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中國地質(zhì)大學(xué)長城學(xué)院
本科畢業(yè)設(shè)計(jì)外文資料翻譯
系 別： 工程技術(shù)系
專 業(yè)： 機(jī)械設(shè)計(jì)制造及其自動(dòng)化
姓 名： 張易成
學(xué) 號(hào)： 05208314
2012 年 01 月 22 日
中國地質(zhì)大學(xué)長城學(xué)院
本 科 畢 業(yè) 設(shè) 計(jì)
題目 滾柱夾持式自動(dòng)送料裝置
系 別 工程技術(shù)系
專 業(yè) 機(jī)械設(shè)計(jì)制造及其自動(dòng)化
學(xué)生姓名 張易成
學(xué) 號(hào) 05208314
指導(dǎo)教師 侯宗濤
職 稱 高工
年 月 日
中國地質(zhì)大學(xué)長城學(xué)院
本科畢業(yè)設(shè)計(jì)文獻(xiàn)綜述
系 別： 工程技術(shù)系
專 業(yè)： 機(jī)械設(shè)計(jì)制造及其自動(dòng)化
姓 名： 張易成
學(xué) 號(hào)： 05208314
2012 年 01 月 28 日
摘 要
隨著自動(dòng)化、半自動(dòng)化在國民經(jīng)濟(jì)各行業(yè)的普及 深入，自動(dòng)送料裝置作為生產(chǎn)線一個(gè)不可缺少的 環(huán)節(jié)，對(duì)其結(jié)構(gòu)、噪音、工作原理、輸送精度及 控制難易程度等方面提出了更高的要求，傳統(tǒng)的 振動(dòng)送料裝置已不能滿足要求。對(duì)滾柱夾持式自動(dòng)送料機(jī)更是進(jìn)行了多方面的改進(jìn)，使其工作更平穩(wěn)，更快捷。讓它在生產(chǎn)過程中具有更簡單的操作方式并達(dá)到高效率的生產(chǎn)狀態(tài)。本次設(shè)計(jì)的滾柱夾持式自動(dòng)傳送裝置是由斜塊、滾柱夾持器、滑動(dòng)裝置、滾輪及機(jī)架構(gòu)成。
本次設(shè)計(jì)的步驟是從滾柱夾持器開始入手，然后依次對(duì)傳送裝置的滑動(dòng)置、大彈簧、滾輪及斜塊進(jìn)行設(shè)計(jì)和選擇。其中大彈簧的選擇，夾持器、滑動(dòng)裝置的設(shè)計(jì)最為主要，其余部分有的只是略作分析。
關(guān)鍵詞：夾持器; 滑動(dòng)裝置; 彈簧; 滾輪
Abstract
As automation and a half in the national economy of industry automation popularization thorough, the automatic feed unit as a production line a the essential link for the structure noise working principle and control precision conveying how easy it is to put forward a higher request, the traditional vibration feed unit already cannot satisfy requirement of roller clamping type automatic assembly is to carry on a various improvement, make it work more stable and more quickly and let it in the process of production is more simple and efficient way to the operation of the production of the design of roller of state holding type automatic transmission device is a inclined piece of roller grippers slide device roller and frame composition.
This design steps starts from roller grippers, which in turn to transfer units of the slide device big spring roller and inclined piece of design and choose one big spring choice, grippers slide device design most major, and the rest of you just slightly analysis.
