Reverse Engineering, Ethics, and other issues in Design

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Reverse Engineering, Ethics, and other issues in
Design

• Necessary qualities for successful
• completion of project
• Curiosity, eagerness to take things apart,
  willingness to learn from mistakes, interest to
  work in a team
• Thinking is not an option

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Objective

• Dissecting a product
• Understanding how it functions
• Learn basic principles
• Designing/building a new product
• Communicating (oral/written)

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Issues involved

• Cost effective
• Ergonomical
• Aesthetically pleasing/Visually appealing
• Problem with GM and Ford even
  though quality is good
• Safe (toys, automotive crash,nuclear power
  plants subjected to
  earthquake or missiles)
• Environment friendly (quiet, use recyclable
  materials, less consumption of energy,
  Biodegradable)
• Testing Warranty issues (7 year/100k
  miles)
• Recent GM Promotions
• Cater to an existing market or create new
  market
• Ethical issues

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• Last lecture involved Electro-magnetic shock
  design to show an interesting project involving
  energy recovery. Also various vibration and
  acoustic issues were addressed.
• Now let us consider some common household items,
  dissect them and then try to design a similar
  product.

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Study a familiar product

• Vacuum cleaner (or power drill or lawn mower)
• Following steps are involved to study the
  product
• Disassembling the product
• Identifying each component
• Understanding their purpose
• Obtaining information about each component

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Why hands-on experience

• I hear, I forget
• I see, I remember
• I do, I understand

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Do not forget Safety Rules

• Wear safety glasses
• Do not work alone
• Do not hurry
• Do not work when tired or under the influence
• Use common sense
• Think before you act
• Prevent accidents

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Working in a Team

• By now, you are working in a team (smooth or
  rough?)
• Working properly in a team is essential to
  the success of the project
• Next few slides are presented to help
  functioning properly in a team
• If you cant operate as a team player, no
  matter how valuable youve been, you really do
  not belong at GE
• John Welch
• past CEO, GE
• .

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Potential Problems

• Since this may be the first course in your
  engineering curriculum, be aware of the potential
  problems of working a group and try to avoid them

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Reverse Engineering

• Reverse Engineering is a very common practice
• in industry to understand the product of
  competitors
• Reverse engineering may also be used for other
• reasons such as reverse engineering of
  legacy
• parts for an Army project (Mechanical
• Engineering Design, pp 12-15, 2004)

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Back to Dissection

• Now that you have some guidelines for working in
  a group successfully, proceed with dissection of
  a vacuum cleaner

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Initial Observation

• Let us explore how a vacuum cleaner works
• First identify the vacuum cleaner type,
  manufacturer, model, and performance
  specifications
• Read the instruction manual
• Plug the vacuum cleaner and run it
• Listen to the sound
• Feel how it runs
• Record your observations

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Dissection

• Wear safety glasses
• Unplug the vacuum cleaner
• Disassemble it as far as possible
• Put all parts in a bin (with label of your group)
• Note each part and their purpose (e.g. belt and
  pulley mechanism, types of bearings/bushings,
  motor, etc.)
• Are there any other alternatives of these
  components?

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Reassemble

• Now reassemble your vacuum cleaner
• Suggest any design changes to make reassemble
  easier
• Once all parts are assembled, plug it in and run
  it (make sure you have your safety glasses)
• If it does not sound or feel like before or smoke
  comes out, unplug immediately and run (try to fix
  the problem later !)

