REVERSE ENGINEERING

1. INTRODUCTION:Engineering is a growing field that continues to evolve to suit the rapid changes of the
21stcentury. Engineering fields are constantly improving upon current designs and methods to
make life simple and easier. When referring to technology, simple and easy can be directly
related to fast and accurate. Simple meaning that, you do not use up valuable time in assembly or
doing a specific task. Easy meaning how many times you will have to do the process or task.
When we think of engineering we think of the general meaning of designing a product from a
blue print or plan. Engineering is described as the application of scientific and mathematical
principles to practical ends such as the design, manufacture, and operation of efficient and
economical structures, machines, processes, and systems. This type of engineering is more
commonly known as Forward Engineering. An emerging engineering concept is utilizing
forward engineering in a reverse way. This method is more commonly referred to as Reverse
Engineering. Reverse engineering is the opposite of forward engineering. It takes an existing
product, and creates a CAD model, for modification or reproduction to the design aspect of the
product. It can also be defined as the process or duplicating an existing component by capturing
the components physical dimensions. Reverse engineering is usually undertaken in order to
redesign the system for better maintainability or to produce a copy of a system without access to
the design from which it was originally produced. With this knowledge, computer vision
applications have been tailor to compete in the area of reverse engineering. Computer vision is a
computer process concerned with artificial intelligence and image processing of real world
images. Typically, computer vision requires a combination of low-level image processing to
enhance the image quality (e.g. remove noise, increase contrast) and higher level pattern
recognition and image understanding to recognize features present in the image. Threedimensional (3D) computer vision uses two-dimensional (2D), images to generate a 3D model of
a scene or object. There has been a mandatory need for 3D reconstruction of scenes and objects
by the manufacturing industry, medical industry, military branches and research facilities.
Manufacturing industry utilizes reverse engineering for its fast rapid prototyping abilities and
accuracy associated with the production of new parts. This fast prototyping is done

2. NEED:

The original manufacturer of a product no longer produces a product

There is inadequate documentation of the original design

The original manufacturer no longer exists, but a customer needs the product

The original design documentation has been lost or never existed

Some bad features of a product need to be designed out. For example, excessive wear
might indicate where a product should be improved

To strengthen the good features of a product based on long-term usage of the product

To analyze the good and bad features of competitors product

To explore new avenues to improve product performance and features

To gain competitive benchmarking methods to understand competitors products and

develop better products

The original CAD model is not sufficient to support modifications or current

manufacturing methods

The original supplier is unable or unwilling to provide additional parts

The original equipment manufacturers are either unwilling or unable to supply

replacement parts, or demand inflated costs for sole-source parts

To update obsolete materials or antiquated manufacturing processes with more current,

less-expensive technologies

3. CASE STUDY:3.1. Important Points to remember Before to Start Reverse Engineering:

Reverse engineering enables the duplication of an existing part by capturing the components
physical dimensions, features, and material properties. Before attempting reverse engineering, a
well-planned life-cycle analysis and cost/benefit analysis should be conducted to justify the
reverse engineering projects. Reverse engineering is typically cost effective only if the items to
be reverse engineered reflect a high investment or will be reproduced in large quantities. Reverse
engineering of a part may be attempted even if it is not cost effective, if the part is absolutely
required and is mission-critical to a system
3.2. Aerospace: Upgrade of a BLACK HAWK Helicopter
To upgrade the electronic technology for the Australian Armys fleet of Black Hawk helicopters,
BAE Systems Australia needed to establish 3D CAD information. Therefore both external and
internal data of a helicopter wasmeasured using photogrammetry and optical digitizing.

BAE Systems Australia was asked to upgrade the electronic technology for the Australian
Armys fleet of Black Hawk helicopters. As part of this project BAE Systems Australia needed to
establish 3D CAD information which accurately reflects the current state of build of the airframe
and ancillary equipment. It was decided that the quickest and most efficient method was to
digitize an actual aircraft so that real 3D data is captured as a factual basis for design
andinstallation upgrade. BAE Systems Australia contracted MOSS / Scan-Xpress to undertake