Keywords: Grippers; slide device; spring; the roller
文 獻(xiàn) 綜 述
一、 前言
在我國和國外的生產(chǎn)和研究中，自動(dòng)送料方式有很多種，但是在這些產(chǎn)品中，存在著一些問題。如日本的RF20SD-OR11機(jī)械手送料裝置與沖床做成一體，從橫向(側(cè)面)送料，結(jié)構(gòu)復(fù)雜，裝配、制造、維修困難，價(jià)格昂貴，又不適合于我國沖床的縱向送料的要求。RF20SD—OR11的結(jié)構(gòu)由沖床上的曲軸輸出軸．通過花鍵軸伸縮，球頭節(jié)部件聯(lián)接機(jī)械手齒輪， 由傘齒輪、圓柱齒輪、齒條、凸輪、撥叉、絲桿等一系列傳動(dòng)件使機(jī)械手的夾爪作伸縮、升降、夾緊、松開等與沖床節(jié)拍相同的動(dòng)作來完成送料，另設(shè)一套獨(dú)立驅(qū)動(dòng)可移式輸送機(jī)，通過隔料機(jī)構(gòu)將工件輸送至預(yù)定位置，這樣一套機(jī)構(gòu)的配置僅局限于日本設(shè)備，不能應(yīng)用于國產(chǎn)沖床。國內(nèi)有的送料機(jī)構(gòu)由沖床工作臺(tái)通過連桿彈簧驅(qū)動(dòng)滑塊在滑道上水平滑動(dòng)，將斜道上下來的料，通過隔料機(jī)構(gòu)推到模具中心，并聯(lián)動(dòng)打板將沖好的料撥掉，往復(fù)運(yùn)動(dòng)的一整套機(jī)構(gòu)比較簡單， 無輸送機(jī)構(gòu)，聯(lián)動(dòng)可靠，制造容易。但機(jī)械手不能將料提升、夾緊，料道傾斜放置靠料自重滑下，如規(guī)格重量變動(dòng)，則料道上工件下滑速度不一致，易產(chǎn)生疊料，推料機(jī)構(gòu)役有將料夾緊，定位不正，增加廢品率，使用也不安全。
現(xiàn)在要求設(shè)計(jì)自動(dòng)送料機(jī)構(gòu)，實(shí)現(xiàn)自動(dòng)送料，消除積累誤差，同時(shí)可以減少勞動(dòng)力成本。目前在生產(chǎn)中還是采用手工模式，即是一人看一臺(tái)機(jī)器，人工送料，這種生產(chǎn)模式生產(chǎn)效率很低，既浪費(fèi)勞動(dòng)力也會(huì)讓工人很疲倦，而且人工送料會(huì)產(chǎn)生累積誤差。為了解決這些問題，減少生產(chǎn)成本，結(jié)合國內(nèi)外送料機(jī)構(gòu)的特點(diǎn)，采用滾柱夾持式自動(dòng)送料裝置，設(shè)計(jì)了具有推廣意義的自動(dòng)送料機(jī)。
二、國內(nèi)外相關(guān)研究狀況
自動(dòng)送料裝置在國內(nèi)外都有廣泛的應(yīng)用，因此目前有多種自動(dòng)送料機(jī)，如滾柱式、沖壓式、電磁式及壓電震動(dòng)式等。
首先介紹一下機(jī)械手自動(dòng)送料裝置，該送料機(jī)的工作原理和結(jié)構(gòu)特點(diǎn)：機(jī)械手是以小車形式通過鋼繩同滑塊聯(lián)接起來， 由沖床滑塊上升運(yùn)動(dòng)牽引小車作前進(jìn)的水平運(yùn)動(dòng)完成送料，由通過鋼繩連接的重物使小車作復(fù)位運(yùn)動(dòng)。機(jī)械手的提升、下降是靠安裝在小車頂架板上的提升缸推動(dòng)滑板作往復(fù)上下運(yùn)動(dòng)來完成；機(jī)械手的夾緊、放松是靠安裝在滑板上的夾緊缸帶動(dòng)連桿鉸鏈機(jī)構(gòu)來完成機(jī)械手的運(yùn)動(dòng)程序如下：
夾緊一提升一前進(jìn)至中心一下降一放松一返回
