Reverse Gear System Engineering Why, When & How (Avoiding Pitfalls & Litigation!)

Reverse Gear System Engineering
− Why, When & How −

(Avoiding Pitfalls …& Litigation!)
INSTRUCTOR:
Raymond Drago, P.E.
Email: [email protected]
COURSE INFORMATION
Course Description
Reverse engineering a gear system is a not too unusual task and in many, but not all, cases the process
goes fairly well, thus it is easy to become complacent. It is important, however, to fully understand the
process and the best practice procedure for reverse engineering a gear system. Failure to fully follow best
practice can result, at best, in an unhappy gear user, but in the worst case it can lead to very expensive,
time consuming and reputation damaging litigation.
We will discuss the basic types of reverse engineering projects (e.g. upgrading an existing system to
increase power or extend operating life or improve noise level; replacing gear that has simply reached the
end of its otherwise successful useful life; emergency, short term, interim gear replacement resulting from
an unexpected failure; responding to a system that is not providing acceptable performance, etc.). The
need for understanding the operation of the system in which the gears will be used, the conditions that
led to the need for the project and especially, the specific nature of the failure that occurred, if that is the
reason for the project, are key, often ignored, elements of the process.
In some cases, no drawings are available at all thus a design must be developed that will yield gears that
provide equivalent load capacity, life, noise performance and smoothness of operation. This scenario will
be discussed with recommended analyses resented. In other cases, where no drawings are available, the
correct procedures to follow in developing a reverse engineered gear that truly meets the system
requirements will be discussed in detail with cautionary procedures outlined.
The concept of applying the AVO (avoid verbal orders) process to the overall reverse engineering process
will be discussed with fact based but names and identifying details eliminated case studies to emphasize
the importance of this concept. The “amnesia” issue will also be addressed in this context. The author’s
experience in serving as an Expert Witness provides first-hand information that will aid in avoiding this
aspect of a reverse engineering project completely…. if followed!
It is recommended that you spend a minimum of 1 hour reading and reviewing the material each day.
Course Rationale/Students Course Designed to Serve

Gear and gearbox design and manufacturing engineers, management and quality control engineers
involved with design and manufacture of reverse engineered parts, especially where minimal or no
original, detailed gear design information is available.
Learning Objectives:
• Recognize the detailed engineering and application understanding required to properly reverse
engineer a gear
1
• Understand the difference between designing from scratch and designing to duplicate an existing
part and its function
• Consider the reasons why reverse engineering an existing gear set, or, especially, a single gear can
often considerably more difficult than designing a new gear or gear set from scratch
• Discuss the possibilities for misunderstanding, which are legion, between purchaser and supplier
• Address the need for all parties involved to agree regarding the purpose of the reverse
engineering effort and the expected results and costs
• Apply an understanding of forensic analysis of gearbox failures to avoid simply duplicating the
original failure
• Understand the difference between a temporary replacement and a duplicate of the original
gear and the discussion and documentation required to avoid misunderstandings that can lead
to litigation
Required Textbooks (Provided by AGMA)

AGMA’s Reverse Gear System Engineering ― Why, When, How & What − (Avoiding Pitfalls …&
Litigation!) - a Practical Guide for the Design Engineer by Raymond J. Drago, PE
COURSE OUTLINE
I. Why is the gear being reverse engineered rather than replaced by OEM or to the OEM
drawing?
II. What is the reason for the reverse engineering effort – unavailability or failure or poor
performance of the original?
III. Who is the primary focus of the reverse effort, gear engineer or customer and?
IV. Understanding the need for communication between customer and supplier and the need for
detailed documentation of expectations
V. Steps required to avoid the possibility of misunderstanding leading to litigation
VI. Discussion of the need to clearly define who owns the design including drawings and
processing procedures which result from the reverse engineering effort
VII. Address the need for both purchaser and supplier to clearly understand exactly what the
purchaser requires.
VIII. Address the difference that can occur between the purchaser’s and designer’s understanding
of the rating and usage of the reverse engineered gears
IX. Guidance in developing a detailed reverse engineering plan that clearly addresses and
documents the responsibilities and expectations of both purchaser and supplier (more
difficult that most engineers recognize)
STUDENT FEEDBACK AND GRADING PROCEDURES
Assignments
A Pre-test and post-test are administered during this course. Immediate feedback is given, and the
material is reviewed by the instructor.
COURSE MANAGEMENT
Weather Delays and Cancelations

We will communicate any cancellations, delays or other concerns for safety prior to class via email,
voicemail, and/or text message. Please be sure that we have all pertinent contact information as you
travel to your class location.
2
Attendance for Domestic and International Students
Please be mindful that these are short, accelerated courses. Attendance is extremely important. If you
are going to be absent from any class day, please contact the course coordinator. Rosemarie Bundoc,
Education Manager, [email protected] or Stephanie Smialek, Education Coordinator,
[email protected]
Plagiarism, Cheating and other types of Misconduct

Plagiarism 1, cheating and other types of misconduct are unacceptable.
Students with Disabilities

Students requiring assistance and accommodation should complete the Special Accommodation
Request form and submit it to Stephanie Smialek, Education Coordinator, at [email protected]. She can
be reached at 703-838-0069.
Grievance Procedures
Students who have concerns about the class are encouraged to contact Stephanie Smialek, Education
Coordinator, at [email protected] or 703-838-0069.
Outline Changes
The instructor reserves the right to modify the outline during the course of the class.
LEARNING AND OTHER RESOURCES
Links for writing resources:

• grammar.ccc.commnet.edu/grammar
• www.merriam-webster.com
Links for Math resources:

• www.sosmath.com
• Khan Academy on www.youtube.com
Links for time management, study skills and note taking resources:
• www.mindtools.com
• www.testakingtips.com
Links for career resources:

• https://www.agma.org/newsroom/jobs/
Industry News:
• https://www.agma.org/newsroom/industry-news/
1
Plagiarism is defined as “the use or close imitation of the language and thoughts of another author and the
representation of them as one’s own original work.”

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What are the main reasons for reverse engineering a gear system?

What steps are involved in properly reverse engineering a gear?

Reverse Gear System Engineering

− Why, When & How −

Course Rationale/Students Course Designed to Serve

Required Textbooks (Provided by AGMA)

STUDENT FEEDBACK AND GRADING PROCEDURES

Weather Delays and Cancelations

Plagiarism, Cheating and other types of Misconduct

Students with Disabilities

LEARNING AND OTHER RESOURCES

Links for writing resources:

Links for Math resources:

Links for career resources:

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