Reverse Engineering

Reverse Engineering: Examining competitive or similar or prior products in great detail by dissecting them or literally taking them apart. - Dym & Little What does this do? How does it do that? Why would you want to do that?

REVERSE ENGINEERING AND REDESIGN

Investigation, Prediction, and Hypothesis Reverse Engineering Concrete experience: Function and Form

Design Models

Modelling and Analysis

Design Analysis

Parametric Redesign

Adaptive Redesign

Original Redesign

Redesign

PROJECT IMPLEMENTATION
Phase One: Identify product to be redesigned
Identify at least 3 consumer products (preferably < R500; industrial sponsorship required) Examine product (black box model; use; interview users; compare with rivals) and predict how the product works (i.e. how it fulfills customer needs)

Required: 1/7th scale retractable undercarriage

PROJECT IMPLEMENTATION
Phase Two: How will you improve the product?
Disassemble products (plan, bill of materials, exploded view drawings)

Describe how product actually works (Function Structures; Energy Flows) Map customer needs with QFD matrix (House of Quality, i.e. matrix showing customer requirements versus functional requirements)

House of Quality
Accurate reproduction of scale geometry and linkages

Functional requirements

Sierra Precision Mark Frankel F4D-1 Skyray Retracts

Rivals Ranking
Spring-air 402 retract units 1 5 5 5 5

Customer requirements

Scale Appearance Reliable Operation Durable Easy to Install and Maintain Lightweight Technical Difficulty Measurement Units Object Target Values Objective Sierra Precision Measures Spring-air Technical Absolute Importance Relative Key: ? = 9 (strong relation) ? = 3 (some relation) = 1 (weak

9 7 6 4 1

? ? ? ?

Maximum Allowable Weight

Time to Install / Remove

Cycles without failure

Relative Importance

Adequate Strength

3 4

? ?

3 4

? 4 n
(consec utive)

? 2 min 15 15 12 36 4 2 kg 1.7 1.05 0.7 15 5

5 % 90 70 20 103 1

3 g 3.5 3.5 4 64 3

50 50 100 81 2

After ranking, indicate where opportunities exist to improve the product

Rating

Functional Analysis
Function of aircraft landing gear

PROJECT IMPLEMENTATION (contd.)

Phase One: Identify product to be redesigned Phase Two: How will you improve the product? Phase Three: Analysis of the redesign proposals Meet with outside experts/practitioners Research of applicable engineering theory for analysis Decide on how the proposed improvements will be achieved Develop alternative concepts for affected subsystems Concept selection using weighted scheme and applying the requirements as identified by QFD Perform rigorous engineering analysis

Selection Criteria

PROJECT IMPLEMENTATION (contd.)

Phase Four: Synthesis and Evaluation
Manufacturing (if possible) Evaluation of improvements

TYPICAL 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 transmitter

Adjustable keyboard support for operation by wheelchair-bound disabled person

Design approach: Adaptive redesign

Design approach: Adaptive redesign

TYPICAL REDESIGN PROJECTS

Self-righting rugby tackle bag
Design approach: Adaptive redesign

Wheelchair with manually operated hydraulic ramp for negotiating road kerbs
Design approach: Original redesign

Clever kettle featuring electronic level sensor, and childproof on-off switch

Design approach: Adaptive redesign

Human-operated Jaws of Life

Design approach: Original redesign

DESIGN IS A PASSIONATE PROCESS

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 Emerson

DESIGN IS A PASSIONATE PROCESS

Use passion as a catalyst to make ideas become reality:
Never stop asking: Is this really the best I can do? Can the design be made simpler? Create, never stagnate

Focus: You cant always get what you want

But if you try sometimes well you might find You get what you need Mick Jagger and Keith Richards, 1969

Reverse Engineering Example

Example Project
Black and Decker Hedge Trimmer

Reverse Engineering Methodology

Investigation, Prediction and Hypothesis Concrete Experience: Function & Form Design Models Modeling & Analysis Reverse Engineering

Design Analysis

Parametric Redesign

Adaptive Redesign

Original Redesign

Redesign

Adapted from Otto and Woods Reverse Engineering and Redesign Methodology UT Austin

1. Investigation, Prediction and Hypothesis

Develop Black Box Model

Reverse Engineering Example Project

Assemble product and conduct a test What goes in? What comes out? (i.e. power, noise, heat, vibration)

Electric Power Finger Switch Safety Off

Noise

Hedge Trimmer

Blade Movement 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?
for small shrubbery Black & Decker Product Catalogue Homeowners with small yards and limited budget For use only 3-4 times a year
Suitable

What are the costs associated with this product?

