The lesson outcomes are to identify prototype types, explain prototypes' importance, and recognize prototyping methods.

1. PROTOTYPE DEVELOPMENT & TESTING
Design Philosophy
Dr. (Ms.) Jayaruwani Fernando, Ph.D. (Ag. & Biosystems Engineering), M.S. (Industrial
& Ag. Technology), M.Phil. (Ag. & Biosystems Engineering), B.Sc. (Agriculture)

2. LESSON OUTCOMES
• Identify types of prototypes
• Explain the importance of prototypes
• Recognize prototyping methods
Dr. (Ms.) Jayaruwani Fernando, Ph.D. (Ag. & Biosystems Engineering), M.S. (Industrial and Ag. Technology), M.Phil. (Ag. & Biosystems Engineering), B.Sc. (Agriculture)

3. PROTOTYPE DEVELOPMENT AND TESTING
• Prototype - A design representation of some aspect such as form/fit
or function of a design
• An early stage/version of the design
• Intends to prove/validate/test the design idea
• Communicates the design idea to both the design team and clients
Recognize the need
Problem definition
Gathering of information
Concept generation
Concept selection
Communication
Detailed design and analysis
Prototype Development and
Testing
Dr. (Ms.) Jayaruwani Fernando, Ph.D. (Ag. & Biosystems Engineering), M.S. (Industrial and Ag. Technology), M.Phil. (Ag. & Biosystems Engineering), B.Sc. (Agriculture)

4. PHYSICAL VS. ANALYTICAL PROTOTYPES
Physical Prototypes Analytical Prototypes
1. Tangible approximation of the product 1. Mathematical model of the product
2. Used to test idea quickly, Validate the
functionality
2. Can only exhibit behavior arising from explicitly
modelled phenomena
3. Often best for communication 3. Often allow more experimental freedom than
physical models
Dr. (Ms.) Jayaruwani Fernando, Ph.D. (Ag. & Biosystems Engineering), M.S. (Industrial and Ag. Technology), M.Phil. (Ag. & Biosystems Engineering), B.Sc. (Agriculture)

5. 3D design of the first prototype of pepper
harvester attached to a walking cultivator
Prototype of pepper harvester attached to a
walking cultivator
Physical prototype Analytical prototype
Kim, T. H., Kim, D. C., & Cho, Y. (2020). Performance Comparison and Evaluation of Two Small Chili Pepper Harvester Prototypes That Attach to Walking Cultivators. Applied Sciences, 10(7), 2570.

6. Finite element representation of the piezoelectric
energy harvester
Finite element analyses of mini
combine harvester chassis and hitch
Abdelkefi, A., Barsallo, N., Tang, L., Yang, Y., & Hajj, M. R. (2014). Modeling, validation, and
performance of low-frequency piezoelectric energy harvesters. Journal of Intelligent Material
Systems and Structures, 25(12), 1429-1444.
Abdulkarim, K. O., Abdulrahman, K. O., Ahmed, I. I., Abdulkareem, S., Adebisi,
J. A., & Harmanto, D. (2017). Finite element analysis of mini combined
harvester chassis and hitch.

7. Applying CFD for Studying the
Dynamic and Thermal Behavior of an
Indirect Solar Dryer
Khaldi, S., Korti, A. N., & Abboudi, S. (2017). Applying CFD for Studying the Dynamic and
Thermal Behavior of Solar Chimney Drying System with Reversed Absorber. International
Journal of Food Engineering, 13(11).

8. Drying uniformity in tray dryer system using CFD simulation
Misha, S., Mat, S., Ruslan, M. H., Sopian, K., & Salleh, E. (2013). The prediction of drying uniformity in tray dryer system using CFD
simulation. International Journal of Machine Learning and Computing, 3(5), 419.

9. FOCUSED VS. COMPREHENSIVE PROTOTYPES
Focused Prototypes Comprehensive Prototypes
1. Implement one or a few attributes of
the product
1. Implement many or all attributes of the
product
2. Answer specific questions about the
product design
2. Offer opportunities for rigorous testing
3. Generally several are required 3. Often best for milestones and
integration
Dr. (Ms.) Jayaruwani Fernando, Ph.D. (Ag. & Biosystems Engineering), M.S. (Industrial and Ag. Technology), M.Phil. (Ag. & Biosystems Engineering), B.Sc. (Agriculture)

10. Focused Prototypes
Comprehensive Prototypes
Kim, T. H., Kim, D. C., & Cho, Y. (2020). Performance Comparison and Evaluation of Two Small Chili Pepper Harvester Prototypes That Attach to Walking Cultivators. Applied Sciences, 10(7), 2570.

