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Reverse EngineeringReverse Engineering
“ Reverse Engineering: “ Reverse Engineering: Examining competitive Examining competitive or similar or prior products in great detail by or similar or prior products in great detail by dissecting them or literally taking them apart.”dissecting them or literally taking them apart.”
-- Dym Dym & Little& Little
“What does this do?”“What does this do?”“How does it do that?”“How does it do that?”
“Why would you want to do that?”“Why would you want to do that?”
REVERSE ENGINEERING AND REVERSE ENGINEERING AND REDESIGNREDESIGN
Investigation, Prediction, and Hypothesis
Concrete experience: Function and Form
Design Models
Design Analysis
Parametric Redesign
Adaptive Redesign
Original Redesign
Reverse Engineering
Modelling and Analysis
Redesign
PROJECT IMPLEMENTATIONPROJECT IMPLEMENTATION
Phase One: “Identify product to be redesigned”Phase One: “Identify product to be redesigned”Identify at least 3 consumer products (preferably < R500; Identify at least 3 consumer products (preferably < R500; industrial sponsorship required)industrial sponsorship required)Examine product (‘black box’ model; Examine product (‘black box’ model; use; interview users; compare with use; interview users; compare with rivals) and rivals) and predict predict how the product how the product works (i.e. how it fulfills customer works (i.e. how it fulfills customer needs)needs)
Required: 1/7th scale retractable undercarriage
PROJECT IMPLEMENTATIONPROJECT IMPLEMENTATION
Phase Two: “How will you improve the product?”Phase Two: “How will you improve the product?”Disassemble products (plan, bill of materials, exploded view Disassemble products (plan, bill of materials, exploded view drawings)drawings)
Describe how product actually works (Function Structures; Describe how product actually works (Function Structures; Energy Flows)Energy Flows)Map customer needs with QFD matrix (House of Quality, i.e. Map customer needs with QFD matrix (House of Quality, i.e. matrix showing customer requirements versus functional matrix showing customer requirements versus functional requirements)requirements)
‘House of Quality’‘House of Quality’
Key: ? = 9 (strong relation) ? = 3 (some relation) Δ = 1 (weak
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Scale Appearance 9 ? 3 1
Reliable Operation 7 ? ? Δ 4 5
Durable 6 ? ? Δ 3 5
Easy to Install and Maintain 4 ? 4 5
Lightweight 1 Δ ? ? 3 5 Technical Difficulty 5 4 3 2 2
Measurement Units % n (consecutive)
‘g’ min kg
Object Target Values 90 50 3.5 15 1.7 Sierra Precision 70 50 3.5 15 1.05 Objective
Measures Spring-air 20 100 4 12 0.7 Absolute 103 81 64 36 15 Technical
Importance Relative 1 2 3 4 5
Cu
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Functional requirementsFunctional requirementsRivals’Ranking
Rating
After ranking, indicatewhere opportunitiesexist to improvethe product
Functional AnalysisFunctional Analysis
Function of aircraft landing gear
PROJECT IMPLEMENTATION PROJECT IMPLEMENTATION (contd.)(contd.)
Phase One: “Identify product to be redesigned”Phase One: “Identify product to be redesigned”Phase Two: “How will you improve the product?”Phase Two: “How will you improve the product?”Phase Three: “Analysis of the redesign proposalsPhase Three: “Analysis of the redesign proposals
Meet with outside experts/practitionersMeet with outside experts/practitionersResearch of applicable engineering theory for analysisResearch of applicable engineering theory for analysisDecide on how the proposed improvements will be achievedDecide on how the proposed improvements will be achievedDevelop alternative concepts for Develop alternative concepts for affected subsystemsaffected subsystemsConcept selection using weighted Concept selection using weighted scheme and applying the scheme and applying the requirements as identified by QFDrequirements as identified by QFDPerform rigorous engineering Perform rigorous engineering analysisanalysis
SelectionSelectionCriteriaCriteria
PROJECT IMPLEMENTATION PROJECT IMPLEMENTATION (contd.)(contd.)
