Design Philosophy From a Domestic Product to an Airplane

Transcription

1 Design Philosophy From a Domestic Product to an Airplane Alan K.T. Lau PhD CEng CPEng RPE FRAeS FIMechE FHKIE FIMMM FIEAust FIED Associate Dean Alex Wong/Gigi Wong Professor in Product Design Engineering Department of Mechanical Engineering The Hong Kong Polytechnic University

2 Design Process Marketing Survey (Identify the need) Design Specification and Concept Generation Product Trials and In-house Tests Product Testing and Certification Next Generation of Products TYPICAL PRODUCT DESIGN PROCESS Product Family Platform

3 Design Process Where success is concerned, people are not measured in inches, or pounds, or college degrees, or family background; they are measured by the size of their thinking PRODUCT DESIGN A New Trend toward a Sustainable Market/Future David Schwartz Engineering Personnel Marketing communication Leadership INNOVATION

4 PD Industry Threats for the Local Industry Relocation of manufacturing hub from Hong Kong to China (Since 1980) High labour and rental costs Changing of business model OEM to ODM to OBM Core Values of Local Students OEM is not a survivable solution Value of Hong Kong (Creativity, Technology and Practicability) Globalization Hong Kong based product manufacturing industry is no long survivable by simply relying on OEM business (Educational Programme Development)

5 Hong Kong based product manufacturing industry is no long survivable by simply relying on OEM business

6 Labour Intensive Low skill/technique Equipment dominated Original Equipment Manufacture (OEM) Original Design Manufacture (ODM) Creativity Problem solving Knowledge is required Design and Engineering Uniqueness Marketing Effort Large investment Risky (IP) Original Brand Manufacture (OBM)

7 (University) (University + Industry) (University + Industry) (Industry)

8 Product Innovation Development of Science and Technology Application of Existing Technologies into Products Product Design Marketing Survey and Opportunities Human Factors and Cultural Difference Product Appearance and User Friendly Product Engineering Effectiveness and Efficiency of Manufacturing Processes Enhancement of Product Safety Marketing Marketing and Presentation Skills Environmental Friendly Up-to-date Technologies Lightweight materials Simulation tools (aerodynamics) Noise reductions Better engines Better noise isolated structures Dimensions inside the cabin Locations of all control buttons Psychology/Physiology Production costs/times Safety regulation Others

9 Stupid Technology Not Innovation!! We have seen the future of high tech, and the future looks... stupid.

10 Human Factors Human Factors are always being ignored by engineers and designers when they design or introduce new technologies into products Design Driven Product Smooth as glass handle How about these designs?? people try to turn the knobs with soap on their hands but not success.

11 What is the major factors that have to be considered in designing a cockpit? Human Factors

12 Human Limit Human Factors

13 Human Factors Safe Condition At the sea level: Ambient pressure is Pa (1 bar); Density is kg/m 3 ; Temperature is 15 O C. At 11,000 m Freezing Condition At m (36000 ft): Ambient pressure is Pa (0.3 bar); Density is 0.5 kg/m 3 ; Temperature is 52 O C. At Sea Level

14 Human Factors

15 Large, flat wings give insects a flight advantage, but also a higher risk of the wings being damaged. They need to be foldable, therefore yet the wings size makes folding difficult. Bees solve this problem by means of a series of hooks known as the hamuli, which join the front and hind wings together in flight. When the bee lands, the hooks separate, and the wings can be comfortably folded away. Biomimetic

16 Biomimetic Mercedes Bionic Car Slide 16

17 Household Structure New Technologies How to Integrate Innovation, Engineering into Design of a Product? For example: Human Behaviour Why backpackers always suffer injury? What is the amount of load or the awkward position required to lift up the backpack?

