Energy-saving Based Innovative Product Design Method

Abstract

This paper presents a research on the development of an innovative product design method with an aim to consider the energy-saving issue throughout the entire product life cycle. The research is based on a comprehensive analysis of regular product design procedures to extract the design information that correlates with energy consumption, itemize and quantify the information, and eventually build up mathematical models for final optimization. The result of this research will be used as guidelines for regular product design and achieving energy- saving design result. The objectives of the research are in threefold: (1) establishing a mechanism that can explicitly demonstrate the product design information that includes energy consumption throughout all stages of product life cycle; (2) modeling energy parameters with quantitative mathematical expressions; (3) developing a decision making system to optimize product design in terms of energy-saving. A concept called Design Unit (DU) will be introduced as a new method to describe product design information related with energy consumption. The axiomatic design theory will be integrated with DU concept, and becomes an important standard for optimizing product design. An new concept called Energy Factor will be introduced briefly in this paper.

Full text

Energy-saving
Based
Innovative
Product
Design
Method
Hua
Li,
Hong-chao
Zhang
Derrick
Tate
Dept.
of
Industrial
Engineering
Dept.
of
Mechanical
Engineering
Texas
Tech
University
Texas
Tech
University
Lubbock,
TX
USA
Lubbock,
TX
USA
hong-chao.zhanggttu.edu
Abstract-This
paper
presents
a
research
on
the
development
of
Last
ten
years,
some
researches
that
correlate
with
energy
an
innovative
product
design
method
with
an
aim
to
consider
the
issue
have
been
done.
A
life
cycle
assessment
tool
was
energy-saving
issue
throughout
the
entire
product
life
cycle.
The
developed
for
electromechanical
products
to
enhance
the
research
is
based
on
a
comprehensive
analysis
of
regular
product
operability
of
LCA
in
green
design
[1].
A
new
approach
for
design
procedures
to
extract
the
design
information
that
environmental
impact
assessment
in
a
multi-attribute
correlates
with
energy
consumption,
itemize
and
quantify
the
framework
was
developed
by
using
a
modified
Quality
information,
and
eventually
build
up
mathematical
models
for
Function
Deployment
(QFD)
methodology
[2].
Although
this
final
optimization.
The
result
of
this
research
will
be
used
as
hybrid
methodology
considers
energy
issue,
which
was
applied
guidelines
for
regular
product
design
and
achieving
energy-
to
computer
displays,
it
mainly
focuses
on
environmental
saving
design
result.
The
objectives
of
the
research
are
in
three-lons
for
fold:
(1)
establishing
a
mechanism
that
can
explicitly
demonstrate
ipea
l
Energ
has
nasti
of
e
oflfeoptis
fo
the
product
design
information
that
includes
energy
consumption
personal
computers
has
been
studied
[3],
but
it
only
focuses
on
throughout
all
stages
of
product
life
cycle;
(2)
modeling
energy
the
resell,
upgrade,
and
recycle.
Specific
method
to
predict
parameters
with
quantitative
mathematical
expressions;
(3)
energy
efficiency
improvement
from
component
changes
was
developing
a
decision
making
system
to
optimize
product
design
also
introduced,
which
was
helpful
to
set
energy
saving
and
in
terms
of
energy-saving.
A
concept
called
Design
Unit
(DU)
will
economic
targets
before
designing
a
product
[4].
But
all
of
them
be
introduced
as
a
new
method
to
describe
product
design
have
some
limitations:
some
of
them
can
not
cover
the
energy
information
related
with
energy
consumption.
The
axiomatic
impact
throughout
the
entire
product
life
cycle;
some
of
them
design
theory
will
be
integrated
with
DU
concept,
and
becomes
only
focus
on
specific
product,
and
the
alternative
technologies
an
important
standard
for
optimizing
product
design.
An
new
can
not
be
applied
to
general
products.
There
are
few
concept
called
Energy
Factor
will
be
introduced
briefly
in
this
researches
considering
the
energy
issues
in
all
of
the
life
cycle
paper.
stages
for
general
product.
In
this
paper,
we
will
present
a
new
innovative
product
design
method
with
an
aim
to
consider
the
Keywords-
product
design;
energy-saving;
axiomatic
design
energy-saving
issue
throughout
the
entire
life
cycle
of
general
product.
