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Reverse
Engineering

DepartmentofMechanicalEngineering,TheOhioStateUniversity
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ReverseEngineering
Examiningcompetitiveorsimilarorprior
productsingreatdetailbydissectingthemor
literallytakingthemapart.
Dym&Little
Whatdoesthisdo?
Howdoesitdothat?
Whywouldyouwanttodothat?
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ReverseEngineering
Gaininsightintoourowndesignproblem
bylookingathowotherpeoplehave
addressedthesameissues.
Restrictions:

Expensivedesigns
Protectedbypatents
Maybethecompetitorsdesign
Designmaynotworkverywell
DepartmentofMechanicalEngineering,TheOhioStateUniversity

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ReverseEngineeringMethodology
Investigation, Prediction and Hypothesis
Concrete Experience: Function & Form

Reverse
Engineering

Design Models
Modeling &
Analysis

Design Analysis

Parametric
Redesign

Adaptive
Redesign

Original
Redesign

Redesign

DepartmentofMechanicalEngineering,TheOhioStateUniversity
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Adapted from Otto and Woods Reverse Engineering and Redesign Methodology UT Austin

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ReverseEngineeringMethodology
1.Investigation,PredictionandHypothesis

Developblackboxmodel
Use/Experienceproduct
Listassumedworkingprinciples
Performeconomicfeasibilityofredesign
Stateprocessdescriptionoractivitydiagram

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ReverseEngineeringMethodology
2.ConcreteExperience:FunctionandForm

Planandexecuteproductdisassembly
Groupdefinedsystemsandcomponentstogether
Experimentwithproductcomponents
Developfreebodydiagrams
Identifyfunctionsharingandcompatibility
Transformtoengineeringspecs.andmetrics

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ReverseEngineeringMethodology
3.DesignModels

Identifyactualphysicalprinciples
Constantlyconsiderthecustomer
Createengineeringmodelsandmetricranges
Alternativelyorconcurrentlybuildprototypetotest
parameters

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ReverseEngineeringMethodology
4.DesignAnalysis
Calibratemodel
Createengineeringanalysis,simulationor
optimization
Createexperimentandtestingprocedures

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ReverseEngineeringMethodology
5.ParametricRedesign
Optimizedesignparameters
Performsensitivityanalysisandtolerancedesign
Buildandtestprototype

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ReverseEngineeringMethodology
6.AdaptiveRedesign

Recommendnewsubsystems
Searchforinventivesolutions
Analyzeforceflowsandcomponentcombinations
Buildandtestprototype

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ReverseEngineeringMethodology
7.OriginalRedesign

Developnewfunctionalstructure
Choosealternatives
Verifydesignconcepts
Buildandtestprototype

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SystemLevelDesign
ReverseEngineeringrequiresunderstanding
theproductordesignasasystemorsetof
systemsthatworkandinteracttogether.
ThisconceptisknownasSystemLevelDesign.

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SystemLevelDesign
System=Components+Connections
Components
Physicalpickup,measure,drawonCAD
Functionalflowcharts,difficulttodefine

Connections
Fundamentalintendeddesign
Incidentalcreatedbyphysicalproximityof
components(vibration,heattransfer,etc.)

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SystemLevelDesign
Developblackboxmodelavoidingbias.
Graphicrepresentationofthesystemorobject
beingdesigned,withinputsshownenteringon
theleftandoutputsleavingontheright.

Inputs

System

Outputs

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SystemLevelDesign
Example:Radio
Power
RF Signal
User Choices
(Volume, Freq.)

RF=radio frequency

Heat & Noise

Convert RF
Signal To
Sound At
Desired Level

Sound
Status
Indications
(Volume, Freq.)

