Reverse engineering p1
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    Reverse engineering p1 Reverse engineering p1 Document Transcript

    • Activity 3.2.1 – Product ObservationPurpose 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 pencilProcedure 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. Project Lead The Way, Inc. Copyright 2007 IED – Unit 3 – Lesson 3.2 – Activity 3.2.1 – Product Observation – Page 1
    • Product Name: Test RackCompany Name: L3 Avionics Systems1. What is the purpose or primary function of the object? To test the various indicators in different environments and make sure that they function properly.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. The testing rack is used primarily for one operation only. It is used to test the various L3 indicators and make sure that each indicator does its job, whether it Project Lead The Way, Inc. Copyright 2007 IED – Unit 3 – Lesson 3.2 – Activity 3.2.1 – Product Observation – Page 2
    • be to count time or shine a LED light. The worker inserts the various 99indicators into the slots. Then he places 3-4 racks in the chamber, plugs them inand starts the testing chamber. But there are little attachments that add theirown functions and change how it operates. The handle allows for the worker tolift up the rack and make it easier to hold. The raised edge at the bottom makesit easier for the worker to stack multiple racks inside the chamber. Project Lead The Way, Inc. Copyright 2007 IED – Unit 3 – Lesson 3.2 – Activity 3.2.1 – Product Observation – Page 3
    • 4. Identify the system inputs, intended product function, and outputs in the table below. Inputs Product Function OutputHeat/Cold Chamber Testing Testing ResultsIndicatorsPower5. What mechanical components are visible? Indicators, Stainless Steel, Indicator Slots, Handle, Raised Edge, Bolts6. What is it about this device’s function that you cannot identify, because the mechanical components are hidden from plain view? Where are the wires connecting the cord to the indicator slot. Project Lead The Way, Inc. Copyright 2007 IED – Unit 3 – Lesson 3.2 – Activity 3.2.1 – Product Observation – Page 4
    • Problem 3.4.3a – Decision Matrix Template Criteria SIZE WEIGHT TEMP # of outlets Durability CHANGE Ideas Totals Checkerboard 2 3 3 3 3 14 pattern outlets with checkerboard holes in frame (made of fiber glass) Horizontal and 1 3 2 1 3 10 vertical outlets and holes in frame(made of carbon fiber) Horizontal and 2 3 3 1 3 12 vertical outlets and holes in frame(made of fiberglass)SIZE: WEIGHT: TEMP CHANGE: # of outlets: Durability:1:Bigger than L3 1: Weighs more than L3 1:-85 F to 285 F 1: Same as L3 1:Less durable than L32:Same as L3 2:Weighs the same as L3 2:-100 F to 400 F 2: Has a couple more 2: Same durability as L33:Smaller than L3 3:Weighs less than L3 3:-200 F to 800 F 3:Has more than 10 extra 3:More durable than L3 Project Lead The Way, Inc. Copyright 2007 IED – Teacher Guidelines – Support Materials – Unit 3 – Lesson 3.4 – Problem 3.4.3a – Decision Matrix Template – Page 1
    • Problem 3.4.3b - Product ImprovementDesign BriefClient Company: The Client Company is L3Designers: Kevin Kubis and Olivia FoyProblem Statement: We need to make a more efficient testing product that withstands high & low temperatures, is light weight, and has as many outlets as possible for testing.Design Statement: We will create a wood model, which will represent various metals that we would use in the real product. Our model will show that the real products could be light weight and have many outlets when made with the real metals.Constraints: It has to withstand temperatures of -85 degrees F to 257 degrees F. It has to be as light or lighter weight then the model used now. & it had to have as many outlets or more then there already is. Project Lead The Way, Inc. Copyright 2007IED – Teacher Guidelines – Support Materials – Unit 3 – Problem 3.4.3b – Design Brief Template– Page 1
    • 1-May 2-May 3-May 4-May 5-May 6-May 7-MayDisassembly ChartProduct ObservationAnalysisSketchesProduct ResearchPresentation DrawingsOrthographic DrawingsInventor ModelsDesign BriefProduct ImprovementModified SketchesOral Presentation
    • 8-May 9-May 10-May 11-May 12-May 13-May 14-May 15-May 16-May
    • 17-May 18-May 19-May 20-May
    • Product Improvement! Kevin Kubis & Olivia Foy1. We are going to make this product lighter in weight.2. We will make it withstand higher and lower temperatures.3. We will make the product have more outlets.4. We will allow a more practical design for storage and practical use.
    • Activity 3.3.2a – Product Disassembly ChartProduct Name: Testing Rack for L3 Group members: Olivia FoyDate: 4/28/11 Kevin KubisTime: 11:54Part Part Qty Dimensions Function Material Texture/Finish Interaction General # Name with Other Notes Parts (i.e.: wear, stress indicators)1 Brown 1 15.5 X 16.5 Keep wires & Phenolic smooth Screwed to Corners have Backing X 1 inches electrical laminate metal frame broken off. functions out of (substance is harm. weak)2 White 99 Total Allow place for plastic Bumpy texture Female part Fixtures have Outlets diameter of fixtures to plug due to holes to the vibrated in the 1.129 inches; into. fixtures, outlets, holes are attached to causing .135 inches metal frame. changes in test results.3 Screws 14 .375 X .5 Keeps metal aluminum Smooth Screws into Flat-head brackets holes in the screw driver attached to brackets. unscrews it. frame.4 Fixtures 99 1inch depth, Keeps track of aluminum smooth Hooks into Used in .75 inch time. outlets planes; has to height, 1.25 withstand inch length temps -85 to 257 degrees F5 Metal 9 1 X 16.5 X Allows a place aluminum smooth Outlets are Are screwed brackets .25 inches for the outlets to inserted into in with screws. be attached. them; attached to metal frame. Project Lead The Way, Inc. Copyright 2007 IED – Unit 3 – Lesson 3.3 – Activity 3.3.2a – Product Disassembly Chart –Page 1
    • Part Part Qty Dimensions Function Material Texture/Finish Interaction General # Name with Other Notes Parts (i.e.: wear, stress indicators)6 Metal 1 3 X 15.5 X To hold brackets Steel & smooth Metal bars Needs to frame 16.5 inches aluminum screwed into withstand it bumping into other objects.7 Hexagonal 6 .375 X .50 Hold brackets to aluminum bumpy Screws into Unscrewed screws metal frames metal with a Allen brackets wrench Project Lead The Way, Inc. Copyright 2007 IED – Unit 3 – Lesson 3.3 – Activity 3.3.2a – Product Disassembly Chart –Page 2