Group 17 - Beginner Dirt Bike

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Image of a dirt bike



Click Here to view Compliance Matrix

The labeled heading for this product design and analyses is reverse engineering. During this process the group members will commence by noticing the easiest method to disengage the engine which seems to be of particular interest to the topic of analyses. The product website services will be employed based on the ease of understanding. Photographs will be taken in the process to better facilitate instruction on the disassembly and reassembly processes. These seem to be the most tedious tasks noticeable from the onset.

The Dirt Bike was not operational at first sight although it seems to have been ridden at some point due to observable tire dirt and wear on the sides of the teeth.

The analyses entails that the engines be kept at less than perfect condition to perform Failure Modes and Effects Analyses on it. The failure mode collectively agreed upon is the flooding of the engine whilst running due to improper fuel air ratios by the carburetor. Probable design reviews are required for submittal. The dexterity of the group is not necessarily high; neither is the hands-on knowhow. This should influence our collective power to approach problems whilst working without our levels of competence, although expedience is relevant to this project. It is also inferential that duties will be assigned.

The closest to a project lead at commencement was the resonance of ideas as seemed fit due to experiential skills gained before the class. This in turn limited delegation of difficult tasks. Contemplating the course of action is not an issue. The path to success has been laid down against such complaints on a generally accessible file, together with the previous schools and years of project outlines made available as templates. The major issue with the group at this point is scheduling meetings which should be taken care of by a timeline consensus explained in a Gantt chart posted.

Executive Summary

The incentive behind the reverse engineering project is to reinforce basic skills learned in previous classes as is applied in the engineering industry. Four stroke engines produce power but the application of the power to different uses defines a company's product. The 70cc engined Baja mini Dirt Bike was assigned this group. The product was divided amongst two groups. Group 11 was responsible for the frame and chassis of the dirt bike. The reverse engineering process for the engine followed the gates as assigned in the project platform. The group was also supposed to devise a method of conflict resolution.

  • Gate 1: This gate was contained three major deliverables which included the Work Proposal, Management Proposal and the Initial Product Review. The Work Proposal was intended to be a familiarizing incentive to initiate critical thinking about the consequent gates. This was achieved by the Gannt chart plan proposed by the group for future gates. The Initial Product review was a deliverable that incorporated the necessity of delegation of duties for the gate. This essentially enforced the Management Proposal which required a formal role assignment as a deliverable. The group was expected to think about the functionality of the internal components of their products without seeing them.
  • Gate 2: The deliverables for this gate were Causes for Corrective Action(CCA) and the Dissection Plan. Individually these entertained questions that spanned the course such as the information on difficulty and the fastener differences. The CCA asked to analyze the potential of the working plan, if it allowed for continuance and how the issues could be fixed. Throughout the course the provision of information on the difficulty of tasks was necessary. The reasons behind the choice of implements was included. The students also created a plan for dismantling the components of the engine. The completely dissected part was a deliverable to the gate as well. The difficulty was also highlighted per step.
  • Gate 3: This gate required the group to produce a component summary of the individual components of the engine. The level of detail was specific to the individual component complexity. The analysis of the models was meant to create an idea of the changes that should needs be made for the purpose of higher quality and efficiencies. Two models were hence required as follows, the Solid Model as well as the Mathematical (Analytical) Model.
  • Gate 4: The product was to be reassembled at this stage. The plan for reassembly was indicated on the Gannt chart as well as . The functionality of the final reassembly was required. Differences between the two processes, and choice of manufacturing processes.
  • Gate 5: This brings the course to an end with a stringent four minute presentation and condensation of practicalities to a synoptic version. The students are given the opportunity to analyze the entire process and give reasons for the missing deliverables through a compliance matrix. The necessary parts of the analysis is completed at this point and minor errors are corrected.

Table 1 shows the design process for the engine based on its functionality as follows.

Table 1

Consideration Vs Constraint

Considerations Parts Required Incorporation Difficulty Constraints
Rotational to Linear Kinetic energy chains and gears 4 Side, Exhaust placement
Direction of motion Steering Handle 2 Opposite Driven Wheel
Power Engine-Fuel System 4 Size, Orientation WRT Wheels
Efficiency Articulation hydraulics, transmission and signalling 5 Size, Cost of production
Safety Suspensions 3 Angle of freedom
Structural Integrity Frame 1 Cost of production, Metal to metal linkage

Gate 1: Request for Proposal

Link to Gate 1: Request For Proposal Page

Included in Gate 1:

- Work Proposal

- Management Proposal

- Initial Product Assessment

Gate 2: Preliminary Project Review

Link to Gate 2: Preliminary Project Review

Included in Gate 2:

- Causes for Corrective Action

- Product Dissection Plan

Gate 3: Coordination Review

Link to Gate 3: Coordination Review

Included in Gate 3:

- Component Summary

- Design Revisions

- Solid Modeled Assembly

- Engineering Analysis

Gate 4: Critical Design Review

Link to Gate 4: Critical Design Review

Included in Gate 4:

- Product Reassembly Plan


[1] "Dirt Bike Website" Link 1

[2] "FMEA, BAE systems" Link 2

[3] " UBlearns_MAE277 09: Purpose of Reverse Engineering Project" Link 3

  • After opening link [3], click on Course Documents tab on left, then Reverse Engineering Project and Project Outline.

[4] "INCOSE Dual V model " Link 4