ReverseEngineering

기계공학부설계방법론20111872 윤승호

contents● Reverse Engineering : Investigation, Prediction, Hypothesis - Task clarification - Customer need analysis and diagnosis of product weaknesses - Functional prediction(TBD) - Functional modeling

● Reverse Engineering : Product Teardown & Experimentation - Product teardown - Experimentation

● Reverse Engineering : Functional Analysis - Actual product function

● Reverse Engineering : Constraint Propagation(TBD) - Morphological analysis - Function sharing and compatibility

● Reverse Engineering : Forming Engineering Specifications

● Model and Analysis : Model Development - High – level model - Balance relationship - Physical prototype models

● Model and Analysis : Analysis Strategies - Model calibration and formulation -Physical prototypes

Abstract

• Shopping cart 의 안정성을 높이기 위하여 자전거의 V- 브레이크를 adaptive redesign 하기로 설정 했다

• Reverse Engineering – Modeling and Analysis – Redesign 순서로 설계 보고서를 수행할것이며 , 이번 보고서에서는 Modeling and Analysis 까지를 다루었다 .– Step1~5 에서 Reverse Engineering 을 , Step 6~7 에서 Modeling

and Analysis 를 다루었다 .

• Adaptive Redesign 으로 Redesign 의 방향이 결정 되었기 때문에 , Design parameter 나 제품의 장단점을 Adaptive Redesign 에 사용하는 방안으로 했다 .

Abstract

• 선정 제품 요약

제조회사 : SHiMANO

제품명 : V- 브레이크 BR-M422

판매가 : 10810 원 ( 인터파크 )

Abstract

• 선정 제품 요약

제조회사 : SHiMANO

제품명 : 브레이크 레버 BL-IM65

판매가 : 16800 원 (JAPANBID STORE)

1.Reverse Engineering : Investigation, prediction, Hypothesis

• Task clarification

Black Box Model

V- 브레이크

손Frictional force

Noise

Stop

레버 당김

악력

1.Reverse Engineering : Investigation, prediction, Hypothesis

• Customer need analysis and diagnosis of product weaknesses

Customer Needs Weight Fix Current

안정성

짧은 제동거리 7 Y 7

짧은 제동시간 7 Y 7

빠른 작동 속도 7 Y 7

외관

외관의 깔끔함 ( 와이어정리 )

5 Y 6

색의 조화 3 N 3

크기작은 부피 5 Y 6

가벼운 무게 5 Y 6

내구성수명 5 Y 6

마모성 5 Y 6

1.Reverse Engineering : Investigation, prediction, Hypothesis

• Customer need analysis and diagnosis of product weaknesses

Customer Needs Weight Fix Current

조작방법

간단한 조작방법 5 Y 5

손이 작은 사람도 사용 6 Y 6

큰힘이 들지 않음 5 Y 6

충격 외부충격을잘 견딤 4 Y 5

소음 제동시 작은소음 3 Y 5

가격저렴한 가격 4 Y 5

낮은 유지비 4 Y 5

사용가능연령 영유아를 제외 모든연령대 4 N 2

1.Reverse Engineering : Investigation, prediction, Hypothesis

• Functional prediction

Customer Needs Functional prediction

안정성

짧은 제동거리브레이크의 큰 마찰력

짧은 제동시간

빠른 작동 속도 레버와 브레이크의 정확한 연결

외관

외관의 깔끔함 ( 와이어정리 )

관을 통한 와이어 선 정리

색의 조화 여러가지 색과 재질 생산

크기작은 부피 큰 마찰력의 작은 브레이크

가벼운 무게 가벼운 재질의 큰 마찰력 브레이크

내구성수명

내 마모성이 좋은 재질마모성

1.Reverse Engineering : Investigation, prediction, Hypothesis

• Functional prediction

Customer Needs Functional Prediction

조작방법

간단한 조작방법 레버와 브레이크를 통한 직관적은 조작

손이 작은 사람도 사용 레버 크기

큰힘이 들지 않음 마찰력이 큰 브레이크

충격 외부충격을잘 견딤 높은 강도의 틀을 사용

소음 제동시 작은소음 높은 마찰력의 브레이크사용

가격저렴한 가격 저렴하고 좋은 재질 브레이크 사용

낮은 유지비 높은 내마모성 브레이크 사용

사용가능연령 영유아를 제외 모든연령대 다양한 크기의 제품 제작

1.Reverse Engineering : Investigation, prediction, Hypothesis

• Functional modeling

레버 당김

wire

boot

shoe

Link

Stop of motion

2.Reverse Engineering : Product Teardown & Experimentation

• Product teardown – exploded view

2.Reverse Engineering : Product Teardown & Experimentation• Product teardown – BOM

