Concept Generation in Design Engineering
Concept Generation in Design Engineering
1 Introduction
Few computational tools exist to assist designers during the conceptual phase of
design, and design success is often heavily weighted on personal experience and innate
ability. Many well-known methods (e.g. brainstorming, intrinsic and extrinsic searches, and
morphological analysis) are designed to stimulate a designer’s creativity, but ultimately still
rely heavily on individual bias and experience. Under the premise that quality designs comes
from experienced designers, experience in the form of design knowledge is extracted from
existing products and stored for reuse in a web-based repository. This paper presents a
concept generation algorithm that utilizes the Functional Basis and a web-based repository of
existing design knowledge to generate and rank viable conceptual design variants. This tool is
intended to augment traditional conceptual design phase activities and produce numerous
feasible concepts early in the design process.
2 Background
The concept generation phase of the design process is, at best, difficult to translate
into a succinct methodology that is useful to both experienced and inexperienced designers.
Quantification and formalization of the conceptual design phase is an active, but immature,
area of research. Many formal methods of conceptual design have yet to be realized as
computational algorithms. The work presented in this paper shows the initial steps taken to
generate a matrix-based algorithm for concept generation and early concept evaluation. The
specific focus of this research is the combination and formalization of function-based
synthesis, constraint management, and state space search to create a comprehensive space of
concept variants and search it for feasible design candidates.
Existing design tools primarily focus on the initial design phases, such as customer
need gathering (e.g. quality function deployment), or on the later steps of design embodiment
or detail design (e.g. design structure matrices, graph grammars, solid models, dynamic
modeling, and finite element analysis.) Few computational tools exist to assist designers
during the conceptual phase of design. Instead, designers have limited options available for
creating a quality design. Available options may include drawing on personal experiences or
the experiences of co-workers, utilizing patent searches to find other approaches or similar
designs, and reverse engineering existing products to evaluate how either the current design
or a redesign could be used to meet the design goals. All of these methods are potentially
limited or biased by a designer’s experiences. In addition, patent searches and reverse
engineering are potentially time intensive and laborious and may not catch solutions that seem
unrelated but are, in fact, analogous.
Innovations cited by Antonnsson and Cagan [1] indicate that certain parts of larger
design problems can be solved automatically and without human expertise. However,
automations in the design process are often only employed once basic design concepts have
been selected but lack specific dimensions. Complete automation of the design process seems
to be restricted by a lack of continuity between conceptual design methods and computational
design tools. We propose a computationally based method of concept generation that quickly
produces a manageable array of concept variants. The automatically generated concept
variants can then be used for concept selection or as a catalyst for generating additional
concept variants through complimentary non-computational creative techniques. The
following sections present a review of the product representation and design tools that have
been used in this paper. We then present our computer-implemented algorithm for
automatically producing conceptual designs and illustrate its effective use to generate viable
concept variants.
3 Related Work
We begin with a limited review of the state of the art in area of conceptual design
research and areas that support automated concept generation. In particular, we first review
systematic approaches to conceptual design and then focus on product function representation
and design knowledge collection.
The fuzzy front end of the conceptual design process has seen few attempts at
automation, perhaps due to the evolving strategies and methodologies that exist for this phase
of design. However, over the past few decades, design methods have matured and systematic
approaches to conceptual design have emerged [2–4]. These design methods provide a
starting point for automating the conceptual design phase. In particular, the systematic
approach of Pahl and Beitz and Hubka [5], representing European schools of design, has
spawned variant methodologies in American design literature [3, 6–12]. Regardless of the
methodology variation, all begin by formulating the overall product function and breaking it
into small, easily solved sub-functions. Solutions to the sub-functions are sought and the form
of the device then follows from the assembly of all sub-function solutions.
