L3 Communications

Reverse Engineering

Presented by Anish Tailor

and Jacob Wilson

Constraints

Certain rules we must abide by

1. Alter the original testing rack, but without changing size and overall design.

2. The timer inputs must not be altered.

3. The structure must support itself.

4. Materials that have a low melting or freezing point cannot be used.

Problem and Design Statement

To Develop a new testing racks to hold timers. This rack must go through any environment the timers would go through. L3 Avionics would put this rack into a testing chamber to see if the structure and timers and withstand the environmental forces.

Target Consumer and Client Co. would be L3 Communications.

Design Statement: To design, model and build a testing rack which holds timers through contrasting temperatures and physical movements.

Problems found

Main Problems

Solutions

Ideas

Material Hardness

Sturdiness Weight Longevity Safety

TotalsIdea #1

4 2 2 2 3 13

Idea #2

1 3 2 1 3 10

Idea #3

3 3 3 3 3 15

Idea #4

2 2 1 4 2 11

1 2 3 4Material Hardness

The material will chip and break easily.

The material has many spots that can fracture, but still retains some of the structure after force has been applied.

The material can withstand much outside force, but can chip or break in small spots.

The material of the structure can experience much force and not break.

Sturdiness The structure will fall multiple times with consistent outside forces.

The structure cannot stand too long with consistent outside forces.

The structure can withstand much of outside forces, but will fall if too much force is applied.

The structure can withstand much movement without falling.

Weight The structure would be too heavy for a person to carry for more than 2 minutes.

The structure is somewhat heavy and cannot be held for too long.

The structure is somewhat light weight and bearable to carry.

The structure is light weight and easy to carry.

Longevity The structure will need many fixes and will not last for a long period of time. The overall product will need replacing multiple times.

The structure will last a moderate amount of time and will need many fixes.

The structure will last a long period of time, but will require a few fixes over time.

The structure will last a long period of time before the need of a replacement.

safety The product has wires sticking out that are used to channel power. If there wires were touched by someone, the person operating could receive serious injuries.

The product has wires and edges that are not covered that may harm the user.

The product has certain edges that may harm the user.

The structure is all-around safe for the users and cannot harm the user if any way, shape or form.

Chosen Idea The proposed structure would contain a handle on

the top and everything will acquire a new material scheme of Titanium.

The steel base of the structure would be removed.

There will be a plastic sheet covering the wiring in the back of the structure that can slide in and out of place for easy access.

The thickness of the Railings will be reduced.

The Titanium is known for its excellent resistance to corrosion.

Final prototype of Chosen Idea

New Back

Assembly Chart Group Members:  

Anish Tailor and Jacob Wilson  

16-May-11

Part # Part Name

Quantity Dimensions Function

Material

Texture/

Finish

Interaction with other parts

General notes

1

back board

1

16.75" X 14.5" X .1" thick

protects wiresphenol

smooth

connected to main partnecessary, could be lighter

2 plastic plugs 99

.725" outer diameter X 1.126" inner diameter X 1.640" length x .127" thick inner

diameter indicator plugs inputed

in hereplastic dull

held in place by screws and panels

cannot remove

3

back hex screws (small) 4

5.26 cm X inner diameter 1.5cm, 2.64 cm outer diameter

holds back boardstee

l dull

connects back to main part

necessary, could be altered

4 handle 1

1.5" length X .25 thick X 6" width

carrying devicemetal

shiny/smoo

th

part of the top, carries the device

add another, change location

5horizontal

bars 9.25" length X 17" depth X 1" width plastic plug outlets are

on here

Garolite

shiny/smoo

th outlits are on them

change shape and material

6 top screws 2.2" diameter X .5" length X .1" diameter

connects the top stee

l

shiny/smoo

th

connects the top to the TN-2588

necessary

7connection

cord 170" length X 1.75" diameter allows it to be plugged

inplastic

dull/rough

provides power to the TN-2588

stays the same

8 plug 1N/A

allow electricity inplastic rigid

main source of powerstays the

same

9horizontal

panel wires 213" length X .03 diameter connect indicator

outletscopper shiny

allows electricity to flow horizontally

stays the same

10vertical

panel wires

162" length X .075" diameter connect panels and

outlitscopper shiny

allows electricity to flow vertically

stays the same

11 Plug screws 198

inner diameter .055" X length .25" X .21" outer diameter X .073" width

hold outlets instee

l shinyholds outlit onto panels Phillips

12handle screws 2

.286" inner diameter X .33" outer diameter X .115" length (top) X .626" width connects handle to the

topstee

l rusty

secures the handle to the top

change location

13

Metal sqaures with

inslits 4

1" length X 1" width X .5" thickholds the small metal bars to the back plate

Garolite

shiny/smoo

th

leaves a space between the small metal bars and the

back plate

stays the same

14 front screws 14

.235" inner diameter X .56" length X .451" outer diameter X .166" width

holds the small metal bars to the big metal

barsstee

l rusty

holds the small metal bars to the big metal

bars

stays the same

15small metal

bar 9

.25"length X 17" depth X 1" width, 0.618" diameter holes (11 each) in them, .9"

diameter holes (22 each .91 from larger holes)

holds the plugs

aluminum

shiny/smoo

th

it is attached to the big metal bars on the ends

stays the same

16 vertical bars 2

.5" length X 15.5" depth X 1" widthholds up the small metal

bars

Garolite

shiny/smoo

th

provides a space between the small metal bars and the

back plate

stays the same

17 hex screws 4

inner diameter .242" x inner length 1" .37 outer diameter x .25" outer length holds in the bottom and

top small metal bars to the big metal bars

steel rusty

secures the metal bars to the big metal bars

stays the same

18green back

screws 2

.187" inner diameter X 1" length X .35" outer diameter X .19" width

holds the structure up

aluminum dull

screws on to the base N/A

19green back

washer 2

inner diameter .215" X outer diameter .57" X thick .056"

secures the screw better

aluminum dull

underneath the screws N/A

20 handle plate 1.25"length X 17" depth X 1" width, 0.618" holds the structure

together

aluminum

smooth

handles are screwed on to it

N/A

Materials used in proposal

Steel Green structure surrounding the product and the nuts and bolts.

Aluminum Bars that create the rows and columns.

Epoxy Resin Slots for the timers to be placed in.

Phenolic Laminates Brown back sheet of structure.

Plastics

Ferrous Metals

Nonferrous Metals

Works Cited

http://www.lenntech.com/periodic/elements/ti.htm

http://www.roymech.co.uk/Useful_Tables/Matter/Titanium.html