CEN 100 Introduction to Engineering _Reverse Engineering FINAL REPORT

Introduction: The act of reverse engineering can be applied to almost any application, machine, product, or structure. A product that caught our interest was the ingeniously designed mechanism of a doorknob. A doorknob is a mechanism which is common in nearly every household or building with more than one room. It prevents the swaying of the door back and forth caused by random forces (i.e. wind) and can either be held in place in a closed position, or open position. When closed, a small rod contained within the mechanism of the doorknob protrudes out the side of the door and into a small hole in the wall designed for doors. And when the door is to be opened, the doorknob must be twisted in order for the small rod to recede from the wall which enables the door to freely swing to the extent which the hinges allow it. The exquisite mechanism of a doorknob was decided to be our reverse engineering project because of our ability to easily reverse engineer this product since we are all in possession of one or more. We have all operated a doorknob a million times in our lives, however, we do not yet know exactly what is inside the doorknob and how it exactly operates and thus, this project has given us the opportunity and time to answer those intriguing questions wandering about in our minds of a doorknob. Also, the doorknob meets the criteria for reverse engineering because it can be dismantled and broken down into different parts which can be examined separately. This is a helpful trait of the doorknob because it is quite difficult to figure out how an object operates without being able to see the different parts to it. In fact, it is quite like inspecting a math equation because it is easier to figure out how the answer shown has come to be, if all the steps leading to the answer are shown. Reverse engineering is an exciting stage of engineering because we are given the opportunity to discover ideas and concepts that we may never have thought of and can use them as an aid to developing our own concepts. We want to be able to inspect almost every part of the doorknob in order to improve key aspects specifically suited for different uses. The reverse engineering of this doorknob is an opportunity to learn where ideas come from and develop the skill of being able to create our own unique ideas and concepts for future works. History and Background Making a barrier between the room and a common living room place is categorized under the day to day life, doors and a way to close them always existed in the ancient times before the invention of door knobs. But, because of the casual attitude towards the mechanism, documentation was never done. As per the archeological remains and the historical evidences it is assumed that bars were used to keep the doors shut. It is also mentioned in the bible. 184594510731500099377560960Door 00 Door 3569335287655Bar 00 Bar 180213089725500189928598488500201358517653000 In early days the locks and keys were also used but due to lack of technical aid they were huge and made up of wood. In mythology it is often mentioned that kings preserve and secure their precious belongings in a chest. Latch-string technology was also famous in the old times; a hole is made through the door. Then a string was used as a tool to unleash the door bar from outside. A cord was used to loop around the door bar from outside through the hole to raise the bar. Parts of a typical Door knob: It comprises of the following parts: Outside knob, Screw posts, Rose insert, Spindle, dead latch, stem, strike plate, rose cover, inside knob 2681605110490 00 The invention of the door knob credit is said to be given to Romans. The first documentation of door knobs invention took place in 1878 by a U.S. patent. Osbourn Dorsey, appeared on the patent list for the improvement of the door knobs. Bathroom Door Knob Door knob is a tool used to open and close the door. However, Door handles should be well and delicate design, user friendly and safety to give theme and decorative to the door. Though, door knobs can be divided into two categories such as interior and exterior door handles. Bathroom handles is an interior door knobs that are mostly used for its functional, enhancing and privacy reasons. It’s designed for safety, accessibility and privacy. However, bathroom is a room for bathing in which has a bathtub or showering and toilet. Therefore, when it comes to look for bathroom door knob, the one should looking for a type of the material in which consider the temperature and damps differences in bathroom that may impact on handle material. Also, the one should consider its cost and its functionality. Thus, bathroom door knobs must be practical, manageable, and affordable and need to provide confidentiality to the elements. Bathroom door knobs are lockable. Since we live in age of innovation and technology, people are always looking for product that most modern, user approachable, inexpensive and practical. That’s why we provide you with material that can be relaxed to clean, accessible and