engineering design and problem solving chapter 3: reverse engineering

Engineering Design and Problem Solving

Chapter 3: REVERSE ENGINEERING

Copyright © Texas Education Agency 2012. All rights reserved.

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Introduction/Description

The 2nd Design Project will introduce the 9-step reverse engineering process through guided practice and examples.

You will select an item and complete the reverse engineering process on that item, document the steps of the reverse engineering process, and present their findings to the class.


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Chapter 3: Outline

1. Introduction to Reverse Engineering

2. Using the Reverse Engineering Process


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Objectives and Results

Objectives Individually, students will complete the “Points to

Ponder” handouts. Working in teams of 2-3, students will go through

the reverse engineering design process for the product and complete the Mini Reverse Engineering Notebook.

Students will present their product and process to the class following the rubric provided.


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Objectives and Results, cont.

Results Students will be able to work in teams of 2-3 and

apply all of the knowledge and skills they have learned to come up with a workable solution to problem: reverse engineering a manual can opener.

Students will create a written explanation of the problem, solution, and processes, and then present their design to the class. Refer to the handouts to guide you through the process and use the rubric and/or examples provided.


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Schedule of Assignments

Class Period(s)

Topic Assignment

1-2 The Reverse Engineering Design Process- Intro

#1-Individual; Point to Ponder Handout(Daily)

3-5 The Reverse Engineering Design Process- Can Opener: Dismantle, sketch, label, and research

#2-In teams of 2-3; Apply the engineering design process to the scenario given; complete the mini engineering notebook (Daily)

6-10 The Reverse Engineering Design Process- Can Opener: Come up with new design and presentation

#3-In teams of 2-3; Complete the communication and presentation of your new design following the rubric given (Major)


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Reverse vs. Forward Engineering

Reverse engineering (REP) is the methodical examination of a device, product, or process in order to understand about its material, manufacture, function, and use.

Forward engineering (EDP) is using the engineering design process to solve a problem.

Where the purpose of the EDP is to develop an innovative solution to a problem, REP is used to understand the solutions that have already been designed.


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Legal/Ethical Uses of RE

Researching an existing process or product to improve it

Determining the source of a systematic problem

Decreasing cost of producing a product or running a process

Ensuring that the product or process is compatible with an existing product or process


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Legal/Ethical Uses of RE, cont.

Determining the cost of developing a product similar to a competitor’s product

Understanding how the engineering design process works

Determining if patent or license agreements have been violated by a competitor


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Reverse Engineering Process (REP)


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Illegal/Unethical Uses of REP

Copying a competitor’s technology and using it to make a profit

Copying a classified piece of equipment or software to sell

Stealing another’s idea to claim as one’s own

1. Are all of the legal uses always ethical?

2. Under what circumstances would they not be?Points to

Ponder


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Engineering Design Process


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Step 1: Goal of the REP

When you first begin a reverse engineering project, it is necessary to determine what you are looking to learn by reverse engineering a product.

What do you intend to learn? The function of the product How the product is constructed How a particular part of the product functions The materials from which the product is made What and where a flaw might be

Determine Goal of the Project


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Step 2: Reverse Engineering Parameters

Every engineering project has parameters that describe the restrictions and requirements of the project.

Any parameter, if not addressed, can prevent a project from reaching completion.

Parameters often include the following: time, money, personnel, and facilities.

Determine Parameters of the

Project


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Step 3: Determine What to RE You need to choose which parts of the

product you will be reverse engineering. You may choose to disassemble and analyze an

entire product. You may choose only to look at a specific

component of the product. Consider the project goals and parameters.

Determine What to Reverse Engineer


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Step 4: Determine the Function

Determining the function of the product is only necessary, if you do not already know the purpose for which the product or part is used.

Knowing the function of the product is crucial to understanding other aspects of the product.

It may involve brainstorming about the function, running tests and experiments on the product, and even taking the product apart.

Determine Function of Product


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Step 5: Disassemble the Product

It is necessary to take the product apart in order to assess how its components work together.

When analyzing a part that is a component in a larger product or process, look at how the part contributes to the overall function of the product.

It is important to make detailed drawings and notes of where each component of the part is located and how it connects with other components.

Disassemble the Product


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Step 6: Analyze Product ComponentsEngineers analyze each component to determine various properties and functions of the product. For physical devices, the engineer may

analyze the function of different assembly parts as well as the materials from which each component is made.

For software programs or processes, the engineer may analyze how the different parts of code or process components work together to function as a system. Analyze Each

Component


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Step 7: Infer the Construction Process

Brainstorming about how the product was constructed can provide useful information about the function and composition of the product components.

The information that the engineer gathers during the disassembly and analysis process can be used to infer the process by which the product was initially constructed.