The lack of a precise definition for small, easily solved sub-functions has spurred
research into the development of a high level design language (sometimes called a vocabulary
or taxonomy) to describe product function and thus enable a systematic approach to
functional modeling. Hundal [13] formulates six function classes complete with more specific
functions in each class, though he does not claim to have an exhaustive list of mechanical
design functions. Another approach uses the 20 subsystem representations from living
systems theory to represent mechanical design functions [14]. Malmqvist, et al. [15] compare
the Soviet Union era design methodology known as the Theory of Inventive Problem Solving
(TIPS) with the Pahl and Beitz methodology. TIPS uses a set of 30 functional descriptions to
describe all mechanical design functions [16]. Malmqvist, et al. note that the detailed
vocabulary of TIPS would benefit from a more carefully structured class hierarchy using the
Pahl and Beitz functions at the highest level. Kirschman and Fadel [17] propose four basic
mechanical functions groups, but vary from the standard verb-object sub-function description
common to most methodologies. This work appears to be the first attempt at creating a
common vocabulary of design that leads to common functional models of products. Japanese
researchers have also explored a consistent language for describing the functionality of
products and relating it to product behavior [18–21].
Recent work continues this pursuit for a standard language that subsumes the previous
work [12, 22–26]. The result of these recent efforts is a design language known as the
Functional Basis. The Functional Basis uses the function and flow words in Tables 1 & 2 to
form a sub-function description as a function and a flow (i.e., a verb-object format). The
Functional Basis is intended to be broad enough to span the entire mechanical design space
while not being repetitive. In Table 1, engineering flows are categorized as three classes
(material, signal and energy) and then further specified as basic categories within each class.
In Table 2, engineering functions are categorized as 8 classes that are further specified as
basic categories.
Figure 1: A schematic representation of creating a product-function repository and its manipulation to produce
a product-product matrix and the corresponding product families.
5.3 Step 3: Compute the Set of Conceptual Variants that Solve the Function
Model
Step 3 utilizes the information from Step 1 and Step 2 to create a set of design
solutions. In step 3 under Theory in Figure 3, a component “tree” is created showing the
chains of components that could potentially solve the flow chain presented in Step 1, based on
the component-function relationship information shown in step 2. Although the example
illustrated in Figure 3 results in a single branching tree for step 2, it is important to note that
multiple branching trees may be formed at this stage when multiple components have the
potential to solve the initiating function in the chain. Computationally, if the transpose of the
row vector from the function-component matrix (FCM) that corresponds to each of the
functions from the flow chain in Step 1 is matrix multiplied by the row vector from the FCM
that corresponds to the forward connected function, a component-component matrix will be
generated for each function connection in the flow chain. This matrix multiplication is
illustrated as the matrix equivalent to Step 3 in Figure 3. Non-zero cells within these newly
created component-component matrices represent all theoretically possible component
combinations that will solve each pair of functions in the flow chain. If these component-
component matrices are then placed into the connectivity matrix, component paths can be
traced through the aggregated matrix much the same way a path is traced along the tree
shown in Step 3 under Theory in Figure 3. Tracing every possible “path” of connections will
give a list of all theoretically possible component chain variations that solve the function
chain presented in Step 1 of Figure 3.
the column containing the cell has been directly connected to the component in the row
containing the cell in an existing product. Step 4 in Figure 3 shows how the design-structure
matrix equivalent describes the component-component connectivity in the sample shown
under the Theory column.
6 Illustrative Example
A tricycle built from a standard Tinkertoy set, shown in Figure 4, is next presented as
a simple proof of-concept example. This simplified example demonstrates the effectiveness of
the described methodology while utilizing a manageable set of artifacts for ease of
illustration.
Figure 4: Tinkertoy tricycle used as the “product” to be redesigned in the following example.
First, a functional model of the tricycle construction was generated as described in Step 1 of
the concept generation algorithm. For demonstration purposes, the subsequent steps of the
concept generation scheme were only applied to the energy flow chain, shown in Figure 5a,
from the complete functional model. The functional model of this flow chain begins by
importing human energy across the product boundary of the tricycle toy. The model follows
the energy flow as it gets converted to translational energy and transmitted through the
product, then gets converted into rotational energy, which is further transmitted through the
product and finally converted back into translational energy. Figure 5b shows the function
connectivity matrix generated from the energy function chain in Figure 5a. Sequential
numbers were used in the function connectivity matrix for easy reference to the connections
labeled in the energy function chain.
