Reverse Engineering, Ethics, and other issues in Design

1. Reverse Engineering, Ethics, and other issues in Design Necessary qualities for successful completion of project: Curiosity, eagerness to take things apart, willingness to learn from mistakes, interest to work in a team Thinking is not an option

2. Objective • Dissecting a product • Understanding how it functions • Learn basic principles • Designing/building a new product • Communicating (oral/written)

3. Issues involved • Cost effective • Ergonomical • Aesthetically pleasing/Visually appealing Problem with GM and Ford even though quality is good • Safe (toys, automotive crash,nuclear power plants subjected to earthquake or missiles) • Environment friendly (quiet, use recyclable materials, less consumption of energy, Biodegradable) • Testing & Warranty issues (7 year/100k miles) Recent GM Promotions • Cater to an existing market or create new market • Ethical issues

4. Last lecture involved Electro-magnetic shock design to show an interesting project involving energy recovery. Also various vibration and acoustic issues were addressed. Now let us consider some common household items, dissect them and then try to design a similar product.

5. Study a familiar product • Vacuum cleaner (or power drill or lawn mower) Following steps are involved to study the product: • Disassembling the product • Identifying each component • Understanding their purpose • Obtaining information about each component

6. Why hands-on experience • I hear, I forget • I see, I remember • I do, I understand

7. Do not forget 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

8. Working in a Team By now, you are working in a team (smooth or rough?) Working properly in a team is essential to the success of the project Next few slides are presented to help functioning properly in a team “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 past CEO, GE .

9. 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

18. Reverse Engineering • Reverse Engineering is a very common practice in industry to understand the product of competitors • Reverse engineering may also be used for other reasons such as reverse engineering of legacy parts for an Army project (Mechanical Engineering Design, pp 12-15, 2004)

19. Back to Dissection Now that you have some guidelines for working in a group successfully, proceed with dissection of a vacuum cleaner

20. 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

21. 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?

22. 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 run (try to fix the problem later !)

23. Big Picture • Understand how different issues are addressed • Conversion of energy (120V power supply to motor providing torque • Conversion of motion (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)

24. Sample project • Build a mini vacuum cleaner, which can suck a paperclip • with constraint of material cost no more than $50 • including the motor

25. Some Equations • Even a small or toy vacuum cleaner operating principle involves some equations • Conversion of electrical power (watts = volt * ampere) to mechanical power • Mechanical power = force * velocity • Power imparted to impeller = torque * angular velocity • In case of pump (vacuum cleaner) required power = mass flow rate * change in pressure Now change of duct size and many other factors would govern the required pressure increase by the impeller.

26. Commercial ones

29. I want to conclude this part of the lecture with a note that just designing and manufacturing a part or a component is not enough. Ultimately you have to interact with other people whether it is personnel within your own company or outside your company. You may work for a company or agency which either sells a product or buys a product You need to be aware of a very important issue – ETHICS(seems to be the primary issue in Illinois gubernatorial election)

30. NSPE Code of Ethics for Engineers PreambleEngineering is an important and learned profession. As members of this profession, engineers are expected to exhibit the highest standards of honesty and integrity. Engineering has a direct and vital impact on the quality of life for all people. Accordingly, the services provided by engineers require honesty, impartiality, fairness, and equity, and must be dedicated to the protection of the public health, safety, and welfare. Engineers must perform under a standard of professional behavior that requires adherence to the highest principles of ethical conduct.

31. Fundamental Canons Engineers, in the fulfillment of their professional duties, shall: 1. Hold paramount the safety, health and welfare of the public. 2. Perform services only in areas of their competence. 3. Issue public statements only in an objective and truthful manner. 4. Act for each employer or client as faithful agents or trustees. 5. Avoid deceptive acts. 6. Conduct themselves honorably, responsibly, ethically, and lawfully so as to enhance the honor, reputation, and usefulness of the profession.

32. Case Studies on Ethics • Personal Value Conflict (helmet design) - Is possible abuse an issue? • Corporate Conflict (1987 Chrysler odometer case, selling of previously tested cars as new) – Is good intention enough? • Boeing defense contract - Hiring a DOD person (resignation of top executives, cancellation of contract, possible loss of jobs if contract goes overseas) • Pressure from own supervisor (compromise results) • Conflict of interest (relatives, friends) • Gifts from suppliers

33. Case Studies in Safety/Liability • Motorcycle gas tank explosion • Lawn Mower • DC10 accident in 1989 • Helium tank • Vat

34. Ethics/Vibrations/Sports Vibration studies is a big part in Sports e.g. golf, tennis, baseball etc (e.g. new golf clubs are designed to hit the ball further). Unlike golf, major league baseball doe not permit changing the traditional wooden bat. However, that does not stop players from trying illegally changing the bats say by corking.

35. Modes of Vibrations of Baseball bat Bending Modes and sweet spot • First Bending Mode • Second Bending Mode Hoop Modes are important for hollow aluminum or composite bats because of the trampoline effect

36. Research shows crime does not pay http://www.kettering.edu/~drussell/bats-new/corkedbat.html Corked bats do not change the distance traveled by the ball Momentum of bat hitting the ball is about the same (more velocity but less mass) Let us consider vibration of aluminum and wooden baseball bats http://www.kettering.edu/~drussell/Demos/batvibes.html How about other sports? – Golf, Tennis, Football, Yacht, etc)

37. Golf and vibrations Steel vs. GraphiteShafts: Graphite shafts transmit fewer vibrations up the shaft to the golfer's hands than do steel shafts Graphite shafts are lighter than steel shafts Shaft flex – related to stiffness

38. Acknowledgement • MEEP (The manufacturing engineering education partnership), J. Lamancusa et. al, PSU, 2004. • Society of Professional Engineers • State of Illinois Ethics Examination • D. Russell, Kettering University • Office of Associate Dean, CEET