Phase Four: Phase Four: Synthesis Synthesis and Evaluationand Evaluation
Manufacturing Manufacturing (if possible)(if possible)Evaluation of Evaluation of improvementsimprovements
TYPICAL REDESIGN PROJECTSTYPICAL REDESIGN PROJECTS
Computerized capsule counter for use in pharmacies. Design approach: Original redesign
Radio controlled helicopter with mini-onboard video camera and 2.5GHz
real-time CCTV transmitterDesign approach: Adaptive redesign
Adjustable keyboard support for operation by wheelchair-bound disabled person Design approach: Adaptive redesign
TYPICAL REDESIGN PROJECTSTYPICAL REDESIGN PROJECTS
Human-operated Jaws of LifeDesign approach: Original
redesign
Wheelchair with manually operated hydraulic ramp for negotiating road kerbsDesign approach: Original redesign
Clever kettle featuring electronic level sensor,
and childproof on-off switch
Design approach: Adaptive redesign
Self-righting rugby tackle bagDesign approach: Adaptive redesign
DESIGN IS A PASSIONATE DESIGN IS A PASSIONATE PROCESSPROCESS
Enthusiasm is one of the most powerful engines to success. When you do a thing, do it with all your might. Put your whole soul into it. Stamp it with your own personality. Be active, be energetic, be enthusiastic and faithful and you will accomplish your object. Nothing great was ever achieved without enthusiasm.
Ralph Waldo EmersonRalph Waldo Emerson
DESIGN IS A PASSIONATE DESIGN IS A PASSIONATE PROCESSPROCESS
Use passion as a catalyst to make ideas Use passion as a catalyst to make ideas become reality:become reality:
Never stop asking:Never stop asking:•• Is this really the best I can do?Is this really the best I can do?•• Can the design be made simpler?Can the design be made simpler?
Create, never stagnateCreate, never stagnate
Focus: Focus: You can’t always get what you wantYou can’t always get what you wantBut if you try sometimes well you might findBut if you try sometimes well you might findYou get what you needYou get what you need
Mick Mick Jagger Jagger and Keith Richards, 1969and Keith Richards, 1969
Example ProjectExample ProjectBlack and Decker Hedge TrimmerBlack and Decker Hedge Trimmer
Reverse Engineering ExampleReverse Engineering Example
Reverse Engineering Reverse Engineering MethodologyMethodology
Investigation, Prediction and Hypothesis
Concrete Experience: Function & Form
Design Models
Design Analysis
Parametric Redesign
Adaptive Redesign
Original Redesign
Adapted from Otto and Wood’s “Reverse Engineering and Redesign Methodology” UT Austin
Reverse Engineering
Modeling & Analysis
Redesign
1. 1. Investigation, Prediction and HypothesisInvestigation, Prediction and HypothesisDevelop Black Box ModelDevelop Black Box Model
Assemble product and conduct a testAssemble product and conduct a testWhat goes in? What comes out? (i.e. power, noise, heat, What goes in? What comes out? (i.e. power, noise, heat, vibration)vibration)
Hedge Trimmer
NoiseElectric Power
Blade MovementFinger Switch
Safety Off Vibration, heat
Reverse Engineering Example Project
Conduct a single test of the performance of the product:•Record product performance attributes
–Shearing speed
–3300 strokes/min
–5:1 Gear reduction = 16,500 rpm for the motor
Reverse Engineering Example Project
What is the market for this product?What is the market for this product?““Suitable for small shrubbery” Suitable for small shrubbery” –– Black & Black & Decker Product CatalogueDecker Product CatalogueHomeowners with small yards and limited Homeowners with small yards and limited budgetbudgetFor use only 3For use only 3--4 times a year4 times a year
What are the costs associated with this What are the costs associated with this product?product?
