Dissection- Gate 2

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Project Management

As a group we executed our management plan relatively perfect and only faced a few minor difficulties. As far as our group meeting schedule went, we have been able to meet every Sunday as planned, but due to our busy schedules a couple times we have had to make a few significant schedule changes. We originally planned to meet in Furnas hall at the dissection lab to perform the dissection, but because nobody could make it in the restricted time slots, we made the decision to perform the dissection in Griener Hall at our usual meeting place. We were able to remove our product from the dissection lab because it easily was taken apart with simple hand tools that several group members owned. Furthermore we couldn’t fit a second group meeting into our schedules this week so we broke the rest of the project down into individual parts for each group member to complete.

Besides these few minor problems our group schedule has gone relatively flawless. We all were able to meet Sunday for the actual dissection, and everyone contributed. We had several members actually breaking down sub-systems while one member took photos and another documented the process. We were able to avoid member conflicts, and everyone performed their respective jobs. Overall we were able to complete the actual dissection in a reasonable four hours, which shows we worked efficiently and productively.

As far as the actual dissection of the toy gun went, we performed well with only a couple small problems. For example, the external screws that held the body of the gun together we clearly hidden so that children couldn’t access them, and made the dissection difficult. Some of the more difficult screws were very small and hidden in deep wells, which made them very easy to strip. Also, the camera we used reverted its memory during the dissection and we lost a lot of material. In response to this we had to reassemble the gun to retake photos and videos. Only to add onto our technical problems, the computer we used also crashed during the photo upload, which forced us to re-document some valuable information we lost.

Other than those minor technical issues we faced, the dissection went quite well. We were able to get high quality pictures and videos that help show the small details of our dissection. We also had no problems distinguishing the different sub-sections along with the energy inputs and outputs of the overall system. The only unresolved challenge we faced was testing the actual gun, and that’s only because we didn’t have the proper batteries.

The groups’ overall work up to this point in the project has improved dramatically. While working on our original plan for the project, we decided that we were going to meet once a week and try to accomplish everything needed for the projects during these meetings. However, we ended up trying to get gate one done in one night and, of course, it turned out at a much lower quality than it could have been. We realized that this process needed to change, and that a new plan for the plan for the project should be worked up. We decided to meet up much more often to work on the project, and try to accomplish simple goals during each meeting. In doing it this way, we would be much more motivated to get the work done at a much higher quality level. For example, we met a total of three times to work on gate two alone, compared to the one time we met for gate one. Also, we all did a little bit of work on our own and this led to the meetings being much more productive, as we all had ideas that could be clearly presented. By working on the project in this fashion, much higher quality work could be obtained.

We plan on working on the remaining gates of the project in this fashion, as well as other group assignments that we are assigned to work in our project groups on. By having more meetings (one to two) per week, more quality work will be accomplished, as well as no extremely late nights. Also, by having each person do a little bit of work outside the classroom, the meetings will be more meaningful. This process is important and will lead to much more successful project.



\'\'\'Battery Cover Removal\'\'\'

  • Tools: Size 1 Phillips Head Screwdriver
  • The battery cover was removed first, as it is the only part of the entire product that is meant to be removed. When taken off, the place to put the batteries (6 D-Batteries) is exposed.
  1. Remove the lone screw holding the cover on.
  2. Lift the cover out of its slots by hand.
  • The removal of this screw and cover was extremely easy as it is meant to be removable by anyone using the toy.

\'\'\'Loosening of Yellow Collar\'\'\'

  • Tools: Size 1 Phillips Head Screwdriver
    Location of the yellow collar
  • The yellow collar is located at the base of the rotating barrels and attaches them to the base of the gun. This is the first step of dissection that would not be done by the typical user.
  1. Remove the 2 screws located on opposite sides of the gun.
  2. Twist the yellow collar counter-clockwise
  • Removal of these two screws had a slightly higher level of difficulty but would be no challenge for anyone who works with tools. Twisting the collar loose required very little effort.