inexpensive. Clip bathroom doors handles are commonly used in interior doors of most modern building. Clip bathroom door knob has locked key form one side and the other side has twisting lock to operate the handle from the outside. Otherwise, stainless steel bathroom door handles can be lock and unlock form the inside and unlock form the outside in case of emergency. On the other hands, since bathroom door handles is most handles that holds germs and bacterial , the handles should be user friendly , easily to clean and sanitize. We guarantee the highest in quality and best price in our door knob. Stainless steel bathroom knobs are solid, sturdy handles and easily to install them. The size and material of the door handle make it user friendly. Clip bathroom door handles are made of high quality material that assures long term solidity resistant to corrosive and attractive design to give our customers confidently to purchase our product. Picture 1 Picture2 These figures show different color of clip (fingertips) bathroom door handles. This door knob is lockable and it’s easy to install. A small twist is required to open the door. However, bathroom door knob needs to be more secure, privacy, easily to operate and easy to sanitize. When it comes to bathroom door handle, Clip (fingertips) door handle provide privacy, user friendly and accessibility. Fingertips or clip bathroom door handle is easy to function from the outside and can operate externally in case of emergency. Application and Details Door knob is a tool used to open and close the door. It has a spindle which running through it, the spindle is located above a cylinder. However the spindle connected to the cylinder. When the door knob is spanned the cylinder will pulls in the same direction of the turn. The end of the cylinder is called latch, the latch function is avoiding the door from being opened if the knob is not rotate. The spring function; however, is to allow the latch to return to its state each time the knob is not being twisted. Door handle located about a few centimeters away from the edge of the door to the center of the door. Many of household use spindle that has one side flat passed through the door jigger. There are four types of household doorknob: Entrance: This type of doorknobs is used on outdoor doors, and has keyed cylinders. Privacy: It’s used on interior door such as bedrooms and bathrooms and they do not have key cylinder so it is not lockable. Passage: It’s used in hall or closet doors and do not lock. Dummy: It used for ball catch doors where a jigger mechanism in not used. Bedroom Doorknobs 30016452461895Figure 2 00Figure 2 Bedroom is a place to relax and refill your energy. Thus, the demands for an ideal bedroom are also high. Everybody crave for an inviting door that leads to their bedroom. They want privacy, security, style and elegance all at once without any compromise. And the lead role in satisfying the customer is played by the ‘door knobs’, which is responsible for privacy, security and style. No matter how costly or stylish a door is, if the door knob is old and dull it ruins the entire elegance and style of the door. A door needs a doorknob that complements its beauty and also serves the purpose of the security and privacy. Bedroom door knobs has higher responsibility as it not only has to provide security and privacy but also has to make sure that it can easily be opened by a simple tool. Thus, bedroom door knobs are categorized under the ‘privacy knobs’, and a typical traditional bedroom knobs looks like the one in figure 1 and figure 2. 2333625158750Roses 00Roses 36664901039495Lever 00 Lever Figure 1 As per its name privacy door knobs can be locked and unlocked from inside only. Privacy door knobs are also used in bathroom doors, locker room doors, guest room doors and other spaces in the house that requires privacy or security. A typical tradition door knob when dismantled looks like figure 3. -257175111760Turn Knob 00Turn Knob 27622501635760Screw 00Screw 3470275697230 00 335597537465Escutcheon trim  00Escutcheon trim  17907001752600Latch 00Latch Figure 3 Latch: Its function is to lock the door as soon as it is shut. It is loaded with spring and is a wedge shaped device. Turn Knob/Lever: It basically serves the security and privacy part of a door bedroom door knob. Turn knob is also known as thumb turn. Both are used to ‘extend or retract’ the deadbolt. Roses or escutcheon trim: roses and escutcheon are same on both sides. It serves the purpose of a washer between handle and the door. Dead bolt: It is ‘extracted or retracted’ using a turn knob or key (if key is included in the design then it can also be used to extract or retract the deadbolt). Modifications: As observed the knob and lever are solid structure thus requires lots of metal for its production. Our design will reduce the metal usage and increase profit. This is so because our design will have carvings on the surface of the knob it will not only serve the purpose served by a traditional privacy door knob but at the same time it would be stylish, elegant and will increasing the profit as now the amount of metal used in the production of the knob would be less. In case of lever, instead of a solid lever a modern hollow lever can be used with designs and artifacts on top of it. This will not only will serve the purpose but enhance the beauty of the door. 29622751118870 It is one of the example of carved knobs but our design would be modern, innovative and personalized according to the customer’s choice. Our doorknobs gives you relief from old and boring colours and provides you with varied range of colours. Alloyed steel provides room for variety of colours to suit your requirement. 