Uma metodologia para adaptação e melhoria de produtos a partir da engenharia reversa

O tema desta dissertação de mestrado é o estudo da Engenharia Reversa como ferramenta de suporte à melhoria e adaptação de produtos. A partir de conceitos teóricos sobre desenvolvimento de produtos e melhoria de processos, propõe-se uma metodologia para adaptação de produtos destinados à exportação. A metodologia proposta consiste de oito passos, contemplando etapas de identificação e priorização das demandas de adaptação de produtos e elencando ferramentas auxiliares no atingimento dos objetivos desejados. A etapa inicial deste trabalho consiste de uma revisão bibliográfica dividida em duas partes: (i) adaptação de produtos através da utilização da Engenharia Reversa e seus habilitadores, e (ii) ferramentas para melhoria de processos. Os tópicos contemplados em (ii) incluem ferramentas para o mapeamento de processos de manufatura e para a sua melhoria. Destaque especial é dado ao Desdobramento da Função Qualidade – QFD (Quality Function Deployment), a Análise de Modos e Efeitos de Falhas (FMEA – Failure Mode and Effect Analysis) e às Cartas de Processos. Na seqüência, apresentam-se os passos da metodologia proposta para a adaptação de produtos às demandas de mercado utilizando a Engenharia Reversa e seus habilitadores. Finalmente, os passos metodológicos são aplicados a um caso prático, cujo objetivo é a adaptação de um pincel, produzido por uma empresa gaúcha, às demandas de um distribuidor alemão de ferramentas manuais.

Comparative analysis between a CAD model design and physical models obtained by manufacturing additive technologies using optical scan

This article presents a detailed study of the application of different additive manufacturing technologies (sintering process, three-dimensional printing, extrusion and stereolithographic process), in the design process of a complex geometry model and its moving parts. The fabrication sequence was evaluated in terms of pre-processing conditions (model generation and model STL SLI), generation strategy and physical model post-processing operations. Dimensional verification of the obtained models was undertook by projecting structured light (optical scan), a relatively new technology of main importance for metrology and reverse engineering. Studies were done in certain manufacturing time and production costs, which allowed the definition of an more comprehensive evaluation matrix of additive technologies.

CAD e engenharia reversa como ferramentas de auxílio na fabricação de cartuchos para próteses ortopédicas

The manufacturing of above and below-knee prosthesis starts by taking surfac measurements of the patient s residual limb. This demands the making of a cartridg with appropriate fitting and customized to the profile of each patient. The traditiona process in public hospitals in Brazil begins with the completion of a record file (according to law nº388, of July 28, 1999 by the ministry of the health) for obtaining o the prosthesis, where it is identified the amputation level, equipment type, fitting type material, measures etc. Nowadays, that work is covered by the Brazilian Nationa Health Service (SUS) and is accomplished in a manual way being used commo measuring tapes characterizing a quite rudimentary, handmade work and without an accuracy.In this dissertation it is presented the development of a computer integrate tool that it include CAD theory, for visualization of both above and below-knee prosthesis in 3D (i.e. OrtoCAD), as well as, the design and the construction a low cos electro-mechanic 3D scanner (EMS). This apparatus is capable to automatically obtain geometric information of the stump or of the healthy leg while ensuring smalle uncertainty degree for all measurements. The methodology is based on reverse engineering concepts so that the EMS output is fed into the above mentioned academi CAD software in charge of the 3D computer graphics reconstruction of the residualimb s negative plaster cast or even the healthy leg s mirror image. The obtained results demonstrate that the proposed model is valid, because it allows the structura analysis to be performed based on the requested loads, boundary conditions, material chosen and wall thickness. Furthermore it allows the manufacturing of a prosthesis cartridge meeting high accuracy engineering patterns with consequent improvement in the quality of the overall production process

Desenvolvimento de métodos construtivos e de novos materiais empregados na confecção de cartuchos de próteses de membros inferiores

