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.

Aug
28
2015

FARO @ GTMA – Make Measurement Matter

FARO UK invites you the GTMA – Make Measurement Matter event. The MMM event is a focal point for technology transfer from the science of measurement into the most demanding manufacturing environments. With keynote speakers from industry-leading ‘blue chip’ manufacturing companies, and over 45 of the country’s leading Metrology specialists,

MMM 2015, taking place on the 15th of October, provides an opportunity for you to learn more about the very latest measurement and inspection technologies and services available; knowledge that could provide a vital competitive edge.”

We will present our cutting-edge metrology products such the FARO Edge with touchscreen computer for basic measurements, FARO Laser ScanArm HD with the lightest laser line probe for non-contact measurements, the FARO Gage with barcode scanner, as well as the brand new FARO Laser Tracker Vantage for large volume measurements.

The 2015 Roadshow will be held at Kettering Conference centre, this is a free to attend event and registration is now open. Click here for more details!

GTMA _ MMM

 

Aug
12
2015

FARO @ TCT Birmingham

FARO staff will demonstrate the FARO Edge touchscreen computer for basic measurements, the FARO Laser ScanArm HD with the lightest laser line probe for non-contact measurements and the revolutionary high speed FARO Laser Scanner Focus3D for detailed 3D modeling and image documentation. To help illustrate the FARO Edge ScanArm HD LLP remarkable data-capture and transfer capabilities it will be connected to a Laser Lines 3D printer.

ddd

 

TCT Live is the event for Product Development and Additive Manufacturing in Europe. It is an essential event for everyone involved in the concept, design, specification and manufacturing process to learn about the latest in Additive Manufacturing, 3D Printing and other cutting edge product development software and technology.

Aug
11
2015

Aturia S.p.A Group utlize the FARO ScanArm

The Aturia S.p.A. Group, based in Gessate in the province of Milan, is currently one of the leading industrial groups in the pump industry at an international level. The main fields of application are submersible pumps (used in heavy industry and in various segments including shipping, off-shore infrastructure and mining); surface pumps (used, for example, in water supply and heating and air conditioning systems); special pumps (used in reverse osmosis, desalination and cryogenic applications) and, last but not least, pumping units used in firefighting, in particularly high demand at refineries and in the petrochemical industry.

Andrea Guercilena, Group Quality & Test  Manager, explains: “The Aturia Group is able to offer high-tech products thanks to its integrated design, 3D modelling and FEM (finite element  method) analysis systems. The production cycle begins with the design phase. With our long-term experience and vast database, we are capable ofdeveloping and manufacturing pumps for special fluids with power values that reach 1,000 kW, pressure values up to 150 bar and temperatures up to 500°C.”

Aturia 1

The various phases of the industrial process are completed at the Gessate production facility, which facilitates coordination among the various company departments. Guercilena notes: “The large fleet of numerical control machines and the networked management of project specifications allow operators to easily obtain the required precision.”

Product quality is guaranteed by “full control” over all components. Pump shapes, sizes, tolerances and performance are checked in the testing room using traditional as well as latest generation devices and software. In this regard, the Quality & Test Manager talks about how the Aturia Group has recently managed to take a significant step forward: “As our workloads increased in recent years, we realised that we were not able to quickly carry out measurements and inspections with our fixed coordinate measuring machine, resulting in the risk of delaying deliveries and disappointing our clients. At the same time, we were witnessing an increase in requests for larger than average pumps, which are difficult to measure using traditional methods. Therefore, we decided to invest in a portable 3D measuring machine with a laser line probe, which is considerably more suited to our new requirements.”

As a result, in late 2013 the companypurchased the FARO Edge ScanArm, a complete system consisting of the portable Edge FaroArm and the laser line probe, ideal for contact and noncontact measurements. “We had seen the machine in action in other workshops,” Guercilena continues, “and we were really impressed. In addition, by speaking with external colleagues and technicians, we understood that for our needs there could be no better tool in terms of quality and reliability than the FARO Edge ScanArm.”

Aturia

The FARO Edge ScanArm is a seven-axis measurement system with an integrated laser scanner, which makes it possible to measure individual points with the sensor and to conduct scans when large volumes of data are required. According to Andrea Guercilena: “The very broad scanning range enabled us to immediately measure parts of any shape and size. The rapid acquisition speed, portability, manageability and ease of use of the FARO instrument also provided a great boost in productivity.”

But that’s not all: thanks to efficient data processing and management and the possibility to immediately generate easy-to-analyse reporting, with the FARO Edge ScanArm scans can be checked in real time. This is a very important feature since, as Guercilena explains, “it allows inspections and checks to be conducted on-site at the premises of clients or certification bodies. This is a very valuable service that guarantees complete security, even for the most demanding users.”

