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UXDs-driven conceptual design process model for contradiction solving using CAIs
Runhua Tan *, Jianhong Ma, Fang Liu, Zihui Wei
Institute of Design for Innovation, Hebei University of Technology, Tianjin 300130, China
1. Introduction
It is generally agreed that the conceptual design is the most
critical phase in the design processes [1]. The inputs for this phase
are product or design specifications, and the outputs are principle
solutions or concepts [2]. There are many research results in this
field, which may be divided into three types: studies on process
models; methods for generating ideas or concepts; and computer
applications. The process models [2–5] for conceptual design are
descriptions at some level for real conceptual design processes in
industrial firms. Pahl and Beitz’s model [2], as a case in point,
includes seven steps. Many methods to generate ideas or concepts
[6] have been developed, such as brainstorming, mind mapping,
lateral thinking, etc. These methods are basically brainstorming-
driven. Different types of methods [7,8] to assist designers to
generate concepts are continuously studied. Computer systems [9–
11] have been applied in conceptual design processes. In these
systems the lack of formal product representations of function,
behaviour and structure [12], which are the knowledge base for
conceptual designs, have been identified as a kind of shortcoming.
Contrary to the brainstorming-driven methods, theory of
inventive problem solving (TRIZ) [13] is a systematic method to
guide designers on a high plane to generate ideas for inventive
problems [14]. Today, several computer-aided innovation systems
(CAIs) [15], such as Goldfire Innovator, IWB, and InventionTool,
have been developed and commercialized to support designers in
conceptual design. The basic theory for developing these systems is
TRIZ. Several knowledge bases are included in the CAIs, which are
abstracted from patent analysis or different scientific branches. By
these knowledge bases, designers have a chance to apply the cases
of other designers and the effects from the scientific world.
Nevertheless, how to integrate the TRIZ and CAIs into a conceptual
design process is also a problem.
Design situation is a particular state of interaction between
designers and the environment at a particular point in time [16].
CAIs are new systems for most designers and will change the
design situations when they are applied. In this new situation, the
interactions mainly happen among designers and a serial of
interfaces of CAIs. The reason that the interfaces will support
designers to generate ideas is needed to be studied.
Contradictions are a kind of inventive problems in conceptual
design. Contradiction matrix in TRIZ is a tool for solving that kind of
problems. The matrix was developed many years ago [13], but it is
still applied today [17,18]. The matrix does help designers to solve
some contradictions faced during the design. This study will be
restricted to find solutions for contradiction solving. The target is
to form a new conceptual process model under the environment of
CAIs.
2. Contradictions in conceptual design and solving them
using CAIs
Pahl and Beitz [2] divided a design process into four phases. The
conceptual design is a phase or process to develop the principle
Computers in Industry 60 (2009) 584–591
A R T I C L E I N F O
Article history:
Available online 4 July 2009
Keywords:
Unexpected discovery
Contradiction solving
Conceptual design
Computer-aided innovation
A B S T R A C T
Design is situational, which means the explicit consideration of the state of the environment, the
knowledge and experience of the designer, and the interaction between the designer and the
environment during designing interact. When computer-aided innovation systems (CAIs) are applied to
the design, the environment and the situation are different from the traditional design process and
environment. The basic principles of some CAIs available in the world market are directly related to
theory of inventive problem solving (TRIZ). Special TRIZ solutions, which have a few inventive principles
and the related cases for contradiction problem solving, are medium-solutions to domain problems. The
second stage analogy process is used to generate domain solutions and in this process, the TRIZ solutions
are used as source designs of analogy-based process. Unexpected discoveries (UXDs) are the key factors
to trigger designers to generate new ideas for domain solutions. The type of UXDs for the specific TRIZ
solutions is studied and a UXDs-driven contradiction solving for conceptual design is formed. A case
study shows the application of the process step by step.
© 2009 Elsevier B.V. All rights reserved.
* Corresponding author. Tel.: +86 22 60204037; fax: +86 22 60204037.
E-mail address: rhtan@hebut.edu.cn (R. Tan).
