Reproducing a Jeep BRC-40 with Reverse Engineering

Michael Raphael,Direct Dimensions, Inc.

Discussion Topics• Historical Overview of the Jeep• Specific Client Request• Identifying the Problem• Overview of the Solution: Jeep Frame

Case Study• Jeep Frame – Review• Benefits/Value• Summary/Conclusion

Historical Overview of the Jeep

• Original “Jeep” Prototype • 1940 American Bantam Car Company

pilot model

Specific Client Request

• Measure various parts from antique BRC-40 Jeep frame

• Parts needed to be completed in an AutoCAD format

• Accurate models needed so client can duplicate them exactly

• Specific parts include: frame rails, spring mounts, and “K” cross member

Identifying the Problem

• Original deteriorating frame posed measurement problems because of frame warping and corroded components

• “Design intent” model needed

• A combination of the LDI Laser Scanner mounted on a 12’ FARO arm and point probing allowed for accurate data capture

• Using RapidForm XOR allowed DDI to import all scan and digitizer data and reverse engineer the parts using one software package

Overview of the Solution: Jeep Frame Case Study

Overview of the Solution: Jeep Frame Case Study

Overview of the Solution: Jeep Frame Case Study

Initial Step – Laser Scanning and Data Capture• Scanning the Jeep frame with the LDI

Laser Scanner

Next Step –Aligning Point Clouds

• Aligning the captured point clouds in RapidForm

Next Step – Mirroring Frame

• Mirroring and Comparing one side of the frame to the other

Next Step – Polygonal Modeling

• Aligning, cleaning, and filling in holes on the polygonal model

• Aligning part positions to hole locations and other features

Next Step – Reverse Engineering Specific Parts

• Aligning part positions to hole locations and other features

Next Step – Reverse Engineering Specific Parts

Next Step – Reverse Engineering Specific Parts• Reverse Engineering and creating specific

features from the polygonal and geometric data

• Continuing to create and align specific parts to the overall rail form

Next Step – Reverse Engineering Specific Parts

• Overlaying the “Design Intent” model on top of the completed polygonal model to check for error and inconsistencies

Next Step – Comparing Captured Polygonal Model to “Design Intent”

Final Step – Deliver Requested Models

• Complete all modeling and deliver the requested models in proper formats

Jeep Frame - Review

Benefits/Value

• Because project was completed using one software package, time was not lost translating compatible files between programs

• Using both a laser scanner and digitizer allowed for a checks/balances and more complete data to build and align parts

Summary/Conclusion

• All parts were modeled to client’s specifications

• With this “digital archive” client can replicate these parts an infinite amount of times and now has a precise digital record of this frame

• This method is far more accurate than any other method to measure aged parts

Questions?

Thank you!

Michael Raphael,Direct Dimensions, Inc.