The technical features of the FARO Edge ScanArm provide very accurate, reliable and repeatable measurement data: “Our pumps,” Guercilena continues, “are complex objects with specific, difficult to measure shapes that require accuracy to the hundredth of a millimetre and just as strict concentricity and parallelism tolerances. Thanks to the FARO ScanArm, we have expanded our measurement possibilities and sped up certification and inspection activities. The high-quality scans also allow us to analyse our products in detail and continuously improve them.” Therefore, the introduction of the FARO Edge Scan- Arm triggered a small but significant revolution at Aturia. “Yes, absolutely,” Andrea Guercilena concludes. “The results achieved are attributable to this excellent technology as well as the FARO personnel who, besides providing the training course, fulfilled our needs by passionately and skilfully responding to our specific requests and supporting us during our technological training and development process.”

Aug
06
2015

FARO @ Northern Manufacturing

Northern Manufacturing & Electronics is the largest exhibition dedicated to serving the needs of manufacturing and electronics industries in the North of England. Event City, Manchester, makes the show easily accessible to visitors from the North.

Make the Northern Manufacturing & Electronics Exhibition 2015 a firm date in your diary to discover and evaluate quality Northern and UK suppliers who can help you redesign and pioneer new products, increase productivity and improve your profit margin. When it comes to sourcing and investigating emerging technologies locally, you won’t find a more comprehensive display of precision engineering products, materials, components and state of the art manufacturing processes.

Northen manufacturing 2015 - Manchester

The event takes place in Manchester at the Event City from 30th September till 1st October 2015. We will present our cutting-edge metrology products such the FARO Edge with touchscreen computer for basic measurements, FARO Laser ScanArm HD with the lightest laser line probe for non-contact measurements, the FARO Gage with barcode scanner, as well as the brand new FARO Laser Tracker Vantage for large volume measurements.

To find out if there is a FARO event near you then check out our other FARO Events!

Jul
25
2015

Muc-Off utilise FARO Edge ScanArm HD as they gear up for Tour de France

Please see this short feature produced by Muc-Off, to tell the story of how their Hydrodynamic Chain Lube was formulated, both as an answer to one of cycling’s unanswered questions and how a concept develops into a product.

Watch this video to “find out more” about its origins and the reason its existence is a necessity for one of the worlds most advanced cycling teams, Team Sky.

Bradley Wiggins and Carsten Jeppeson of Team Sky talk about the substantial gains and advantages to be made over their competitors following an advancement in technology in this area.

slider_muc-off_large

We were able to assist Muc-Off and their drive for chain lubrication perfection, through the use of our very own FARO ScanArm HD which combines the flexibility and the functionalities of a FARO Edge measuring Arm with the high-definition Laser Line Probe HD creating a powerful contact/non-contact portable measurement system ideal for challenging application requirements.

The FARO ScanArm HD itself can be seen being used in the video at 2.15!

To find out more then visit our FARO Website or even check out or FARO GB Youtube Channel! and be sure to keep an eye out for the latest Muc-Off kit too. They’ve currently an insanely busy R&D program so please keep checking to see the exciting products they’re about to launch!

Jul
13
2015

FARO Laser Line Probe HD with optically-superior blue laser technology

FARO Edge ScanArm HD  combines all of the advantages of a hard probing system with the capabilities of the FARO Laser Line Probe HD to provide rapid point cloud collection with high-definition resolution and precise accuracy – all in a compact, easy-to-use, and fully-integrated system.

The FARO Edge ScanArm HD is ideal for product development, inspection and quality control, and offers capabilities such as point-cloud comparison with CAD, rapid prototyping, reverse engineering, and 3D modeling of free-form surfaces.

The FARO Laser Line Probe HD brings together the power of a blue laser, state-of-the art camera and optics to maximize:

  1. Scanning speed, delivering highest possible productivity
  2. Accuracy
  3. High-Definition resolution that captures clear, noise-free data with intricate details
  4. Scanning of challenging surfaces including dark and reflective materials

SSSL1651_edit

In designing the Laser Line Probe HD, FARO’s engineers recognized and seamlessly integrated all the key factors that work in harmony to optimize performance.

For a laser line probe product, the key design parameters impacting performance are:

  1. Laser Type – typically blue laser or red laser
  2. Optics – The lenses used on the camera
  3. Frame Rate – the speed at which the camera can capture a scanned area, measured in points per second and driven by the chip set that the camera uses
  4. Laser Line Width – also called beam width or scan stripe width

Laser Type

Today’s scanners employ one of two laser types: blue laser or red laser. The Laser Line Probe HD leverages an optically-superior blue laser technology.

Blue lasers have a shorter wavelength, which delivers improved scanning results with higher resolution thanks to greater ability to discern smaller detail in an object.

Blue laser technology also provides a 50% reduction in speckle noise that is proportional to wavelength and degrades measurement accuracy.

For the user the benefits are immediately evident: the FARO Laser Line Probe HD’s blue laser offers 50% better optical resolution than a red laser scanner. This difference is most noticeable when scanning optically challenging objects with dark, shiny or reflective surfaces. With red laser technology, it is sometimes necessary to use a special spray on the scanned object to make the surface less reflective, or multiple target placements.