Contents lists available at ScienceDirect
Computers in Industry
journal homepage: www.elsevier.com/locate/compind
0166-3615/$ – see front matter © 2009 Elsevier B.V. All rights reserved.
doi:10.1016/j.compind.2009.05.019

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solution. Several sub-processes are divided, which are an abstract
of the essential problems, establishment of the function structure,
search for suitable working principles, and combinations of these
principles, to form a working structure. Some difficult problems,
which exist during conceptual design, may be as follows:
(1) Adoption for a suitable principle solution of a function in a
function structure that will result in the existence of a new
harmful function, or intensifying an existing harmful function.
(2) Elimination or reduction of a harmful function in a function
structure will deteriorate a useful function.
(3) Intensification of a useful function or reduction of a harmful
function will cause the unacceptable complication of the
design.
All of the above problems are technical contradictions from the
point of view of TRIZ [13]. As a result, designers in conceptual
design face some difficulties to solve these contradictions. The tool
in TRIZ for solving technical contradictions includes 39 generic
engineering parameters to represent contradictions; 40 inventive
principles to solve the contradictions; and a matrix to find a few
suitable inventive principles. Under each inventive principle there
are several design cases abstracted from patent bases of the world.
Every case shows a result to solve a contradiction by former
designers. Fig. 1 shows the structure of the tool.
Every case under an inventive principle in Fig. 1 is the result of
analyzing patent bases from outside world. The knowledge, which
is tacit in different domains of a patent base, is difficult to have
them applied by designers because it is a problem to find a useful
one from different domain. If a patent abstracted from any domain
is stored in the case base of TRIZ it becomes explicit knowledge or
codified knowledge, which can be found following the TRIZ
problem solving routine and applied for idea generation.
The TRIZ world in Fig. 1 has been programmed as a kind of
arithmetic and a module of CAIs, such as in the Goldfire Innovator
and InventionTool, which are cases of CAIs. Interaction between
TRIZ world and outside world is realized by the interfaces of the
CAIs. Fig. 2 shows a used cases model to describe an interface of a
module for contradiction solving in InventionTool. The application
of different CAIs based on TRIZ has made the TRIZ more powerful
and applicable. There are a few knowledge bases in CAIs. The
knowledge is arranged by the framework of TRIZ. By applying the
knowledge base, the design cases from different industrial fields
are accessed by designers.
In the knowledge base of CAIs, a case for a technical contra-
diction solving is described using a sketch with text to explain the
working principle of that sketch. Fig. 3 shows an example of a case
in which the sketch shows the working principle for cutting with
microwave heating and the text is the explanation. When one
principle as a TRIZ special solution is selected, all the cases relevant
to that principle can be browsed one by one. New ideas for the
domain solutions may be formed from designers’ mind during the
browsing process.
3. An analogy-based concept generation for contradiction
solving
The process of solving inventive problems using TRIZ is shown
in Fig. 4. The TRIZ process is supported by CAIs, in which the TRIZ’s
special solutions, inventive principles and the cases related to the
principles, are produced automatically after TRIZ mapping. The
designer can browse them one by one as shown in use case model
in Fig. 2.
From the TRIZ special solutions to domain solutions is an
analogy-based process. Analogies are partial similarities between
different situations that support further inference. Analogy-based
conceptual design (ABCD) means the application of an analogy to
generate a new concept in the process of the conceptual design. In
this process, the existing designs and the designs to be carried out
are source designs and goal designs, respectively. One of the
Fig. 1. Contradiction solving model in TRIZ.
Fig. 3. A cases in knowledge base of CAIs.
Fig. 2. Use cases for contradiction solving in InventionTool.
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conditions to carry out ABCD is the existence of source or base
designs in different domains in large number. In the situation of the
conceptual design supported by CAIs, there are many source
designs because every case included in a TRIZ special solution,
which is stored in the case bases of CAIs, is a source design.
Fig. 4 shows two mappings from a domain problem to domain
solutions, which are from domain problem to TRIZ special solution
and from TRIZ special solution to domain solution. Both mappings
are analogy processes [19], which are the first stage and the second
stage analogy process, respectively [19]. The first stage analogy
process is completed by the application of CAIs and the outputs are
TRIZ special solutions. The second stage analogy process is a process
of analogy-based conceptual design, which is a human-based
process.
