Chapter 7: Concept Generation

Functional Decomposition

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 Decomposition
A common tactic in solving any complex problem is to decompose
the problem into smaller parts.

§ Product (physical) decomposition

decompose the product into subassemblies and components

§ Functional decomposition
identify main function of design and decompose the overall
function into sub-functions

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 Product Decomposition
Automobile

Drive Suspension Steering

Engine Body
train system System

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 Functional Decomposition
Function tells what the product must do. Form tells how.
Form follows function.

1. It is important to first establish the what, then the how.

2. Similar to QFD where what the customer wanted was

mapped into the how engineering specs were developed.

3. Functional decomposition involves determining the

principal functions of each subassembly.

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 Reverse Engineering
Reverse engineering can be used to understand the function of an
existing device.

Step 1: For the device, examine interfaces with other objects (gives
an idea of the overall function)

Step 2: Remove a component for more detailed study

Step 3: Examine interfaces of the component to find the flow of

energy, information, or material

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 Functional Model (First Prototype)

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 Irwin Quick Grip Bar Clamp

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 Examine Interfaces

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 Functional Decomposition
Describe the system’s functions as a transformation between an
initial state and the final state

Functional decomposition describes the design problem in terms

of:
§ Flow of energy
Mechanical, electrical, chemical, thermal, fluid, etc.
§ Flow of material
Through-flow (lift, hold, move, translate, rotate), diverging flow
(disassemble, separate), converging flow (assemble, join, attach)
§ Flow of information
Mechanical or electrical signal, software instruction

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 Functional Decomposition
Use action words to describe function:

§ Flow of energy
transformed, stored, conducted, supplied, dissipated
§ Flow of material
position, lift, hold, support, move, translate, rotate, guide
disassemble, separate
mix, attach
§ Flow of information
control, limit, start, stop, verify, actuate

Refer to TABLE 7.1 (page 188) for other examples of describing

functions.

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 Functional Decomposition

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 Functional Decomposition
Step 1: Find the overall function that needs to be accomplished
(represent the problem as a “black box”)

• Energy must be conserved

• Material must be conserved
Some guidelines
• Interfacing objects must be identified
• Use action verbs to convey flow

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 Functional Decomposition

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 Example: Bike Suspension

Overall function: Transfer and modulate forces between wheel,

chain, and frame.

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 Functional Decomposition
Step 2: Create subfunction descriptions

• Consider What, not How

• Use objects described in the problem

specification
Some guidelines
• Break the function down as finely as
possible

• Consider operational sequences

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 Creating Subfunctions
Transfer and modulate
forces btw wheel,
chain and frame

Transfer forces Absorb peak

btw wheel, Load btw wheel
chain and frame and frame

Transmit wheel Transmit chain

force to body Force to body

1 2
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 Creating Subfunctions

Transf vertical wheel 1

force to susp system
Transf horiz wheel force
to suspension system
Transf vertical suspension
system force to body
Transf horiz suspension
system force to body
Attach wheel to
suspension system
Attach suspension
system to body

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 Creating Subfunctions
1

Store energy from

Small bumps
Dissipate energy
from small bumps
Store energy
from large bumps
Dissipate energy
from large bumps

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 Functional Decomposition
Step 3: Order the Subfunctions

• Flow must be in a logical order

• Redundant functions must be combined
Some guidelines • Functions not within the system boundary
must be eliminated
• Energy and material must be conserved

Step 4: Refine the Subfunctions

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 EXAMPLE Bulk Material Transporter
(ASME Competition)
Portion of Problem Statement Summarized by a Previous Team:

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 Functional Decomposition Diagram
(Bulk Material Transporter)

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 FEASIBILITY STUDY
§ Create a functional decomposition diagram
§ Create concepts for each function
§ Integrate concepts to generate 3 feasible ideas

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 References
§ The Mechanical Design Process, David Ullman, 5th Edition,
McGraw Hill, NY.
§ Engineering Design: A Materials and Processing Approach, G.E.
Dieter, 3rd Edition, McGraw Hill, NY.

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