\'\'\'Removal of Rotating Barrels\'\'\'

  • Tools: Flat Head Screwdriver
    Location of the rubber ring
  1. Remove the orange rubber ring located at the end of the center orange firing barrel. To do this use the flat head screwdriver to pry the rubber ring off.
  2. Slide the rotating barrel assembly off of the orange firing barrel
  • The orange ring that has been removed was added as a safety feature to cover the corners of the hard plastic barrel.
  • This was a fairly difficult step and took a couple minutes of “wriggling” to remove the part. Our disassembler actually cut himself a bit while doing this (very minor).
  • After this step the rotating barrel assembly should be set aside for further dissection later after the rest of the Punisher is disassembled.
  • See Step 17 for the dissection of this assembly
Img 0023.jpg

Removal of Ammo Belt Cover

  • Tools: Size 1 Phillips Head Screwdriver.
    Location of the ammo belt cover
  • The ammo cover is the orange piece located on the top of the gun.
  1. Remove the two screws, one located on each side of the gun directly opposite from each other.
  2. By hand remove the two orange plastic pieces that the screws came out of.
  3. Lift the entire ammo cover up off the gun.
  • This was a quick and easy task taking no more than a minute
  • Set the ammo cover aside for further dissection later.
  • See Step 18 for the dissection of this assembly
Img 00123.jpg

Removal of Yellow Handle

Yellow Handle
  • Tools: Size 1 Phillips Head Screwdriver
  • The yellow handle is located on the top if the gun to allow for more stability while using it
  1. Remove the six screws located on the handle.
  2. By hand pull the two pieces of plastic that make up the handle apart from one another.
  • This step took about 2 minutes to complete as it required more work, but not much more effort to complete.


Removing the "Sound Causer"

  • Tools: Size 1 Phillips Head Screwdriver, Needle-Nosed Pliers
  • The sound causer is a small white plastic piece located on the front of the gun that was made visible after the removal of the barrels.
  1. Remove the screw holding the piece in place.
  2. Use pliers to pull the white plastic piece off.
    • You will need to use the pliers here because the piece is greasy and pressed into place
  • This step was quick and easy to complete.

Removal of Orange Firing Barrel

Barrel before being taken off
  • Tools: Size 1 Phillips Head Screwdriver
  • This is the barrel that the dart is actually fired through, located in the front of the gun.
  1. Remove the two screws holding the barrel on.
  2. Pull the barrel of by hand
  • This was a quick and easy step requiring less than a minute
Img 0027.jpg

Removal of Outer Shells

Gun after the outer shells have been remoed
  • Tools: Size 1 Phillips Head Screwdriver
    • It is important that for this step that your screwdriver have a long
  • In this step we will remove the outer shells of the gun, once this step is completed all of the interior components will be visible.
  1. There are 24 screws located on the outer shell that will need to be removed.
    • This step has the highest difficulty and requires the most time of any step this far. These screws were not intended to be removed by the average consumer. It took several minutes to complete this task with two people working on removing the screws. Some of the screws were difficult to reach and some screws were being "stubborn" (difficult to unscrew), requiring a higher level of torque to get them out.
  2. The first piece to come off is the black handle as it incloses part of the blue shell.
    • This step will reveal parts of the electrical subsystem. The power (simple on-off switch) was visible, as were several red and blue wires that led to other parts of the gun.
    • This will also reveal part of the trigger mechanism.
  3. We now remove one half of the blue shell containing the guns internal components. To do this we had two people slowly slowly pry, and lift the shell apart from other half that it was attached to.
    • Watch the video here - http://www.youtube.com/v/J9TXgmsDhMM?version=3&hl=en_US&rel=0
    • Upon completion of this step all of the guns internal components are now visible. We can now follow wires from the battery pack and switch to the three motors that they supply power to. You can see the complete trigger, loading and firing mechanisms.

Removal Orange Stock Piece

  • Tools: Size 1 Phillips Head Screw Driver.
  • Gun before stock removed
  1. By hand, lift the orange piece out of the slot that it is resting in.
    • After removing the piece we realize that this is not one piece but actually two pieces screwed together
    1. Remove the (check the piece to see how many screw holes there are in it) screws
    2. Pull the two pieces apart from one another
  • This step was extremely easy and took less than a minute.


Removal of Ammo Loading Motor

  • Tools: Size 1 Phillips Head Screwdriver
Location of screws to remove motor
  1. Remove the four screws holding the motor (and gearbox) in place
  2. Lift the motor out.
  • This task was easy and required minimal effort and time
  • This motor and gear box assembly can be further dissected
Location of screws holding on cover
  1. Remove the four screws holding the cover on
  2. Lift the cover of
    • This will reveal the internal gearing. The gearing consists of worm gear, a compound gear and a larger gear to help increase the torque of the motor. The worm gear makes it impossible to back drive the motor

Trigger Removal

  • Tools: Size 1 Phillips Head Screwdriver
  • As is visible once the outer shell is removed the trigger mechanism consisted of the actual trigger lever, five white plastic pieces that all moved together in sync, and one small spring.
  • Watch video here - http://www.youtube.com/embed/70c9z34w7Mw?rel=0
Trigger mechanism before it was removed
  1. Remove the 11 screws.
  2. Remove the upper level plastic pieces, first then work your way down to the other side of the outer shell
    • Be careful when removing the spring as it is stretch and storing energy
  • After completing this step the wiring to the first motor (ammo feeder) are now completely visible, and it is now possible to see that they are glued in place (easily removable by prying the glue off)
  • This step took several minutes to complete, the screws were not hard to remove, but there were more than in most other steps. We also had to be careful of how we removed each part due to the fact that many of the parts were interlocking and moved in sync with one another.