Suwa et al. [20] have developed a concept ‘‘situated-
invention (S-invention)’’, which means a designer generates
the issue or requirement for the first time in the current design
task in a way situated in the design setting. Gero et al. [16,21–
23] have studied the generation of S-invention, and summarized
a design process. Firstly, the designer apperceives the domain
problem and determines source design and goal design. Then the
designer finds unexpected discoveries (UXDs) through the
matching of source design and goal design; UXDs are transferred
to goal design by mapping, and a new goal is generated, and
then the modified goal design is produced. There may be multi-
source designs, and the last modified goal design is the concept
of solving domain problems through modifying goal designs
continually.
Gero and his group have majored in architectural design, so the
source designs are drawings of different kinds of architectures. If
the source designs are substituted by TRIZ special solutions the
design process for generation of S-invention can be applied to
generate the domain solutions in TRIZ-based design processes.
Designers find several UXDs and modify goal design depending on
their design experience, their comprehension of domain problems,
and the situation. At times some modified goal designs are domain
solutions. The macro-process of ABCD for contradiction solving
using CAIs and TRIZ is shown in Fig. 5.
The contradiction analogs are the technical contradictions
selected from the 39 engineering parameters, which have similar
meanings to the domain contradictions. The UXDs solving
contradiction analogs are found from the principles solving
contradiction analogs and cases.
The main processes of implementation of the process in Fig. 5, is
how to find UXDs in solving the contradiction analogs, and
converting these UXDs into ideas for solving the domain contra-
dictions. UXDs enlighten designers on invention and make new
ideas appear, so discovering and transferring UXDs is the key to
success. According to the concept of constructive memory [21], the
memory is not a direct reappearance of a former experience but a
function of a former experience, which changes after producing
these experience and situation of memory requirement. An UXD is a
‘‘new’’ perceptual action that has a dependency on ‘‘old’’ physical
action(s) [20]. This means that if a designer traces or pays attention
to the existence of source designs, the perceptual action is an
instance of UXD. Experiences and UXDs drive designers to generate
new ideas. The new ideas are mapped to the goal design to produce a
new goal design. The last few goal designs are the solutions for a
conceptual design.
Perceptual actions [20] are operated for architectural drawings.
They must be extended to TRIZ special solutions for TRIZ-based
design. Ideas from the constructive memory driven by UXDs are
developed to form concepts. Concepts are described using working
principles, combinations of these principles to form a working
structure or system working principles, or sketches.
4. UXDs from TRIZ special solutions
Suwa et al. [20] have divided UXDs into three types, depending on
the types of visuo-spatial feature, which are the discovery of a visual
feature; a spatial or organizational relation among more than one
previously drawn element; and a space that exists in previously
drawn elements. The types are suitable for the design of an
architecture, in which the basic elements are dots, lines, rectangles,
circles, arrows and so on. For complex system design, such as
complex mechanical system design, the basic elements are more
complex. The types divided are not suitable for them. New types are
needed.
Currently, there are several well-known design theories and
methodologies, such as Systematic Design Methodology [2],
Axiomatic Design Theory [24], and General Design Theory [25].
The common feature for all these theories and methodologies is the
function-based design. The first step for the design is to transform
the design specifications or the product needs to a function model,
such as a function structure. Then, the structure model of the
design, such as a working principle or a sketch, is developed from
function model by mapping.
There are two kinds of mapping: function–structure mapping
and function–behaviour–structure mapping, as shown in Fig. 6.
The former is suitable for the mapping of extrinsic functions and
the latter is suitable for intrinsic functions. There are different
kinds of functions, behaviours and structures [26–28]. Functions
are divided into atomic, source, destination and transfer functions.
Behaviours are divided into three kinds, continuous-time-beha-
viour, discrete-time-behaviour, and state-transition-behaviour.
According to the specific design context, a structure may refer
to a sub-system, a sub-assembly, a component, a feature, or a
geometric entity, and a physical relationship.
Fig. 4. The process of solving problem using TRIZ.
Fig. 5. The macro-process of ABCD for contradiction solving using TRIZ.