The blue laser’s higher resolution dramatically reduces the need to spray parts. This removes an unnecessary step from your measurement process and saves you valuable time and productivity.

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

Please download our tech sheet or contact us by phone!

Stay tuned!

 In the next weeks we will post more details about the other Key Design Parameters and Features (Optics, Frame Rate and Laser Line Width) that are seamlessly integrated in the FARO Laser Line Probe HD to deliver simultaneous high-definition resolution and fast scanning!

Jul
10
2015

FARO @ Advanced Manufacturing Show Success 2015

FARO UK staff reported great interest in, and high levels of sales leads related to the company’s new technologies exhibited at the Advanced Manufacturing Show 2015.

As the UK’s only dedicated market place for global manufacturing technologies, the Advanced Manufacturing Show was the ideal venue for FARO to demonstrate its world-class advanced measurement technologies.

Through visitor demand, FARO’s advanced Edge ScanArm HD was demonstrated throughout the course of the show. The Edge ScanArm HD combines the flexibility and the functionalities of a FARO Edge measuring Arm with the high-definition Laser Line Probe HD, creating a powerful contact/non-contact portable measurement system that is ideal for challenging application requirements.

DSC_0111

Also in great demand from customers needing to measure smaller parts were demonstrations of the FARO Gage measuring arm. An industry leader in portable CMMs, this accurate 3D gauge ends users’ reliance on expensive and hard-to-use fixed CMMs. The FARO Gage offers high accuracy levels, improves measurement consistency, reduces inspection time and the ability to generate automatic reports.

FARO UK staff are now busy following-up the large volume of sales leads  received at the exhibition and performing in-house practical demonstrations for potential customers throughout the UK.

Jun
22
2015

FARO Laser Tracker – Machine Tool Production & Tool Setup

The FARO Laser Tracker is particularly helpful for Machine Tool production and set up. It supports different types of control and measuring tasks. Companies can speed up and maximize the ROI with a single technology to be learned, extremely useful for a wide range of applications.

Laer Tracker Landing Page - Machine Tools

The FARO Laser Tracker is an extremely accurate, portable coordinate measuring machine for precise quality and dimensional analysis of large components, machine calibration, alignment and assembly, reverse engineering and tool building.

With the FARO Laser Tracker you can produce more competitive products and machines whilst efficiently optimizing your production processes.

Want to learn more about the versatility of our FARO Laser Tracker, then click here!

Jun
16
2015

Pratt & Miller Uses FARO Laser ScanArm for GM’s Corvette Racing Program

PROBLEM

Based in New Hudson, Michigan, Pratt & Miller is a world-class engineering company that takes automotive programs from concept to reality. They are a respected industry leader providing cutting-edge engineering and manufacturing solutions to their clients. Their total design team uses the most advanced research and development technologies available. Pratt & Miller performs first-article inspection for most parts; reverse engineers models, fabricated parts, and any purchase parts that lack accurate CAD; and verifies complicated bodywork, surface features, machine parts, and full interiors. Basically, they measure everything from small components to complete race cars.

Measuring with hand tools is time consuming and creates inaccuracies due to individual error. These tools also did not provide Pratt & Miller with the means to measure its more complicated parts and freeform surfaces without undesirable contact. This work had to be farmed out and they lost direct control of data.

Corvette racing FARO

SOLUTION

FARO provided the accuracy Pratt & Miller was looking for at the speed they need. They have the utmost confidence in the results they getfrom FARO. Co-founder Gary Pratt says, “We use FARO to design, construct, and analyze ‘virtual’ components, CFD, systems, and complete cars – every facet of a project from initial conception to the finished product.”

The FARO ScanArm was selected for its portability, flexibility, accuracy, compact design, and reputation. Mike Kurylo, a design engineer at Pratt & Miller, says, “The quality of the FARO equipment, the ease of training, and the knowledge of their support are all first rate. Their customer service goes well above and beyond what one would expect from such a globally recognized technology firm. It feels like having your own pit crew!”

Gary Latham, a lead engineer at Pratt & Miller, says, “FARO is incredibly useful with our tight timeframes. About 30-40 percent of our parts are manufactured in the workshop and they need to be entered into CAD and now we can do that easily with faster data capture.” They also use the ScanArm in their Computational Fluid Dynamics (CFD) to fill in any missing pieces of the puzzle. FARO returns control of the data process to Pratt & Miller and eliminates the need to farm out projects.

Corvette racing FARO_1

ROI

In today’s ever increasingly competitive conditions, Pratt & Miller is always searching for every last bit of performance enhancement – be it in the form of speed, time, accuracy, or efficiency. FARO answers the call on each of these.

The most intelligent design solutions are centered on the integration of the best tools. Pratt & Miller engineers use the most up-to-date and powerful computer software and hardware in existence. The next logical step for them was a FARO solution.

“We’re constantly updating, expanding technology and FARO opened new parameters in manufacturing and engineering for us,” Gary Pratt says. “FARO has really opened our eyes and they’ve been fantastic for us. Once you get something like this, you can’t see how you did without it.”



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