節(jié)拍是恒定的， 且每一循環(huán)均需在3秒鐘內(nèi)完成。
另一種是沖床自動(dòng)送料機(jī)，一種用于冷擠壓套圈類零件的送料機(jī)器，是沖床進(jìn)行技術(shù)改造的理想附機(jī)。該送料機(jī)克服了國內(nèi)外有關(guān)沖床送料機(jī)的不足。如RF20SD—0R11型沖床送料機(jī)，結(jié)構(gòu)由沖床上曲軸輸出軸，通過花鍵軸伸縮，球頭節(jié)部件聯(lián)接機(jī)械手齒輪，由傘齒輪、圓柱齒輪、齒條、凸輪、撥叉、絲桿等一系列傳動(dòng)件使機(jī)械手的夾爪作伸縮、升降、夾緊、松開等與沖床節(jié)拍相同的動(dòng)作來完成送料，另設(shè)一套獨(dú)立驅(qū)動(dòng)可移式輸送機(jī)，通過隔料機(jī)構(gòu)將工件輸送至預(yù)定位置，這樣一套機(jī)構(gòu)的配置僅局限于日本設(shè)備，不能應(yīng)用于國產(chǎn)沖床。國內(nèi)有的送料機(jī)構(gòu)由沖床工作臺(tái)通過連桿彈簧驅(qū)動(dòng)滑塊在滑道上水平滑動(dòng)，將斜道上下來的料，通過隔料機(jī)構(gòu)推到模具中心，并聯(lián)動(dòng)打板將沖好的料撥掉，往復(fù)運(yùn)動(dòng)的一整套機(jī)構(gòu)比較簡單，無輸送機(jī)構(gòu)，聯(lián)動(dòng)可靠，制造容易。但機(jī)械手不能將料提升、夾緊，料道傾斜放置靠料自重滑下，如規(guī)格重量變動(dòng)，則料道上工件下滑速度不一致，易產(chǎn)生疊料，推料機(jī)構(gòu)沒有將料夾緊，定位不正，廢品率較高，使用也不安全。
所以隨著自動(dòng)化、半自動(dòng)化在國民經(jīng)濟(jì)各行業(yè)的普及深入，自動(dòng)送料裝置作為生產(chǎn)線一個(gè)不可缺少的 環(huán)節(jié)，對(duì)其結(jié)構(gòu)、噪音、工作原理、輸送精度及 控制難易程度等方面提出了更高的要求，傳統(tǒng)的 振動(dòng)送料裝置已不能滿足要求。對(duì)滾柱夾持式自動(dòng)送料機(jī)更是進(jìn)行了多方面的改進(jìn)，使其工作更平穩(wěn)，更快捷。讓它在生產(chǎn)過程中具有更簡單的操作方式并達(dá)到高效率的生產(chǎn)狀態(tài)。
隨著現(xiàn)代生產(chǎn)和科學(xué)技術(shù)的發(fā)展，對(duì)自動(dòng)化技 術(shù)提出越來越高的要求，送料機(jī)同 時(shí)也為自動(dòng)化技術(shù)的革新提供了必要條件。70年代以后，自動(dòng)化開始向復(fù)雜的電氣自動(dòng)化系統(tǒng)控制和高級(jí)的智能控制發(fā)展，并廣泛地應(yīng)用到國防、科學(xué)研究和經(jīng)濟(jì) 等各個(gè)領(lǐng)域，實(shí)現(xiàn)更大規(guī)模的自動(dòng)化，例如大型企業(yè)的綜合自動(dòng)化系統(tǒng)、全國鐵路自動(dòng)調(diào)度系統(tǒng)、國家電力網(wǎng)自動(dòng)調(diào)度系統(tǒng)、空中交通管制系統(tǒng)、城市交通控制系 統(tǒng)、自動(dòng)化指揮系統(tǒng)、國民經(jīng)濟(jì)管理系統(tǒng)等。自動(dòng)化的應(yīng)用正從工程領(lǐng)域向非工程領(lǐng)域擴(kuò)展，如醫(yī)療自動(dòng)化、人口控制、經(jīng)濟(jì)管理自動(dòng)化等。自動(dòng)化將在更大程度上 模仿人的智能，機(jī)器人已在工業(yè)生產(chǎn)、海洋開發(fā)和宇宙探測等領(lǐng)域得到應(yīng)用，專家系統(tǒng)在醫(yī)療診斷、地質(zhì)勘探等方面取得顯著效果。工廠自動(dòng)化、辦公自動(dòng)化、家庭 自動(dòng)化和農(nóng)業(yè)自動(dòng)化將成為新技術(shù)革命的重要內(nèi)容，并得到迅速發(fā)展。
