Complete Reverse Engineering

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Design Brief JAMES V. DUNN MATTHEW P. MUHS The product is now mostly made out of garolite, besides the handles which are made out of steel. The two large handles are on the sides, instead of the one small handle on the top. Test rack is set up in a sort of grill pattern which hold the ticker being tested (same as old design). The material that the tickers are inserted into is made of plastic. Electricity is delivered to the tickers so that they work during the entire testing process. There is also a thin sheet on the back to protect the wires from getting damaged, as to not risk the legitimacy of the entire test.

Project Lead The Way, Inc. Copyright 2007

IED – Unit 3 – Lesson 3.2 – Activity 3.2.1 – Product Observation – Page 1

JAMES DUNN, MATT MUHS

Activity 3.2.1 – Product Observation Purpose

Have you ever noticed how children are fascinated with how objects work? Many engineers have stated that they can trace back their interest in their chosen field to their childhood, when they would tear apart broken objects to figure out what caused them to move and function.

Reverse engineering is a process that relies on this childhood fascination with objects, and how they work. The process involves the study of an object’s visual, functional, and structural qualities. Though it does not imply redesign, reverse engineering is often a tool that is used to aid in the redesign of an object so that its performance may be improved. Other reasons for performing reverse engineering include reducing an object’s negative environmental impacts, maximizing manufacturing techniques through the substitution of more appropriate materials, discovering how a competitor’s product works, and increasing a company’s profit margin.

You have performed a visual analysis of your selected product to identify the visual design principles and elements that give the object its visual appeal, or lack there of. The next step in the reverse engineering process involves the study of the object’s function. This is done through careful observation of the object’s sequential operation before it is disassembled. By first observing the product, you can hypothesize how a product operates and then compare your predictions to your actual findings after the part is dissected.

Equipment

• Activity 3.2.1a Example Product Observation • Engineer’s notebook • Number 2 pencil

Procedure

In this activity, you will analyze the function of your consumer product.

Before measurement and dissection, you must theorize how the product functions through non-destructive observation. Identify your product’s name and the company that produced it, and answer the following questions.



Product Name: Test Rack Company Name:

1. What is the purpose or primary function of the object?

The purpose of the test rack to test indicators in various temperature conditions in the test oven.

2. Sketch an isometric pictorial of the product in your engineer’s notebook, and

label the individual components. If you are not sure what a particular component is called, then make a logical guess.

3. Make an educated guess as to how this product operates. Use simple machines’ terminology to explain the object’s sequential operation. All of the indicators are plugged into the test rack. The rack receives electricity and the makes the indicators spin, changing their numbers. The indicators are pushed to temperature extremes of positives and negatives.



4. Identify the system inputs, intended product function, and outputs in the table below.

Inputs Product Function Output

Indicator To count and track usage of certain devices

Strong numbers to use to new designs

5. What mechanical components are visible?

The indicator has a wheel with numbers on it that spins to count numbers.



6. What is it about this device’s function that you cannot identify, because the mechanical components are hidden from plain view? The only thing hidden is what is inside the indicator. For example, what turns the indicator? You can see everything on the test rack, but it is not mechanical devices it is just wires.


IED – Teacher Guidelines – Support Materials – Unit 3 – Problem 3.4.3b – Design Brief Template– Page 1

Problem 3.4.3b - Product Improvement Design Brief

Client Company: L3

Designers: Matt Muhs and James Dunn

Problem Statement:

There has been numerous complaints of the weight of the test rack. Our job is to redesign the test rack so that it is lighter and make it more portable than before. The test rack must be able to withstand extreme heat and cold conditions without deforming as well as testing a large amount of tickers/trackers.

Design Statement:

The product is now mostly made out of garolite, besides the handles which are made out of steel. The two large handles are on the sides, instead of the one small handle on the top. Test rack is set up in a sort of grill pattern which hold the ticker being tested (same as old design). The material that the tickers are inserted into is made of plastic. Electricity is delivered to the tickers so that they work during the entire testing process. There is also a thin sheet on the back to protect the wires from getting damaged, as to not risk the legitimacy of the entire test.

*Weight must be lighter *The test rack must still fit inside the testing chamber

*New material must be able to withstand testing conditions

Constraints:


IED – Teacher Guidelines – Support Materials – Unit 3 – Problem 3.4.3b – Design Brief Template– Page 2

MATT MUHSJAMES DUNN

Weight must be lighterPricing of new design must be

reasonableThe new test rack must still fit inside

the testing chamber New material must be able to

withstand testing conditions

Cost Workability Weight Total

Garolite 3 4 4 11

AVCOAT 2 3 5 10

Aluminum 5 3 2 10

Steel 3 2 1 6

Aluminum Oxide 5 2 2 9

SCALE: 1 through 5. 1 being the lowest, 5 being the highest.

