session 4 reverse engineering and redesign

8/13/2019 Session 4 Reverse Engineering and Redesign

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Session 4

Reverse Engineering and Redesign

Dr. Ing. Sheila Lascano Farak

Engineering Design Methodology:

A Global Perspective



Outline

General Reverse Engineering and RedesignMethodology

Types of Redesign

Reverse Engineering & Product Dissection Dissection Process

Dissection Steps

Dissection Reporting Disassembly Plan

Bill of Materials



Reverse Engineering:

• Reverse engineering starts with a current product andis the process of understanding the components,

functions, mechanisms, and systems used by theproduct.

• Reverse Engineering gives an overall picture of howother designers have combine parts to satisfy thecustomer needs.

Redesign Process:

• It is a process that follows reverse engineering, wherethe product is evolved to its next offering in the market.

Definitions



Fixes

• A fix is a design modification that is required due to less than

acceptable performance once the product has been introducedinto the marketplace.

• Example: redesign of refrigeration systems (use of fluorinatedhydrocarbon refrigerants because of the “ozone-hole problem”)

Updates

• Updates are usually planned as part of the product’s life cyclebefore the product is introduced to the market.

• An update may add capacity and improve performance to theproduct or improve its appearance to keep it competitive.

Definitions

Redesign: There are two categories of redesigns:



General Reverse Engineering and Redesign

Methodology

Reverseengineering

Modelingandanalysis

Redesign

Reverse engineering and redesign methodology has three distinct phases:

This approach allows us to understand the product.



Investigation,

Prediction &

Hypothesis

Concrete experience:

Function & form

Design models

Design analysis

Parametric

Redesign

Adaptive

Redesign

Original

Redesign

ReverseEngineering

Modeling &

Analysis

Redesign



Types of Redesign

Adaptive Redesign

(synthesis)

Involves adapting a known system to a

changed task or evolving a significant sub-

system of a current product.

Parametric Redesign

(modification)

Involves varying the parameters (size,

geometry, materials, etc..) of certain aspects

of a product to develop a new and more

Robust design.

Original RedesignImplies that a product already exists that isperceived to fall short in some criteria and a

new solution is needed.



Reverse Engineering & Product

Dissection

Discover the operationalrequirements of the

product

How does the product operate?What conditions are necessary for proper function of the

product?

Examine how the product

performs its functions

What mechanical, electrical, control system or other devices are

used in the product to generate the desired functions?

What are the power and force flow through the product?

What are the spatial constraints for subassemblies andcomponents?

Is clearance required for proper functioning? If a clearance is

present, why is it present?

Determine the

relationships between

component parts of the

product.

What is the product’s architecture ?

What are the major sub-assemblies?

What are the key component interfaces?

Determine the

manufacturing and

assembly processes used

to produce the product.

Of what material and by what process is each component

made?

What are the joining methods used on the key components?

What links and fasteners are used and where are they located?



The most important aspect of a product dissection is to make clear

why we are doing it.

What are the objectives of this activity?

What are the purposes of the new, evolved product?

What is expected to be uncovered through the dissection?

It is always fun to tear apart mechanical devices; however,

nothing will be accomplished if data are not collected on

important factors

Dissection Process

???



STEP 1: List the Design Issues If it is a new product, the design issues may be unknown

Investigate: Customer market, competitors, features of competitors

products

If the project entails a redesign, an investigation can ask of theprevious team:

What was difficult for them?

What design problem did they solve that they are proud of?

What related technologies were they interested in?

Last set of design issues that needs recording is basic

information on the components in the assembly

Quantity of parts, dimensions, weight, material, color/finish,

manufacturing process, geometric tolerances, primary function, etc.

Dissection Steps



STEP 2: Prepare for Product Dissection

Identify:

All sensors and test equipment required for measurement process

Camera

Videotape (of product operating)

Multimeter

Hardness tester

Optical sensor

Flow meter

Dynamometer

Calipers

Strobe

Etc.

Dissection Steps



STEP 3: Examine the Distribution and Installation

Examine means used to:

Acquire parts

Contain parts

Ship, distribute, and market the product

Examine also:

the distribution packaging of the product

Consumer installation instructions and procedures (for cost,effectiveness and liability)

Dissection Steps



STEP 4: Disassemble, Measure, and Analyze Data byAssemblies

First take pictures and measurements on the whole assembly

before disassembly

Then

Take apart the assembly

Take pictures in a exploded view

Take measurements on the parts and assemblies to complete thedata sheet

In this step is important to avoid destructive testing during the

first iteration.

Dissection Steps



STEP 5: Form Bill a Materials (BOM)

During disassembly, the team should complete a written form

that details the product.

Add a sequence of assembly photos.

The data collected in each column of the BOM area that required

for subsequent analyses, including cost and performance.

Dissection Steps



Disassembly PlanProduct Disassembly

Project name

Engineer(s)

Date:

Known Desired Information

Disassembly Plan:

Step Task Needed Tools

Measurements

Comparison with Predictions

*Could be components, features, physics, functions



Bill of Material (BOM)

Bill of Materials

ProjectName

Engineer(s):

Date

Part # Name Qty

Functional Analysis DFM Cost Analysis

Function Flows-In Flows-Out Manuf. Process Dimensions Mass Material FinishOther

variable



References

Otto , K . and K . Wood , Product Design:Techniques in Reverse Engineering and New

Product Development , Prentice Hall, Upper

Saddle River, NJ , 2001.

Dieter, G and Schmidth L. Engineering Design,,

Fourth Edition, Mc Graw Hill, New York, NY,

2009.



Resources

https://sites.google.com/a/umn.edu/me2011/resources/product-dissection

http://www.mne.psu.edu/lamancusa/html/ProdDi

ss.htm



http://www.mne.psu.edu/lamancusa/html/ProdDiss.htm









session 4 reverse engineering and redesign

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