00 It is one of the example of carved knobs but our design would be modern, innovative and personalized according to the customer’s choice. Our doorknobs gives you relief from old and boring colours and provides you with varied range of colours. Alloyed steel provides room for variety of colours to suit your requirement. The parts would be made of alloy steel, instead of pure steel. Alloy steel has variety of elements in the proportions of 1% to 50%. This would increase its resistance from rusting, it would be stronger, harder, tougher, and will have comparatively more wear resistance, hardenability and hot hardness. Alloy steel is also lot cheaper than stainless steel, aluminum, copper etc. 92900531432500 46609031432500793757683500 11252201435100018478514351000 466090508000 56007033020003251201701800097599517018000 A simple small carved door knob for children’s room. Exterior Doorknobs Whether someone is purchasing a new home, selling their home or even just returning home after a long day, people want their house to be welcoming with stylish doorknobs. Believe it or not, the front door affects how a person feels as they enter a home because the first impression is what matters most. However, the most important feature to be stressed about exterior doorknobs is their safety features. There is a large variety of exterior doorknobs available from the commonly used rounded knobs, to handle sets, and even to door levers. And although doorknobs have one specific base function—to open doors—there are many subsections like locking features and/or security features. When it comes to safety, doorknobs are ranked by grades where Grade 3 is meant for low-security needs such as bedroom doors, next there is Grade 2 which is more secure and people have the option to use for their front doors. The highest is Grade 1 which is known for having the highest level of security. Nevertheless, security is one of the most stressed components to be aware of when it comes to doorknobs, but the last thing people want is an ugly, busy-looking doorknob which immediately loses the attraction factor. Though not important, it is preferred that the front doorknob has a stylish modern appeal to it, due to the fact that every home built nowadays is all about safety and appearance. A sleek door lever or curvy handle set doorknobs are commonly used for exterior doors because of the modern trend of sleek designs. Inclusively, the exterior doorknobs should not only be secure and fashionable, but be cost-efficient, otherwise the product won’t sell. Hence the production cost, labor cost, and the material-import cost needs to be taken into account. People don’t want to have to buy a new doorknob every couple months because the doorknob rusts, cracks, or squeaks. The common doorknobs are usually made of stainless steel because they are less expensive than brass. However the newly designed doorknobs will be made of brass, which may be more expensive to purchase, but at the end of the day taking into account the production cost, machining cost, and allowance from brass turnings, brass will be the least expensive. The purchase price of brass is $1.08/lb and Steel is $0.42/lb so people would buy the steel since it appears to be cheaper, but that is not that case according to new studies performed by a “Midwestern screw machine shop” (Copper Development Association) show that the net cost to produce steel is $248.19 and the net cost to produce brass is $210.94 because steel turnings are practically worth nothing, but brass turnings can be allowanced at $0.88/lb and plus, more money is saved since brass does not require any rust-resistant coating whereas steel does. Brass is an alloy of copper and zinc. When making the deadbolts, brass is compressed in a mold creating a brass rod with particles being extremely dense. Since the brass rod will be much denser, it increases the durability of the deadbolt and nearly impossible to open using a credit card, unlike how a lock using sheeted plate metal compressed together can be easily disengaged during a “break-in entry”. The deadbolt mechanism will have a 1.5 inch throw rather than the common .5 inch throw, making it more unsusceptible to “break-in entry”. Although the latch mechanism is quite unfriendly to “uninvited guests”, it will be much easier for people with disabilities to open the door with the new “torque wrench” feature. Common doorknobs requires a 270 degree turn of the wrist after putting the key in the keyhole, however, the “torque wrench” feature