1) The material is much heavier than that of the original, so it does not solve the problem at all.

2) The material is equal in weight to the weight of the current test rack.

3) The material is slightly lighter than the current design, but will weight is not reduced enough for a difference

4) Material is lighter, the weight difference is noticeable and will reduce the strain on the worker

5) Material is a great deal lighter. Lifting this it seems effortless is comparison to the old material

1. The material it incredibly expensive to make and/or obtain.

2. The material costs a great deal of money 3. The material costs a moderate amount of

money4. The material is on the not quite expensive.

Still costs a lot of money to get though.5. The material is cheap and easy to get, very

common and doesn’t use up the entire budget.

1. It is very hard to work with and may have problems during the manufacturing with the material

2. Some difficulties occur while working with the material, but they are minor and result in miniscule adjustments.

3. It works fine and posing no problems while working

4. The material is OK for working with. It can be hard to maneuver

5. The material is excellent for working with. A very low amount of effort is needed to do anything with it.

The product is now mostly made out of garolite, besides the handles which are made out of aluminum.

The two large handles are on the sides, instead of the one small handle on the top.

Test rack is set up in a sort of grill pattern which hold the indicators being tested (same as old design). The material that the sockets are made out of is ABS plastic.

There is also a thin sheet on the back to protect the wires from getting damaged, as to not risk the legitimacy of the entire test.

MATT MUHS JAMES DUNN

Group Norms Distribute work evenly between partners

Respect each other’s ideas and listen

Final decision should be the best work from both partners

Complete all parts of project in order of the Gantt chart and turn everything in on time

Opposite partner double checks and go over work for errors and completeness

Be nice and considerate of the significant other’s feelings

Ignore distractions because they produce lower quality work

Keep the language PG

25-Apr 26-Apr 27-Apr 28-Apr 29-AprSelect Project and get approval from

Gantt Chart of Entire ProjectFully completed Disassembly Chart

3.3.2a (typed)Activity 3.2.1 Product Observation

(typed)

Mass Properties Analysis for all parts of the Reverse Engineering Project (Info

can be put on each drawing.)

Fully Measured, sketched and Product Research (Individual Project

Presentation Drawing (balloons, parts list assembly and explosion drawings

Orthograpic Drawings of individual parts of assembly (use rubric) Drawing

d ill b d

Modified and/ or New Inventor Models

Activity 3.4.1 Writing a Design Brief

Problem 3.4.3 Product Improvement

Measured, sketched and annotated sketches of all the Modified parts of th R E i i P j t i th Oral Presentation (group project only)

Extra CreditBest group project as indicated by outside engineer(s).

1 pdf file of all the documentation used or discovered for the entire Reverse Engineering Project

Team Norms

30-Apr May-11 May-11 5/3/2011 5/4/2011 5/5/2011 5/6/2011 7-May

8-May 9-May 10-May 11-May 12-May 13-May 14-May 15-May 16-May

17-May 18-May 19-May OTHER

[Type text]

[Type text]

Garolite Density: 1.83g/cm3 Aluminum Density @ 293 K: 2.702 g/cm3 The density of mild steel is approximately 7.85 g/cm3 AVCOAT: 0.512 g/cm3

Tungsten: 19.25 g·cm3 Aluminum Oxide: 3.95 g/cm3

Carbon Fiber: 1.8 g/cm3

Weight

1. The material is much heavier than that of the original, so it does not solve the problem at all.

2. The material is equal in weight to the weight of the current test rack.

3. The material is slightly lighter than the current design, but will weight is not reduced enough for a difference

4. Material is lighter, the weight difference is noticeable and will reduce the strain on the worker

5. Material is a great deal lighter. Lifting this it seems effortless is comparison to the old material.

Cost

1. The material it incredibly expensive to make and/or obtain.

2. The material costs a great deal of money 3. The material costs a moderate amount of money 4. The material is on the not quite expensive. Still costs a lot

of money to get though. 5. The material is cheap and easy to get, very common and

doesn’t use up the entire budget. Survival

1. The material stands up to the everyday extreme cold and extreme heat conditions without much wear and tear for a very long period of time.

