Reverse Engineering Applied to a Circuit Breaker Lever: Case Study

Resumo

The obsolescence of components in industrial systems has become a significant and growing challenge for corrective maintenance and operational continuity of complex and high-cost equipment. To address this issue, this work proposes an integrated multidisciplinary approach combining reverse engineering, design for additive manufacturing, structural simulation, and 3D printing technique for recovering and refurbishing obsolete components. As a detailed case study, the functional restoration of a high-power circuit breaker used in a hospital environment was performed, where conventional replacement would involve high costs and prolonged downtime, with direct impact on system safety and reliability. The process involved precise 3D scanning of the original component, followed by parametric modeling with geometric and structural optimization. Computational simulations were conducted to verify mechanical performance under operating conditions. The component was manufactured using an additive manufacturing technique with high-performance engineering resin. The result was a carefully redesigned part showing significant improvements in geometry, strength, and robustness while maintaining full dimensional compatibility and functional interchangeability with the original system. Comprehensive tests demonstrated adequate dimensional accuracy and satisfactory mechanical performance, along with substantial reductions in costs and repair time compared to conventional replacement methods. The developed methodology proved effective as a strategic alternative to address parts’ unavailability in the market, providing greater technical autonomy and flexibility in maintaining complex industrial assets, and highlighting the promising potential of integrating digital technologies with reverse engineering as a sustainable and innovative solution for managing obsolescence challenges in electromechanical systems.