Effort flow analysis: a methodology for directed product evolution
Part count reduction through part combination is a recognized goal of design for assembly (DFA). Some of the many benefits of part count reduction are: a reduced number of assembly operations, reduced procurement costs, cycle time reduction, supply chain reduction, and higher potential profits. In previous work, force flow analysis, a new technique to map forces as they flow across interfaces in a product, was shown to be successful at systematically providing creative insights for part combination. These insights arise by highlighting components having no relative motion between them. This paper presents a novel concept that extends the theoretical basis of force flow analysis to a much broader scope, referred to as effort flow analysis, addressing component combinations having varying degrees of relative motion. A systematic method for classifying these sets of components is given, and compliant mechanisms are presented as an example of successful combinations across interfaces with relative motion. Examples are provided for the redesign of a Quick Grip Clamp and a staple remover, both of which highlight a specific class of relative motion components.
component combination design methods product design product modelling