Design - Manufacturing - Assembly Packaging Resale: R1600)

Reverse Engineering Example Project

How long will this product last? Assumed durability of each component (outdoor use, dirt) Availability of replacement parts and service shops What features does this product have that are important? Molded-in cord retainer Lock off switch prevents accidental start-up Lock on switch for continuous running Lightweight design for less fatigue (10 kg)

Additional Comments and Remarks -1

by: jennifer_021 (Fri Apr 7 '00) Pros: lightweight, very durable Cons: 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

REF: http://www.epinions.com/hmgd-review-5AC4-E92BC14-38EDE974-prod4

Additional Comments and Remarks -2

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 Remarks -3

by: lpvandermerwe (Tue Jun 27 '00) Pros: Cheap, powerful, lightweight Cons: 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, Im just not that stupid, on the other hand...well, we all know someone, dont 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

Patent Search on Hedge Trimmers

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

Function and Form

2. Concrete Experience: Function and Form
Carefully begin Disassembly Document steps and components with photographs, sketches or video

Hedge Trimmer Sub-Systems and Interactions

Group defined systems and subsystems together.

Switch

Motor

Blade

Case

Motor
120 V - 8 ampere Motor 350 rpm Why not batteries? How important is size, speed? Was weight a consideration?

Photo of Motor

Switch
Safety lock allows trigger action. Is this a regulatory requirement? Ergonomic issues of size and lever force What type of spring mechanism is used?

Switch
MOTOR

Sketch of Switch

Blades
How fast do the blades need to move? Force? Are the blades sharp? What are the blades made of ? Can we replace the blades?

Transmission
Pin for upper blade Input gear from motor

Output gear

Pin for lower blade

Slot for upper blade Blades

Slot for lower blade

Case
How was the case made? Was the case designed to be aesthetically pleasing? Why isnt the case made out of metal? What sort of costs are involved in the manufacturing of this case?

Feature List
Switch - Plastic Injection Molded Gear Die Cast Steel Case Plastic Injection Molded Handle Plastic Injection Molded Guard Plastic Injection Molded

Reassemble Product

Engineering Specifications
Transforming to engineering specifications Example - Motor-Blade Kinematics
Helical gears Number of teeth: input = 4 output = 60 Motor speed = 22800 rpm
4 1 in = (22800 rpm ) 15 Output speed = 60

= 1520 rpm = 159 rad/s Maximum blade speed = 1 m/s

Engineering Specifications

Engineering Specifications
Transforming to engineering specifications T T
in
1

Input gear from motor

Tin T1 = I 11

T1 = Ft

I 11

d1 2

T2 = Ft

d2 2

T2

Output gear to blades

F1

T2 F1 r1 F2 r2 = I 2 2

r1
r2 F2
I 2 2

2 F1 = m1 r1 2 sin r1 2 cos

2 F2 = m2 r2 2 sin + r2 2 cos

Design Models
3. Design Models Identify actual physical principles Create engineering models and metric ranges Alternatively or concurrently build prototype to test parameters

Design Analysis
4. Design Analysis Calibrate model Create engineering analysis, simulation or optimization Create experiment and testing procedures

Parametric Redesign
5. Parametric Redesign Optimize design parameters Perform sensitivity analysis and tolerance design Build and test prototype

Adaptive Redesign
6. Adaptive Redesign Recommends new subsystems Searches for inventive solutions Analyzes force flows and component combinations Builds and tests prototype

Environmental Impact
To determine the environmental impact of the existing design evaluate each step of the Product Life Cycle Pre-production Manufacturing Process Product Life The After Life

Pre-production
Replaceability of natural resources Availability of an alternative resource Energy required to obtain Energy to process Amount of waste created during processing Waste disposal method

Manufacturing Process
Energy to produce Waste created during production Type of waste- solvents, emissions? Reuse of in-process material waste? Material yield

Product Life

Energy consumption Waste production Length of product life

The After Life

Reuse Recycle- design for disassembly? Neither- harmful pollutants? Discussion: Reuse vs. Recycle

Summary
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