allows people to twist the key 30 degrees to retract the deadbolt x amount of inches then twist 30 degrees back to start position without undoing any changes and keep repeating the pattern until the lock is disengaged and can be opened. A spring feature ensures that if the key is pulled out prematurely before the lock is fully opened; it pushes the deadbolt back into the locked position. The safety features will leave people without worry when they step out of the house, knowing their doorknobs are doing their job right. No matter how secure and cost-efficient a doorknob is, if it doesn’t have a pleasant appearance, the sales will not be as successful as they would have been if the appearance factor had been taken into consideration. Hence, the newly designed doorknob takes style quite seriously and adds a sleek stainless steel coating handle set. Except this isn’t just any handle set, it has the durability of brass, with the protection of a thin layer of stainless steel to prevent corrosion from acid rain, salt, snow, etc. In fact, it’s not a handle set at all except for looking like one because with just a simple pull of the handle, the door can be opened and the handle bar snaps back into place. People would find this an ideal feature to have when hands are full. Doorknobs are what welcome people into their homes, however, without reliable ones; people may still be able to get into their homes but may find their valuables stolen during a robbery. Not only does the newly designed doorknob keep you feeling safe, it brings cheap, secure, and style together in a marvelous package that surely cannot go unnoticed. Exterior Doors: Resources The process of reverse engineering a product cannot be overcome by a single person’s thoughts and insights, instead, engineering requires the thoughts of more than one mind to create an extraordinary idea or at least get the gears spinning. Every successful product on the market has been put together by a team of engineers who brainstormed thoughts and concepts; hence it would be rather an ideal approach for me to consult someone other than myself about reverse engineering a doorknob. Sunny realized that he wasn’t going to be able to do this on my own so he began conducting research specifically on exterior doorknobs and the different functions they consist of. Sure enough, he was able to come across an informative resource on the internet, a website named “The House Designers” with a webpage providing bountiful information as per needed. Soon he had begun to realize that online resources wouldn’t be enough and required assistance from a person with first hand experience, thus I made my way to Home Depot. At Home Depot he met a worker named Mike from the house hardware aisles and proposed his ideas and problems about reverse engineering a doorknob and he classified different functions that a doorknob can have. The functions mentioned were: Typical Passage (2 blank doorknobs just for opening and closing), Storage (a keyed entrance doorknob which requires a key to open every time), Regular Entry (lockable from one side and has a panic release feature to unlock door just be twisting the knob), and lastly the Privacy feature (lockable but can be opened from the outside in case of emergency). After inspecting each of these functions, it was obvious that exterior doors require all these functions to increase safety since it is the most important doorknob in a household. Hence, after stumbling upon obstacles on numerous occasions, an innovative idea gave birth to his newly modified exterior doorknob. Garage Door Handle The garage door handle is commonly used as a substitution when the electrical garage door opener isn’t working, or when it is just more convenient to just open the door by pulling the handle up. However how could we improve their efficiency? The garage door handles are made out of many different materials therefore they could always be improved to lighter and stronger which would allow them to be in use for longer periods of time. For example a plastic garage door handle (which is still commonly used amongst society) could be instead made out of some cheaper and more environmentally friendly metal that’s simultaneously stronger. The special feature that could be added to the garage door handle is an electrical warmer that could be activated by a person when needed. This bonus feature would prevent freezing of the lock during winter. How about a specific material that a garage door handle could be potentially made out of? Prices of common metals: From the above charts we know that Nickel is way too expensive, Aluminum is too malleable. Magnesium on the other hand could be useful if combined with other metals. However the most suitable would be Copper mixed with Zinc, which is commonly known as Brass, or Copper mixed with tin also known as bronze. Brass is used for decoration for its bright gold-like appearance for applications where low friction is required like locks, bearings, doorknobs, or valves. That’s why Brass would be the most suitable material for a garage door handle, because its cheap strong