Design Design -- Manufacturing Manufacturing -- Assembly Assembly ––Packaging Packaging –– Resale: R1600)Resale: R1600)
Reverse Engineering Example Project
How long will this product last?How long will this product last?Assumed durability of each component (outdoor use, Assumed durability of each component (outdoor use, dirt)dirt)Availability of replacement parts and service shopsAvailability of replacement parts and service shops
What features does this product have that are important?What features does this product have that are important?MoldedMolded--in cord retainerin cord retainerLock off switch prevents accidental startLock off switch prevents accidental start--upupLock on switch for continuous runningLock on switch for continuous runningLightweight design for less fatigue (10 kg)Lightweight design for less fatigue (10 kg)
Reverse Engineering Example Project
by: jennifer_021 (Fri Apr 7 '00) Pros: lightweight, very durableCons: none
•Trimming the bushes is my only contribution to our 2 acre yard.
•I bought my first Black & Decker hedge trimmer at Hypermarket because it was very inexpensive compared to most other trimmers
•Black & Decker has an excellent reputation.
•The 13" seemed a little too small… The 18" seemed heavier
•I also wanted electric rather than gas because being a busy woman, I had no time to learn about mixing gas.
Durability: Excellent Noise Level: Average Purchase Price: R1550.00
Additional Comments and Additional Comments and Remarks Remarks --11
REF: http://www.epinions.com/hmgd-review-5AC4-E92BC14-38EDE974-prod4
by: mchristians (Fri Apr 7 '00) Pros: Easy to handle and light too! Cons: Electric and water never mix!
•While it may be a good trimmer it also has it's downside!
•The first problem with it being electric is that you need a drop cord.
•The second problem is that since it is electric and you use it outside, you run the risk of being electrocuted! Remember most people doing lawn work are also running sprinklers to water the lawn. I have had good friends killed simply by using these trimmers on wet grass.
•Over all this tool does a great job of trimming but the hazards to your personal safety far out weigh the pros of this tool.
Durability: Good Noise Level: Average Purchase Price: R1650
Additional Comments and Additional Comments and Remarks Remarks --22
by: lpvandermerwe (Tue Jun 27 '00) Pros: Cheap, powerful, lightweightCons: Weak manual, requires an outlet.
•just about the cheapest thing you'll find on the market
•as usual the fine people at B & D come through.
•As long as the cord reaches, I have the power I need.
•safety lock located at the top of the trimmer; release the trigger, the safety clicks on
•One of the safety tips that really amused me was, “Do not use in rain.” On the one hand, I’m just not that stupid, on the other hand...well, we all know someone, don’t we? Folks, it is an electric trimmer. Do Not Use In Rain. Or the bathtub. Really.
Durability: Excellent Noise Level: Average Purchase Price: R1520.00
Additional Comments and Additional Comments and Remarks Remarks --33
After completing a search on the U.S. Patent and Trademark website:
http://www.uspto.gov
Patent # 5,778,649 (1998)
Power Driven Hedge Trimmer
Patent # 5,581,891 (1996)
Hedge Trimmer with Combination Shearing and Sawing Blade Assembly
Patent Search on Hedge TrimmersPatent Search on Hedge Trimmers
2. Concrete Experience: Function and FormCarefully begin Disassembly
Document steps and components with photographs, sketches or video
Function and Form
Hedge Trimmer SubHedge Trimmer Sub--Systems and Systems and InteractionsInteractions
Case
MotorSwitch Blade
Group defined systems and subsystems together.
120 V 120 V -- 8 ampere Motor8 ampere Motor350 rpm350 rpmWhy not batteries?Why not batteries?How important is size, How important is size,
speed?speed?Was weight a Was weight a
considerationconsideration??
Photo of Motor
Motor
Safety lock allows Safety lock allows trigger action.trigger action.Is this a regulatory Is this a regulatory requirement?requirement?Ergonomic issues Ergonomic issues of size and lever of size and lever forceforceWhat type of What type of spring mechanism spring mechanism is used?is used?
Switch
V+
-
MOTOR
Sketch of Switch
Switch
How fast do the blades need How fast do the blades need to move? Force?to move? Force?Are the blades sharp?Are the blades sharp?What are the blades made of What are the blades made of ??Can we replace the blades?Can we replace the blades?