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Big Picture

• Understand how different issues are addressed
• Conversion of energy (120V power supply to motor
  providing torque
• Conversion of motion (Belt and pulley
  system)
• Safety issues (Child proof)
• Environmental issues (quiet but not too
  quiet, hepa filter)
• Ergonomic (Carry up the stair, notice the cg
  location at the stair grip)
  
• Material choice (Plastic cover, metal
  rod for the roller axle)
• Cost (50 to 800!)
• Market (household, commercial)

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Sample project

• Build a mini vacuum cleaner, which can suck a
  paperclip
• with constraint of material cost no more than 50
  
• including the motor

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Some Equations

• Even a small or toy vacuum cleaner operating
  principle involves some equations
• Conversion of electrical power (watts volt
  ampere) to mechanical energy
• Mechanical power force velocity
• Power imparted to impeller torque angular
  velocity
• In case of pump (vacuum cleaner)
• required power mass flow rate change in
  pressure
• Now change of duct size and many other factors
  would
• govern the required pressure increase by the
  impeller.

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Commercial ones
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I want to conclude this part of the lecture with
a note that just designing and manufacturing a
part or a component is not enough. Ultimately
you have to interact with other people whether it
is personnel within your own company or outside
your company. You may work for a company or
agency which either sells a product or buys a
product You need to be aware of a very
important issue ETHICS(seems to be the primary
issue in Illinois gubernatorial election)
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• NSPE Code of Ethics for Engineers
• PreambleEngineering is an important and learned
  profession. As members of this profession,
  engineers are expected to exhibit the highest
  standards of honesty and integrity. Engineering
  has a direct and vital impact on the quality of
  life for all people. Accordingly, the services
  provided by engineers require honesty,
  impartiality, fairness, and equity, and must be
  dedicated to the protection of the public health,
  safety, and welfare. Engineers must perform under
  a standard of professional behavior that requires
  adherence to the highest principles of ethical
  conduct.

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• Fundamental Canons
• Engineers, in the fulfillment of their
  professional duties, shall
• 1. Hold paramount the safety, health and welfare
  of the public.
• 2. Perform services only in areas of their
  competence.
• 3. Issue public statements only in an objective
  and truthful manner.
• 4. Act for each employer or client as faithful
  agents or trustees.
• 5. Avoid deceptive acts.
• 6. Conduct themselves honorably, responsibly,
  ethically, and lawfully so as to enhance the
  honor, reputation, and usefulness of the
  profession.

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Case Studies on Ethics

• Personal Value Conflict (helmet design) - Is
  possible abuse an issue?
• Corporate Conflict (1987 Chrysler odometer case,
  selling of previously tested cars as new) Is
  good intention enough?
• Boeing defense contract - Hiring a DOD person
  (resignation of top executives, cancellation of
  contract, possible loss of jobs if contract goes
  overseas)
• Pressure from own supervisor (compromise
  results)
• Conflict of interest (relatives, friends)
• Gifts from suppliers

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Case Studies in Safety/Liability

• Motorcycle gas tank explosion
• Lawn Mower
• DC10 accident in 1989
• Helium tank
• Vat

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Ethics/Vibrations/Sports

• Vibration studies is a big part in Sports e.g.
  golf, tennis, baseball etc (e.g. new golf clubs
  are designed to hit the ball further).
• Unlike golf, major league baseball doe not permit
  changing the traditional wooden bat. However,
  that does not stop players from trying illegally
  changing the bats say by corking.

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Modes of Vibrations of Baseball bat

• Bending Modes and sweet spot
• First Bending Mode
• Second Bending Mode
• Hoop Modes are important
• for hollow aluminum or composite
• bats because of the trampoline effect

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• Research shows crime does not pay
• http//www.kettering.edu/drussell/bats-new/corked
  bat.html
• Corked bats do not change the distance traveled
  by the ball
• Momentum of bat hitting the ball is about the
  same (more velocity but less mass)
• Let us consider vibration of aluminum and
  wooden
• baseball bats
• http//www.kettering.edu/drussell/Demos/batvibes.
  html
• How about other sports? Golf, Tennis, Football,
  Yacht, etc)

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Acknowledgement

• MEEP (The manufacturing engineering education
  partnership), J. Lamancusa et. al, PSU, 2004.
• Society of Professional Engineers
• State of Illinois Ethics Examination
• D. Russell, Kettering University
• Office of Associate Dean, CEET