and it looks spectacular which satisfies all of the aspects of reverse engineering from engineer point of view as well as from the customers point of view. So the functions of those door handles would be: - Lock, which will prevent people from opening the door - Warmer used during winter so the door handle doesn’t freeze and jam - Twists making it easier to open Marketing Door handle allow opening and closing the door. However, some door handle can be difficult to some people to operate such as elderly, disability and children, therefore the Baser doorknob will make it easy to operate the door by fingertips without twisting or grasp. It does not require an effort to open the door just a touch in your finger tips and the door can easily open. It has privacy model key that can be lock in one side, and in case of emergency it can easily unlock form the outside. A baser door knob comes in three different types such as brass and nickel. Baser door handle is functional, practical, and decorative. Also, it’s affordable and convenience and it’s easy to install. http://www.youtube.com/watch?v=xS6f6Azpdbo centercenterDecorative. Practical. Cheapest Price Door Knob We guarantee the highest in quality and best price in our new product. Our door handles are made of high quality material that assures long term solidity and our attractive design give our customers confidence to purchase. Hardware Door Knob 1800 (647)-5643 2360 Eglinton West, Toronto, ON www.hardwaredoorknob.ca www.hardwaredoorhandles.ca Monday to Friday 9 a.m. to 8 p.m. Saturday 10 a.m. to 5 p.m. 0Decorative. Practical. Cheapest Price Door Knob We guarantee the highest in quality and best price in our new product. Our door handles are made of high quality material that assures long term solidity and our attractive design give our customers confidence to purchase. Hardware Door Knob 1800 (647)-5643 2360 Eglinton West, Toronto, ON www.hardwaredoorknob.ca www.hardwaredoorhandles.ca Monday to Friday 9 a.m. to 8 p.m. Saturday 10 a.m. to 5 p.m. Results After analyzing the four different type of door knob/handle, it was clear that all handles needed adjustments, whether it be minor or major. To begin with, the bathroom door’s main purpose is to provide privacy and be easily accessible. By physically changing the knob into a clip, it made it far more user friendly than the original knob. With the new look, the metal used has significantly dropped, allowing the companies to save more materials. This clip handle also has a lock which can be operated exteriorly in case of emergencies. Although this goes against the purpose of privacy, safety will always come first. Stainless steel will also be used in the making of the handle, since there will always be people who take thirty minute showers and build a wall of fog in the bathroom. The stainless steel will prevent the clip from rusting. The bedroom door handle’s main purpose is to provide privacy as well as give off a welcoming feel. In order to meet these needs, the original knob was changed into a handle to allow easier accessibility. Next, the handle was given engraved designs which looks a lot better than a plain door handle as well as save a little bit of metal each time a handle is being produced. The materials used will also help reduce the cost of producing it. Alloy steel will be used in place of pure steel. This does not only reduce the cost but, increase resistance to rusting as well. Exterior doors are the first impression of a house. Its main purpose is to prevent any break ins, withstand all sorts of weather, and allow easy accessibility. To meet these needs, a lock will be placed on the door and brass with a thin layer of stainless steel will be used. The brass is a strong but, cheap material which will reduce the cost of producing the handles. While the stainless steel protects the handle from the varying weather. Adding a torque wrench feature makes the handle more user friendly, requiring less effort to open the door. Last but not least, the garage door’s main purpose is for security and withstanding the weather. With a lock on the door and an electric handle warmer, the door is secure and able to withstand freezing temperature. Its brass material also helps reduce the cost to produce each handle. References http://www.catalogs.com/info/home-decor/who-invented-the-doorknob.html http://alsnetbiz.com/homeimprovement/drknob.gif http://www.thehousedesigners.com/articles/entryhardware.asp http://www.copper.org/applications/rodbar/alloy360/whybrass.html http://www.doorknobdiscountcenter.com/ http://en.wikipedia.org/wiki/Door_handle http://www.homedit.com/shake-hand-door-knob-by-naomi-thellier-de-ponchville/ http://locks210.blogspot.com/2007_06_01_archive.html http://pogue.blogs.nytimes.com/2007/05/18/teaching-a-door-new-tricks/ http://hometolife.co.za/furniture-furnishings/bathroom-door-handle-design-and-decor-trends/ http://www.youtube.com/watch?v=2-1gcpy5_9M http://www.youtube.com/watch?v=xS6f6Azpdbo http://baserdoorhandles.com/ http://www.matchproduct.com/Products/PrinterFriendly/490 www.metal-pages.com http://en.wikipedia.org/wiki/Brass