Blades
Transmission
Input gear from motor
Output gear
Pin for upper blade
Pin for lower blade
Blades
Slot for upper blade
Slot for lower blade
How was the case made?How was the case made?Was the case designed to Was the case designed to be aesthetically pleasing?be aesthetically pleasing?Why isn’t the case made Why isn’t the case made out of metal?out of metal?What sort of costs are What sort of costs are involved in the involved in the manufacturing of this case?manufacturing of this case?
Case
Switch - Plastic Injection Molded
Gear – Die Cast Steel
Case – Plastic Injection Molded
Handle – Plastic Injection Molded
Guard – Plastic Injection Molded
Feature List
Reassemble Product
Transforming to engineering specificationsTransforming to engineering specificationsExample Example -- MotorMotor--Blade KinematicsBlade Kinematics
Helical gearsNumber of teeth: input = 4
output = 60
Motor speed = 22800 rpm
Output speed =
= 1520 rpm = 159 rad/sMaximum blade speed = 1 m/s
( )rpm 22800151
604
=inω
Engineering Specifications
Engineering SpecificationsEngineering Specifications
Transforming to engineering Transforming to engineering specificationsspecifications1TinT
11ωI
Input gear from motor
111 ωITTin =−2
11
dFT t=2
22
dFT t=
2T
22ωI
1r
2r
1F
2F
Output gear to blades
2222112 ωIrFrFT =−−
( )φωφω cossin 2212111 rrmF −=
( )φωφω cossin 2222222 rrmF +−=
Engineering Specifications
3. Design Models3. Design ModelsIdentify actual physical principlesIdentify actual physical principlesCreate engineering models and metric Create engineering models and metric rangesrangesAlternatively or concurrently build Alternatively or concurrently build prototype to test parametersprototype to test parameters
Design Models
4. Design Analysis4. Design AnalysisCalibrate modelCalibrate modelCreate engineering analysis, simulation Create engineering analysis, simulation or optimizationor optimizationCreate experiment and testing Create experiment and testing proceduresprocedures
Design Analysis
5. Parametric Redesign5. Parametric RedesignOptimize design parametersOptimize design parametersPerform sensitivity analysis and tolerance Perform sensitivity analysis and tolerance designdesignBuild and test prototypeBuild and test prototype
Parametric Redesign
6. Adaptive Redesign6. Adaptive RedesignRecommends new subsystemsRecommends new subsystemsSearches for inventive solutionsSearches for inventive solutionsAnalyzes force flows and component Analyzes force flows and component combinationscombinationsBuilds and tests prototypeBuilds and tests prototype
Adaptive Redesign
Environmental ImpactEnvironmental ImpactTo determine the environmental To determine the environmental impact of the existing design evaluate impact of the existing design evaluate each step of the each step of the Product Life CycleProduct Life Cycle
PrePre--productionproduction
Manufacturing ProcessManufacturing Process
Product LifeProduct Life
The After LifeThe After Life
PrePre--productionproduction
Replaceability Replaceability of natural resourcesof natural resourcesAvailability of an alternative resourceAvailability of an alternative resourceEnergy required to obtainEnergy required to obtainEnergy to processEnergy to processAmount of waste created during Amount of waste created during processingprocessingWaste disposal methodWaste disposal method
Manufacturing ProcessManufacturing Process
Energy to produceEnergy to produceWaste created during productionWaste created during productionType of wasteType of waste-- solvents, solvents, emissions?emissions?Reuse of inReuse of in--process material process material waste?waste?Material yieldMaterial yield
Product LifeProduct Life
Energy consumptionEnergy consumptionWaste productionWaste productionLength of product lifeLength of product life
The After LifeThe After Life
ReuseReuseRecycleRecycle-- design for design for disassembly?disassembly?NeitherNeither-- harmful pollutants?harmful pollutants?
Discussion: Reuse vs. RecycleDiscussion: Reuse vs. Recycle
SummarySummary
Reverse engineering• Tool to understand current design
solutions and technology• Use dissection, experimentation and
analysis• Save time and gain insight on current
design challenges and solutions