在工業(yè)發(fā)達(dá)國家或地區(qū)，日本、美國最具代 表性，尤其是日本，由于滾柱式自動(dòng)送料機(jī)機(jī)構(gòu)相對(duì)簡單，故而對(duì)其涉及的研究較少。但是對(duì)新型的壓電振動(dòng)送料裝置的理論、 設(shè)計(jì)與計(jì)算的研究則比較深入與完整，也推出了許 多新型與異型機(jī)構(gòu)的振動(dòng)送料裝置。
三、總結(jié)
綜上所述，由于滾柱夾持式自動(dòng)送料裝置在設(shè)計(jì)結(jié)構(gòu)上與其他自動(dòng)送料裝置相比，略顯簡單，但是正是由于這一優(yōu)點(diǎn)，他在生產(chǎn)生活中得到了較為廣泛的應(yīng)用。但是在生產(chǎn)效率和使用精度方面來講，滾柱夾持式自動(dòng)送料裝置還存在些許的問題，如傳送過程的疊料，定位不正，增加廢品率等。所以在生產(chǎn)過程中，我們還要再仔細(xì)研究和設(shè)計(jì)，盡量優(yōu)化送料裝置，使其更完善的在生產(chǎn)過程中發(fā)揮作用。
參考文獻(xiàn)
(1) 濮良貴.機(jī)械設(shè)計(jì).8版.高等教育出版社
(2) 高澤遠(yuǎn)，王金主編，機(jī)械設(shè)計(jì)基礎(chǔ)課程設(shè)計(jì) 沈陽：東北工學(xué)院出版社
(3) 席偉光.楊光，李波.機(jī)械設(shè)計(jì)課程設(shè)計(jì) 高等教育出版社
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外文資料翻譯譯文
機(jī)械設(shè)計(jì)和制造過程
機(jī)械設(shè)計(jì)和制造過程的機(jī)械設(shè)計(jì)是一種運(yùn)用科學(xué)技術(shù),設(shè)計(jì)新的或改進(jìn)的產(chǎn)品為宗旨滿足人類的需要。這是一個(gè)廣闊的研究領(lǐng)域的工程技術(shù),不僅關(guān)系到自身產(chǎn)品的原始概念角度大小、形狀和施工細(xì)節(jié),而且考慮了各種因素參與的生產(chǎn)、銷售和使用的產(chǎn)品。
人履行的各種職能機(jī)械設(shè)計(jì)通常稱為設(shè)計(jì)師,或設(shè)計(jì)工程師。機(jī)械設(shè)計(jì)基本上是一個(gè)創(chuàng)造性的活動(dòng)。然而,除了是創(chuàng)新、設(shè)計(jì)工程師還必須有一個(gè)扎實(shí)的機(jī)械制圖領(lǐng)域、運(yùn)動(dòng)學(xué)、動(dòng)力學(xué)、材料工程、材料強(qiáng)度和生產(chǎn)工藝。
綜上所述,機(jī)械設(shè)計(jì)的目的是生產(chǎn)一種產(chǎn)品,為需要的人。發(fā)明、發(fā)現(xiàn)和科學(xué)知識(shí)本身并不一定利益的人,只要他們引入一個(gè)設(shè)計(jì)的產(chǎn)品將會(huì)得到好處。我們要認(rèn)清,因此,一個(gè)人必須確定之前需要一個(gè)特定的產(chǎn)品設(shè)計(jì)。