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SystemLevelDesign
Continuewiththeglassboxapproach.
Identifysubsystems
Electrical
Mechanical
Taskoriented
Defineinteractionsandflowofforces
Intentional
Unintentional
Wires,signals,material,data,etc.
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GlassBoxExample

Ink Jet Printer

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SystemLevelDesign
FinalBreakdown

Foreverypieceorcomponentofinterest,
discuss:
1)Howwasitmade
2)Whyitwasmadethisway
3)Designissues
4)Thematerialitismadeoutof
5)Complexityandcost
6)Ergonomicissues
7)Interactionwithothercomponents
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ReverseEngineeringExample
ExampleProject
BlackandDeckerHedgeTrimmer

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ReverseEngineeringMethodology
Investigation, Prediction and Hypothesis
Concrete Experience: Function & Form

Reverse
Engineering

Design Models
Modeling &
Analysis

Design Analysis

Parametric
Redesign

Adaptive
Redesign

Original
Redesign

Redesign

DepartmentofMechanicalEngineering,TheOhioStateUniversity
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Adapted from Otto and Woods Reverse Engineering and Redesign Methodology UT Austin

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Reverse Engineering Example Project

1.Investigation,PredictionandHypothesis
DevelopBlackBoxModel
Assembleproductandconductatest
Whatgoesin?Whatcomesout?(i.e.power,noise,heat,vibration)

Electric Power
Finger Switch
Safety Off

Noise

Hedge
Trimmer

Blade Movement
Vibration, heat

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Reverse Engineering Example Project

Conduct a single test of the performance of the product:
Record product performance attributes
Shearing speed
3300 strokes/min
5:1 Gear reduction = 16,500 RPM for the motor

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Reverse Engineering Example Project

Whatisthemarketforthisproduct?
SuitableforsmallshrubberyBlack&Decker

ProductCatalog
Homeownerswithsmallyardsandlimitedbudget
Foruseonly34timesayear

Whatarethecostsassociatedwiththisproduct?
DesignManufacturingAssemblyPackaging
Resale($40.00)

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Reverse Engineering Example Project

Howlongwillthisproductlast?
Assumeddurabilityofeachcomponent(outdooruse,dirt)
Availabilityofreplacementpartsandserviceshops

Whatfeaturesdoesthisproducthavethatareimportant?

Moldedincordretainer
Lockoffswitchpreventsaccidentalstartup
Lockonswitchforcontinuousrunning
Lightweightdesignforlessfatigue(4.5lbs.)

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AdditionalCommentsandRemarks1
by: jenni796 (Fri Apr 7 '00)
Pros: light weight, very durable
Cons: none
Trimming the bushes is my only contribution to our 2 acre yard.
I bought my first Black & Decker hedge trimmer at Wal*Mart because it was very
inexpensive compared to most other trimmers
Black & Decker has an excellent reputation.
The 13" seemed a little too small The 18" seemed heavier
I also wanted electric rather than gas because being a busy woman, I had no time to
learn about mixing gas.
Durability: Excellent Noise Level: Average Purchase Price: $25.00

DepartmentofMechanicalEngineering,TheOhioStateUniversity
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REF: http://www.epinions.com/hmgd-review-5AC4-E92BC14-38EDE974-prod4

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AdditionalCommentsandRemarks2
by: dadof6 (Fri Apr 7 '00)
Pros: Easy to handle and lite too!
Cons: Electric and water never mix!
While it may be a good trimmer it also has it's downside!
The first problem with it being electric is that you need a drop cord.
The second problem is that since it is electric and you use it outside, you run the risk of
being electrocuted! Remember most people doing lawn work are also running sprinklers
to water the lawn. I have had good friends killed simply by using these trimmers on wet
grass.
Over all this tool does a great job of trimming but the hazards to your personal safety
far out weigh the pros of this tool.
Durability: Good

Noise Level: Average Purchase Price: $39.95

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AdditionalCommentsandRemarks3
by: lpmiller (Tue Jun 27 '00)
Pros: Cheap, powerful, lightweight
Cons: Weak manual, requires an outlet.
just about the cheapest thing you'll find on the market
as usual the fine folks at B & D come through.
As long as the cord reaches, I have the power I need.
safety lock located at the top of the trimmer; release the trigger, the safety clicks on
One of the safety tips that really amused me was, Do not use in rain. On the one
hand, Im just not that stupid, on the other hand...well, we all know someone, dont
we? Folks, it is an electric trimmer. Do Not Use In Rain. Or the bathtub. Really.
Durability: Excellent Noise Level: Average Purchase Price: $29.99

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PatentSearchonHedgeTrimmers
After completing a search on the U.S. Patent
and Trademark website:
http://www.uspto.gov

Patent # 5,778,649 (1998)

Power Driven Hedge Trimmer

Patent # 5,581,891 (1996)

Hedge Trimmer with Combination
Shearing and Sawing Blade Assembly
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Function and Form

2. Concrete Experience: Function and Form

Carefully begin Disassembly

Document steps and components with photographs,

sketches or video

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HedgeTrimmerSubSystemsandInteractions

Group defined systems and subsystems together.

