires engineering
judgment.

• One can only make one thing best

at a time.”
NEED FOR MDO???

• Multidisciplinary Design Optimization (MDO) can be defined as a formal

methodology for the design of complex coupled systems in which the synergistic
effects of coupling between various interacting disciplines/phenomena are explored
and exploited at every stage of the design process

• To enable the design of high performance products

• Balance product performance considerations with manufacturing, economics, and

life cycle issues

• Achieve design process timetable compression

• Achieve Economic competitiveness

Mechanical Systems engineering
• Definition of Systems Engineering
(NASA SE Handbook)
• Systems Engineering is a robust approach to the design, creation,
and operation of systems.
• Systems Engineering consists of
Identification and quantification of system goals
Creation of alternative system design concepts
Performance of design trades
Selection and implementation of the best design (balanced and
robust)
Verification that the design is actually built and properly integrated
in accordance with specifications
Assessment of how well the system meets the goals 46
• Systems Engineering is a top-down, life-cycle approach to the design,
development, and deployment of large-scale systems, processes, or operations
to meet the effective needs of users and stakeholders in a cost-effective, high-
quality way.
• Systems Engineering typically involves an interdisciplinary approach and
means to enable the realization of successful systems.

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 Role of systems engineering in product
development
• Integrates Technical Effort Systems Engineering
Across the Development Project

Chem Engrg
Mech Engrg
• Functional Disciplines

Civil Engrg
Elec Engrg

SW Engrg
• Technology Domains
• Specialty Concerns

Systems Engineering Systems Engineering

Communications
Maintainability
Environment

Producibility

Computers
Reliability

Processes
Structures
Avionics
Safety

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 Building blocks of systems engineering

• Math & Physical Sciences

• Qualitative modeling
• Quantitative modeling
• Physical modeling
• Theory of Constraints
• Physical Laws
• Management Sciences
• Economics
• Organizational Design
• Business Decision Analysis
• Operations Research

Unique to Systems Engineering

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 Building blocks of systems engineering

• Social Sciences
• Multi-disciplinary Teamwork
• Organizational Behavior
• Leadership

• Body of Knowledge
• Problem definition
• System boundaries
• Objectives hierarchy
• Concept of operations
• Originating requirements
• Concurrent engineering
• System life cycle phases
• Integration/Qualification

Unique to Systems Engineering 50

 Other considerations

• Achieving balance between inherent conflicts

• System functionality and performance

• Development cost and recurring cost

• Development schedule (Time to Market)

• Development risk (Probability of Success)

• Business viability and success

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 Continued…….

• System Optimization
– Subsystems often suboptimal to achieve best balance at system level
– Ultimate system purpose must prevail against conflicting considerations
– Long-term considerations (e.g., disposal) may drive technical decisions
• Customer Interface
– Often must act as “honest broker”
– Carries burden of educating customer on hard choices
– Must think ahead to the next customer and next application
– Must “challenge” all requirements

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 Systems engineering heritage

• Water distribution systems in Mesopotamia 4000 BC

• Irrigation systems in Egypt 3300 BC

• Urban systems such as Athens, Greece 400 BC

• Roman highway systems 300 BC

• Water transportation systems like Erie Canal 1800s

• Telephone systems 1877

• Electrical power distribution systems 1880

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 Modern origins of the systems approach

• British multi-disciplined team formed (1937) to analyze Air Defense

System

• Bell Labs supported Nike development (1939-1945)

• SAGE Air defense system defined and managed by MIT (1951-1980)

• ATLAS Intercontinental Ballistic Missile Program managed by systems

contractor, Ramo-Wooldridge Corp (1954-1964)

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 Spread of the systems approach

• Early Proponents
• Research and Development Corporation (RAND)
• Robert McNamara (Secretary of Defense)
• Jay Forrester (Modeling Urban Systems at MIT)
• Growth in systems engineering citations (Engineering Index)
• Nil in 1964
• One Page in 1966
• Eight Pages in 1969
• Nine Universities Offered Systems Engineering Programs in 1964

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Summary :

• Elements of systems engineering are embedded in all engineering

endeavors

• Successful component design will definitely fail if system design fails

• For successful product , Robust System design is Must

• Feasible solutions and everlasting life of design can be achieved only by

Robust Mechanical System engineering

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 References

Text books
Modern Heuristic Optimization Techniques, Kwang Y Lee, Mohamed A El-
Sharkawi, John Wiley, 2008.
Numerical Optimization Techniques for Engineering Design, Vanderplaats,
Garret N, 3rd ed., Colorado Springs: Vanderplaats Research & Development
Inc., 2001.
Optimization Techniques, George Leitmann, Academic Press, NY
Continued…….

Books
 Belegundu, A. and Tirupathi, R., Optimization Concepts and Applications in Engineering,
Prentice Hall, 1999.
 Onwubiko, C., Introduction to Engineering Design Optimization, Prentice Hall, 2000.
 Venkataraman, P., Applied Optimization with MATLAB programming. Interscience, 2001.
 Goldberg, David E. Genetic Algorithms – in Search, Optimization & Machine
Learning. MA: Addison-Wesley, 1989. ISBN: 0201157675
 Murray B. Anderson, Genetic Algorithms In Aerospace Design: Substantial Progress,
Tremendous Potential, Sverdrup Technology Inc./TEAS Group Eglin Air Force Base,
FL 32542, USA.
 Kennedy J, Eberhart R. and Shi, Y.H., Swarm Intelligence, [M] Morgan Kaufmann
Publishers, 2001.
Continued…….

 Kwang Y Lee, Mohamed A El-Sharkawi, Modern Heuristic Optimization Techniques,

[M] John Wiley and Sons, 2008.
 Vanderplaats, Garret N. Numerical Optimization Techniques for Engineering Design.
3rd ed. Colorado Springs: Vanderplaats Research & Development Inc., 2001. ISBN:
0944956017
 Gill, P. E., W. Murray and M. H. Wright. Practical Optimization. Academic Press, 1986
 Blair J.C., Ryan R.S., Schutzenhofer L.A. Launch Vehicle Design Process:
Characterization, Technical Integration, and Lessons Learned, Marshall Space Flight
Center, Alabama NASA/TP2001–210992, 2001
 Phadke, M. S., Quality Engineering Using Robust Design. Prentice Hall. 1989.
 Taguchi, G., Elsayed, E., Hsiang, T., Quality Engineering in Production Systems.
McGraw-Hill, NY. 1989.

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