(a)
(b)
Figure 5: (a) Function chain for the energy flow through the Tinkertoy tricycle. (b) Function connectivity matrix
that describes the function connections graphically shown in (a).
Next, in Step 2 of the concept generation scheme, a function-component matrix (FCM) was
constructed for the complete set of Tinkertoy components. In contrast to the web-based
repository method of generating a FCM from existing products, the FCM was generated by
subjectively defining the functionality by inspection of the Tinkertoy component set, which
is, in effect, a mini-repository of Tinkertoys. First, a list of all relevant function/flow
combinations was selected from a FCM generated for all product design knowledge that is
currently included in the web-based repository. Then, each component in the Tinkertoy set
was evaluated for its potential to solve each function from the subset list. The complete FCM
generated for the Tinkertoy set is shown below in Figure 6. For instance, we can see that the
yellow bearing component is capable of embodying the following functionality: Guiding a
solid, distributing translational energy, transmitting translational energy, converting human
energy to translational energy, and converting translational energy to rotational energy.
Red Yellow Yellow Orange Orange Purple Green Purple
Blue Hub Red Rod Blue Rod
Wheel Hub Bearing Spacer Cap Connector Rod Rod
Import Solid 1 1 1 0 0 0 0 1 1 1 1
Translate Solid 0 0 0 0 0 0 0 0 0 0 0
Guide Solid 0 0 1 1 0 0 0 0 0 0 0
Rotate Solid 0 0 0 0 0 0 0 0 0 0 0
Support Solid 1 1 1 0 0 0 0 1 1 1 1
Stabilize Solid 1 1 1 0 0 0 0 1 1 1 1
Secure Solid 0 0 0 0 0 0 0 0 0 0 0
Position Solid 1 1 1 0 0 0 0 0 0 0 0
Distribute T.E. 1 1 1 1 1 1 1 1 1 1 1
Import H.E. 1 1 1 0 1 1 0 1 1 1 1
Transmit R.E. 1 1 1 0 0 0 1 1 1 1 1
Transmit T.E. 1 1 1 1 0 0 1 1 1 1 1
Convert H.E. to R.E. 1 1 1 0 1 1 0 0 0 0 0
Convert H.E. to T.E. 1 1 1 1 1 1 1 1 1 1 1
Convert R.E. to T.E. 1 1 1 0 1 1 0 0 0 0 0
Convert T.E. to R.E. 0 0 1 1 0 0 0 0 0 0 0
Using the function connectivity information from Figure 5b and the component functionality
from Figure 6, the entire set of theoretical concept variants for the redesign was calculated for
Step 3 of the concept generation algorithm. As illustrated in Figure 7, rows for each of the
connected function pairs were multiplied together to generate the unfiltered matrices of
design solutions for each function pair. These unfiltered matrices are then embedded into the
function connectivity matrix to describe the full set of theoretical solutions.
Figure 7: Matrix row multiplication is used to generate the set of theoretical design solutions for each
connected function pair. Resulting matrices are embedded in the function connectivity matrix.
In Step 4, a similar method to that used to create the FCM was employed to construct the
design structure matrix (DSM) for the set of Tinkertoy components. The DSM, shown in
Figure 8, describes the component compatibility between each component, where 1’s entered
into each cell identifies components that can be connected together, and 0’s indicate
incompatibility.
