Reverse Engineering 기계공학부 설계방법론 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 보고서 를 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 : 원 ( 인터파크 )

Abstract 선정 제품 요약 제조회사 : SHiMANO 제품명 : 브레이크 레버 BL-IM65 판매가 : 원 (JAPANBID STORE)

1.Reverse Engineering : Investigation, prediction, Hypothesis Task clarification Black Box Model V- 브레이크 손 Frictional force Noise Stop 레버 당김 악력

1.Reverse Engineering : Investigation, prediction, Hypothesis Customer need analysis and diagnosis of product weaknesses Customer Needs WeightFixCurrent 안정성 짧은 제동거리 7Y7 짧은 제동시간 7Y7 빠른 작동 속도 7Y7 외관 외관의 깔끔함 ( 와이어정리 ) 5Y6 색의 조화 3N3 크기 작은 부피 5Y6 가벼운 무게 5Y6 내구성 수명 5Y6 마모성 5Y6

1.Reverse Engineering : Investigation, prediction, Hypothesis Customer need analysis and diagnosis of product weaknesses Customer Needs WeightFixCurrent 조작방법 간단한 조작방법 5Y5 손이 작은 사람도 사용 6Y6 큰힘이 들지 않음 5Y6 충격외부충격을잘 견딤 4Y5 소음제동시 작은소음 3Y5 가격 저렴한 가격 4Y5 낮은 유지비 4Y5 사용가능연령영유아를 제외 모든연령대 4N2

1.Reverse Engineering : Investigation, prediction, Hypothesis Functional prediction Customer Needs Functional prediction 안정성 짧은 제동거리 브레이크의 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 크기 작은 부피 큰 마찰력의 작은 브레이크 가벼운 무게 가벼운 재질의 큰 마찰력 브레이크 내구성 수명 내 마모성이 좋은 재질 마모성

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 충격외부충격을잘 견딤 높은 강도의 틀을 사용 소음제동시 작은소음 높은 마찰력의 브레이크사용 가격 저렴한 가격 저렴하고 좋은 재질 브레이크 사용 낮은 유지비 높은 내마모성 브레이크 사용 사용가능연령영유아를 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 PartName & # of PartsFunctionPriceFinish 1 Link Fixing Bolt (M6 x 16)Fix Link$1.3/pieceSteel Link Fixing Bolt (M6 x 25)Fix Link$2.1/pieceSteel 2 Spring Tension Adjustment Screw (M4 x 7) & Stopper Adjustment Spring Tension $0.8/piece TBD Steel + Plastic 3Shoe Fixing Nut UnitFix Shoe$0.5/pieceSteel 4S65T Brake Shoe Set (10 pairs) Brake the bicycle $21/piece Rubber 5M65T3 Brake Shoe Set (10 pairs)$21/piece 6M65T4 Brake Shoe Set (10 pairs)$21/piece 7Cable Fixing Bolt (M6 x 11.5) & PlateFix Cable$1.1/pieceSteel 8Boot Protect brake $6Rubber 9 Inner Cable Lead Unit (90 ゜ : Middle) Lead Cable $6 Steel Inner Cable Lead Unit (135 ゜ : Long) $6 Inner Cable Lead Unit (45 ゜ : Short) $6

2.Reverse Engineering : Product Teardown & Experimentation Experimentation PartName & # of PartsFunctionDOF type Deduced Subfunction & Affected Customer Needs 1 Link Fixing Bolt (M6 x 16)Fail to Fix Link0Stability Link Fixing Bolt (M6 x 25)Fail to Fix Link0Stability 2 Spring Tension Adjustment Screw (M4 x 7) & Stopper Fail to Adjustment Spring Tension 0Stability 3Shoe Fixing Nut UnitFail to Fix Shoe0Stability 4S65T Brake Shoe Set (10 pairs) Fail to Brake the bicycle 0 Necessary for safety 5M65T3 Brake Shoe Set (10 pairs)0 6M65T4 Brake Shoe Set (10 pairs)0 7Cable Fixing Bolt (M6 x 11.5) & PlateFail to Fix Cable1Stability 8Boot Fail to Protect Brake 1Durability 9 Inner Cable Lead Unit (90 ゜ : Middle) Fail to Lead Cable 1 Stability Inner 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 partname&#of partsfunctionpriceFinish 1L.H. Adjustment Block & ScrewAdjustment L.H.$0.5Plastic + Steel 2Cable Adjusting Bolt (M10 x 19) & NutAdjustment Cable$2.6/pieceSteel 3Reach Adjusting Screw (M4 x 10.8)Adjustment Reach$0.9/pieceSteel 4Clamp Bolt (M6 x 10.8)Fix Clamp$1.1/pieceSteel 5Grip (Ø22.2 mm / Black)Grip$12/pieceRubber 6Wire(1.5mm x 1700mm) Connect brake & lever $1.3/pieceSteel

2.Reverse Engineering : Product Teardown & Experimentation Experimentation partname&#of partsfunctionDOF type Deduced Subfunction & Affected Customer Needs 1L.H. Adjustment Block & Screw Fail to Adjustment L.H. 0Stability 2Cable Adjusting Bolt (M10 x 19) & Nut Fail to Adjustment Cable 0Stability 3Reach Adjusting Screw (M4 x 10.8) Fail to Adjustment Reach 1Stability 4Clamp Bolt (M6 x 10.8)Fail to Fix Clamp0Stability 5Grip (Ø22.2 mm / Black)Not smooth Grip2soft 6Wire(1.5mm x 1700mm) Fail to Connect brake & lever 0Stabililty

3.Reverse Engineering : Functional Analysis Actual product function Glass Box 레버 와이어 shoe wheel 악력 레버 당김 (Signal) 손 (Material) Pull lever function NoiseHeat Stop function NoiseHeat

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 NeedSub-functionMetricsTarget 빠른 정지능력충돌방지사람의 무게 (N) 700N 정리된 와이어와이어가 걸리는것 방지와이어 관의 길이 (m) 2m 작은 크기작은 물체에도 장착가능부피 (cm³) 5cm*12cm*15cm 가벼움무게가 얼마 증가하지 않음 Kg1kg 작은 소음조용한 환경에서 사용가능 dB70dB

6.Model and Analysis : Model Development High – level model Free Body Diagram for CNs(safety)

6.Model and Analysis : Model Development High – level modelFree 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, Massa chusetts Institute of Technology, Cambridge, MA; 2 Department of Mechanical Engineering, The University of Texas, Austin, TX, USA