機(jī)械設(shè)計(jì)應(yīng)該被認(rèn)為是一個(gè)機(jī)遇,利用創(chuàng)新人才來想象一個(gè)設(shè)計(jì)的一種產(chǎn)品,分析系統(tǒng),然后做出正確判斷如何生產(chǎn)產(chǎn)品。很重要的一點(diǎn)就是要了解基本的工程,而不是僅僅記住的事實(shí)和方程。沒有事實(shí)或方程就可以被用來提供所有的正確決策的需要產(chǎn)生一個(gè)好的設(shè)計(jì)。
另一方面,必須做任何計(jì)算以最大的保健和精度。例如,如果一個(gè)小數(shù)點(diǎn)是不合理的,否則不得接受設(shè)計(jì)功能。
好的設(shè)計(jì)需要嘗試新的想法和心甘情愿地采取一定數(shù)額的風(fēng)險(xiǎn),如果明知不工作的新理念存在的方法可以恢復(fù)。因此一個(gè)設(shè)計(jì)師必須要有耐心,因?yàn)闆]有保證成功的時(shí)間和精力耗盡。創(chuàng)造一個(gè)全新的設(shè)計(jì)通常要求,許多老和信譽(yù)卓著,被推開方法。這并不容易,因?yàn)楹芏嗳耸煜さ娜吮е碌睦砟?、技巧和態(tài)度。設(shè)計(jì)工程師應(yīng)不斷尋找途徑來提高現(xiàn)有的產(chǎn)品,必須決定什么老,證明應(yīng)使用什么概念和新觀點(diǎn)應(yīng)該嘗試股份有限公司。
新設(shè)計(jì)一般都有“臭蟲”或一些無法預(yù)料的問題,必須制定出優(yōu)越的特點(diǎn)在新設(shè)計(jì)可以享受。因此有一個(gè)機(jī)會(huì),為建立一個(gè)優(yōu)質(zhì)的產(chǎn)品,但只有更高的風(fēng)險(xiǎn)。我們必須強(qiáng)調(diào),如果一個(gè)設(shè)計(jì)不保證激進(jìn)的新方法,這種方法不應(yīng)該應(yīng)用僅僅是為了改變。
在起步階段的設(shè)計(jì)、創(chuàng)新,要允許蓬勃發(fā)展沒有大量的約束。盡管許多不切實(shí)際的想法可能出現(xiàn),它通常是容易消除他們?cè)谠缙谠O(shè)計(jì)階段,細(xì)節(jié)之前要求公司制造。通過這種方式,創(chuàng)新思想不壓抑。通常,超過一設(shè)計(jì)開發(fā),到的地方會(huì)比較相互爭斗。這是完全可能的設(shè)計(jì)思想最終接受將使用中存在的設(shè)計(jì)的一個(gè)拒絕不給盡可能多的整體的承諾。
心理學(xué)家經(jīng)常談?wù)撛噲D健康的人們,他們的機(jī)器操作。它本質(zhì)上是一位設(shè)計(jì)工程師的職責(zé)努力適應(yīng)機(jī)器的。這不是一個(gè)容易的任務(wù),因?yàn)榇_實(shí)沒有一般人的尺寸和特定操作程序的最佳狀態(tài)。
另外重要的一點(diǎn),我們應(yīng)該認(rèn)識(shí)到這一點(diǎn)是一個(gè)設(shè)計(jì)工程師必須能夠?qū)e人交流思想,如果他們想被合并。溝通設(shè)計(jì)給別人是決賽,在設(shè)計(jì)過程中至關(guān)重要的一步。毫無疑問,許多偉大的設(shè)計(jì)、發(fā)明、以及創(chuàng)造性的作品已經(jīng)丟到了人類無所不包,只不過是因?yàn)椴荒芤膊辉附忉屗麄兊某删徒o別人。介紹一個(gè)推銷工作。工程師,設(shè)計(jì)一種新的解的行政、管理、監(jiān)督人員、正試圖出售或證明給他們看,這個(gè)方案是一個(gè)更好的。除非這可以做成功,時(shí)間和精力花在獲得解決大部分已經(jīng)被浪費(fèi)了.
