Jul
21
2016

Reverse engineering: principles, applications and solutions

What is reverse engineering?

Reverse engineering allows the duplication of an existing product, without having the plans, documents or technical details of the product.

In a classical production procedure, the creator creates a detailed plan, in which the production properties of a product are explained. After that, the product goes into production and is built according to that plan.

Reverse engineering follows a reversed method. First, engineers identify the components of a system, as well as finding out how they all relate to one another in order for the system to work. The object is decomposed to ascertain the inner structure, the function of all parts and the way they operate. The making of a duplicate comprises of discovering the physical dimensions, the functionalities and the material qualities of an object.

After that, the moment has arrived to construct a representation of the system analysis with the aid of a computer. The next final entails the reproduction of the original system with extreme accuracy, following the previously laid out plan.

Why do we need reverse engineering?

This is a classical scenario in which reverse engineering is warranted: A company has a machine, but one of the components has broken down, so it needs to be replaced. However, the manufacturer has ceased production of that machine and all of its parts; they don’t supply spare pieces anymore. The owner of the machine can set up a procedure of reverse engineering of the broken piece, rather than having to buy a new machine.

Reverse engineering allows for shorter delays in product development, because this method can rapidly deliver a replacement for a faulty piece, that can be used in a prototype as equipment or in the production process.

However, reverse engineering has a whole array of uses:

  • To replace an original piece of which the documentation is incomplete or non-existent;
  • To redesign a piece in order to eliminate an error or to enhance some beneficial aspects;
  • To analyse products made by the competition;
  • To support new functions in case the original plans did not allow for that
  • To still make use of older or obsolete technologies that are no longer in production
  • To create plans or documentation of original products when there are no plans to be found, even after these products are already in use;
  • To deliver an essential piece in a short time span, without having to shut down the production process for a long time.

How are objects measured in a reverse engineering procedure?

To recreate an object, you have to ascertain the physical dimensions precisely. If you don’t have extremely accurate object measurements, it is possible that the recreated object won’t work because it is not an exact copy of the original.

It is possible to make these very precise measurements manually, with the help of a marking gauge, a micrometre, or other instruments of that type. In modern reverse engineering however, a tridimensional measuring machine is able to determine the geometrics of an object faster and more accurately than any manual measuring device is capable of.

A tridimensional measuring machine measures on three axels, X, Y and Z, and uses a coordinated system in three dimensions. Every axel has a basis, which determines the position of a point on that axel.

Tridimensional measuring machines use feelers to register a point as soon as the instrument comes in contact with the surface of the object that needs to be measured. Each point is measured individually, until the tridimensional measuring machine has collected enough data to allow the software to determine the length, angles and other geometric information of the object. The machine reads the data that enters through the feelers in function of the instructions that the operator has provided. The XYZ-coordinates of each point are then used to ascertain the size and position. A tridimensional measuring machine can measure the dimensions in two different ways: on the hand through direct contact with the object, on the other hand with the help of a laser scanner. The cloud of gathered points is then converted to recreate the surface of the object. This data print is then sent to a computer programme in order for it to be refined, analysed and expanded.

 

design scanarm 2

 

A solution for the digitalisation of a high resolution Arm for reverse engineering: the Design ScanArm combined with Geomagic software.

In order to answer to the needs of the market while designing a product, FARO has developed the Design ScanArm, a new measuring arm combined with a 3D scanner. This innovation is a digital, portable 3D solution made for 3D modelling in designing and the entire managing process, which lasts for the entire product life span.

The FARO Design ScanArm uses modern blue laser technology with an increased digitalisation speed in order to obtain point clouds with a high resolution and to be able to digitalise existing materials without problems, without having to use sprays and other such materials. The apparatus is very light and easy to move, so it can be placed in a lab or study room with ease. The Design ScanArm has a simplified user interface which allows for an easy use, even for users with limited experience or competence in 3D digitalisation.

Due to the combination of the FARO 3D digitalisation and the possibilities of the modelling software by Geomagic, the Design ScanArm offers a key solution that allows its users to digitalise, recreate and modify existing models or test prototypes quickly and with ease. This solution enables users to quickly transfer digitalised data to computer models, that can still be modified. Once the data is received, you can use the modelling functions in different ways, without having to use any other application.

Conclusion  

Reverse engineering is an important discipline that can contribute immensely to the life span of machines by enabling the proprietor of the machine to manufacture spare parts at will, even when these are not in production anymore. Reverse engineering also allows for new pieces to be added, to add additional functions or to eliminate errors.