The
research
is
based
on
a
comprehensive
analysis
of
I.
INTRODUCTION
regular
product
design
procedures
to
extract
the
design
Energy
and
Environmental
issues
are
worldwide
concerns
information
that
correlates
with
energy
consumption,
itemize
in
the
21't
century.
As
the
world's
population
and
standard
of
and
quantify
the
information,
and
eventually
build
up
living
increases,
the
demand
for
energy
consequently
increases
mathematical
models
for
final
optimization.
as
well.
Following
the
increasing
consumption
of
energy
are
the
environmental
problems:
the
reduction
of
carbon
dioxide
II.
METHODOLOGY
emission
seems
to
be
quite
difficult,
and
the
global
warming
effect
is
severer
than
ever.
Governments
worldwide
are
A.
Definition
working
to
meet
this
challenge
including
developing
substitute
The
new
product
design
method
integrates
the
Axiomatic
energies,
e.g.
nuclear
energy
and
solar
energy;
exploring
Design
theory,
Energy
Factor
concept,
and
Design
Unit
renewable
energy
resources,
and
reducing
consumption
of
concept.
energy.
Energy
efficiency
and
economic
development
have
an
intrinsic
and
mutual
relationship.
Energy-saving
is
also
the
Axiomatic
Design
theory,
which
is
well
developed
and
most
effective
strategy
for
environmental
protection.
Despite
provides
a
logical
path
for
product
development,
will
become
a
the
significance
of
energy-saving,
no
research
has
been
veryimportant
standard
in
ourdesignmethod
[5]Energy
Fator
conducted
in
the
identification
of
systematic
methods
to
make
is
a
new
and
significant
concept
we
propose
in
the
whole
energy-saving
products
and
manufacturing
systems.
From
this
research
project.
We
define
the
Energy
Factor
as
a
variable
point
of
view,
one
of
our
current
major
concerns
is
to
develop
coefficient
mathematical
model
for
calculating
product
or
innovative
methodologies
that
will
reduce
energy
consumption
subassembly
energy
consumption
during
its
life
cycle.
It
is
a
throughout
the
entire
product
life
cycle
(from
cradle
to
grave),
general
mathematical
model
to
calculate
or
estimate
product
1-4244-0861-X/07/$25.O0
2007
IEEE
134

energy
consumption
in
its
entire
life
cycle.
These
studies
about
1
2
3
4
Energy
Factor
are
the
most
important
subject
of
further
Fxisted
modularity
Axiomatic
Design
Lower
level
Energy
Product
LCA
&
research.
Product
Analysis
Theory
Factor
Modeling
parts
The
second
new
concept
we
propose
is
called
Design
Unit,
which
is
defined
as
a
new
method
to
describe
product
design
5
6
information
related
with
energy
consumption
over
all
stages
of
Completed
New
Concept
New
Configuration
Axiomatic
Design
Energy
Factor
a
product's
life
cycle.
It
consists
of
five
elements,
which
can
be
DU
Generation
Generation
Theory
Modeling
expressed
as
follows:
9'
10
where,
DU=<ID,
FR,
P,
I,
DP>3
D
sg
DU~~~<ID,
FR,
F,
I~~~~~~
DP>
~Life
Cycle
0-Detail
Desg
New
Energy-savhmg
wxhere,
Assessment
einProduc-t
Design
ID
---
Is
the
Identification
Number
of
the
DU,
and
it
Figure
2.
Design
Procedures
for
improving
an
existed
product
provides
a
one-to-one
correspondence
with
DU.
FR
---
Is
Functional
Requirements,
which
is
a
minimum
set
1
2
3
of
independent
requirements
that
completely
characterize
the
New
Axiomatic
Design
New
Concept
New
Configuration
New
_
1xomh
Delo
_
e
ocp
NwCniuao
functional
needs
of
the
product
throughout
the
stages
of
Customer
needs
Theory
Generation
Generation
manufacturing,
utilization
and
recycle.
4
5
6
P
---
Is
the
Process,
which
contains
information
related
to
the
manufacturing
process,
recycle
process
and
utilization
E
Fr
C
De
New
Ener-saving
method.
Modehing
Assessment
eisg
product
Design
I
---
Is
the
energy
consumption
Information.
I
consists
of
Figure
3.