The manufacture of prostheses for lower limb amputees (transfemural and transtibial) requires the preparation of a cartridge with appropriate and custom fit to the profile of each patient. The traditional process to the patients, mainly in public hospitals in Brazil, begins with the completion of a form where types of equipment, plugins, measures, levels of amputation etc. are identified. Currently, such work is carried out manually using a common metric tape and caliper of wood to take the measures of the stump, featuring a very rudimentary, and with a high degree of uncertainty geometry of the final product. To address this problem, it was necessary to act in two simultaneously and correlated directions. Originally, it was developed an integrated tool for viewing 3D CAD for transfemoral types of prostheses and transtibial called OrtoCAD I. At the same time, it was necessary to design and build a reader Mechanical equipment (sort of three-dimensional scanner simplified) able to obtain, automatically and with accuracy, the geometric information of either of the stump or the healthy leg. The methodology includes the application of concepts of reverse engineering to computationally generate the representation of the stump and/or the reverse image of the healthy member. The materials used in the manufacturing of prostheses nor always obey to a technical scientific criteria, because, if by one way it meets the criteria of resistance, by the other, it brings serious problems mainly due to excess of weight. This causes to the user various disorders due to lack of conformity. That problem was addressed with the creation of a hybrid composite material for the manufacture of cartridges of prostheses. Using the Reader Fitter and OrtoCAD, the new composite material, which aggregates the mechanical properties of strength and rigidity on important parameters such as low weight and low cost, it can be defined in its better way. Besides, it brings a reduction of up steps in the current processes of manufacturing or even the feasibility of using new processes, in the industries, in order to obtain the prostheses. In this sense, the hybridization of the composite with the combination of natural and synthetic fibers can be a viable solution to the challenges offered above

Adaptação eletrônica de um leitor mecânico de coto, investigação e desenvolvimento de interface CAD

Due to advances in the manufacturing process of orthopedic prostheses, the need for better quality shape reading techniques (i.e. with less uncertainty) of the residual limb of amputees became a challenge. To overcome these problems means to be able in obtaining accurate geometry information of the limb and, consequently, better manufacturing processes of both transfemural and transtibial prosthetic sockets. The key point for this task is to customize these readings trying to be as faithful as possible to the real profile of each patient. Within this context, firstly two prototype versions (α and β) of a 3D mechanical scanner for reading residual limbs shape based on reverse engineering techniques were designed. Prototype β is an improved version of prototype α, despite remaining working in analogical mode. Both prototypes are capable of producing a CAD representation of the limb via appropriated graphical sheets and were conceived to work purely by mechanical means. The first results were encouraging as they were able to achieve a great decrease concerning the degree of uncertainty of measurements when compared to traditional methods that are very inaccurate and outdated. For instance, it's not unusual to see these archaic methods in action by making use of ordinary home kind measure-tapes for exploring the limb's shape. Although prototype β improved the readings, it still required someone to input the plotted points (i.e. those marked in disk shape graphical sheets) to an academic CAD software called OrtoCAD. This task is performed by manual typing which is time consuming and carries very limited reliability. Furthermore, the number of coordinates obtained from the purely mechanical system is limited to sub-divisions of the graphical sheet (it records a point every 10 degrees with a resolution of one millimeter). These drawbacks were overcome by designing the second release of prototype β in which it was developed an electronic variation of the reading table components now capable of performing an automatic reading (i.e. no human intervention in digital mode). An interface software (i.e. drive) was built to facilitate data transfer. Much better results were obtained meaning less degree of uncertainty (it records a point every 2 degrees with a resolution of 1/10 mm). Additionally, it was proposed an algorithm to convert the CAD geometry, used by OrtoCAD, to an appropriate format and enabling the use of rapid prototyping equipment aiming future automation of the manufacturing process of prosthetic sockets.