The simplest, fastest, and easiest-to-use tool to measure and create products in the context of a recreating procedure, is a light-weight, portable tridimensional measuring machine. This tool allows you to measure objects with or without contact. The combination of these advantages that the FARO Design ScanArm offers, gives operators a fast and efficient solution in the present work environment and gives them a competitive advantage.

Jul
12
2016

FARO Factory Array Imager

The next generation of automated probes offer advanced in-process inspection for integration and infrastructure at minimal costs.

The FARO Factory Array Imager is a scanner with extremely high accuracy for contactless measurements which, with its blue-light technology measurement, within seconds computes several million 3D coordinates on component surfaces – regardless of colour, texture, reflectance or ambient light.

Structured light and stereo recordings open up new possibilities in 3D measurement & inspection and reverse engineering. The new optical 3D measurement system by FARO, the FARO Factory Array Imager, combines the two processes and complements them with high-performance 3D processing.

The combination of flexibility, portability, speed and accuracy makes the compact and light FARO Factory Array Imager an ideal but cost-effective solution for 3D data capture or reverse engineering of components or modules in many different industries, such as automotive, aviation and space flight, and mechanical and plant engineering.

cobalt 3 [Read more …]

May
23
2016

FARO delivers flexible measurement to Panasonic – Precisely

Panasonic operates an advanced testing facility that performs precise emission measurement tests across a range of products including TV, IT, video, microwave and medical products. To establish self-regulated quality assurance processes in each group company, Panasonic published Quality Management System Development Guidelines in 2004. Each group company then implemented the Panasonic Quality Management System (P-QMS). P-QMS complement the requirements of the ISO9001 standard with Panasonic’s own quality assurance methods and experience to create a quality management system that aims to deliver the level of quality that the company demands. Panasonic Manufacturing UK’s stringent quality standards, diverse nature and size of the products that are both developed and produced on site, requires the use of a wide range of relatively dedicated measuring instruments……

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Read more

Apr
08
2016

4 Reasons to attend the MACH Fair

It’s that time of the year again! FARO will be attending the UK’s premier manufacturing technologies exhibition, MACH 2016. This event runs every 2 years.

With a 7 days left until the exhibition check out the 4 reasons to be at the FARO stand booth 5910.

 

MACH2016_slider_v4

 

 FARO Robo Imager- The first mobile, ready to work 3D measurement solution will be on show at the MACH Fair. A mobile and flexible robot with a setup time of less than 5 minutes, it is seen as a product with great benefits for the automotive, aerospace and mechanical engineering industry.

FARO experts on hand to help – The wonderful expert team will be on hand to help you out with any queries you may have. You will be provided with the opportunity to see live demonstrations from a wide range of products from Metrology & 3D Documentation.

 

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Great Quality stands – There will be a wide range of innovative products from many different exhibitors. FARO will be exhibiting a wide range of products from Metrology and 3D Documentation. This will include the newly highly-adaptable FARO Factory Array 3D Imager, a metrology grade non-contact scanner which utilizes blue light technology to capture millions of high resolution 3D coordinate measurements in seconds. We will also be presenting the high speed FARO Laser Scanner Focus3D X Series for detailed 3D modelling and image documentation as well as the recently released 3D Laser Scanner Freestyle3D X with enhanced accuracy of 1 millimetre at a 1-metre range.

Raffle Prize – Test your knowledge of the FARO Factory Array 3D Imager and your in with a chance to win a prize. Test your knowledge of our new scanner metrological level FARO 3D Imager Array Cobalt for the production workshop and assembly . Come to stand booth 5910 and take our quiz and return your completed ballot in the ballot box at the FARO booth. You can also download the quiz here.

 

COBALT RAFFLE

 

You will be able to find the answers on our FARO Factory Array Imager information page.

Don’t forget stand booth 5910

 

 

Jan
13
2016

FARO presents the new FARO Factory Array 3D Imager! 3D Scanning for the shop floor and the assembly line

The FARO Factory Array 3D Imager is a metrology-grade, non-contact scanner, which utilizes blue light technology to capture millions of high-resolution 3D coordinate measurements in seconds.

Ideal for the production environment and easily deployed within manual or automated manufacturing workflows, Array Imager delivers fast and consistent measurements, independent of the operator, for quality inspection and reverse engineering applications on parts, assemblies, and tools.