基本上,只有3家的通信手段提供給我們的。這些都是書面、口頭、圖形化的形式。因此,成功的工程師將合格技術(shù)和最多才多藝的并且在所有的三個(gè)形式的溝通。一個(gè)技術(shù)能力缺乏能力的人,他們中的任何一個(gè)形式是嚴(yán)重殘疾。如果能在所有的三個(gè)形態(tài)缺乏,沒有人會(huì)知道主管那個(gè)人!
主管工程師不應(yīng)該害怕沒有成功的可能在一個(gè)表現(xiàn)。事實(shí)上,偶爾失敗應(yīng)該會(huì)因?yàn)槭』蚺u(píng)似乎伴隨每一個(gè)真正具有創(chuàng)造性的想法。有許多讓你從中得到教訓(xùn)是失敗的,并得到了最大的收獲是那些愿意冒險(xiǎn)失敗。在最后的分析中,真正的失敗在于決定不要讓演示。有效溝通,必須回答以下問題:(1)是否真的能夠設(shè)計(jì)一個(gè)人類需要什么?(2)將它與現(xiàn)有的產(chǎn)品競爭對(duì)手公司嗎?(3)是經(jīng)濟(jì)生產(chǎn)多少?(4)可以容易保持下去嗎?(5)將它出售和賺錢嗎?
只有時(shí)間能提供真正的答案在前的問題,但是產(chǎn)品應(yīng)在設(shè)計(jì)、制造和銷售初始肯定只有答案。設(shè)計(jì)工程師也必須傳達(dá)最終設(shè)計(jì)到制造通過使用細(xì)節(jié)和圖紙。
通常,一個(gè)問題將是發(fā)生在制造周期[3]。可能需要改變尺寸與寬容的一部分,這樣更容易產(chǎn)生了。這個(gè)失敗的工程變更的范疇,必須經(jīng)設(shè)計(jì)工程師,使得產(chǎn)品功能并不會(huì)受到不良影響。在其他情況下,不足之處,設(shè)計(jì)可裝配和測試過程中出現(xiàn)之前發(fā)貨。這些現(xiàn)實(shí)只是證實(shí)這一事實(shí)是一個(gè)活生生的設(shè)計(jì)過程。總是有一個(gè)更好的方法來做到這一點(diǎn),并不斷向設(shè)計(jì)人應(yīng)發(fā)現(xiàn)更好的方法。
設(shè)計(jì)始于一個(gè)需要的,真實(shí)的,還是想象中的。可能需要改進(jìn)現(xiàn)有的設(shè)備在耐久性、高效、重量、速度、成本。新設(shè)備可能需要做一個(gè)函數(shù)由男人以前做過,如計(jì)算、裝配、或維修。全部或者部分和客觀的定義后,下一步的設(shè)計(jì)觀念和他們的安排,將機(jī)制執(zhí)行所需的功能。
為此,徒手畫草圖是很有價(jià)值的,不僅是記錄某個(gè)人的思想和作為一種輔助討論與他人溝通,尤其是自己的意志,激勵(lì)創(chuàng)新的想法。
設(shè)計(jì)始于一個(gè)需要的,真實(shí)的,還是想象中的?？赡苄枰倪M(jìn)現(xiàn)有的設(shè)備在耐久性、高效、重量、速度、成本。新設(shè)備可能需要做一個(gè)函數(shù)由男人以前做過,如計(jì)算、裝配、或維修。全部或者部分和客觀的定義后,下一步的設(shè)計(jì)觀念和他們的安排,將機(jī)制執(zhí)行所需的功能。
為此,徒手畫草圖是很有價(jià)值的,不僅是記錄某個(gè)人的思想和作為一種輔助討論與他人溝通,尤其是自己的意志,激勵(lì)創(chuàng)新的想法。
通用形狀和少數(shù)幾個(gè)部件的尺寸變得明顯,分析就可以開始中解脫出來。這種分析可以作為它的目標(biāo)“滿意”或“卓越的性能,以及安全性和耐久性與最小重量,以及具有競爭力的東方。最佳比例和尺寸將尋找每個(gè)極加載部分,結(jié)合強(qiáng)度之間的一個(gè)平衡點(diǎn)的若干部件。材料及其治療將被選中。這些重要的目標(biāo),就可以達(dá)到只有通過分析力學(xué)原則的基礎(chǔ)上,諸如穩(wěn)定的反應(yīng)力和摩擦的優(yōu)化利用,動(dòng)力學(xué)慣性、加速度、能源、材料彈性和強(qiáng)度的應(yīng)力和撓度。
最后,基于功能和可靠性設(shè)計(jì)將完成,一個(gè)樣機(jī)可以被建立。如果它的測試是滿意的,如果這個(gè)裝置產(chǎn)生的數(shù)量、初始設(shè)計(jì)將接受一定的修改,使它生產(chǎn)的數(shù)量以較低的成本。在接下來的幾年的生產(chǎn)和服務(wù),設(shè)計(jì)可能要進(jìn)行構(gòu)思的變化或新思想的基礎(chǔ)上進(jìn)一步分析測試和經(jīng)驗(yàn)表明變更。銷售的吸引力,客戶滿意度
和制造成本所有相關(guān)的設(shè)計(jì),而且在設(shè)計(jì)能力密切地參與到工程的成功的合資企業(yè)。
外文原文
Mechanical design and Manufacturing processes
Mechanical Design and Manufacturing Processes Mechanical design is the application of science and technology to devise new or improved products for the purpose of satisfying human needs. It is a vast field of engineering technology which not only concerns itself with the original conception of the product in terms of its size, shape and construction details, but also considers the various factors involved in the manufacture, marketing and use of the product.
People who perform the various functions of mechanical design are typically called designers, or design engineers. Mechanical design is basically a creative activity. However, in addition to being innovative, a design engineer must also have a solid background in the areas of mechanical drawing, kinematics, dynamics, materials engineering, strength of materials and manufacturing processes.