Design
Procedures
for
designing
a
new
product
I,n
I,
and
Ir,
which
are
the
energy
consumption
information
in
the
stages
of
manufacturing,
utilization
and
recycle
The
detail
design
procedures
for
improving
a
existed
respectively.
For
one
product,
each
stage
will
have
different
product
are
described
as
below:
processes,
and
each
process
has
its
own
energy
consumption
mathematical
model.
Through
this
variable,
we
want
to
Step
1
(Modularity
analysis):
Once
we
get
an
existed
summarize
the
similarities
of
different
models,
and
describe
the
product,
modularity
analysis
will
be
used
to
divide the
product
models
using
a
general
function,
which
we
will
designate
as
the
into
different
modules
based
on
the
modular
design
theory.
energy
factor.
We
will
also
apply
a
statistical
sensitivity
Step
2
(Axiomatic
design
theory):
After
getting
the
analysis
to
determine
the
relationship
among
I,
I,
and
I,
and
modules
of
the
product,
we
can
use
axiomatic
design
theory
to
establish
the
priority
to
be
optimized.
analyze
the
different
modules,
find
the
detail
function
DP
---
Is
current
Design
Parameters,
which
are
the
key
requirements
and
design
parameters,
and
build
the
design
variables
that
characterize
the
design
that
satisfies
FR.
matrices.
Through
further
classification
the
factors
can
be
sub-
Step
3
(Lower
level
energy
factor
modeling):
Based
on
the
divided
into
lower
levels
(shown
in
Fig.
1),
and
each
FRs
and
DPs,
the
lower
level
energy
factors
can
be
developed
subassembly
will
have
its
own
DU.
to
calculate
the
energy
consumption.
Step
4
(Product
LCA
&
Rank
of
stages
and
parts):
Product
life
cycle
assessment
will
be
done
to
compare
the
energy
DU,(ID,FRPJI,DP)
Productlevel
consumption
information
of
the
product
in
different
stages.
Though
analyzing
the
energy
consumption
information
using
sensitivity
analysis
or
fuzzy
logic
system,
the
rank
for
different
DU1(ID
D
DU12
(D,I,DP)
DUn(ID,FRY,I,DP)
Functionalparts
parts
and
different
stages
can
be
found
in
terms
of
the
importance
to
energy-saving.
After
this
step,
we
can
get
all
the
information
needed
in
design
unit,
and
then
the
completed
DUs
for
different
parts
can
be
finished.
DUnn
(
ID,FRP,I,DP)
Subassembly
Step
5&6
(New
concept
generation
&
new
configuration
Figure
1.
Design
Unit
Decomposition
Hierarchy
generation):
Based
on
the
information
in
design
unit,
designers
can
begin
to
generate
new
concepts
and
configurations
to
B.
Design
Procedures
optimize
the
existed
product.
The
sequence
of
optimization
will
In
the
new
innovative
product
design
method,
there
are
ten
be
same
as
the
rank
we
get
in
step
4.
steps
for
improving
an
existed
product
(shown
in
Fig.
2),
and
Step
7
(Axiomatic
design
theory):
The
new
configurations
SiX
steps
for
designing
a
new
product
(shown
in
Fig.
3).
will
be
analyzed
using
axiomatic
design
theory.
If
the
design
Actually,
the
procedures
for
designing
a
new
product
can
be
matrices
of
new
configurations
are
qualified
for
an
uncoupled
considered
as
a
part
of
the
procedures
for
improving
an
existed
or
decoupled
design,
designers
can
go
to
next
step,
otherwise,
product.
designers
have
to
return
to
step
5.
1-4244-0861-X/07/$25.00
2007
IEEE
135

Step
8
(Energy
factor
modeling):
The
energy
consumption
1DP=
{aAFRI
-
/JAFR
-
AFR}
information
for
new
configuration
will
be
calculated
using
1
|DM
2
F13
energy
factor
models.
If
the
energy
consumed
in
new
configurations
is
less
than
the
existed,
designers
can
go
to
next
The
expressions
for
DP2
and
DP3
are
similar
forms.
In
step,
otherwise
designers
have
to
go
back
to
step
5 to
generator
addition,
based
on
the
analysis
of
energy
consumption
models,
new
concept.
we
can
also
obtain
another
feasible
range
for
DP.
