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Method. Hua Li, Hong-chaoZhang. Derrick Tate. Dept. ofIndustrial Engineering. Dept. ofMechanical Engineering. Texas Tech University. Texas Tech University.
Energy-saving Based Innovative Product Design Method Hua Li, Hong-chao Zhang Dept. of Industrial Engineering Texas Tech University Lubbock, TX USA

Derrick Tate Dept. of Mechanical Engineering Texas Tech University Lubbock, TX USA

hong-chao.zhanggttu.edu

Last ten years, some researches that correlate with energy

Abstract-This paper presents a research on the development of

issue have been done. A life cycle assessment tool was developed for electromechanical products to enhance the operability of LCA in green design [1]. A new approach for environmental impact assessment in a multi-attribute framework was developed by using a modified Quality Function Deployment (QFD) methodology [2]. Although this hybrid methodology considers energy issue, which was applied to computer displays, it mainly focuses on environmental

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 energysaving design result. The objectives of the research are in fold: (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

three-lonsipea for

l Energ oflfeoptis fo has nasti of e personal computers has been studied [3], but it only focuses on the resell, upgrade, and recycle. Specific method to predict energy efficiency improvement from component changes was also introduced, which was helpful to set energy saving and economic targets before designing a product [4]. But all of them have some limitations: some of them can not cover the energy impact throughout the entire product life cycle; some of them only focus on specific product, and the alternative technologies can not be applied to general products. There are few researches considering the energy issues in all of the life cycle

stages for general product. In this paper, we will present a new innovative product design method with an aim to consider the energy-saving issue throughout the entire life cycle of general product. 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.

paper.

Keywords- product design; energy-saving; axiomatic design I. INTRODUCTION Energy and Environmental issues are worldwide concerns in the 21't century. As the world's population and standard of living increases, the demand for energy consequently increases as well. Following the increasing consumption of energy are the environmental problems: the reduction of carbon dioxide emission seems to be quite difficult, and the global warming effect is severer than ever. Governments worldwide are working to meet this challenge including developing substitute energies, e.g. nuclear energy and solar energy; exploring renewable energy resources, and reducing consumption of energy. Energy efficiency and economic development have an intrinsic and mutual relationship. Energy-saving is also the most effective strategy for environmental protection. Despite the significance of energy-saving, no research has been conducted in the identification of systematic methods to make energy-saving products and manufacturing systems. From this point of view, one of our current major concerns is to develop innovative methodologies that will reduce energy consumption throughout the entire product life cycle (from cradle to grave),

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II.

METHODOLOGY

A. Definition The new product design method integrates the Axiomatic Design theory, Energy Factor concept, and Design Unit concept.

Axiomatic Design theory, which is well developed and provides a logical path for product development, will become a veryimportant standard in ourdesignmethod [5]Energy Fator is a new and significant concept we propose in the whole research project. We define the Energy Factor as a variable coefficient mathematical model for calculating product or subassembly energy consumption during its life cycle. It is a general mathematical model to calculate or estimate product 134

energy consumption in its entire life cycle. These studies about are the most important subject of further

Fxisted modularity

research.

Product

The second new concept we propose is called Design Unit, which is defined as a new method to describe product design information related with energy consumption over all stages of a product's life cycle. It consists of five elements, which can be expressed as follows:

where,

DU=3

Analysis

DU

Generation

DU~~~

Energy Factor

Theory Modeling

DeinProduc-tsg

9'

10

0-Detail Desg New Energy-savhmg

Customer needs

Design

Theory

4

Generation

5

3 New Configuration NwCniuao

Generation

6

Fr C New Ener-saving De eisg product Design Assessment Modehing Figure 3. Design Procedures for designing a new product E

The detail design procedures for improving a existed product are described as below:

Step 1 (Modularity analysis): Once we get an existed product, modularity analysis will be used to divide the product into different modules based on the modular design theory. Step 2 (Axiomatic design theory): After getting the modules of the product, we can use axiomatic design theory to

analyze the different modules,

find

the detail function

requirements and design parameters, and build the design

matrices.

Step 3 (Lower level energy factor modeling): Based on the FRs and DPs, the lower level energy factors can be developed 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 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 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

Functionalparts

for different parts can be finished. Step 5&6 (New concept generation & new configuration generation): Based on the information in design unit, designers can begin to generate new concepts and configurations to optimize the existed product. The sequence of optimization will be same as the rank we get in step 4. Step 7 (Axiomatic design theory): The new configurations will be analyzed using axiomatic design theory. If the design matrices of new configurations are qualified for an uncoupled or decoupled design, designers can go to next step, otherwise, designers have to return to step 5.

Subassembly

Figure 1. Design Unit Decomposition Hierarchy B. Design Procedures In the new innovative product design method, there are ten steps for improving an existed product (shown in Fig. 2), and SiX steps for designing a new product (shown in Fig. 3). Actually, the procedures for designing a new product can be considered as a part of the procedures for improving an existed product.

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Axiomatic Design

1 2 NewNew _ Axiomatic Design New _ e Concept ocp 1xomh Delo

Productlevel

DUnn ( ID,FRP,I,DP)

Generation

parts

Figure 2. Design Procedures for improving an existed product

summarize the similarities of different models, and describe the models using a general function, which we will designate as the energy factor. We will also apply a statistical sensitivity analysis to determine the relationship among I, I, and I, and establish the priority to be optimized. DP --- Is current Design Parameters, which are the key variables that characterize the design that satisfies FR. Through further classification the factors can be subdivided into lower levels (shown in Fig. 1), and each subassembly will have its own DU.