Cobalt’s versatility supports a variety of deployment options including rotary stage, industrial robot inspection cells and multiple imager arrays.

Technical key features that support challenging applications include, among other, the following:

> Multiple Imager Arrays: Expand field of view with flexible configurations of multiple Array units operating  simultaneously

> On-Board Processing: Delivers fast, reliable performance and ease of integration

> Stereo Cameras: Enable high accuracy, stability and self-monitoring

> Enhanced Stereo Mode: Maximizes coverage area in each scan and shortens inspection time

> Interchangeable Lenses: Provide flexibility for multiple fields of view

Cobalt on robot Scanning Door

The most significant benefits of the new FARO Factory Array 3D Imager:

> Increase productivity by automating measurement workflows

> Multiply productivity with multiple imager arrays

> Real-time 3D data for statistical process control (SPC)

> Measurement accuracy ensured by self-monitoring

> Easy to configure and integrate

> Easy set-up and transport

Do you want to learn more about the FARO Factory Array 3D Imager?

Please click here for more information or contact us by phone 00800-3276-7253

Stay tuned!

During the next few weeks, we will post more details about the key features of the new FARO Factory Array 3D Imager!

Jan
11
2016

Bringing individuality to the road

When it comes to safety, care is the top priority. At Indi- Kar in Wilkau-Haßlau near Zwickau, safety is accurately and almost invisibly incorporated. Armoured steel is very easily concealed within the bodies of production cars and provides optimum protection inconspicuously but effectively. At IndiKar Individual Karosseriebau GmbH, a member of the WELP Group, the name says it all. The individual modification of car bodies is particularly in demand; special protection vehicles are just one aspect of this. Other important business areas include small batch production and prototypes, which are used at trade shows for example. When the company was founded in 2003, there were initially 20 members of staff; it now employs 156 people.

With the success and increasing number of employees, the car body manufacturers have also upgraded their technology. The requirements are becoming increasingly varied, and standards of precision and quality are increasing with experience. So for many years, as well as a double-stand measuring machine, a portable FARO coordinate measuring device and the software PolyWorks have been used to check whether everything fits together.

EU_1601_AGLT_IndiKar_Big

After initially using a FaroArm with a Laser Line Probe V3, a FARO Edge with Laser Line Probe HD (a 3D laser scanner attached to the FARO Edge ScanArm HD) has now been added to Indi- Kar’s portfolio of efficient FARO measuring systems. “When upgrading our measuring equipment, flexibility was key,” recalls Sascha Dorst, Head of Prototype Construction and Measuring Technology.

The daily challenges consist of ever changing measuring tasks on a wide repertoire of parts. A perfect habitat for a FARO Edge ScanArm HD, which enables both precise tactile and remote measurement in just one operation. In addition, the measuring probe for tactile measurement and the Laser Line Probe for remote scanning can be used alternately for digitisation, without needing to remove any other components.

Read More !

Dec
09
2015

FARO ‘state-of-the-art’ Scanning

FARO is a renowned supplier of high-quality portable coordinate measuring machines (CMMs) and 3D imaging devices, FARO technology is used throughout the world for high-precision 3D measurement and scanning. Due to it’s ease of use, accuracy and reliability it has become the measurement of choice across a diverse range of sectors including the Architecture, Construction and Crime scene analysis.

Installation with Focus scanner

FARO has now extended application of products to new areas. Tracy Hill who worked at the University of Central Lancashire was able to manipulate the FARO Focus 3D x 130 and the FARO Software from here colleagues to allow the creation of a major installation – Sensorium. Given the fact she has never used it before, the ease of use meant that she could experiment and create the effects of visualisation that she was looking for.

Click here to read the full text.

Nov
23
2015

Medical Cast Re-Invented with the Support of the FARO Edge ScanArm HD

The FARO Edge ScanArm HD can now add medical casts to the list of areas it can be applied to!

When Doc Mike North broke his leg, this affected his social and professional life as an active person. In particular, with a normal cast, it is not possible to fly – and he flies a lot! Indeed, if you want to fly, doctors normally have to cut the cast in half, put it on your leg, wrap it with a bandage, so that you can loosen it on the plane and your leg can expand with the pressure. The problem is that you cannot walk on that!