2. The material does not stand up to the everyday grind that it is put through and will quickly become worn beyond use

Weight 1. The material is much heavier than that of the original, so it does

not solve the problem at all. 2. The material is equal in weight to the weight of the current test

rack. 3. The material is slightly lighter than the current design, but will

weight is not reduced enough for a difference 4. Material is lighter, the weight difference is noticeable and will

reduce the strain on the worker 5. Material is a great deal lighter. Lifting this it seems effortless is

comparison to the old material. Cost

1. The material it incredibly expensive to make and/or obtain. 2. The material costs a great deal of money 3. The material costs a moderate amount of money 4. The material is on the not quite expensive. Still costs a lot of money

to get though. 5. The material is cheap and easy to get, very common and doesn’t

use up the entire budget. Workability

1. It is very hard to work with and may have problems during the manufacturing with the material

2. Some difficulties occur while working with the material, but they are minor and result in miniscule adjustments.

3. It works fine and posing no problems while working 4. The material is OK for working with. It can be hard to maneuver 5. The material is excellent for working with. A very low amount of

effort is needed to do anything with it.

Cost Workability Weight Total

Garolite 4 4 4 16

AVCOAT 2 3 5 10

Aluminum 5 3 2 10

Steel 3 2 1 6

Aluminum Oxide 5 2 2 9 SCALE: 1-5, 1 being the worst, 5 being the best.

1

1

2

2

A A

B B

STUDENT NAME

TEACHER NAME

DRAWING NAME

SCALE

MATERIAL

DATE

CLASS & PERIOD

muhs3543

WEDOFF

TEST STRIP.ipt

1/4

Garolite

5/4/2011

T-202/ P3

17.00

1.00

.63

.25

.25

.50

1.56

1

1

2

2

A A

B B

STUDENT NAME

TEACHER NAME

DRAWING NAME

SCALE

MATERIAL

DATE

CLASS & PERIOD

muhs3543

WEDOFF

teststripbase.ipt

1/4

Garolite

5/9/2011

T-202/ P3

14.50

.25

1.00

.25

.60

DETAIL D

SCALE 1 : 1

D

1

1

2

2

A A

B B

STUDENT NAME

TEACHER NAME

DRAWING NAME

SCALE

MATERIAL

DATE

CLASS & PERIOD

muhs3543

WEDOFF

handle.ipt

1/4

Garolite

5/16/2011

T-202/ P3

13.41

.10

.31

.17

.75

1

1

2

2

A A

B B

STUDENT NAME

TEACHER NAME

DRAWING NAME

SCALE

MATERIAL

DATE

CLASS & PERIOD

muhs3543

WEDOFF

Outlet.iam

2:1

Garolite & Copper

5/6/2011

T-202/ P3

1.13

.63

.13

.17

.75

.31

.13

1

1

2

2

A A

B B

STUDENT NAME

TEACHER NAME

DRAWING NAME

SCALE

MATERIAL

DATE

CLASS & PERIOD

muhs3543

WEDOFF

spacer.ipt

2:1

Garolite

5/13/2011

T-202/ P3

1.00

1.00

.75

.17

.25

1

1

2

2

A A

B B

STUDENT NAME

TEACHER NAME

DRAWING NAME

SCALE

MATERIAL

DATE

CLASS & PERIOD

muhs3543

WEDOFF

backprotector.ipt

1/6

Garolite

5/17/2011

T-202/ P3

17.00

15.00

.20

.06

1

1

2

2

A A

B B

STUDENT NAME

TEACHER NAME

DRAWING NAME

SCALE

MATERIAL

DATE

CLASS & PERIOD

phardy

WEDOFF

cap screw ANSI B18.6.2 - 1_4-20 UNC - 0.5(17).ipt

4:1

Aluminum

2/7/2010

T-202/ P3

.08

.38

.44

.47

.69

1

1

2

2

A A

B B

STUDENT NAME

TEACHER NAME

DRAWING NAME

SCALE

MATERIAL

DATE

CLASS & PERIOD

muhs3543

WEDOFF

Full Assembly.iam

1/3

Garolite & Copper &

Aluminum

5/10/2011

T-202/ P3

Parts List

DENSITYMASSPART NUMBERQTYITEM

1.83g/c

m^3

0.127

lbmass

teststripbase21

1.83g/c

m^3

0.238

lbmass

rowwithoutlets92

1.83g/c

m^3

0.011

lbmass

ANSI B18.6.2 -

1/4-20 UNC -

0.5

223

1.83g/c

m^3

.047

lbmass

spacer

44

2.702g/c

m^3

.145

lbmass

handle25

1.83g/c

m^3

0.552

lbmass

backprotector16

1

1

2

2

A A

B B

STUDENT NAME

TEACHER NAME

DRAWING NAME

SCALE

MATERIAL

DATE

CLASS & PERIOD

muhs3543

WEDOFF

Full Assembly.iam

1/5

Garolite & Copper &

Aluminum

5/10/2011

T-202/ P3

45

1

6

2

2

3

Documents

Complete Reverse Engineering