Removal of Ammo Belt Feeder

  • After careful inspection, it was determined that the feeder was held in place by the parts around it, because many of the parts around it had been previously removed, removing this part was extremely quick and easy.
  • Ammo belt feeder
  1. Remove the feeder by hand by "popping" it out of the slots it sits in.
    • The belt feeder on its own is a small assembly which we then took apart.
    1. Using a Size 1 Phillips Head Screwdriver, remove the 3 screws and pull the pieces of plastic apart from one another.
      • This step posed as a difficulty for us. During this process, one of the screws was stripped and this proved to be a fairly large problem the group had to overcome. It took about ten minutes of trying different methods to get this screw out. However, finally the feeder belt came apart into two plastic pieces.
Location of small white piece
  1. Remove the one screw holding down the small white plastic piece
  2. Pull the piece out
    • This piece was put in place so that the ammo feeder could not bee back driven

Removal of Black Support Bar

  • Tools: Size 1 Phillips Head Screw Driver
  1. Remove the five screws holding the support in place
  2. Lift the support out by hand
  • These screws were easily removed and the task as a whole took about a minute

Removing the Battery Pack

  1. Remove the tape holding the battery pack down
  2. Pull the battery pack out of the slots it rests in
  • The battery pack was only snapped into place to it was a very quick and easy removal

Remove Ammo Box Holder

  • Tools: Size 1 Phillips Head Screwdriver
Locations of screws on the ammo box holder
  1. Remove the single screw holding the piece down
  2. Lift the plastic piece out of the gun
  3. Remove the spring by undoing the single screw holding it down
  • this is an easy task requiring about a minute to do.

Removal of Motor Used to Rotate Barrels

  • Tools: Size 1 Phillips Head Screwdriver
Location of screws to remove motor
  1. Remove the five screws holding the motor in place
  2. Remove the motor and gear box combination
  • This step was quick and easy

Img 001231834.jpg

Removal of Firing Motors

  • Tools: Size 1 Phillips Head Screw Driver
Location of motor
  • You will have to have all of the other components removed in order to get this part out
  1. Remove the two screws holding the motors in place
  2. Lift the motors out
  • With all the other components out of they way this step was simple and quick to do.
Img 01234567.jpg

Dissection of Rotating Barrels

  • Earlier in the dissection the rotating barrel assembly had been removed and set aside for further dissection. This is the steps in which this assembly will be dissembled.
  • Tools: Size 1 Phillips Head Screw Driver
Location of screws on the gear
  1. Looking at the end that was attached to the rest of the gun, remove the 4 screws holding down the (67) tooth gear.
  2. Lift the gear up, as you do this be aware that four small white spacers (also used as wheels to allow the barrels to spin more easily and smoothly around the main firing barrel) will be lose and fall out.
    • This step required little effort and less than a minute to complete
  3. Next we will remove the four screws in the second level of blue rings
    • This step was slightly more difficult due to the awkward angles the screw driver had to be held in, in order to reach the screws. This step also required a little more time.
  • This is the furthest we dissected the rotating barrel assembly. We did not dissect any further because we determined that the gray barrels were held in place by an extremely strong glue/epoxy, this part was clearly designed to never be taken apart.

Dissection of Orange Ammo Belt Cover

  • Earlier the Orange Ammo Belt Cover was removed and placed aside for further dissection
  • Tools: Size 1 Phillips Head Screwdriver
Ammo belt cover before dissection
  1. Remove five screws holding the whole assembly together.
    • This will reveal two small springs and one large one.
  2. Remove the 2 screws holding down the springs
  3. Remove the finals two screws revealing a plastic box and larger spring
  • The removal of the five exterior screws was difficult and clearly not intended to be removed. Due to the difficulty in removing these screws this step took several minutes.
Img 00124.jpg Img 00125.jpg Img 00126.jpg