O design industrial e as engenharias: uma possibilidade de integração por intermédio da engenharia reversa

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Simplificação de malhas visando representações em multirresolução

The representation of real objects in virtual environments has applications in many areas, such as cartography, mixed reality and reverse engineering. The generation of these objects can be performed through two ways: manually, with CAD (Computer Aided Design) tools, or automatically, by means of surface reconstruction techniques. The simpler the 3D model, the easier it is to process and store it. However, this methods can generate very detailed virtual elements, that can result in some problems when processing the resulting mesh, because it has a lot of edges and polygons that have to be checked at visualization. Considering this context, it can be applied simplification algorithms to eliminate polygons from resulting mesh, without change its topology, generating a lighter mesh with less irrelevant details. The project aimed the study, implementation and comparative tests of simplification algorithms applied to meshes generated through a reconstruction pipeline based on point clouds. This work proposes the realization of the simplification step, like a complement to the pipeline developed by (ONO et al., 2012), that developed reconstruction through cloud points obtained by Microsoft Kinect, and then using Poisson algorithm

Um método para reconstrução de superfícies baseado em nuvem de pontos visando representações em multirresolução

The representation of real objects in virtual environments has applications in many areas, such as cartography, mixed reality and reverse engineering. The generation of these objects can be performed in two ways: manually, with CAD (Computer Aided Design) tools, or automatically, by means of surface reconstruction techniques. The simpler the 3D model, the easier it is to process and store it. Multiresolution reconstruction methods can generate polygonal meshes in different levels of detail and, to improve the response time of a computer program, distant objects can be represented with few details, while more detailed models are used in closer objects. This work presents a new approach to multiresolution surface reconstruction, particularly interesting to noisy and low definition data, for example, point clouds captured with Kinect sensor

Computer graphics applied to anatomy: a study of two bio-cad modeling methods on finite element analysis of human edentulous hemi-mandible

Modeling is a step to perform a finite element analysis. Different methods of model construction are reported in literature, as the Bio-CAD modeling. The purpose of this study was to perform a model evaluation and application using two methods of Bio-CAD modeling from human edentulous hemi-mandible on the finite element analysis. From CT scans of dried human skull was reconstructed a stereolithographic model. Two methods of modeling were performed: STL conversion approach (Model 1) associated to STL simplification and reverse engineering approach (Model 2). For finite element analysis was used the action of lateral pterygoid muscle as loading condition to assess total displacement (D), equivalent von-Mises stress (VM) and maximum principal stress (MP). Two models presented differences on the geometry regarding surface number (1834 (model 1); 282 (model 2)). Were observed differences in finite element mesh regarding element number (30428 nodes/16683 elements (model 1); 15801 nodes/8410 elements (model 2). D, VM and MP stress areas presented similar distribution in two models. The values were different regarding maximum and minimum values of D (ranging 0-0.511 mm (model 1) and 0-0.544 mm (model 2), VM stress (6.36E-04-11.4 MPa (model 1) and 2.15E-04-14.7 MPa (model 2) and MP stress (-1.43-9.14 MPa (model 1) and -1.2-11.6 MPa (model 2). From two methods of Bio-CAD modeling, the reverse engineering presented better anatomical representation compared to the STL conversion approach. The models presented differences in the finite element mesh, total displacement and stress distribution.

Arte reversa: aplicando a engenharia reversa na arte

This study aimed to examine the reverse engineering and respond to a concern about the possible application of this concept in art, breaking down barriers and breaking paradigms. Using 3D scanning, the art of computer aided design and manufacturing – CAD/CAM, machining by computer numerical control - CNC, engineering, and applying this methodology in the arts especially in sculpture, it is possible to dematerialize a artwork, virtualizes it in 3D programs, make speeches, and process a new work, a new art elsewhere. By the example of surgeries at a distance, the artist, or technical author could produce their works, and materialize them anywhere. In other words, do the reverse gear. It discusses the relationship between art and technology, the role of the author, the viewer, which can interfere with the interactivity that case by stating that art, exists only in the look and feel of the viewer.

An experimental and theoretical approach to correct for the scattered radiation in an X-ray computer tomography system for industrial applications