Doc North contacted FATHOM (www.studiofathom.com) to create together a better solution. They had the idea for a more aesthetically pleasing and technological cast and have been able to turn the breaking of a leg into a positive experience! The FARO Edge ScanArm HD played an important role in reaching this result.

 

At FATHOM, they took a scan of Doc North’s leg and got an STL mesh. NURBS curves became the solid model of Mike’s leg. That model was used to build the cast, which is basically an offset of that solid model. They brought it into SolidWorks where they added the split line that separates the two bodies of the cast… This would help alleviate pressure on his legs when travelling on planes.

In the sole, they added additional components, including Wi-Fi, Bluetooth, a force sensitive resistor and other technological features that allow you to sense what the human is doing.

All things that can also be exploited by Mike’s doctor, who can e.g. track the pressure put on the cast and track the movements.

They called this first prototype the “BoomCast”, because it also has a sound system!

But the development process continues and the project is now an open source.

Nov
18
2015

Vestas generates the Power of Precision with FARO

In the world of wind turbines, size and shape matters. The quicker its turbine rotates, the more energy a turbine can capture from the wind and the greater its
electricity generating capacity. In addition to size, the efficiency of a wind turbine blade is determined by the precision of its airfoil profile, a shape similar to that of an aeroplane wing. Given the potential difficulties related to the critical measurement of the world’s largest blades used on the record breaking V164-8.0 MW turbines, MHI Vestas Offshore Wind selected FARO Laser Trackers as its preferred large-volume, high-precision measuring technology.

Despite the impressive scale (80m – almost as long Vestas generates the Power of Precision with FARO as a football field) of the V164-8.0 MW turbines blades, the advanced FARO instruments are able to quickly and accurately measure aerodynamic profiles and a wide range of other critical blade features. MHI Vestas Offshore Wind is a joint venture between Vestas Wind Systems A/S and Mitsubishi Heavy Industries (MHI). The company’s sole focus is to design, manufacture, install and service wind turbines for the offshore wind industry. The company aims to drive down the cost of energy from offshore wind parks through reducing the costs and increasing efficiency.

P1010880

 

MHI Vestas’ V164-8.0 MW prototype turbine broke the record for power production by a wind turbine in a 24 hour period from the 6th-7th October 2014. The
turbine produced 192,000 kW/h during steady wind conditions. The power produced by the turbine in one day was enough to supply the energy needs of approximately 13,500 households. MHI Vestas Offshore Wind’s CEO Jens Tommerup said the record demonstrates the full capacity of the V164-8.0 MW. “This power production record further underlines both the quality of the technology as well as the skills of the team involved who have been working hard to ensure the turbine is performing according to our testing schedule.”

Nov
04
2015

FARO Laser Line Probe HD: faster and more productive scanning thanks to a wider laser line width

We have already provided you with some details concerning 3 of the 4 key factors that work in harmony to optimize the performance of the FARO Laser Line Probe HD: the Blue Laser Technology, its large-diameter custom optics and the frame rate.

Today we conclude this short series of posts, with some specific information on the fourth key factor, namely the laser line width (also called beam width or stripe width):

The laser line width is the end-to-end distance of the laser line produced by the scanner’s laser. The FARO Laser Line Probe HD features a laser line width of 150mm. The wider the laser line width, the wider the area that can be scanned in a single pass.

Additionally, the Laser Line Probe HD features a solid, blue laser beam. This is a big benefit compared to other technologies as for example “flying dot” arrangement, whereby the laser oscillates via moving mirrors, potentially causing errors and impacting productivity by forcing the user to repeat scans over the same areas.

LLP-HD

For the user the benefits are immediately evident:
•    A wider beam, coupled with larger optics means that more data can be gathered in each scan frame.

•    The Laser Line Probe HD’s industry-best frame rate and the laser line width can be multiplied by one another to obtain a number that can be used to compare scanning productivity.

For example, we know that the Laser Line Probe HD’s frame rate is 2.8 times higher than most competing products. If the Laser Line Probe HD’s beam width happens to be 1.7 times that of a competing product, the resulting scan speed differential is 2.8 X 1.76 = 4.8 times better than the competing product.
The Laser Line Probe HD would scan nearly five times the surface area versus a competing product in the same time.

•    In addition, the solid stripe results in a more even distribution of the data point samples scanned, and therefore, greater resolution and quality.

Do you want to learn more about the FARO Edge ScanArm HD and its Laser Line Probe HD

Visit our website or contact us by phone 00800-3276-7253!



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