Part Name & # of Parts Function Price Finish

1Link Fixing Bolt (M6 x 16) Fix Link $1.3/piece Steel

Link Fixing Bolt (M6 x 25) Fix Link $2.1/piece Steel

2Spring Tension Adjustment Screw (M4 x

7) & Stopper

Adjustment Spring Tension

$0.8/pieceTBD

Steel + Plastic

3 Shoe Fixing Nut Unit Fix Shoe $0.5/piece Steel

4 S65T Brake Shoe Set (10 pairs)Brake the

bicycle

$21/piece

Rubber5 M65T3 Brake Shoe Set (10 pairs) $21/piece

6 M65T4 Brake Shoe Set (10 pairs) $21/piece

7 Cable Fixing Bolt (M6 x 11.5) & Plate Fix Cable $1.1/piece Steel

8 BootProtectbrake

$6 Rubber

9

Inner Cable Lead Unit (90 ゜ : Middle)

Lead Cable

$6

SteelInner Cable Lead Unit (135 ゜ : Long) $6

Inner Cable Lead Unit (45 ゜ : Short) $6

2.Reverse Engineering : Product Teardown & Experimentation• Experimentation

Part Name & # of Parts Function DOF type

Deduced Subfunction & Affected Customer

Needs

1Link Fixing Bolt (M6 x 16) Fail to Fix Link 0 Stability

Link Fixing Bolt (M6 x 25) Fail to Fix Link 0 Stability

2Spring Tension Adjustment Screw (M4 x

7) & Stopper

Fail to Adjustment

Spring Tension0 Stability

3 Shoe Fixing Nut Unit Fail to Fix Shoe 0 Stability

4 S65T Brake Shoe Set (10 pairs)Fail to Brake

the bicycle

0Necessary for safety

5 M65T3 Brake Shoe Set (10 pairs) 0

6 M65T4 Brake Shoe Set (10 pairs) 0

7 Cable Fixing Bolt (M6 x 11.5) & Plate Fail to Fix Cable 1 Stability

8 BootFail to Protect

Brake1 Durability

9

Inner Cable Lead Unit (90 ゜ : Middle)Fail to

Lead Cable

1

StabilityInner Cable Lead Unit (135 ゜ : Long) 1

Inner Cable Lead Unit (45 ゜ : Short) 1

2.Reverse Engineering : Product Teardown & Experimentation

• Product teardown – exploded view

2.Reverse Engineering : Product Teardown & Experimentation• Product teardown – BOM

part name&#of parts function price Finish

1 L.H. Adjustment Block & Screw Adjustment L.H. $0.5 Plastic + Steel

2 Cable Adjusting Bolt (M10 x 19) & NutAdjustment

Cable$2.6/piece Steel

3 Reach Adjusting Screw (M4 x 10.8)Adjustment

Reach$0.9/piece Steel

4 Clamp Bolt (M6 x 10.8) Fix Clamp $1.1/piece Steel

5 Grip (Ø22.2 mm / Black) Grip $12/piece Rubber

6 Wire(1.5mm x 1700mm)Connect brake &

lever$1.3/piece Steel

2.Reverse Engineering : Product Teardown & Experimentation• Experimentation

part name&#of parts function DOF type

Deduced Subfunction & Affected Customer

Needs

1 L.H. Adjustment Block & ScrewFail to

Adjustment L.H.0 Stability

2 Cable Adjusting Bolt (M10 x 19) & NutFail to

Adjustment Cable

0 Stability

3 Reach Adjusting Screw (M4 x 10.8)Fail to

Adjustment Reach

1 Stability

4 Clamp Bolt (M6 x 10.8) Fail to Fix Clamp 0 Stability5 Grip (Ø22.2 mm / Black) Not smooth Grip 2 soft

6 Wire(1.5mm x 1700mm)Fail to Connect brake & lever

0 Stabililty

3.Reverse Engineering : Functional Analysis

• Actual product function

Glass Box

레버

와이어 shoe wheel악력

레버 당김(Signal)

손(Material)

Pull lever function

Noise Heat

Stop function

Noise Heat

4.Reverse Engineering : Constraint Propagation

• Morphological analysis

TBD

4.Reverse Engineering : Constraint Propagation

• Function sharing and compatibility

TBD

5.Reverse Engineering : Forming Engineering Specifications

• House of Quality

Customer Need Sub-function Metrics Target

빠른 정지능력 충돌방지 사람의 무게 (N) 700N

정리된 와이어 와이어가 걸리는것 방지 와이어 관의 길이 (m) 2m

작은 크기 작은 물체에도 장착가능 부피 (cm³) 5cm*12cm*15cm

가벼움 무게가 얼마 증가하지 않음 Kg 1kg

작은 소음 조용한 환경에서 사용가능 dB 70dB

6.Model and Analysis : Model Development

• High – level model

Free Body Diagram for CNs(safety)

6.Model and Analysis : Model Development

• High – level model Free Body Diagram for CNs(safety)

6.Model and Analysis : Model Development

• Balance relationships

TBD

6.Model and Analysis : Model Development

• Physical prototype models

TBD

7.Model and Analysis : Analysis Strategies

• Model calibration and formulation

TBD

7.Model and Analysis : Analysis Strategies

• Physical prototypes

TBD

Reference

• Product Evolution: A Reverse Engineering and Redesign Methodology Kevin N. Otto1 and Kristin L. Wood2 1 Engineering Design Research Laboratory, Massachusetts Institute of Technology, Cambridge, MA; 2 Department of Mechanical Engineering, The University of Texas, Austin, TX, USA