Conference Agenda

This study explores challenges in decision-making for product design due to insufficient cost transparency because of product variety across the value chain. Utilizing a literature review and a case study on a company, it delves into issues such as value chain consideration, product family assessment, linking effects to specific product levels, and converting measured effects. Highlighting the critical need to address these challenges for decision-making. Future research should focus on a comprehensive costing framework, explore effect interdependencies, and expand the value chain analysis.

The design of gear boxes is a complex challenge characterized by conflicting requirements and seemingly circular dependencies. Existing tools support engineers but focus on a single predefined design, often leading to costly iterative processes and non-optimal solutions. Solution Space Engineering (SSE) alleviates this by generating multiple designs represented by solution spaces. For this, a particular model structure is needed, and thus restructuring existing models, e.g., from industry standards. The application of solution spaces to a two-stage gear box is presented.

This paper addresses the underexplored domain of hydraulic energy harvesters (HEH). Through a literature review, existing designs are identified, aiding in the categorisation of energy conversion technologies and fluid-mechanical interfaces. Recognizing a lack of standardized approaches to testing HEH, the paper proposes a re-configurable test platform. The platform, accommodating diverse configurations, operates at high pressures, aligns with existing hydraulic setups, and functions in static or dynamic modes. This tool aims to assist researchers further explore the implementation of HEHs.

This study compares empirical and topology optimization methods for reducing gear body mass. Specimens produced via empirical guidelines and topology optimization were compared to referent full-disc gear, focusing on stresses and deformations. Values were determined numerically (Ansys was used) and the calculation method was verified using ISO 6336. The empirical approach exhibited substantial increases in stress and deformation while topology optimization method had promising outcomes. While decreasing mass, it also diminished tooth root stress on the tensile side by 17.1%.

In sandwich structures, mass can be reduced or mechanical properties increased if the challenging local load distribution can be improved. Through numerical optimizations, novel designs can be determined and investigated in physical and virtual tests. This paper presents an approach for load path-optimized design of sandwich structures and novel design concepts. The approach is applied to the design concept of honeycombs filled with potting compound. Due to the shown transferability to higher structural levels, it can be used as a basis for the design optimization of any sandwich structure.

This study investigates the relationship between the number and type of prototypes developed in rapid prototyping contexts, a team's performance self-estimations, and final actual performance. Findings suggest a strong correlation between each of these elements, with the converse also found to be true, motivating the introduction of the concept of Design Delusion - a type of cognitive dissonance due to differences between perceived and actual states. The paper suggests that early prototyping helps identify and mitigate design delusion, improving design decisions and preventing technical debt.