Reverse Engineering Project

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

.63


2X .25 THRU
1/4-20 UNC - 2B 2X .19 THRU

1.00 .25
.75
.50

.75
1.75
2.25

STUDENT NAME DRAWING NAME SCALE DATE

cox1723 Two rectangle blocks.ipt 1" = 1"
5/3/2011


Product Name: TN-2588 -- Indicator Fixture

Teardown Group Members:

Time: 10:28AM Kira Heggeland, Patrick Witt, and Jennifer Seiben

Date: 4-May-11

Part # Part Name Quantity Dimensions Function Material Texture/Finish Interaction with other parts General notes
back board
16.75" X 14.5" X .1" thick
1 1 protects wires plastic-like smooth connected to main part necessary, could be lighter

.725" outer diameter X 1.126" inner diameter X 1.640" height x .127" thick inner diameter
2 indicator outlit 99 indicator plugs in here plastic-like dull held in place by screws and panels cannot remove

5.26 cm X inner diameter 1.5cm, 2.64 cm outer diameter
3 back hex screws (small) 4 holds back board steel dull connects back to main part necessary, could be altered

1.5" height X .25 thick X 6" length
4 handle/top 1 carrying device metal shiny/smooth part of the top, carries the device add another, change location

.25"height X 17" depth X 1" width
5 horizontal panels 9 outlits are on here metal shiny/smooth outlits are on them change shape and material

3.5" width X 17" length X .25"height
6 base 1 stands fixture up wood wood holds up the entire object eliminate

.2" diameter X .5" height X .1" diameter
7 top screws 2 connects the top steel shiny/smooth connects the top to the TN-2588 necessary

70" lenghth X 1.75" diameter
8 connection cord 1 allows it to be plugged in plastic dull/rough provides power to the TN-2588 stays the same

N/A
9 plug 1 allow electricity in plastic rigid main source of power stays the same

13" long X .03 diameter
10 horizontal panel wires 2 connect indicator outlits copper shiny allows electricity to flow horizontally stays the same
16
2" long X .075" diameter
11 vertical panel wires connect panels and outlits copper shiny allows electricity to flow vertically stays the same

inner diameter .055" X length .25" X .21" outer diameter X .073" length
12 outlit screws 198 hold outlits in steel shiny holds outlit onto panels phillips

.286" inner diameter X .33" outer diameter X .115" length (top) X .626" length
13 handle screws 2 connects handle to the top steel rusty secures the handle to the top change location

1" length X 1" width X .5" thick
14 square metals 4 holds the small metal bars to the back plate aluminum shiny/smooth leaves a space between the small metal bars and the back plate possibly eliminate

.235" inner diameter X .56" length X .451" outer diameter X .166" length
15 front screws 14 holds the small metal bars to the big metal bars steel rusty holds the small metal bars to the big metal bars stays the same

.25"height X 17" depth X 1" width, 0.618" diameter holes (11 each) in them, .09" diameter holes (22 each .91 from larger holes)
16 small metal bar 9 holds the indicators aluminum shiny/smooth connects the indictators to device change shape and material

.5" height X 15.5" depth X 1" width
17 big metal bar 2 holds up the small metal bars aluminum shiny/smooth connects the horizontal panels together change shape and material

inner diameter .242" x inner length 1" .37 outer diameter x .25" outer length
18 hex screws 4 holds in the bottom and top small metal bars to the big metal bars steel rusty holds small and big metal bars together stays the same

Patrick Witt, Kira Heggeland, Jennifer Sieben

Criteria
Efficiency Weight Amount of change
to original design
Ideas Totals

2 2 2 6
(Alternating socket positions)

2 3 3 8
(Removal of base)

(Vertical bars instead of horizontal)
2 2 2 6

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

Efficiency
Ranking Definition
1 Making this change will have no effect on the performance
of the test rack.
2 Making this change will only affect the external components
of the test rack.
3 Making this change will affect both the external and internal
components of the test rack.

Weight
Ranking Definition
1 Making this change will take off 0-4 pounds.
2 Making this change will take off 4-10 pounds.
3 Making this change will take off an estimated 10+ pounds.

Amount of change to original design
Ranking Definition
1 This change is no different from the original test rack.
2 This change is only partially different from the given test
rack.
3 This change is a completely different component from the
given test rack.

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 2

Mon. Tue. Wed. Thu. Fri. Weekend Mon. Tue. Wed. Thu. Fri. Weekend Mon. Tue. Wed. Thu. Fri. Weekend Mon. Tue. Wed. Thu.
Patrick Witt, Kira
Heggeland, Jennifer Sieben
3.30.11 - 4.7.11 - 4.14.11 -
3.25.11 3.26.11 3.27.11 3.28.11 3.29.11 4.2.11 4.3.11 4.4.11 4.5.11 4.6.11 4.9.11 4.10.11 4.11.11 4.12.11 4.13.11 4.16.11 4.17.11 4.18.11 4.19.11
4.1.11 4.8.11 4.15.11