The main problem connected to cone beam computed tomography (CT) systems for industrial applications employing 450 kV X-ray tubes is the high amount of scattered radiation which is added to the primary radiation (signal). This stray radiation leads to a significant degradation of the image quality. A better understanding of the scattering and methods to reduce its effects are therefore necessary to improve the image quality. Several studies have been carried out in the medical field at lower energies, whereas studies in industrial CT, especially for energies up to 450 kV, are lacking. Moreover, the studies reported in literature do not consider the scattered radiation generated by the CT system structure and the walls of the X-ray room (environmental scatter). In order to investigate the scattering on CT projections a GEANT4-based Monte Carlo (MC) model was developed. The model, which has been validated against experimental data, has enabled the calculation of the scattering including the environmental scatter, the optimization of an anti-scatter grid suitable for the CT system, and the optimization of the hardware components of the CT system. The investigation of multiple scattering in the CT projections showed that its contribution is 2.3 times the one of primary radiation for certain objects. The results of the environmental scatter showed that it is the major component of the scattering for aluminum box objects of front size 70 x 70 mm2 and that it strongly depends on the thickness of the object and therefore on the projection. For that reason, its correction is one of the key factors for achieving high quality images. The anti-scatter grid optimized by means of the developed MC model was found to reduce the scatter-toprimary ratio in the reconstructed images by 20 %. The object and environmental scatter calculated by means of the simulation were used to improve the scatter correction algorithm which could be patented by Empa. The results showed that the cupping effect in the corrected image is strongly reduced. The developed CT simulation is a powerful tool to optimize the design of the CT system and to evaluate the contribution of the scattered radiation to the image. Besides, it has offered a basis for a new scatter correction approach by which it has been possible to achieve images with the same spatial resolution as state-of-the-art well collimated fan-beam CT with a gain in the reconstruction time of a factor 10. This result has a high economic impact in non-destructive testing and evaluation, and reverse engineering.

A Semantic-based Framework for Digital Survey of Architectural Heritage

The research aims at developing a framework for semantic-based digital survey of architectural heritage. Rooted in knowledge-based modeling which extracts mathematical constraints of geometry from architectural treatises, as-built information of architecture obtained from image-based modeling is integrated with the ideal model in BIM platform. The knowledge-based modeling transforms the geometry and parametric relation of architectural components from 2D printings to 3D digital models, and create large amount variations based on shape grammar in real time thanks to parametric modeling. It also provides prior knowledge for semantically segmenting unorganized survey data. The emergence of SfM (Structure from Motion) provides access to reconstruct large complex architectural scenes with high flexibility, low cost and full automation, but low reliability of metric accuracy. We solve this problem by combing photogrammetric approaches which consists of camera configuration, image enhancement, and bundle adjustment, etc. Experiments show the accuracy of image-based modeling following our workflow is comparable to that from range-based modeling. We also demonstrate positive results of our optimized approach in digital reconstruction of portico where low-texture-vault and dramatical transition of illumination bring huge difficulties in the workflow without optimization. Once the as-built model is obtained, it is integrated with the ideal model in BIM platform which allows multiple data enrichment. In spite of its promising prospect in AEC industry, BIM is developed with limited consideration of reverse-engineering from survey data. Besides representing the architectural heritage in parallel ways (ideal model and as-built model) and comparing their difference, we concern how to create as-built model in BIM software which is still an open area to be addressed. The research is supposed to be fundamental for research of architectural history, documentation and conservation of architectural heritage, and renovation of existing buildings.

Integrazione di dati antropometrici e termografici per l'analisi della distribuzione di temperatura all'interfaccia moncone-protesi d'arto inferiore

Le immagini termiche all’ infrarosso sono utilizzate da molte decadi per monitorare la distribuzione di temperatura della pelle umana. Anormalità come infiammazioni ed infezioni causano un aumento locale della temperatura, visibile sulle immagini sotto forma di hot spot. In tal senso la termografia ad infrarossi può essere utilizzata nel campo ortopedico per rilevare le zone sovra-caricate dalla protesi. Per effettuare una valutazione precisa dell’interfaccia moncone-invasatura può essere utile combinare i dati termografici e i dati antropometrici (superficie tridimensionale del moncone), relativi ai singoli pazienti. Di ciò si occupa tale studio, che dopo aver fornito una panoramica sulla termografia e sulla reverse engineering, sperimenta delle tecniche semplici e low-cost per combinare i dati termici e i dati antropometrici. Buoni risultati si riescono ad ottenere utilizzando un Kinect come scanner e un software open-source per il texture mapping. I termogrammi 3D ricreati costituiscono un ottimo strumento di valutazione, per medici e tecnici ortopedici, circa il design dell’invasatura.