DUn(ID,FRY,I,DP)

Factor Modeling

6

Assessment

I --- Is the energy consumption Information. I consists of I,n I, and Ir, which are the energy consumption information in the stages of manufacturing, utilization and recycle respectively. For one product, each stage will have different processes, and each process has its own energy consumption mathematical model. Through this variable, we want to

DU12 (D,I,DP)

4 Product LCA &

New Configuration

~Life Cycle

method.

D

3 Lower level Energy

Theory

5

of independent requirements that completely characterize the functional needs of the product throughout the stages of manufacturing, utilization and recycle. P --- Is the Process, which contains information related to the manufacturing process, recycle process and utilization

DU1(ID

Axiomatic Design

Completed New Concept

wxhere, ID --- Is the Identification Number of the DU, and it provides a one-to-one correspondence with DU. FR --- Is Functional Requirements, which is a minimum set

DU,(ID,FRPJI,DP)

2

1

Energy Factor

135

Step 8 (Energy factor modeling): The energy consumption information for new configuration will be calculated using energy factor models. If the energy consumed in new configurations is less than the existed, designers can go to next step, otherwise designers have to go back to step 5 to generator new concept. Step 9 (Life cycle assessment): Life cycle assessment will 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. Step 10 (Detail Design): Detail design can be done based on the new configurations in this step, and then a new product will be finished based on the existed product, which will have better energy-saving property. To design a new energy-saving product, the input becomes new customer needs, and the following steps are same with thene corresponding steps in the procedures of improving an existed product. Energy factor, as we mentioned before, is a very important part in the innovative product design method. A case study is conducting in our lab to develop the detail energy factor models for different processes. The results will be shown in our future publications. C. Optimization After we finish every DU for the product, develop all the energy factors to calculate the energy consumption, the optimization will be simple to perform. To optimize the product design, energy-saving can not be the only rule. We also need to maintain the relationship between FR and DP. Therefore, through axiomatic design concept, there is a design matrix A will be utilized to describe the relationship between FR and DP as follows: A,j =- aFR {FR}=

[A]{DP while

To realize the FRs, axiomatic design provides some theories and formulas to limit the DPs, so we can get a feasible range of DPs, e.g., t FR A A A 1rDP FRI| 11 12 13 D1P FR2 h A21A22A23 4 DP2

AFR} 1DP= {aAFRI - /JAFR2 - F13 1 |DM The expressions for DP2 and DP3 are similar forms. In addition, based on the analysis of energy consumption models, we can also obtain another feasible range for DP. The overlapping area of the two feasible ranges is the optimal

solution.

III. SUMMARY AND FURTURE WORK "We do not inhibit the earth from our parents; we borrow it from our children," with this old proverb we summarize the underlying objective of this project. The objectives of the research are in three-fold: (1) establishing a mechanism that information can explicitly demonstrate the product design that icue nrycnupintruhu l l tgso rdc life cycle; (2) modeling Energy Factor with quantitative mathematical expressions; (3) developing a decision making system to optimize product design in terms of energy-saving. Following the procedures we provided, designers can easily design a real energy-saving product in the entire product life cycle. Since the new concept DU was introduced, it will be easy to program software to realize the new innovative product design method. Based on the three objectives, our future work will focus on the energy factor modeling by analyzing actual specific products. IV. CONCLUSION The result of this research will be used as guidelines for regular product design and achieving energy-saving design result. In addition, academic institutes will be able to use the general methodologies to be developed in this research as a platform for further energy-saving product research. Industry will be able to use the product design decision making system to improve their products' energy efficiency and use the innovative method as a powerful tool for their new energysaving product designs. It is also expected that through improved product energy efficiency, this research will help to energy sustainability of the nationwide and throughout |improve the world, in addition to maintain the harmony between human beings and nature.

A31A32A33 LDP3

FR3 J

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, =

~DM~ {acFRI

-

8FR2 - fR3}

REFERENCES [1] X. Feng, X. X. Zhu, R. Smith, "Effect of component changes to system energy performance", Energy Conversion & Management, vol. 99, pp. 1305-1312, 1999.

where a = /3 =

A22A33- A23A32 A

A

-

A

[2]

A

32 13 M-12 33 y = A22A13 -A12A23

[3]

For a given set of design ranges of FRs, the maximum allowable tolerances for DPs may be expressed as

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2007 IEEE

X. Y. Zhou, J. M. Schoenung, "Development of a hybrid environmental impact assessment model: a case study on computer displays", Proceedings of the 2004 IEEE International Symposium on Electronics & the Environment, pp. 91-96. E. D. Williams, Y. Sasaki, "Energy analysis of end-of-life options for

personal computers: resell, upgrade, recycle", 2003 IEEE International Symposium on Electronics & the Environment, pp. 187-192.

D. Xiong, X. P. Liu, Y. Wu, J. S. Wang, G. H. Duan, "Life cycle assessment toll for electromechanical products gree design", 2003 IEEE International Symposium on Electronics & the Environment, pp. 120124. [5] N. P. Suh, Axiomatic design, advances and applications. Oxford University Press, Inc. 2001.

[4]

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