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Reverse Engineering Methods

Reverse Engineering Methods. TEC 316 Dr. Lou Reifschneider. Why Perform Product Teardown. Want to learn how product function was achieved via Reverse Engineering – not reinventing the wheel.

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Reverse Engineering Methods

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  1. Reverse Engineering Methods TEC 316 Dr. Lou Reifschneider

  2. Why Perform Product Teardown • Want to learn how product function was achieved via Reverse Engineering – not reinventing the wheel. • Want to build personal experience of “how things are made” – types of materials, processes to make parts, and how parts are assembled. • Want to perform competitive benchmark of product you are designing – how does your design compare?

  3. Five Steps for Teardown • List Design Issues • How does product solve customer problems? • What are the DFM and DFA data: • # parts per unit • Dimension of parts • Max, min, average material thickness • Weight • Material used • Color/finish • Manufacturing process • Geometric (between features), spatial tolerances • Primary part functions • Cost per part or subassembly

  4. Five Steps for Teardown 2. Prepare for Teardown – what tools are needed? • Micrometer, • Hardness tester, • Multimeter, • Scale, • Camera, etc. 3. Examine how product is distributed and installed • Packaging costs can be significant, • If customer assembles – what are costs/liabilities?

  5. Five Steps for Teardown 4. Disassemble, Measure, & Analyze Assemblies • Take apart assembly, • Take picture of an exploded view (or neatly draw an exploded view), • Measure parts and assemblies for data sheets. 5. Document teardown data for DFM & DFA • Complete Assembly Tree Diagram • Note parent/child relationship during disassembly, • Note assembly method between mated parts. • Complete Assembly Analysis Form • Note assembly operations and required tooling • Complete Bill of Materials Form • Note function, manufacturing process, dimensions, etc.…

  6. No. Assembly Part Name 1 Cap_Assm Cap 2 Cap_Assm Clip 3 Cap_Assm Color_Tip 4 Body_Assm Tail 5 Ink_Assm Ink_Plug 6 Ink_Tube_Assm Ink 7 Ink_Tube_Assm Clear 8 Tube_Assm Tube 9 Stylus_Assm Stylus 10 Stylus_Assm Coupler 11 Grip_Assm Tip 12 Grip_Assm Body 13 Grip_Assm Rubber Grip Assembly Tree Diagram Example Assembly Tree Diagram Project Name: UniBall Pen Engineer(s): By Example Clip Interference fit Date: Cap Cap_Assm Interference fit Tube Color_Tip Stylus Interference fit Tube_Assm Interference fit Pen Interference fit Stylus_Assm Ink_Tube_Assm Clear Coupler Interference fit Body_Assm Ink_Assm Ink Ink_Plug Tail screw thread Tip Interference fit Grip_Assm Rubber Grip over molded Body Clip Color_Tip Cap Body & Rubber Grip Tip Stylus Clear Ink Ink_Plug Tube Coupler Tail 13 Unique Parts Identified

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