Infer the Process to Construct Product


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Step 8: Look for Possible Improvements

Consider materials, efficiency, and function. Consider whether the construction process

could be streamlined, whether it would be possible to make the product easier to use, or if there is another function that the product or process was not initially designed to do.

Look for Possible Improvements


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Step 9: Document and Communicate

Document your REP in detail with notes and drawings.

This allows others to review the process and determine if any mistakes were made.

It is crucial to communicate the results of the reverse engineering process, so that the information obtained can be applied by others. Document and

Communicate Results


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Things to Consider

You will create your own descriptions of each step of the reverse engineering process.

Some people refer to reverse engineering as an engineering design process; others refer to it as an application of a scientific method.

1. In what ways is it a design process?

2. In what ways does it use a scientific method?Points to Ponder


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Engineering in Reverse!

Reverse engineering an existing product provides you with exposure to engineering designs and the engineering design process.

Reverse engineering can be used as a discovery tool, to explore design principles, to learn about a specific product, or to figure out how to improve a product.

Engineering in Reverse!

http://www.teachengineering.org/view_activity.php?url=http://www.teachengineering.org/collection/cub_/activities/cub_engineering_in_reverse/cub_engineering_in_reverse.xml


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Research on Reverse Engineering

Research at Purdue University on the use of reverse engineering to teach engineering concepts showed that

“Significantly more of the students who learned about the interconnectedness of the camera components from the reverse engineering activity were able to describe reasonable redesign solutions than those that learned about the camera’s design in the lecture.”

Researching Reverse Engineering

https://engineering.purdue.edu/ENE/HomepageFeatures/Spotlights/Researchingreverseengineering2


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Looking for product flaws and improvements Reproducing an existing product Conducting espionage (including corporate

espionage) Learning about a subject

When Osama Bin Laden was killed by the U. S. military, a Marine Corps helicopter crashed in Pakistan. The U. S. government insisted that the wreckage be returned to the United States. Why would the U.S. want a broken helicopter back?

Point to Ponder

Uses of Reverse Engineering


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Software engineers use the REP to identify and correct any security vulnerabilities in computer programs.

Drug companies often reverse engineer drugs with patents that have recently expired.

Many electronic products are reverse engineered to gain information about how their competitors engineered a specific product.

Students often use the REP, to learn about systems such as engines, appliances, HVAC, and computers.

Examples of Reverse Engineering


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One of the grand challenges posed by the National Academy of Engineering (NAE) is the reverse engineering of the human brain.

Understanding how the brain works will provide valuable information and allow humans to build smarter machines, create better biotechnology products, design more accurate computer simulations of

human systems, and better understand how brain injuries, mental

illness, and mental and physical disabilities can be treated.

Reverse Engineering the Human Brain


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In a literal sense, we cannot disassemble the brain to see how it functions, but there are several different approaches to reverse engineering the brain: Developing computer simulations to

emulate brain function Using non-invasive monitoring of the brain

with electrodes, CT scans, and MRIs Developing super computers, such as

IBM’s “Watson,” which has beaten Jeopardy champions

Reverse Engineer a Brain?


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Guided Practice Student Challenge

In your team of 2-3 students, you will perform a reverse engineering case study on a product that has many “exposed” components that you can observe and disassemble easily: a manual can opener.

The disassembly process itself will be brief, but going through the rest of the reverse engineering process will take longer.


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Practice Student Challenge, cont.

When taking the can openers apart to see how they were constructed, do you see any hidden components?

You will determine what improvements you could make to the can opener.

You will create a design (drawing) for that new product.


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Reverse Engineering Student Challenge

The next step is to apply the reverse engineering process, so that you can truly understand it.

To start, be sure to choose something in which you are interested and would not have trouble taking apart.

After choosing what you will reverse engineer, go through the reverse engineering process.


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Logistics of RE Student Challenge

Make sure you have plenty of room to disassemble the product and can lay out/store all of the components.

Make sure you practice good time management.

Do a quick run through the reverse engineering steps and rubric, before you begin.

Make sure you have all the tools and materials you need.

Consider the problems that the engineers encountered, when developing the product and propose alternative solutions to this.


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RE Student Challenge RubricReverse Engineering

ProcessReport

Product Selection and/or Disassembly

Conclusion

Product Sketch/Diagram and Material Cost List

Grammar and Spelling

Presentation/Working Drawing

of ProductAttractiveness

Purpose/Problem Presentation

Procedure Promptness


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Credits

ClipArt; http://www.clipart.com/en/

http://www.clipart.com/en/

engineering design and problem solving chapter 3: reverse engineering

Documents

reverse engineering

existing process

mini engineering notebook

forward engineering

new design

design project

existing product

results students