Reverse Engineering of Steel Strapping Machine for a USA based Tool Manufacturer

Business Needs.

• Assess the threats posed innovations and features introduced by both new entrants & current competitors to the market.
• Digitizing legacy designs, modify and add value to existing component with detailed engineering and simulation insights.
• Remanufacture obsolete part to restore operational performance /output and efficiency.
• Functional / non-functional assessment of competitor’s product, to make own product & marketing stand out.
• Identify design flaws restricting client product from being user friendly.
• Comparative analysis of competitor’s and the client’s product to extract user friendly features along with customer feedback for improvements.
• Set prices competitively and yield productive response to rivals market strategy.

Challenges.

• Measuring and scanning geometry and surface curvature meticulously to maintain original design intent and functionality of the tool.
• Studying and documenting the triangular meshes or point could obtained from scanning to create CAD models.
• As scanning arms are prone to vibrations and have obstructed line of sight scanned information is to be interpolated to get exact geometry and obtain proof of concepts.
• Performing manual dimension measurements using CMM to obtain missed-out or impossible to record otherwise during the 3D scanning process.
• Validating design innovations in existing products as a response to meet financial and component operational requirements.

HitechDigital’s Solution.

• HitechDigital studied the client and competitor’s product by scanned and geometrical measured information using CAD models, to come up with comparative analytics of the complete machine.
• High-end software like ANSYS verified machine stability and assess strength for new innovative features using simulation.
• Analysis results pointed out the modifications needed in design to sustain stress generated during machine operation.

Approach.

• Geometrical information of every machine component was recorded with scanning and CMM technique for generating CAD model by step by step disassembling of parts.
• Deviation analysis was performed for geometry comparison by overlaying 3D scanned geometry over the CAD model.
• Individual component drawings & detailed manufacturing drawings were prepared.
• The components were then analyzed separately for structural integrity and stress concentration to identify critical areas in design requiring optimization.
• Analysis brought insights for design modification to withstand higher loads.

Benefit.

• 30% reduction in prototyping test trials which accelerated the design cycle time.
• Major design flaws identified that helped maintain the design integrity.
• Competitive advantage in the market with greater accuracy, speed and reliable product design.
• Digital documentation for future design modification needs, referencing, and PLM applications.
• Client was able to remove surplus material which further helped him reduce product price.

Client Speaks.

We handed them a sample, and their skilled engineers work backwards, disassembling it to identify its components, for design innovation. Having them on our side saved us a lot of time and money.

Result.

• Reduced cost of initial testing & errors at the product design stage.
• Addition of new feature and value as per customer feedback.
• Reduced costing due to removal of access material used.
• Increased market penetration with reliable products.