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

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

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

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

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

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

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

Scanning the Jeep frame with the LDI Laser Scanner

Next Step –Aligning Point Clouds Aligning the captured point clouds in RapidForm

Aligning the captured point clouds in RapidForm

Next Step – Mirroring Frame Mirroring and Comparing one side of the frame to the other

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, 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

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 Reverse Engineering and creating specific features from the polygonal and geometric data

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

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

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”

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

Final Step – Deliver Requested Models Complete all modeling and deliver the requested models in proper formats

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

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

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.