11. PROTOTYPING
• Alpha prototypes
• first testable prototype variant of a potential product
• Beta prototype
• much closer to the final product than alpha prototypes
Dr. (Ms.) Jayaruwani Fernando, Ph.D. (Ag. & Biosystems Engineering), M.S. (Industrial and Ag. Technology), M.Phil. (Ag. & Biosystems Engineering), B.Sc. (Agriculture)

12. TYPES OF PROTOTYPES

13. IMPORTANCE OF USING PROTOTYPES
1. Learning “will our design work?”, “how well does the design meet the customer needs?”
2. Communication Communicate with customer,
top management, vendors, engineers etc.
3. Integration combine sub-systems into a system model
4. Milestones a goal for the development team
Dr. (Ms.) Jayaruwani Fernando, Ph.D. (Ag. & Biosystems Engineering), M.S. (Industrial and Ag. Technology), M.Phil. (Ag. & Biosystems Engineering), B.Sc. (Agriculture)

14. PRINCIPLES OF PROTOTYPING
• Analytical prototypes are generally more flexible than physical prototypes
Example: changing a dimension in 3D CAD modeling is really quick
• Physical prototypes are required to detect anticipated phenomena
Physical prototypes often exhibits unanticipated phenomena
Physical prototypes intended to investigate purely geometric issues will also have
thermal and optical properties
Dr. (Ms.) Jayaruwani Fernando, Ph.D. (Ag. & Biosystems Engineering), M.S. (Industrial and Ag. Technology), M.Phil. (Ag. & Biosystems Engineering), B.Sc. (Agriculture)

15. A prototype may reduce the risk of Costly Iterations
Dr. (Ms.) Jayaruwani Fernando, Ph.D. (Ag. & Biosystems Engineering), M.S. (Industrial and Ag. Technology), M.Phil. (Ag. & Biosystems Engineering), B.Sc. (Agriculture)

16. A prototype may reduce the risk of Costly Iterations
Dr. (Ms.) Jayaruwani Fernando, Ph.D. (Ag. & Biosystems Engineering), M.S. (Industrial and Ag. Technology), M.Phil. (Ag. & Biosystems Engineering), B.Sc. (Agriculture)

17. A prototype may expedite other development stage
Dr. (Ms.) Jayaruwani Fernando, Ph.D. (Ag. & Biosystems Engineering), M.S. (Industrial and Ag. Technology), M.Phil. (Ag. & Biosystems Engineering), B.Sc. (Agriculture)

18. A prototype may restructure task dependencies
Dr. (Ms.) Jayaruwani Fernando, Ph.D. (Ag. & Biosystems Engineering), M.S. (Industrial and Ag. Technology), M.Phil. (Ag. & Biosystems Engineering), B.Sc. (Agriculture)

19. PROTOTYPING METHODS
• 3D CAD Modeling and Analysis
• Solidworks
• Finite Element Method
• Computational Fluid Dynamics
• Free Form Modeling → rapid prototyping
• Stereolithography
• 3D printing
• Conventional manufacturing technology
• CNC machining
• Rubber molding, silicone molding
• Material: wood, plastic, foam
Dr. (Ms.) Jayaruwani Fernando, Ph.D. (Ag. & Biosystems Engineering), M.S. (Industrial and Ag. Technology), M.Phil. (Ag. & Biosystems Engineering), B.Sc. (Agriculture)

20. PLANNING FOR PROTOTYPES – 4 STEPS
• Step 1: Define the purpose of the prototype. – What is the prototype for? Is it for learning,
communication, integration, or milestone?
• Step 2: Establish Level of Approximation. – Is an analytical prototype good enough or a physical
prototype necessary? Should it “works like” or just “looks like”?
• Step 3: Outline an Experimental Plan – Decide on what measurements have to be taken. What
combinations of configurations need to be tested? Test conditions?
• Step 4: Create a Schedule for Procurement, Construction, and Testing. – Prototyping is a sub-
project within the overall product development project. What parts need to be ordered,
assembled? When must it be completed? How much time for testing?
Dr. (Ms.) Jayaruwani Fernando, Ph.D. (Ag. & Biosystems Engineering), M.S. (Industrial and Ag. Technology), M.Phil. (Ag. & Biosystems Engineering), B.Sc. (Agriculture)

21. MANUFACTURING
• Workshop
Recognize the need
Problem definition
Gathering of information
Concept generation
Concept selection
Communication
Detailed design and analysis
Prototype Development and
Testing
Manufacturing
Dr. (Ms.) Jayaruwani Fernando, Ph.D. (Ag. & Biosystems Engineering), M.S. (Industrial and Ag. Technology), M.Phil. (Ag. & Biosystems Engineering), B.Sc. (Agriculture)