GATEWAY

Step by Step Reverse Engineering

Examples

Instructions
1. Follow these examples to complete the
reverse engineering part in the results
section of your project report
2. All steps are of the product that you used in
product dissection (reverse engineering
methodology as shown in lecture series 2)
3. Some of the steps may not apply to your
product you must leave them. If you are not
sure you can ask
4. After step 4, comes the design process part
{lecture
series 3
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Example 1
Product Name : Black and Decker Hedge
Trimmer

Sl.#2

Reverse Engineering
Methodology

GATEWAY

1. Investigation, Prediction and Hypothesis

2. Concrete Experience: Function & Form

Reverse
Engineering

3. Design Models
Modeling &
Analysis

4. Design Analysis

Parametric
Redesign

Sl.#3

Adaptive
Redesign

Original
Redesign

Redesign

Reverse Engineering Example Project

Step 1
Investigation, Prediction and Hypothesis
Develop Black Box Model (as shown below) for your product by
answering the following questions: What goes in? What comes out?
(i.e. power, noise, heat, vibration)

Electric Power
Finger Switch
Safety Off

Noise

Hedge
Trimmer

Blade Movement
Vibration, heat

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Step 1 continued

Use the product to understand the performance of the

product:
Record product performance attributes (see product
manual): e.g.
Shearing speed
3300 strokes/min
5:1 Gear reduction = 16,500 RPM for the motor

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Step 1 cont.
What is the market for this product?
Examples
Suitable for small shrubbery Black &
Decker Product Catalog
Homeowners with small yards and limited
budget
For use only 3-4 times a year

What are the costs associated with this

product?
Example
Design - Manufacturing - Assembly
Packaging - Resale ($40.00)
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Step 1 cont
How long will this product last?
Assumed durability of each component
(outdoor use, dirt)
Availability of replacement parts and service
shops
What features does this product have that are
important?
Molded-in cord retainer
Lock off switch prevents accidental start-up
Lock on switch for continuous running
Lightweight design for less fatigue (4.5 lbs.)
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Step 2 : Concrete Experience: Function and Form

After Disassembly identify the various subsystems
Describe issues related to use of the product e.g.
product-customer interaction (you also watch videos of
your product and you can include the video DVD of your
product in action. If you do not have a video, please
record one e.g. ask your brother to use the product while
you record the video)

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Drive Mechanisms

GATEWAY

Pin for upper blade

Input gear
from motor

Output gear

Pin for lower blade

Slot for upper blade

Blades

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Slot for lower blade

Step3DesignModels

GATEWAY

Identify actual physical principles and

mathematical equations that were used to
design this product
What are the engineering specifications of
your product?

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Step 3 cont..
Transforming to engineering specifications
Example - Motor-Blade Kinematics
Examples of engineering specifications
Helical gears
Number of teeth: input = 4
output = 60
Motor speed = 22800 rpm
Output speed =

4
1
in 22800 rpm
60
15

= 1520 rpm = 159 rad/s

Maximum blade speed = 1 m/s

EngineeringSpecifications
Tin

Transforming to engineering
specifications
T
1

Input gear from motor

Tin T1 I 1 1

T1 Ft

I 1 1

T2

d1
2

Output gear to blades

F1

T2 F1 r1 F2 r2 I 2 2

r1
r2

I 2 2

F2

F1 m1 r1 2 sin r1 22 cos

F2 m2 r2 2 sin r2 22 cos

T2 Ft

d2
2

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Step4.DesignAnalysis
Create engineering analysis, simulation
(for example solidworks) or
optimization

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