RAPID PRODUCT DEVELOPMENT

REVERSE ENGINEERING AND REDESIGN

Presented by: Sumeet Ghodke (Reg. No. - 122090005) & Mahesh Awati (Reg. No. - 122090104)

INTRODUCTION
Reverse Engineering is the practice of studying a finished product, a physical device or a software package, in order to learn something about how it works or how it was manufactured. It often involves taking something apart and analyzing its working in detail to try to make a new device or program that does the same thing without copying anything from the original.

REASONS FOR REVERSE ENGINEERING

Lost documentation Product analysis. To examine how a product works, what components it consists of, estimate costs, and identify potential patent infringement. Military or commercial spying- Learning about an enemy's or competitor's latest research by stealing or capturing a prototype and dismantling it. Creation of unlicensed/unapproved duplicates Academic/learning purposes Curiosity Learning: learn from others' mistakes.

REVERSE ENGINEERING OF MECHANICAL

DEVICES The reverse-engineering process involves measuring an object, testing and then reconstructing it as a 3D model. The physical object can be measured using 3D scanning technologies like CMMs, laser scanners, structured light digitizers or computed tomography. The scanned object is studied for its defects, optimization and redesigned accordingly. A prototype is prepared and tested and accordingly the changes are made. Using NC/CNC machines the object is manufactured.

ANTIKYTHERA MECHANISM
A famous example of reverse engineering Ancient mechanical computer Discovered in wreck in 1900, dated around 150100 BC

DEVELOPMENT CYCLE
The waterfall model Reverse Engineering moves through this process in reverse. May not end up with the same implementation.

SCANNING METHODS
Manual measurement Profile projector Touch probe mounted on a CMM Laser scanning Industrial Computer Tomography (CT) scan Magnetic Resonance Imaging (MRI) Ultrasonic scanning Photogrammetry

ANALYZING THE DESIGN AND OPTIMIZING

Study the design Look for advantages and drawbacks Improvise Look for best possible design Final design

CASE STUDY: 1
DESIGN AND FABRICATION OF A PRESSURE TRANSDUCER FOR THE CONDITION MONITORING OF THE OIL LUBRICATION SYSTEM FOR GENERATOR SET

INTRODUCTION TO SYSTEM

The bottom line here is that any rather sudden rise or fall in oil pressure should be taken as a signal that your engines oiling system needs attention.

PRESSURE GAUGE MOUNTING ON GEN-SET

CAUSE OF LOW PRESSURE:

Filter blockage Low oil level Damaged oil pan or pick-up tube High Oil Worn Oil Pump

MARKET SURVEY
MANUFACTURER Pricol RICO Saudamini VDO

RICO COMPONENT ANALYSIS

ADVANTAGES Robust construction Small in size Easy to mount

DRAWBACKS Hystersis due to torsional spring Not precisely and accurate Assembly not easy to repair Less life due to use of diaphragm

DIFFERENT MECHANISMS FOR PRESSURE MEASUREMENT

BOURDON BELLOW U-TUBE MANOMETER

DIAPHRAGM

SINGLE ACTING CYLINDER

DESIGN SELECTION

Final Design

CASE STUDY: 2 DIGITIZING OF A FULL SCALE FALCON 20 "ZERO G" JET AIRCRAFT

The National Research Council (NRC) Institute for Aerospace Research had a requirement to digitize their Falcon 20 parabolic aircraft to capture its "As Built" condition for CFD analysis, moveable aero surfaces positions and aircraft symmetry checks.

THE NRC FALCON 20 WAS ONLY AVAILABLE FOR A 2.5 DAY PERIOD FOR THE DATA ACQUISITION PROCESS.
Utilized two complimentary non-contact data acquisition devices, ATOS II Structured White Light TRITOP Digital Photogrammetry,

THE GOALS OF THE DATA ACQUISITION PROCESS:

Full aero surfaces for CFD model creation Scan past centerline - assuming aircraft symmetry, checks done for validation Capture various positions of the moveable control surfaces Fast and easy integration into downstream processing requirements-creation of STL file to support rapid surfacing

TRITOP DIGITAL PHOTOGRAMMETRY PROCESS

MARKER AND RECONSTRUCTED CAMERA POSITIONS.

ATOS II OPTICAL SCANNING PROCESS

INDIVIDUAL ATOS SCANS ARE SHOWN IN THEIR GLOBAL POSITION. THE AUTOMATIC SCAN PLACEMENT AND MATCHING OF EACH ATOS SCAN INTO THE ACCURATELY DEFINED TRITOP GENERATED REFERENCE GRID, IS A KEY
FEATURE IN BOTH THE DELIVERY OF AN ACCURATE PROJECT AND PROMOTES TIME EFFECTIVE DIGITIZING.

Wing tip data to check for symmetry and allow an accurate mirroring to create a full aero model.

The capturing of the needed positions of the flaps and airbrake are shown

Well-known examples from WWII and later include Jerry can : British and American forces noticed that the Germans had gasoline cans with an excellent design. They reverse-engineered copies of those cans. The cans were popularly known as "Jerry cans". Tupolev Tu-4 : Three American B-29 bombers on missions over Japan were forced to land in the USSR. The Soviets, who did not have a similar strategic bomber, decided to copy the B-29. Within a few years, they had developed the Tu-4, a nearperfect copy. V2 Rocket : Technical documents for the V2 and related technologies were captured by the Western Allies at the end of the war. Soviet and captured German engineers had to reproduce technical documents and plans, working from captured hardware, in order to make their clone of the rocket, the R-1, which began the postwar Soviet rocket program that led to the R-7 and the beginning of the space race.

CONCLUSION
Case Study 1: The design of the pressures transducer gets better with the reverse engineering of the competitors product by knowing their drawbacks and advantages. Case Study 2: The reverse engineering of a Full Scale Falcon 20 "Zero G" Jet Aircraft is possible with the use of 3D scanning technologies with the use of ATOS II Optical Scanning Process and TRITOP Digital Photogrammetry Process.

Questions?

Thank you!!!