  • \'\'\'Electrical Subsystem\'\'\'
    • The power that is used throughout the gun is provided by the batteries located right next to and in the handle. The six batteries provide power for all three motors in the gun, and is located in the spot it is in order to reach all three motors, while also allowing for a power switch in order to save power when the gun is not in use. The batteries provide energy through wires to the rest of the gun. Batteries are one of the most cost effective ways to provide power in a product like this, and having an on/off switch will help save power. The gun is completely mobile (does not have to be connected to an outlet or another power source) and so using this type of power addresses environmental concerns, as well societal concerns.
  • \'\'\'Ammo Loading Subsystem\'\'\'
    • Looking at one of the major subsystems of the part, this was one of three motors in the gun. This motor was powered by the electrical energy provided to it by the batteries. Wires connected the batteries two the motor. When electricity was sent to the motor, the motor would provide mechanical energy to the ammo feeder of the gun and would constantly push darts into the firing mechanism. The motor was located near where the darts entered the gun, but also close enough that wires could easily connect the two sources. This motor was very important, because with the trigger held down, the motor would constantly push new darts to be fired, and thus is responsible for the automatic function of the gun.
    • One of the biggest features of the gun is that it is automatic firing (constantly shoots), and so putting in this motor helps with societal concerns. The gun is more realistic and more fun to use because this motor functions in this way.
  • \'\'\'Trigger Subsystem\'\'\'
    • The trigger mechanism was very important to overall function of the gun, and it accomplished two main tasks. First, when the trigger was pressed down, the small barrier preventing the dart from being pushed through to the firing mechanism was removed (by function of the small spring) and so the first dart could be fired. The second function was that when the trigger was pressed and the barrier removed, a signal was sent to the motor to actually start spinning and so the automatic firing could commence. The trigger had to be located in a part of the gun where one would normally hold the gun, so its location is important.
  • \'\'\'Barrel Rotating Subsystem\'\'\'
    • This subsystem was again a motor that ran on electricity from the batteries. Electricity was carried through wires that connected the motor to the batteries, and the motor converted this power to mechanical power. This motor basically powered two gears to spin, and those gears in turn spun the outside barrel. The darts did not actually shoot through those barrels, but they do look nice spinning and help the overall appeal of the product.
  • \'\'\'Firing Subsystem\'\'\'
    • This subsystem was the third motor of the system, and again it ran on electricity from the batteries. Electricity was carried through more wires to the motor which converted the electrical power to mechanical power. It basically spun two wheels that, when the dart was pushed through, shot the dart out at considerable power. This method of firing basically allowed for the darts to be shot continually without problems. This again helps the overall appeal of the product.

GSEE Factors

\'\'\'Global Factors\'\'\'

Safety is one of the main concerns for any product entering the market, as there are many different standards to meet, all depending on the region selling the product. The “Punisher” must meet worldwide safety standards and the subsystems in place (batteries with three motors and a simple trigger mechanism) are all commonly recognized as being safe. With all these subsystems secure inside the outer shell of the gun, there is very that little that could actually go wrong with any type of user interaction. Another global factor that relates to the design of the gun is the use of batteries, as batteries are a convenient use for power. The gun does not need to be plugged in to work which makes it convenient to use at any location around the world. Also, one does not need to worry about power conversions that could be different all around the world.

\'\'\'Societal Factors\'\'\'

Societal Factors that could possibly influence the design of the subsystems of the “Punisher” include more safety aspects and the fact that the gun is more realistic and fun to use. By putting all the subsystems inside the shell, no user will be able to play with the motors or wires, which could possibly lead to breaking the product, or worse, injuring them. Also, the entire gun is safe as there are no sharp edges anywhere, and the barrel has rubber tips on the end of it. The third motor is a subsystem that was added in order to make the gun have a very “fun” feature. This feature is that the outside barrel of the gun revolves around as the gun is firing. This is an example of a societal factor that helps makes the product more appealing to the consumer.

\'\'\'Economical Factors\'\'\'

The “Punisher” is a product that is made of fairly cheap parts, and thus the subsystems need to be cheap to produce as well. This is the main economical factor that was considered in designing the subsystems for the gun. The motors and trigger mechanism are all made with plastic and thus is not very expensive. Most of the parts of the gun can be mass produced and this allows for cheap production costs, and keeps the cost of the gun for consumers as low as possible. Also, the subsystems are not very complex, and thus it makes it easy to actually assemble the gun. This again cuts back on costs as it is quick for the laborer to do, as well as requiring not very much skill.

\'\'\'Environmental Factors\'\'\'

There were some environmental factors that were considered in the design of the subsystems of the gun. First off, the systems chosen all have a long lifespan and are not likely to get broken, so one does not have to worry about getting rid of the product for a long time. Also, when firing, there is no waste product that is released into the environment. This important, because if for some reason something was released into the environment, the product might not be allowed to be sold on certain markets.

Functional Model

Overall Function


Secondary Sub-Function Level