Switch

Motor

Blade

Case
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Motor
120V8AmpMotor
350RPM
Whynotbatteries?
Howimportantissize,
speed?
Wasweighta
consideration?

Photo of Motor

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Switch

Safetylockallows
triggeraction.
Isthisaregulatory
requirement?
Ergonomicissuesof
sizeandleverforce
Whattypeofspring
mechanismisused?

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Switch
MOTOR

Sketch of Switch
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Blades

Howfastdothebladesneedto
move?Force?
Arethebladessharp?
Whatarethebladesmadeof?
Canwereplacetheblades?

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Transmission
Pin for upper blade
Input gear
from motor

Output gear

Pin for lower blade

Slot for upper blade

Blades

Slot for lower blade

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Case

Howwasthecasemade?
Wasthecasedesignedto
beestheticallypleasing?
Whyisntthecasemade
outofmetal?
Whatsortofcostsare
involvedinthe
manufacturingofthis
case?
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FeatureList
Switch - Plastic Injection Molded
Gear Die Cast Steel
Case Plastic Injection Molded
Handle Plastic Injection Molded
Guard Plastic Injection Molded

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Reassemble Product

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EngineeringSpecifications
Transformingtoengineeringspecifications
ExampleMotorBladeKinematics
Helical gears
Number of teeth: input = 4
output = 60
Motor speed = 22800 rpm
4
1
in = 22800 rpm
15
Output speed = 60

= 1520 rpm = 159 rad/s

Maximum blade speed = 1 m/s
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EngineeringSpecifications

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EngineeringSpecifications
Transformingtoengineeringspecifications
T
T
Input gear from motor
1

in

Tin T1 =I 1&1

T1 Ft

I 1&1

T2

d1
2

T2 Ft

d2
2

Output gear to blades

F1

T2 F1 r1 F2 r2 =I 2&2

r1
r2
F2

I 2&2

F1 = m1 r1&2 sin r1 22 cos

F2 = m2 r2&2 sin + r2 22 cos

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DesignModels
3.DesignModels
Identifyactualphysicalprinciples
Createengineeringmodelsandmetricranges
Alternativelyorconcurrentlybuildprototypetotest
parameters

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DesignAnalysis
4.DesignAnalysis
Calibratemodel
Createengineeringanalysis,simulationor
optimization
Createexperimentandtestingprocedures

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ParametricRedesign
5.ParametricRedesign
Optimizedesignparameters
Performsensitivityanalysisandtolerancedesign
Buildandtestprototype

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AdaptiveRedesign
6.AdaptiveRedesign

Recommendsnewsubsystems
Searchesforinventivesolutions
Analyzesforceflowsandcomponentcombinations
Buildsandtestsprototype

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AnotherReverseEngineeringExample
ExampleProject
BlackandDeckerCordlessScrewdriver

SKIP
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Reverse Engineering Example Project

1.Investigation,PredictionandHypothesis
DevelopBlackBoxModel
Assembleproductandconductatest
Whatgoesin?Whatcomesout?(i.e.power,noise,heat)
Electric Power

Noise

On/Off Switch

Cordless

Power/Manual
Switch

Screwdriver

Screwdriver rotation
vibration, heat

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Product Performance
Conduct a single test of the performance of the
product:
Record product performance attributes
No load Rotational speed:

150 rpm (claimed)

142 rpm (measured)

81:1 Gear reduction = 12,200 RPM for the motor

Drove in 94 #6, self tapping screws into dry pine
(not predrilled)

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Product Market
Whatisthemarketforthisproduct?
GreatforEverydayUseBlack&Decker

Manual
Homeownerswithneedforoccasionaluse

Whatarethecostsassociatedwiththisproduct?
DesignManufacturingAssemblyPackaging
Resale($20.00)

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Product Features
Howlongwillthisproductlast?
2yearfullwarrantyprovided

Whatfeaturesdoesthisproducthavethatare
important?
Cordless,rechargeablebattery
Reversibledirection
Power/manualswitch
Relativelyhightorque
Relativelylongbatterylife
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AdditionalCommentsandRemarks1
by Staceys1 (Nov 03 '00)
Pros: Durable and easy to use
Cons: none
Recommended: Yes

Owned for about 5 years and is still going strong.