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A structure of a design implicates all the information about the
behaviour and the functions for that design. If a TRIZ special
solution with some cases is applied as source designs for analogy,
the designers will find the explicit behaviours and functions,
except for structures. As a result, some functions, behaviours, or
structures stimulate the designers and the new concepts are
appeared in their minds. Therefore, the implicit functions,
behaviours and structures in TRIZ special solutions in different
levels are UXDs for designers when TRIZ and CAIs are applied. The
UXDs here are different from types of the definitions applied in
Gero’s group.
For technical contradiction problem solving, forty the inventive
principles in TRIZ will be applied. One principle selected from the
forty has implicit meaning, which will be a kind stimulus for
designers. For example, if a circle is applied for a product design, in
order to make some modifications by the inventive principle 6
‘asymmetry’, designers may image different forms to substitute
the circle, as shown in Fig. 7. As a result an inventive principle for
technical contradiction solving is also a UXD, when it is selected.
There are four types of UXDs when TRIZ special solutions are
applied as resource designs under the situation applying CAIs. The
first type is to find an inventive principle and the others are to find
a function, a behaviour, or a structure in different levels. Table 1
shows the types, definition of each type, and the instances of each
type and how to find an UXD.
For the designers using CAIs, the physical actions to find a UXD
are only looking, which means designers viewing the computer
screen: the principles of contradiction solving and the cases shown
by pictures and contexts. By viewing actions, designers discover
the UXDs implied.
5. An UXDs-driven process model for conceptual design
A top-model for conceptual design is shown in Fig. 8. The inputs
are design specifications and outputs are selected solutions.
However, the process is supported by CAIs. This implicates that
the new ideas for the solutions are developed by the stimulation of
TRIZ special solutions.
There are several models for conceptual design process from
literatures. Refs. [2,3], and [6] are examples of these. In this study,
Pahl and Beitz’s model [2], as a traditional and human-oriented
process model, is selected as a base to extend from. Fig. 9 shows a
new model of conceptual design process which is driven by UXDs
and supported by CAIs.
According to Fig. 9, the process is divided into eight steps, which
are as follows:
Step 1: Establish or modify function structures. For original
design [2], the function structure of the design is established
from the design specification directly. For adoptive design [2],
the existing function structure is modified to adopt the changed
specifications.
Step 2: Search for working principles for sub-functions. The
working principles for every sub-function in the existing
function structure are found by searching.
Step 3: Analyze the working principles of sub-functions and find
whether there are technical contradictions or not. If there are no
contradictions turn to step 7. Otherwise continue the process.
Step 4: Identify contradictions. Analyze all the working
principles again and identify all the contradictions clearly.
There may be multi-contradictions and they need to be
identified one by one.
Step 5: Find TRIZ special solutions. For each contradiction, the
TRIZ special solutions are found under support of CAIs.
Step 6: Find UXDs for every contradiction. Designers analyze
the selected inventive principles, browse the cases one by one
and find UXDs implied.
Step 7: Form solutions. There are two sub-processes in this step.
One is following step 3 and the other is continuing from step 6.
(1) Combine every working principle of sub-functions into a few
system working principles, named working structures.
(2) Find new working principles for sub-functions which relate to
the contradictions and eliminate all the contradictions. Then,
combine every principle into a few system working principles.
Step 8: Evaluate solutions. Identify one or two working
structures as the outputs of conceptual design processes.
Table 1
Types of UXDs.
Types
Definition
Instances
How to find
UXD-1
An inventive principle which is suitable
for solving the contradiction faced
One to four inventive principles
Check the matrix using two
engineering parameters
UXD-2
A function that one case implicated
Atomic, source, destination and transfer functions
Physical actions
UXD-3
A behaviour that one case implicated
Continuous-time-behaviour, discrete-time-behaviour,
state-transition-behaviour
Physical actions
UXD-4
A structure that one case implicated
A sub-assembly, a component, a feature,
or a geometric entity, and a physical relationship
Physical actions
Fig. 7. Some images from a source using an inventive principle.
Fig. 6. Function–behaviour–structure and function–structure mapping.
Fig. 8. Conceptual design supported by CAIs.
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Step 5 belongs to the first stage analogy process and step 6 to 7(2)
belongs to the second stage analogy process. The second stage
analogy process is a UXDs-driven process. The evaluation is included
in step 8, and many methods have been developed for this
application.