18 New Technologies How to Integrate Innovation, Engineering into Design of a Product? Problems identification Too heavy; Backbone injury; Difficult to lift up; Energy problems Study on available knowledge in relation to human reaction on carrying a backpack Increase of heart rate; Fatigue; Pain on the shoulder; Hard to breathe Research possible technologies to solve the problems Hip belt design; Front-pack design; Chest-belt design; Shift of C.G; Energy absorbing materials and structures Integration of technologies into design concept Energy absorbing material inserted into the shoulder belts to absorb vibration energy Possible manufacturing skills and financial judgement Marketing Shape Memory Alloy

19 New Technologies Green Products/Airplanes Renewable resources Energy and materials Biodegradable materials Natural fibre, bioresin and biocomposites Recyclable materials Polymer types Durable materials and structures Non-corrosive and environmental inert materials Lightweight and durable materials Save energy for transportation and manufacturing Mining industry

20 New Technologies Flying Objects with Zero Carbon Emission 20

21 New Technologies 21

22 New Technologies According to the comment given by NASA s report on Green Aviation, several suggestions are made to help make greener future for aviation: Increase the direct flight from one destination to end destination Changes in aircraft design by using lighter and durable materials, and frictionless coating Better design to increase laminar/smooth air flow over aircraft structures and reduce the number of joints and fasteners Changes in engine design by using ultra-high-by-pass engine and open rotor engine alternative fuels noise reduction design and heat-free propulsion system???? 22

23 New Technologies The newest of the Boeing fleet, the 787 (Dreamliner), uses composites for 9 percent of its structural weight as compared to about 3 percent on other Boeing Jets. The 787 has a 43 foot tall composite vertical fin box made of carbon and glass fibre (prepreg materials). It also utilizes carbon fibre floor beams throughout the fuselage. The engineer cowlings are made of carbon fibre and epoxy skins covering a core of Nomex honeycomb. 23

24 New Technologies Jet fuel price accounts almost for about half of airline operating cost; Reduce the gross weight and thus, fuel use in the long run. 24

25 New Technologies Weight reduction Design criteria Buckling failure prevention Traditional Aluminum Structure Carbon Fibre Composite Structure 25

26 New Technologies LNG and hydrogen fuel system Weight increment Storage tank A feed and distribution system Interface fuel panel Cooling system (LNG ~ -423 o F and hydrogen ~ o F) Increase of overall frontal area Increase the complexity in design TRL(a) TRL (b) TRL(c) LNG driven engine Detail design and test Integration and test of fuel control system, fuel pump and combustor module Integration and test of LNG based propulsion system, and conduct a full scale test TRL = Technology Readiness Level 26

27 New Technologies Hydrogen contains 2.8 times more energy than kerosene which is shown as below. But this advantage will be compensated to some extent because the volume of hydrogen will be 4 times more than kerosene. For the airborne application, hydrogen must be maintained in a liquid states (LH2), the cylindrical or spherical LH2 tank need to permit the differential pressure and insulation requirement. 27

28 New Technologies Flammability comparison of hydrogen and kerosene Danger zone of spilled liquid gas 28

29 New Technologies LNG fueled aircraft require heavier aircraft systems and larger propellants tankage as compared to conventionally fueled aircraft Temperature characteristics hydrogen and kerosene Hydrogen aircraft with different hydrogen tank configuration 29

30 New Technologies Electric-driven Engine (Concept Stage) - Rolls-Royce distributed propulsion concept 30

31 New Technologies Aircraft noise continues to be regarded as the most significant hindrance to increasing the capacity of the National Airspace System, largely because of nuisance noise near major metropolitan. 31

32 New Technologies In term of the reduction of noise level, many measures are adopted: Asymmetrical engine nozzle chevron design Sawtooth smooth the mix of airflow Noise suppressor Nozzle design Sound absorption materials 32

33 New Technologies Changes in aircraft design to minimize the creation of turbulent flow and thus the drag force of an aircraft is essential. Nano-coating technology Easyjet reduction of the drag up to 40% (fuel saving ~ 1-2%) Winglet design (save fuel about 5%) new design or installation Jointless design Shape optimization by using smart concept morphing wing 33

34 Materials How to Integrate Innovation, Engineering into Design Process of a Product? Location Advanced Design Process The law of conservation of energy

35 Finite Element Modeling and Analysis Advanced Design Process

36 Advanced Design Process Advanced Technologies: Electrical and Electronic; Advanced Materials; New Computer-aided Software; Their Functionalities: Facilitate the quality of life; Reduce the cost of products; Increase the functions of products; Ensure the safety of life; Prolong the service life of products; Enhance the reliability of products; Reduce the processing times; Alleviate the inherent pressure of human

37 Product Design Basically, the design process of a domestic product is similar to a biggest airplane. Integration of knowledge, cross-disciplinary teams and appreciation of new technologies are required.

38 Thank You for Your Attention