As stated previously, the purpose of mechanical design is to produce a product which will serve a need for man. Inventions, discoveries and scientific knowledge by themselves do not necessarily benefit people; only if they are incorporated into a designed product will a benefit be derived. It should be recognized, therefore, that a human need must be identified before a particular product is designed.
Mechanical design should be considered to be an opportunity to use innovative talents to envision a design of a product, to analyze the system and then make sound judgments on how the product is to be manufactured. It is important to understand the fundamentals of engineering rather than memorize mere facts and equations. There are no facts or equations which alone can be used to provide all the correct decisions required to produce a good design.
On the other hand, any calculations made must be done with the utmost care and precision. For example, if a decimal point is misplaced, an otherwise acceptable design may not function.
Good designs require trying new ideas and being willing to take a certain amount of risk, knowing that if the new idea does not work the existing method can be reinstated. Thus a designer must have patience, since there is no assurance of success for the time and effort expended. Creating a completely new design generally requires that many old and well-established methods be thrust aside. This is not easy since many people cling to familiar ideas, techniques and attitudes. A design engineer should constantly search for ways to improve an existing product and must decide what old, proven concepts should be used and what new, untried ideas should be incorporated.
New designs generally have "bugs" or unforeseen problems which must be worked out before the superior characteristics of the new designs can be enjoyed. Thus there is a chance for a superior product, but only at higher risk. It should be emphasized that, if a design does not warrant radical new methods, such methods should not be applied merely for the sake of change.
During the beginning stages of design, creativity should be allowed to flourish without a great number of constraints. Even though many impractical ideas may arise, it is usually easy to eliminate them in the early stages of design before firm details are required by manufacturing. In this way, innovative ideas are not inhibited. Quite often, more than one design is developed, up to the point where they can be compared against each other. It is entirely possible that the design which is ultimately accepted will use ideas existing in one of the rejected designs that did not show as much overall promise.
