Mechanical Dissection A method for understanding product design

Mechanical Dissection: A method for understanding product design

Learning Objectives After this presentation you will be familiar with: Design concepts and scientific principles behind the working of mechanical devices Learning about design by example Analysis of mechanical devices in the system and subsystem levels Understanding customer needs of a product Design thinking that may lead to product modification

Reading Material Required Reading: Chapter 9: Product Dissection, Reverse Engineering, and Redesign

What is Product Dissection? “Examining competitive or similar or prior products in great detail by dissecting them or literally taking them apart. ” Dym & Little, 2004

Dissection Helps You to: Improve mechanical aptitude Gain basic knowledge of manufacturing processes, materials selection, assembly and disassembly Understand the design process by example Understand the relationships between form, functions and objectives Appreciate how ergonomics influence design

What is Reverse Engineering? Reverse engineering is often a follow up activity of mechanical dissection It is a systematic analysis of the product with the aim of duplicating or improving the product

How is it Done? By asking theses questions: “What does this do? ”. . …. to learn about functions of the design “How does it do that? ” …… to learn about means by which functions are done “Why would you want to do that? ” …… to learn about design objectives of the design “How else can we do this? ” …. . to suggest alternative designs and materials “How can this be made better? …. . to improve design features

Formal Design Process Formal and Reverse Engineering

Levels of Reverse Engineering Activity Pre-dissection analysis Dissection Product documentation Product analysis Product improvement Product assembly Communication

Pre-dissection Analysis Looking at the whole product, investigate: How the product works The mechanical/physical principles it uses The purpose for what the product does (objectives) Design specifications (measurements) Subsystems and components

Dissection Analysis Begin Dissection Plan ahead Document disassembly Determine parts, shapes, materials and manufacturing Determine product hierarchy

Assembly Tree

Product Documentation Create a bill of materials Sketch all components Measure dimensions Model all components Create assembly model

Bill of Materials

Component Models / Exploded Assembly

Assembly Models

Product Analysis Functional analysis Stress analysis Weight analysis Cost analysis

Documentation Document dissection activity results using data sheets and models Bill of materials Assembly tree Functional decomposition charts Component and assembly models

Conclusions Product dissection involves studying a product at the system, subsystem and component level for the purpose of understanding how it works to meat its objectives Product dissection is documented using datasheets and graphics Product dissection sets the stage for reverse engineering