Class 2:

Reverse Engineering and Team Project

Assignment

2.1 Reverse Engineering

2.2 Team Project Written Proposal

 What is Reverse Engineering?

Reverse engineering is a systematic methodology for

analyzing the design of an existing device or system,
either as an approach to study the design or as a
prerequisite for re-design.

Figure 2.1 Reverse engineering is a method of studying how mechanical

systems are designed and put together. For engineering students, it is a good
way to develop a systematic approach about the design of devices and systems.
It also helps to acquire a mental data bank of mechanical design solutions.

Levels of Analysis in Reverse Engineering

1. System-Wide Analysis
 Customer Perspective
 Engineering Requirements and Specifications
 Black-Box Diagram
2. Sub-System Dissection Analysis
 Dissection Notes
 Fishbone Diagram
 Exploded Assembly Sketch and Computer Model
3. Individual Component Analysis
 Sketch Parts
 Build Computer Model of Parts
 Mass Properties Analysis and FEA
 Materials and Manufacturing Analysis
 Rapid Prototypes
 Engineering Drawings
Figure 2.2 The reverse engineering process has three levels of analysis. The
most effort is placed on the individual components of the system.
 Examples of Reverse Engineering Items
Baby Toy Fuel Pump Piston Assembly
Bathroom Scale Gate Valve Pipe Clamp
Beer Faucet Hand Tool Ratchet Tie-Down
Bicycle Pump Hose Nozzle Shower Massage Head
Bolt Cutter Lug Wrench Spinning Disk Launcher
Deadbolt Lock Master Cylinder Sprinkler Head
Desktop Clamp Model Car Drive Train Toy Nerf Gun
Differential Gear Oil Pump Vise Grip
Flashlight Oscillating Sprinkler Water Faucet Valve

Figure 2.3 A list of reverse engineering items that have been successfully used
in an introduction to engineering design and graphics laboratory project.
Other engineering items not on the list are acceptable, but must be approved
by the instructor.

Example: Small Kitchen Scale

Figure 2.4 A small kitchen scale is a useful device in the kitchen. It works on
basic engineering principles and has a sufficient number of parts to be used as
an example of the reverse engineering project.
 System Wide Analysis of Small Kitchen Scale
Customer’s Perspective
The customer will be looking for the cost, size, and appearance of the devise
first. They will also be concerned with ease of operation, durability, and the
readout accuracy. They may also want to determine how easy it is to clean and
maintain. Basically they are looking for quality for the price.

Engineer’s Perspective
The engineer will be concerned with materials selection, the strength of the
materials, and the total weight of the device. The engineering designer will also
need to consider the mechanism needed to transform the weight of food placed
on the scale to the readout value.

Engineering Specifications List

 The range of weights the scale can measure (0 to 1 lb.)
 Size and type of readout (minimum of 16 point font)
 Safety features and operating instructions (booklet)
 The connection linkages needed to yield accurate readouts (to 0.1 oz.)
 Testing and long-term quality assurance (1 year warranty)

Figure 2.5 Contrasting the customer’s perspectives versus the engineer’s

perspective and specifications list for the small kitchen scale.

Design Graphics Team Project

Fall 2018

Figure 2.6 An example cover page that can be used for the introduction to
engineering design and graphics laboratory project proposal.
 Design Check #1:
Team Project Written Proposal
1. You will work in teams as established in class. Plan a meeting and select one member to
serve as team leader. The team leader will be the primary point of communication with the
instructor and TA’s, and will be responsible for coordinating the overall efforts of the team.

2. Discuss, select, and purchase a small system to reverse engineer. It may be, for example, a
mechanical toy, a hand tool, or a small home appliance. It should have overall dimensions such
that you can hold it easily in one hand. The system should preferably be mechanically-driven
(e.g., spring-wound or friction-flywheel driven rather than battery-operated).

3. Your device must have at least 2 subsystems, and each subsystem must have at least 2
components. You should be able to disassemble and reassemble it with readily available tools.
Be cautious about choosing something that is difficult (or impossible) to take apart, like a plastic
toy with glued joints or an appliance with a welded casing. Try to select an inexpensive device,
and you might want to buy an extra one in case you have to "sacrifice" the device in the process
of disassembling it for the first time. Pool your money together as a team, and again try not to
select something too expensive.*

4. Prepare and submit the team proposal. It should include the following main components:

a. Cover page, listing the title of the project (e.g., "Reverse Engineering of a Hand-Operated
Mechanical Kitchen Mixer"), your team name (e.g. “Alpha Engineering Group”) and logo, the
names of the team members, including designation of the team leader, everyone's email address,
your graphics section unique number, and your graphics lab instructor name.

b. General Description (about 1-2 pages) of the system selected for reverse engineering. The
description should include:
1. Customer’s perspective
2. Engineer’s perspective,
3. Engineering specifications list.

c. Graphical Picture (additional 1 page) of the system selected for reverse engineering. The
graphic can be a sketch of the system-wide device, a photo (analog or digital) of the device, or an
original/Xerox copy from the package cover illustrating what the device looks like.

_______________________________________________

*Note: When selecting your device, keep in mind also that you will later be sketching
components, building 3-D computer models of them, redesigning components if needed, and
making rapid physical prototypes of the parts. So, avoid objects that have complex or sculpted
surfaces that encase the mechanical components inside. Also do not select a device that is too
small (cigarette lighter) or too thin (ball point pen). These will not work.
Team Name _____________________________ Unique No. __________

Design Check No. 1 Grading Form

Grade

Cover Sheet (5 points)

1. Semester and Year
2. Project Title
3. Team Name and Logo
4. Team Members Names, Emails, Leader
5. Instructor Name and Section Unique No.

Customer’s Perspective (5 points)

1. Customer Perspective #1
2. Customer Perspective #2
3. Customer Perspective #3
4. Customer Perspective #4
5. Writing Quality and Format

Engineer’s Perspective (5 points)

1. Engineer Perspective #1
2. Engineer Perspective #2
3. Engineer Perspective #3
4. Engineer Perspective #4
5. Writing Quality and Format

Engineer’s Specifications List (5 points)

1. Engineer Specification #1
2. Engineer Specification #2
3. Engineer Specification #3
4. Engineer Specification #3
5. List Format

Graphical Picture (5 points)

1. Relevance of Picture
2. Placement of Picture
3. Quality of Picture
4. Appropriate Size of Picture
5. Picture Caption

Total Grade (25 max.)