6. Case study
Dropping pills, produced by dropping pill machines, are a kind
of Chinese traditional medicine. After dropping and drying, the
pills should be put into little bottles for selling in the market. The
machine to put the pills into bottles is a kind of packaging machine.
There are no standard machines of this kind. The machines have
been developed by one or two firms in China. New operating
principles for the machines are needed to be produced by other
firms of medicine production.
The sub-functions of the machine are distributing pills, dischar-
ging pills, bottling and lidding. The working principle of existing pills
packaging machines is shown in Fig. 10. Certain amount of pills are
carried by pills board fixed on a tumbling cylinder. When running
the tumbling cylinder, the pills are transferred, discharged, and then
put into bottles. The pills board which is not full of pills will be
detected by a counting sensor array. The bottles, which are filled
with unqualified amount of pills, will be removed after lidding.
There are two problems in the existing design of pills packaging
machines:
(1) The sub-function of distributing certain amount of pills is
implemented by a pills board. This results a difficulty in
changing the amount of packaging. The flexibility of the
machine is poor.
(2) The amount of pills is detected twice in the original design,
which leads to a large number of photoelectric counters.
The model in Fig. 9 is applied to form a new working principle
for this kind of machines.
Step 1: Establish or modify function structures.
To solve the above problems, the original function structure for
the existing product is modified as shown in Fig. 11. In order to
express the modified structure clearly, some sub-functions of
converting energy is omitted. In Fig. 11 the sub-function of
distributing pills is substituted for the sub-function of distributing
certain amount of pills, the pills are detected once, and the sub-
function of counting pills is added.
Step 2: Search for working principles for sub-functions.
To implement the modified functions, i.e. distributing pills, a pills
board is added, and a tumbling cylinder in Fig. 12 is adopted to
distribute pills. To adapt to this change, counter array correspon-
dence with pills board is replaced by a single counter. But the
counter in the tumbling cylinder cannot implement the sub-
function of counting pills. New position of the counter is set on top of
filler as shown in Fig. 13.
Step 3: Find contradictions.
Contradiction 1: distribute pills and discharge pills.
Fig. 9. An UXD driven process model for conceptual design.
Fig. 10. The working principle of existing pills package machine.
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The pills are distributed in the several circles. The implementa-
tion of discharging pills is based on the principle of distributing
bills. Fig. 14 shows a principle for discharging pills that is used at
present. When the roller is redesigned and used inside the cylinder,
a transmission mechanism is also needed, which leads to the
complexity of the device.
Contradiction 2: distribute pills and transfer bottles filled with
pills.
Transferring bottles requires a pause in distributing and
discharging pills. Tumbling cylinder must be stopped accurately
and frequently. This is difficult and harmful.
Step 4: Identify contradictions.
Contradiction 1 defined as a technical contradiction between
adaptability (No. 35) and complexity of a device (No. 36).
Contradiction 2 defined as a technical contradiction between
adaptability (No. 35) and complexity of control (No. 37).
Step 5: Find TRIZ special solutions.
InventionTool 3.0, which is CAIs, is applied in this step. The
module ‘contradiction solving’ in InventionTool 3.0 is used to find
TRIZ special solutions. Select the improved parameter ‘adapt-
ability’ and worse parameter ‘complexity of a device’, then, the
interfaces shows the TRIZ special solutions of contradiction 1,
which are No. 29 (Pneumatic or hydraulic construction), No. 15
(Dynamicity), No. 28 (Replacement of mechanical system), No. 37
(Thermal expansion). The four principles and the relevant cases in
the case base are the TRIZ special solutions.
By the same process, special solutions of contradiction 2 can be
found, which is No. 1 (Segmentation) and No. 15 (Dynamicity).
Step 6: Find UXDs for every contradiction.
For the solutions of contradictions the designers may find several
UXDs and generate several ideas under the stimulations of UXDs by
browsing the cases in InventionTool 3.0. Fig. 15 is a case, which
shows the principle of a component used in a kitchen machine. The
ball moves up under the pressure of air flow to releases the
Fig. 11. Modified function structure.
Fig. 15. A case in no. 15.
Fig. 12. Tumbling cylinder.
Fig. 13. New position of the counter.
