Research Papers: Design Theory and Methodology

Excess Identification and Mapping in Engineered Systems

[+] Author and Article Information
Ethan Z. Cansler, Samantha B. White

Department of Mechanical
and Aerospace Engineering,
North Carolina State University,
Raleigh, NC 27695

Scott M. Ferguson

Associate Professor
Department of Mechanical
and Aerospace Engineering,
North Carolina State University,
Raleigh, NC 27695
e-mail: scott_ferguson@ncsu.edu

Christopher A. Mattson

Associate Professor
Department of Mechanical Engineering,
Brigham Young University,
Provo, UT 84602

1Corresponding author.

Contributed by the Design Theory and Methodology Committee of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received July 8, 2015; final manuscript received June 6, 2016; published online July 1, 2016. Assoc. Editor: Andy Dong.

J. Mech. Des 138(8), 081103 (Jul 01, 2016) (11 pages) Paper No: MD-15-1473; doi: 10.1115/1.4033884 History: Received July 08, 2015; Revised June 06, 2016

A system must continue to meet stakeholder needs throughout its service life to maintain value. Excess that is embedded into components during the design phase can enable in-service system evolution when new or changed requirements are introduced. However, while the concept of excess has been established in the literature, it is not clear how to identify and quantify the set of excesses in a particular design. This paper uses component properties and functional flow information to map and quantify the excess that exists within a system. Understanding the functional flow relationships between components allows for the bottlenecks at component interfaces to be identified. Those flows that do not limit the potential evolvability of a system can be removed from consideration, allowing for critical interface parameters to be highlighted and their capabilities quantified. The method is demonstrated on a consumer heat gun, where quantifying the excess within components allows for a reduced map to be created with irrelevant flows removed. Finally, changes to the system are explored to demonstrate how knowledge of component excess can be used to initially validate a proposed evolution.

Copyright © 2016 by ASME
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Fig. 1

Sample HD-DSM faces for a consumer heat gun

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Fig. 2

Portion of a functional diagram for a heat gun

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Fig. 3

Formalized excess mapping approach

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Fig. 4

Component–flow representation

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Fig. 5

Component–flow model structure

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Fig. 6

Internal components of the heat gun

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Fig. 7

Case and cover (numbers written by manufacturer)

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Fig. 8

Component–flow representation for the heating element

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Fig. 9

Component–flow representation for the motor

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Fig. 10

Component–flow representation of the heat gun

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Fig. 11

Quantified component–flow diagram for motor

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Fig. 12

Quantified component–flow diagram for case

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Fig. 13

Critical component–flow map for the heat gun




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