Easy to use: position the screwdriver on the screw and press a button.
It has a switch that reverses the way the head spins depending on whether you are
trying to remove or put in a screw.
The tip is easily taken out to switch between a Phillips head and a flathead
screwdriver.
Very durable. Its been dropped on concrete, and other than a few scratches, it still
works fine.
Amount Paid (US$): 20 (on sale)

DepartmentofMechanicalEngineering,TheOhioStateUniversity
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http://www.epinions.com/hmgd-review-5AC4-E92BC14-38EDE974-prod4

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AdditionalCommentsandRemarks2
By: YYvonne (Jan 19 '01)
Pros: Makes tougher jobs a breeze for me
Cons: none
The Bottom Line: Makes screwing around a breeze! (Couldn't resist!)
Recommended: Yes

Not really designed for heavy duty jobs

Saves me a lot of strain in my wrists
Lightweight and easily held
I like the directional buttons on the screw driver
I've never had the rechargeable battery die on me in the middle of a job.
The batteries recharge quickly

Amount Paid (US$): 25

DepartmentofMechanicalEngineering,TheOhioStateUniversity
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http://www.epinions.com/hmgd-review-5223-748E473-38EEAF23-prod6

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AdditionalCommentsandRemarks3
By: Seeker1 (dec0900)
Pros: Easy to use, reversible heads, rechargeable
Cons: none known
Recommended: yes

Best gift I ever bought my husband for myself!!!

This is a tool we use constantly, for any household project, big or small
Practically anyone could use, my daughter and myself included!!
Has a battery pack which is rechargeable. When it loses it's charge, you simply plug
it in, let it recharge and you're ready to go again.
Has interchangeable bits, one on either end (phillips head and a slotted head).
The feature that I really like is that it's reversible. You can either drive a screw in or
back it out.
Wonderful lifesaver of a tool.
Amount Paid (US$): 19.95

DepartmentofMechanicalEngineering,TheOhioStateUniversity
Sl.#53

http://www.epinions.com/hmgd-review-7EC8-6221B35-39592C7E-prod4

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FunctionandForm
2. Concrete Experience: Function and Form

Carefully begin Disassembly

Document steps and components with photographs,

sketches or video

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CordlessScrewdriverSubSystems
andInteractions

Group defined systems and subsystems together.

Battery/
charger

Motor

Switch

Transmission

Screwdriver
Bit

Case
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Battery/Charger
Nickel Cadmium battery
Jack for connection to AC
transformer
Diode to half-wave rectify
the AC signal (charging)

Diode
Jack

Battery

Wires to
switch
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Switch
rotation

Rotationofswitchingdevice
linesupthecontactsfor
eitherforwardorreverse
directions
Pushingtheswitching
devicecreatescontact
betweentheuppercontacts
Howimportantissize,
speed?
Wasweightaconsideration?

Contacts
to motor
Contacts coming from battery

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Switch

Sketch of Switch
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Motor
2.4VMotor
12200RPM(noload)
3.567Amps(noload)
Torque=.056Nm(atstall)
Howimportantissize,
speed?
Wasweighta
consideration?
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Transmission

Sun gear: 6 teeth

Planet gear: 19 teeth
Ring gear: 48 teeth
Gear ratio = 81:1

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Transmission

output to
screwdriver
bit

Second stage of
planetary gears

First stage of
planetary gears

(Ring gear not shown)

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ScrewdriverBit

Howfastdoesthebit
needtoturn?Torque?
Whatisthebitmadeof?