Select Project

Gantt Chart

Disassembly Chart

Product Observation

Mass Properties Analysis

Annotated Sketches

Presentation Drawing

Orthographic Drawings

Modified Models

Design Brief

Prodcut Improvement

New Annotated Sketches

Presentation



14.125

2.875 .85
.50

1.313
4.188
7.063
9.938
12.812


sieben2938 new attach bars.ipt 1" = 4"
5/17/2011



.0625

14.125


13.725
.15

.15

17.76

.406

.15
13.725

huff1645 newBackplate.ipt .16" =
5/3/2011
1"




.10
.20

.40 .15 THRU
.50

8-32 UNC - 2B .15

.20 THRU
.56 .26
12-24 UNC - 2B


huff1645 newCornerBoxes.ipt 5" = 1"
5/3/2011




26.00

6.00

48.00


sieben2938 side of rack.ipt .08" =
5/18/2011
1"



10.00


2.00

27
63
5.00

11.18


sieben2938 supports for rack.ipt 1" = 4"
5/18/2011



2.00


26.00

29.00


sieben2938 top of rack.ipt .09" =
5/18/2011
1"



.06


17.00
16.60
.40

.25 THRU X 4

13.30 14.50

.27


huff1645 Backplate.ipt 0.16"=1"
5/3/2011



17.000


.335 x6
.500 .125
.250
.25
.555
3.50

1.400
.500
.500
TYP


brady3218 base of test rack.ipt 1" = 4"
5/10/2011




.50

.74
.250

.150 .15
THRU

.500
.75
.244
8-32 UNC - 2B
.20
THRU

12-24 UNC - 2B


huff1645 CornerBoxes.ipt 1":1"
5/3/2011


.19

.50


.13

R.17
.31

.31
.06

10-24 UNC - 2A

10-24 UNC - 2A
.06


boldt2559 handle screw (2).ipt 4":1"
5/3/2011



R.75

.75
1.50


R.50
.75
4.13
4.875

.20x2
.313

.625

.125 1/4-20 UNC - 2B X 2


boldt2559 finalhandle.ipt 1" = 4"
5/3/2011




.25

.45 X2 .62 X11

.88 X11
.69 .44
X2 X22 .50
1.00

.50 X2 .50
X10
.09 X22
17.00

sieben2938 horizontal bar.ipt 1" = 1"
5/2/2011



2.63
.45 x2
.62 x20 .50 .20
.09 x40

2.08
1.28


1.60
1.60

17.76

.44 .44
.88 .88

.75 .75
1.31


sieben2938 new vertical bars.ipt 1" = 4"
5/16/2011


5 8

9 7
6

10
1


3

2
11

4

Parts List
ITEM QTY PART NUMBER
1 4 CornerBoxes
2 2 Two rectangle blocks
3 2 Vertical Bar
4 1 base of test rack
5 1 Backplate
6 1 top bar
7 2 handle screw (2)
8 1 finalhandle
9 9 horizontal bar new
10 2 Longer Screw 2
11 99 SocketAssembly


lee2075 Assembly Use.iam Varies
5/4/2011



.13

.313


1.05
.14 THRU
.563 .75
.3105 .186 .267
.13 .443

.14 THRU X4

1.126
.621


witt2634 SocketAssembly.iam 1" = 1"
5/5/2011



.25


.19 .25 X 4
1.00
.75 .50

6.19
10.81
17.00


sieben2938 top bar.ipt 1" = 4"
5/3/2011


Our GOals
• Problem Statement:
To develop a new test rack to withstand extreme temperatures, have long
term durability, to be lighter than the current model, and be easy to store.

• Design Statement:
Design an updated test rack that is light weight, durable, resists extreme
temperatures, is ergonomically friendly, and is nonmagnetic.

• Constraints:
1.The distances between the units in the fixture must be maintained in order to allow the
largest and the smallest flange configurations to load side by side.
2. Non-Magnetic materials with the exception of hardware must be used in the fixture
configuration.
3. Test Panel.
• a. Size: 20” Wide X 21” Deep X 4” Height (With component installed) / Equivalent to
TN-2588
• b. Orientation: Units to be inserted into fixture in a vertical orientation. The holding
fixture shall be horizontal when used in testing.
• c. Fixture shall accommodate for two (2) handle lift and carry

9986 Brainstorming:
• Alternate outlit plugs to use
9986 space provided efficiently.
• Change the horizontal bars to
9986 vertical (while still readable) so
9986 that the pattern is possible.
•Each bar holds two
columns of indicators.
9986
• Eliminate the base completely
9986 because we have designed a new
9986 way of storage.
• Create a top that extends past
9986 the rack so that it can be stored
properly (on next slide).
9986

The problem presented
was to create a more
ergonomic test rack, but
the test racks did not have
a proper storage location.
We challenged ourselves
to design a housing unit.

Protective casing is
durable and helps
guard the test racks
from elements that
could place wear
and tear on them.

“Wine Rack” Style Supports
– The Test Shelves designed to
have been altered help hold the
to have a wider test racks
top to slide into
the shelves and
hang downward.

0.413 lb mass 1.246 lb mass

•Base of rack =
1.432 lb mass
Eliminated =
.599 lb mass

.745 lb mass

0.783 lb mass
x 4 = 3.915 lb mass
0.324 lb mass
x 9 = 2.916 lb mass
4.66 lb mass

Reverse Engineering Project

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