Red Yellow Yellow Orange Orange Purple Green Purple
Blue Hub Red Rod Blue Rod
Wheel Hub Bearing Spacer Cap Connector Rod Rod
Red Wheel 0 0 0 0 0 0 1 1 1 1 1
Yellow Hub 0 0 0 0 0 0 1 1 1 1 1
Blue Hub 0 0 0 0 0 0 1 1 1 1 1
Yellow Bearings 0 0 0 0 0 0 1 1 1 1 1
Orange Spacers 0 0 0 0 0 0 1 1 1 1 1
Orange Caps 0 0 0 0 0 0 1 1 1 1 1
Purple Connectors 1 1 1 1 1 1 0 0 0 0 0
Green Rods 1 1 1 1 1 1 0 0 0 0 0
Red Rods 1 1 1 1 1 1 0 0 0 0 0
Blue Rods 1 1 1 1 1 1 0 0 0 0 0
Purple Rods 1 1 1 1 1 1 0 0 0 0 0
Figure 8: Design structure matrix (DSM) generated for the set of Tinkertoy components.
Finally, in Step 5, each cell of the DSM was multiplied by the corresponding cell for each of
the connected function pairs in order to filter out design solutions that are infeasible due to
component incompatibility. The entire set of filtered design solutions is shown in Figure 9. To
clarify the pertinent information, cells that contained zero values in the original function
connectivity matrix are grayed out. Additionally, non-zero entries that indicate feasible
component combinations for each connected function pair are highlighted in yellow.
Figure 9: Function connectivity matrix with embedded component connection information that describes the
complete set of feasible design solutions for the tricycle redesign.
Figure 10a-10d presents four of the design variants encompassed in the matrix presented in
Figure 9. The design variants shown are unstable asymmetric versions of the original tricycle
concept since the energy function chain generated in Step 1 does not encompass requirements
that the design be stable. The design variant in Figure 10a was constructed by selecting the
component connections highlighted in green in Figure 9. For instance, using Figure 9, we can
look at the embedded matrix describing potential component connections that simultaneously
solve the functions import human (i.e. the row defined as Import H.E.) and convert human
energy to translational energy (i.e. the column defined as Convert H.E. to T.E). From this
matrix, the green highlighted entry indicates that a blue rod connected to a yellow hub will
successfully embody these two connected functions. Next, examining the embedded matrix
contained by the row defined as convert human energy to translational energy (Convert H.E.
to T.E.) and the column defined as transmit translational energy (Transmit T.E.), we can next
choose a component compatible with the already selected yellow hub (e.g. the green rod cell
highlighted in green) to solve the next pair of connection function pairs in the chains.
Continuing in a similar fashion produces a chain of components that solves the function chain
generated in Step 1.
Figure 10: (a)-(d) Concept variants selected from the matrix of feasible solutions presented in Figure 9.
Using this technique, we can identify all possible feasible design solutions for the product to
be designed or redesigned. Although not feasible due to the manual generation of the FCM
and DSM for the simple example presented here, ranking of the design solutions can be
accomplished by calculating a “score” for each concept variant based on the component
connections selected using stored measures of frequency of occurrence, manufacturability,
assemblability, etc.
7 Conclusions
Application of our concept generation algorithm to the tricycle design example has
demonstrated the capability to automatically produce viable conceptual design variations
based on existing component knowledge. Although not presented here, application of the
presented methodology to actual product design and redesign results in similar success in
producing concept variants. Future work will focus on fine tuning the process and generating
conceptual variants for multiple interacting functional chains. In addition, the algorithm will
incorporate identification of potential function sharing opportunities looking for instances
where connected functions can be solved by the same component. Further improvements to
the algorithm can address product functionality that is typically solved at the assembly level
rather than the component level of a product, for instance balance and stabilization. Next,
issues with the number of potential connections a component can handle and loss of
component functionality following connection to another component can be addressed
through the use of port information [44] and assembly diagrams. Finally, other areas of
expansion include compensation for novel solutions that might stem from component
compatibility and functionality that may be possible although not historically found and
inclusion of manufacturing needs in addition to customer needs to seed the concept generation
of a product.
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Robert B. Stone
University of Missouri – Rolla
Basic Engineering Department
107A Basic Engineering
1870 Miner Circle
Rolla, MO, 65409
USA
Phone: (573) 341-4086
Fax: (573) 341-6593
E-mail: rstone@[Link]