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Case

Howwasthecase
made?
Wasthecasedesigned
tobeesthetically
pleasing?
Whyisntthecase
madeoutofmetal?
Whatsortofcostsare
involvedinthe
manufacturingofthis
case?
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FeatureList
metal leads extruded and bent
plastic switch injection molded
plastic switching mechanism injection molded
plastic gears injection molded
casing injection molding
metal bit extruded

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Reassemble Product

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EngineeringSpecifications
Transformingtoengineeringspecifications
ExampletransmissionKinematics
1. Calculate gear ratio if carrier was fixed
*

6
1

48
8

2. Calculate carrier speed out of first set of planetary gears

* 18
1
1
*

12200 rpm 1356 rpm

1 98
9
9

3. Calculate carrier speed out of second set of planetary gears

1
1
1356 rpm 151 rpm
9
9

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EngineeringSpecifications
Transformingtoengineeringspecifications
2 mm

16 mm

Ft1

6.33 mm

8.33 mm

TS1 .056 Nm

9.33N
3rs 3(.002m)

Tc1 3Ft1 rc 3(9.33N )(.00833m) 0.233Nm

Ts 2 Tc1 0.233Nm
Ft 2

Ts 2 0.233 Nm

0.039 N
3rs 3(.002m)

Tc 2 3Ft 2 rc 3(0.039 N )(.00833m) 0.971Nm 8.6inlbf

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DesignModels
3.DesignModels
Identifyactualphysicalprinciples
Createengineeringmodelsandmetricranges
Alternativelyorconcurrentlybuildprototypetotest
parameters

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DesignAnalysis
4.DesignAnalysis
Calibratemodel
Createengineeringanalysis,simulationor
optimization
Createexperimentandtestingprocedures

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ParametricRedesign
5.ParametricRedesign
Optimizedesignparameters
Performsensitivityanalysisandtolerancedesign
Buildandtestprototype

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AdaptiveRedesign
6.AdaptiveRedesign

Recommendsnewsubsystems
Searchesforinventivesolutions
Analyzesforceflowsandcomponentcombinations
Buildsandtestsprototype

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EnvironmentalImpact
Todeterminetheenvironmentalimpactof
theexistingdesignevaluateeachstep
oftheProductLifeCycle
Preproduction
ManufacturingProcess
ProductLife
TheAfterLife
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Preproduction

Replaceabilityofnaturalresources
Availabilityofanalternativeresource
Energyrequiredtoobtain
Energytoprocess
Amountofwastecreatedduring
processing
Wastedisposalmethod
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ManufacturingProcess

Energytoproduce
Wastecreatedduringproduction
Typeofwastesolvents,emissions?
Reuseofinprocessmaterial
waste?
Materialyield

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ProductLife

Energyconsumption
Wasteproduction
Lengthofproductlife

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TheAfterLife

Reuse
Recycledesignfordisassembly?
Neitherharmfulpollutants?

Discussion:Reusevs.Recycle

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Summary
Reverseengineering

Tooltounderstandcurrentdesign
solutionsandtechnology
Usedissection,experimentationand
analysis
Savetimeandgaininsightoncurrent
designchallengesandsolutions

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Credits

Thismoduleisintendedasasupplementtodesignclassesinmechanical
engineering.ItwasdevelopedatTheOhioStateUniversityunderthe
NSFsponsoredGatewayCoalition(grantEEC9109794).Contributing
membersinclude:

GaryKinzel..Projectsupervisors
JimPiperandRachelMurdell..Primaryauthors
PhuongPhamandMattDetrick...Modulerevisions
L.Pham...Audiovoice

Reference:

Otto and Woods Reverse Engineering and Redesign Methodology UT Austin

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Disclaimer
This information is provided as is for general educational purposes; it can
change over time and should be interpreted with regards to this particular
circumstance. While much effort is made to provide complete information,
Ohio State University and Gateway do not guarantee the accuracy and
reliability of any information contained or displayed in the presentation. We
disclaim any warranty, expressed or implied, including the warranties of
fitness for a particular purpose. We do not assume any legal liability or
responsibility for the accuracy, completeness, reliability, timeliness or
usefulness of any information, or processes disclosed. Nor will Ohio State
University or Gateway be held liable for any improper or incorrect use of the
information described and/or contain herein and assumes no responsibility for
anyones use of the information. Reference to any specific commercial
product, process, or service by trade name, trademark, manufacture, or
otherwise does not necessarily constitute or imply its endorsement.
DepartmentofMechanicalEngineering,TheOhioStateUniversity
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