3D Photogrammetry and 3D Scanning of the aircraft. Both external and internal data was
required.
BLACK HAWK Objectives & Overview
The objectives for the 3D Scanning project were to:
1. Measure the external airframe and produce 3D scan data to within a verifiable accuracy of 0.1
mm
2. Measure certain internal areas of interest to the same accuracy.
3. Produce an integrated set of data with both the external and internal datain the same coordinate frame work.
4. Complete the work on site and within the required project time frame.
5. Model the aircraft using the scan data and produce an integrated 3D modelfor CAD analysis
Because of the size of the aircraft and tight accuracy requirements, normal digitizing techniques
with scanning only could not meet the requirements. A combination of photogrammetry and
optical scanning was needed. A GOM TRITOP (photogrammetry) and ATOS (optical scanning)
system was used to carry out the 3D measurement. These systems are accurate and portable, thus
allowing data capture on site in the working environment. The helicopter was mounted in a welldefined position and the markers were attached to capture the needed surface using TRITOP only
(lines and individual reference markers) or surface scanning by ATOSTRITOP Photogrammetry
The TRITOP system takes high resolution and professional quality two-dimensional pictures of
objects to provide an accurate large scale 3D coordinate framework based on digital
photogrammetry techniques. This technique is similar as used in large scale construction and
land surveying. Coded and encoded markers are applied to the object to be measured and
multiple images are captured by the photogrammetry camera. Then the three-dimensional
coordinates of the center of the reference markers are calculated precisely using photogrammetry.
These marker positions are then the reference framework to integrate scanning data captured by
ATOS into the global coordinate system of the object. Big coded reference markers are used to
establish an accurate global framework in the helicopter coordinate system. Then individual
TRITOP measurements define the exact 3D position (outside and inside the helicopter) of the
smaller coded and encoded reference markers. ATOS Digitizing The ATOS (Advanced
Topometric Sensor) system is a white light optical scanner which scans three-dimensional
objects and converts the images to high density point clouds. This allows accurate measurement
and capture of the shape and size of the visible surface of almost any 3D object. The scanning is
based on optical triangulation and stereo-viewing. A projector is used to project striped fringe
patterns onto the object's surface. These images are captured simultaneously by the two
measurement cameras from different angles. This stereo-setup supports an easy and very
accurate 3D capturing of the reference markers. With the help of digital image processing, 3Dcoordinates are computed fast and with high accuracy for up to 4 million camera pixels using the
supplied high end System PCs. The captured scan data is then automatically integrated in the
predefined reference marker framework. The additional data captured with two cameras of the
ATOS system are used to verify the calibration of the system, detect movements and high
ambient light changes during the measurement and verify the matching accuracy of the
individual scans into the global coordinate system. Therefore this system is often used for critical
applications and in automotive and aerospace.

CAD model developed from scan data(WIP)

3.2.1. Scanning Methodology Preparation

The aircraft structure was prepared with all doors and hatches in place. MOSS / Scan-Xpress
then placed coded and un-coded targets onto the airframe. Reference data were established and
accurately measured to support the accurate integration of multiple measurements from outside
and inside the helicopter. In total, 41 scan data files were created covering both external and
internal areas of the aircraft. These contained 12 million data points while maintaining an
accuracy of 0.1 mm overall.

Fuselageprepared for scanning

3.2.2.Stage 1 - TRITOP
An accuracy test with the reference targets was set up to compare the TRITOP results with Laser
tracker data to make sure the data meet the accuracy expectation and the TRITOP system fit into
the existing measuring equipment standard of the Australian Army. This measurement was also
used to pre-adjust the coordinate system of the big coded reference markers into the helicopter
coordinate system. Then a photogrammetric survey was carried out with the TRITOP system.
The result of this first stage is shown in the screen dump below. The accuracy of this first stage
was in addition checked by confirming several physical measurements using established
measuring equipment.

External skin panels Scan data established by

TRITOP (photogrammetry) (9,000 points, accuracy of
0.1 mm, object size > 15 m

3.2.3.Stage 2 - ATOS
After the TRITOP stage had been completed, the ATOS 3D scanning stage was started. A typical
area which had to be scanned, the nose section, is shown in Figure

3.2.4.Stage 3 - Modeling
Following the data capture stages, the scan data was processed by the ATOS system into a nice
polygon mesh data set in the STL format. The polygon model was then registered to the aircraft
data position. The total project consisted of 24 million polygons and was subdivided into a
number of distinct areas for ease of handling. Each area was then modeled using a combination
of 3D CAD packages. To make sure the CAD data fit the scan data in the needed tolerance,
ATOS can read in the CAD data and display the deviation of as built to the Reverse Engineered
surface as a color coded cloud of data. The resulting and approved overall CAD model was then
used by BAE Systems Australia to plan and design the electronic upgrades.

4.Conclusion:Quick and accurate data capture of a relatively large object Confidence that the data reflects the
"as built" state of the aircraft. Data that can readily be imported into the desired CAD software
for planning and design purposes Savings in time and cost compared to more traditional methods

5. References:-

1. http://www.mechanicalengineeringblog.com/tag/need-for-reverseengineering/
2. http://turbinereverseengineering.com/
3. http://www.gom.com/fileadmin/user_upload/industries/helicopter_EN.pdf