Psychologists frequently talk about trying to fit people to the machines they operate. It is essentially the responsibility of the design engineer to strive to fit machines to people. This is not an easy task, since there is really no average person for which certain operating dimensions and procedures are optimum.
Another important point which should be recognized is that a design engineer must be able to communicate ideas to other people if they are to be incorporated. Communicating the design to others is the final, vital step in the design process. Undoubtedly many great designs, inventions, and creative works have been lost to mankind simply because the originators were unable or unwilling to explain their accomplishments to others. Presentation is a selling job. The engineer, when presenting a new solution to administrative, management, or supervisory persons, is attempting to sell or to prove to them that this solution is a better one. Unless this can be done successfully, the time and effort spent on obtaining the solution have been largely wasted.
Basically, there are only three means of communication available to us. These are the written, the oral, and the graphical forms. Therefore the successful engineer will be technically competent and versatile in all three forms of communication. A technically competent person who lacks ability in any one of these forms is severely handicapped. If ability in all three forms is lacking, no one will ever know how competent that person is!
The competent engineer should not be afraid of the possibility of not succeeding in a presentation. In fact, occasional failure should be expected because failure or criticism seems to accompany every really creative idea. There is a great deal to be learned from a failure, and the greatest gains are obtained by those willing to risk defeat. In the final analysis, the real failure would lie in deciding not to make the presentation at all. To communicate effectively, the following questions must be answered: (1) Does the design really serve a human need? (2) Will it be competitive with existing products of rival companies? (3) Is it economical to produce? (4) Can it be readily maintained? (5) Will it sell and make a profit?
Only time will provide the true answers to the preceding questions, but the product should be designed, manufactured and marketed only with initial affirmative answers. The design engineer also must communicate the finalized design to manufacturing through the use of detail and assembly drawings.
Quite often, a problem will occur during the manufacturing cycle [3]. It may be that a change is required in the dimensioning or tolerance of a part so that it can be more readily produced. This fails in the category of engineering changes which must be approved by the design engineer so that the product function will not be adversely affected. In other cases, a deficiency in the design may appear during assembly or testing just prior to shipping. These realities simply bear out the fact that design is a living process. There is always a better way to do it and the designer should constantly strive towards finding that better way.
Designing starts with a need, real or imagined. Existing apparatus may need improvements in durability, efficiently, weight, speed, or cost. New apparatus may be needed to perform a function previously done by men, such as computation, assembly, or servicing. With the objective wholly or partly defined, the next step in design is the conception of mechanisms and their arrangements that will perform the needed functions.
For this, freehand sketching is of great value, not only as a record of one's thoughts and as an aid in discussion with others, but particularly for communication with one's own mind, as a stimulant for creative ideas.
When the general shape and a few dimensions of the several components become apparent, analysis can begin in earnest. The analysis will have as its objective satisfactory or superior performance, plus safety and durability with minimum weight, and a competitive east. Optimum proportions and dimensions will be sought for each critically loaded section, together with a balance between the strength of the several components. Materials and their treatment will be chosen. These important objectives can be attained only by analysis based upon the principles of mechanics, such as those of static for reaction forces and for the optimum utilization of friction; of dynamics for inertia, acceleration, and energy; of elasticity and strength of materials for stress and deflection.
Finally, a design based upon function and reliability will be completed, and a prototype may be built. If its tests are satisfactory, and if the device is to be produced in quantity, the initial design will undergo certain modifications that enable it to be manufactured in quantity at a lower cost. During subsequent years of manufacture and service, the design is likely to undergo changes as new ideas are conceived or as further analysis based upon tests and experience indicate alteration. Sales appeal, customer satisfaction
And manufacture cost are all related to design, and ability in design is intimately involved in the success of an engineering venture.