The
overlapping
area
of
the
two
feasible
ranges
is
the
optimal
Step
9
(Life
cycle
assessment):
Life
cycle
assessment
will
solution.
be
applied
to
the
new
configurations.
If
the
results
become
better,
designers
can
go
to
next
step,
otherwise,
designers
have
to
go
back
to
step
5 to
generator
new
concept.
III.
SUMMARY
AND
FURTURE
WORK
Step
10
(Detail
Design):
Detail
design
can
be
done
based
"We
do
not
inhibit
the
earth
from
our
parents;
we
borrow
on
the
new
configurations
in
this
step,
and
then
a
new
product
it
from
our
children,"
with
this
old
proverb
we
summarize
the
will
be
finished
based
on
the
existed
product,
which
will
have
underlying
objective
of
this
project.
The
objectives
of
the
better
energy-saving
property.
research
are
in
three-fold:
(1)
establishing
a
mechanism
that
can
explicitly
demonstrate
the
product
design
information
that
To
design
a
new
energy-saving
product,
the
input
becomes
icue
nrycnupintruhu
l
tgso
rdc
new
customer
needs,
and
the
following
steps
are
same
with
thene
l
corresponding
steps
in
the
procedures
of
improving
an
existed
life
cycle;
(2)
modeling
Energy
Factor
with
quantitative
product.
Energy
factor,
as
we
mentioned
before,
is
a
very
mathematical
expressions;
(3)
developing
a
decision
making
important
part
in
the
innovative
product
design
method.
A
case
system
to
optimize
product
design
in
terms
of
energy-saving.
study
is
conducting
in
our
lab
to
develop
the
detail
energy
Following
the
procedures
we
provided,
designers
can
easily
factor
models
for
different
processes.
The
results
will
be
shown
design
a
real
energy-saving
product
in
the
entire
product
life
in
our
future publications.
cycle.
Since
the
new
concept
DU
was
introduced,
it
will
be
easy
to
program
software
to
realize
the
new
innovative
C.
Optimization
product
design
method.
Based
on
the
three
objectives,
our
After
we
finish
every
DU
for
the
product,
develop
all
the
future
work
will
focus
on
the
energy
factor
modeling
by
energy
factors
to
calculate
the
energy
consumption,
the
analyzing
actual
specific
products.
optimization
will
be
simple
to
perform.
To
optimize
the
IV.
CONCLUSION
product
design,
energy-saving
can
not
be
the
only
rule.
We
The
result
of
this
research
will
be
used
as
guidelines
for
also
need
to
maintain
the
relationship
between
FR
and
DP.
regular
product
design
and
achieving
energy-saving
design
Therefore,
through
axiomatic
design
concept,
there
is
a
design
result.
In
addition,
academic
institutes
will
be
able
to
use
the
matrix
A
will
be
utilized
to
describe
the
relationship
between
general
methodologies
to
be
developed
in
this
research
as
a
FR
and
DP
as
follows:
platform
for
further
energy-saving
product
research.
Industry
A,j
=
aFR
will
be
able
to
use
the
product
design
decision
making
system
{FR}=
[A]{DP
while
-
to
improve
their
products'
energy
efficiency
and
use
the
To
realize
the
FRs,
axiomatic
design
provides
some
innovative
method
as
a
powerful
tool
for
their
new
energy-
theories
and
formulas
to
limit
the
DPs,
so
we
can
get
a
saving
product
designs.
It
is
also
expected
that
through
feasible
range
of
DPs,
e.g.,
improved
product
energy
efficiency,
this
research
will
help
to
t
FR
|
A
A
A
1rDP
|improve
energy
sustainability
of
the
nationwide
and
throughout
FRI
11
12
13
D1P
the
world,
in
addition
to
maintain
the
harmony
between
human
FR2
h
A21A22A23
4
DP2
beings
and
nature.
FR3
J
A31A32A33
LDP3
JACKNOWLEDGMENT
If
the
determinant
of
the
design
matrix
IDMI
is
not
equal
The
authors
would
like
to
acknowledge
the
contributions
of
to
zero,
the
solution
for
DP1
is
everyone
in
Texas
Tech
Advanced
Manufacturing
Laboratory.
DP,
=
{acFRI
-
8FR2
-
fR3}
REFERENCES
~DM~
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X.
Feng,
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Zhu,
R.
Smith,
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1305-1312,
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a
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allowable
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