Fig. 14. A principle for discharging pills.
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exhausted gas produced during frying. The principle implies an UXD,
which is the ball moving under the pressure of the exhausted gas.
The UXD is a kind of behaviour, which is an UXD-3 in Table 1.
Fig. 16 is a case in InventionTool 3.0 that shows adjusting the
pipe’s hydraulic pressure by using valves dynamically. This case
implies an UXD for the solutions of contradiction 2.
Step 7: Form solutions.
Solutions of contradiction 1: transfer UXDs in Fig. 15 to goal
designs. Convert the UXD into the new ideas and generate a
principle for discharging pills. The pill moves under the pressure of
airflow. A possible structure for this principle is shown in Fig. 17.
Solutions of contradiction 2: to solve contradiction between
distributing pills and transferring bottles, a valve is used to control
the falling of pills, which is similar to the valve in Fig. 16. When the
required amount of pills fall into the bottle, the valve turns off to
ensure that no pills fall during the shifting of bottles. A possible
structure for this principle is shown in Fig. 18.
7. Conclusions
CAIs show all inventive principles and cases, which are the
source designs of ABD. The databases of CAIs are a fruit of TRIZ
researchers for many years, which have broad applicability. The
application of the database will improve the validity of ABD that
has been extensively accepted by designers.
When TRIZ is applied to solve a contradiction in design the first
and second stage analogy processes exist. The results of the first
stage analogy process are source designs of the second stage
analogy process. To find UXDs from the sources is the key step to
generate successful ideas for innovation. Four types UXDs have
been divided. The physical action for finding UXDs on the
computer screen of CAIs is by viewing.
A human-oriented eight-process step model is formed for
conceptual design, in which UXDs are the driving force for
generating new ideas. Designers find UXDs from the TRIZ special
solutions and react with experiences that designers have to
construct memories suddenly. Then new ideas for domain solutions
are formed.
The model put forward is only related to contradiction solving
of TRIZ. It needs to be extended to technological evolution, effects,
and standard solutions of TRIZ, in order to be effective in future
application of CAIs.
The eight-step model is suitable for the experienced designers.
For the inexperienced designer, a detailed or formal model is
needed. This is a future work.
Acknowledgements
We would like to thank the reviewers for their valuable
comments, which have greatly improved the presentation of this
paper. The research is supported in part by the Chinese Natural
Science Foundation (grant numbers 50675059) and by National
Innovation Project (grant number 2008IM30100). No part of this
paper represents the views and opinions of any of the sponsors
mentioned above.
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Runhua Tan is currently a Professor in the School of
Mechanical Engineering and Vice-President of Hebei
University of Technology. He received his MS and PhD,
both in Mechanical Engineering from HUT in 1984 and
from Zhejiang University in 1998, respectively. He
worked as a Visiting Scholar at Brunel University (UK)
from 1994 to 1995 and had a 3-month stay at Munich
University of Applied Science (Germany) in 2001. He
has authored 2 books, and authored or co-authored
over 210 refereed papers. He holds eight patents and
seven software copyrights. His research interests
include design theory and methodology and innova-
tion management.
Jianhong Ma is a Professor at the School of Computer
Science and Software Engineering of Hebei University
of Technology in Tianjin, China. Her research fields
include software engineering, software design technol-
ogy, and AD in software design. She has presented more
than 20 high level papers during the last 3 years. Prof.
MA and her software development group have been
working in developing Innovation Tools for more than
10 years, and have released Computer-Aided Invention
Design Software System-InventionTools version 1.0,
2.0, and 3.0.
Fang Liu is a member of the Institute of Design for
Innovation, School of Mechanical Engineering, Hebei
University of Technology. She received her MS in
Mechanical Engineering from Hebei University of
Technology (China) in 2005. Currently, she is pursuing
a PhD in Mechanical Engineering, at Hebei University of
Technology. Her research interests include mass
customization, product platform and innovation
design.
Zihui Wei is a doctoral candidate of the Institute of
Design for Innovation, School of Mechanical Engineer-
ing, Hebei University of Technology. He received his MS
in Mechanical Engineering from Naval University of
Engineering (China) in 2002. His research interests
include innovation design and electromechanical inte-
gration.
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