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Reverse Engineering Product Dissection and Design. Prerequisite for the course: Curiosity, eagerness to take things apart, willingness to learn from mistakes, interest to work in a team. Objective. Dissecting a product Understanding how it functions Learn basic principles

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reverse engineering product dissection and design

Reverse Engineering Product Dissection and Design

Prerequisite for the course:

Curiosity, eagerness to take things apart, willingness to learn from mistakes, interest to work in a team

objective
Objective
  • Dissecting a product
  • Understanding how it functions
  • Learn basic principles
  • Designing/building a new product
  • Communicating (oral/written)
mechanical engineering
Mechanical Engineering
  • Mechanical Engineering involves
  • Conversion of energy (engine, turbine, motor, etc.)
  • Conversion of motion (gears, piston-cylinder, etc.)
  • Analysis of a structure (strength, stiffness, etc)
  • Choosing the correct material (metal, composite, etc)
  • Building a structure or machine (building components and assembly)
  • Mechanical engineers play a major role in building everything (toys to cars to airplanes)
issues involved
Issues involved
  • Cost effective
  • Ergonomical
  • Aesthtically pleasing
  • Safe
  • Environment friendly
  • Cater to an existing market or create new market
study a familiar product
Study a familiar product
  • Vacuum cleaner (or power drill or lawn mower)
  • Following steps will be involved to study the product:
  • Disassemble the product
  • Identify each component
  • Understand their purpose
  • Obtain information about each component
why hands on experience
Why hands-on experience
  • I hear, I forget
  • I see, I remember
  • I do, I understand
safety rules
Safety Rules
  • Wear safety glasses
  • Do not work alone
  • Do not hurry
  • Do not work when tired or under the influence
  • Use common sense
  • Think before you act
  • Prevent accidents
team building
Team Building

“If you can’t operate as a team player, no matter how valuable you’ve been, you really do not belong at GE”

John Welch

CEO, GE (1993)

Since working properly in a team is essential to the success of the project following few slides are presented to help functioning properly in a team.

potential problems

Potential Problems

Since this may be the first course in your engineering curriculum, be aware of the potential problems of working a group and try to avoid them

back to dissection

Back to Dissection

Now that you have formed a group successfully, proceed with dissection of a vacuum cleaner

initial observation
Initial Observation
  • Let us explore how a vacuum cleaner works
  • First identify the vacuum cleaner: type, manufacturer, model#, and performance specifications
  • Read the instruction manual
  • Plug the vacuum cleaner and run it
  • Listen to the sound
  • Feel how it runs
  • Record your observations
dissection
Dissection
  • Wear safety glasses
  • Unplug the vacuum cleaner
  • Disassemble it as far as possible
  • Put all parts in a bin (with label of your group)
  • Note each part and their purpose (e.g. belt and pulley mechanism, types of bearings/bushings, motor, etc.)
  • Are there any other alternatives of these components?
reassemble
Reassemble
  • Now reassemble your vacuum cleaner
  • Suggest any design changes to make reassemble easier
  • Once all parts are assembled, plug it in and run it (make sure you have your safety glasses)
  • If it does not sound or feel like before or smoke comes out, unplug immediately and try to fix the problem.
big picture
Big Picture
  • Understand how different issues are addressed
  • Conversion of energy (120V power supply to motor providing
  • Torque
  • Conversion (Belt and pulley system)
  • Safety issues (Child proof)
  • Environmental issues (quiet but not too quiet, hepa filter)
  • Ergonomic (Carry up the stair, notice the cg location at the
  • stair grip)
  • Material choice (Plastic cover, metal rod for the roller axle)
  • Cost ($50 to $800!)
  • Market (household, commercial)
your project
Your project
  • Your group project
  • Build a mini vacuum cleaner, which can suck a paperclip
  • with constraint of material cost no more than $50 including the motor
acknowledgement
Acknowledgement
  • MEEP (The manufacturing engineering education partnership), J. Lamancusa et. al, PSU, 2004.