Gate 1: Work and Management Proposal, Product Archeology

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In order to complete a successful disassembly and assembly of the bait-casting reel, several points must be addressed. In the following flow chart, these points are laid out such that each factor is considered prior to disassembly:

Affecting Factors
Step 1 Step 2 Step 3
Approach for Disassembly & Assembly • Time Taken
• Tools Needed
• Specific Challenges
Commence Disassembly

\'\'\'Time Taken:\'\'\' Based on the observation of research surrounding the disassembly of a bait-casting reel, we estimate that an organized disassembly, in which all parts are accounted for, will take approximately 30 – 45 minutes.

\'\'\'Tools Required:\'\'\' In order to reverse engineer our product properly, we will need the following:

• Phillips-head Screwdriver

• Flat-head Screwdriver

• A sheet on which there are labeled sections for each component.

To elaborate on the sheet, we feel that it will be helpful to disassemble the reel on an arbitrarily large sheet of paper that has been prepared with labeled sections, in clear writing, for each component. This will hopefully prevent us from losing track of any small pieces, such as screws and nuts.

\'\'\'Specific Challenges:\'\'\' In our discussion about the key potential challenges of disassembly and assembly, we decided to be aware of a couple certain aspects that might cause adversity in our efforts to complete a successful reverse engineering process. The potential difficulties associated with disassembling the complex gear system, in an organized manner, is one of these aspects; This was considered in our reasoning to create the disassembly sheet prior to starting, and will hopefully go smoothly due to the degree of organization provided by the sheet. Another point of concern for us was the handling of the components during and after disassembly. Based on research and the observation of the reel, we were able to assume that some of the smaller parts might be small and delicate, and we decided to store our disassembled product in a safe container that will not threaten the integrity of the components.

While the previously mentioned aspects of preparation may cover the tangible information necessary in order to commence disassembly, it is also imperative that the qualitative traits of each group member be assessed and laid out. This aspect is important because the group, as a whole, can work together to help improve the shortcomings of its members while simultaneously taking advantage of their skills to optimize the end result. In the following chart, we have compiled the capabilities and shortcomings of our group members.

Group Profile
Group Members Capabilities Shortcomings
Md Fahad Hossain •Good leadership skills
•Ability to motivate people and put everyone to work
•Not much time to dedicate to the project due to other obligations (work, other projects…)
•No web editing experience
Paul Tabellion •Good global overview of things
•Ability to motivate people and put everyone to work
•Primary experience in the mechanical industry (7 months of internship in the aeronautic sector)
•Gives a foreign(global) perspective
•Oral and written communication: (Exchange Student with English as a second language)
•Lack of time to dedicate to the project due to two other projects of senior level
Connor McCafferty •Good computer skills
•Good knowledge of CAD systems
Mike Persic •Always put lots of efforts and skills into his portion of the work
•Meet his deadlines in time
•Meets assigned expectations, doesn’t exceed
Kevin Dailey •Had adequate experience with fishing reels

Management Proposal

To handle our work in the most efficient way possible, our team will be composed of 4 people, each in charge of one aspect of the project and all organized around one manager, in charge of leading the project. For this semester, our organization will be the following:

Team Members Job Title Roles
\'\'\'Md Fahad Hossain\'\'\'
Project Manager •Gives the deadlines of the project
•Define the work direction
•Deals with the group conflicts
\'\'\'Paul Tabellion\'\'\'
Co-Project Manager •Assist Project Manager with tasks
•Internal communication
\'\'\'Connor McCafferty\'\'\'
External Communication/ Compiler/Editor •In charge of communicating with all people outside the group
•All work will be sent to him to be compiled into a technical format
•Proofread/Edit all work sent to him
\'\'\'Mike Persic\'\'\'
Schedule Manager •Keeps track of the deadlines
•Makes sure we follow the planning defined at the beginning of the semester
•Mediates group conflicts
\'\'\'Kevin Dailey\'\'\'
Technical Expert •Technical questions concerning assembly/disassembly/materials will be referred to him

To meet our deadlines and accomplish our work in time with the quality expected from engineering students, we will meet at least once a week during this semester. More precisely, we will have two hours meetings in Capen Library every Tuesday from 3:00 p.m. to 5:00 p.m.. This will give us the opportunity to check on everyone’s work, gather our results, and see how the project is advancing. It will also be the occasion to discuss the headlines of the project and assign the different tasks ahead of us. If necessary, additional meeting will be added to our schedules to make sure that our deadlines are met, especially in critical moments.

Product Archeology

Development Profile

A fishing reel is a device that deploys and retrieves fishing line by using a spool mounted on an axle. They are most often (but not always) used in conjunction with a fishing rod.

Although the birth of fishing reels is a mystery as it dates back far before any known records, the first use of a fishing reel can be seen in Chinese paintings from around 1195 A.D. However, unlike today, fishing reels were used for fishing as a means of living rather than a sport. As nearly all of East Asia relied majorly on fishing for their income, they were the first people known to use fishing reels.

In 1651, English literature first reported a "wind” that was placed within two feet of the lower end of the fishing rod. This date is usually accepted as the first reference to a winch fishing reel in the western world.

Until the 1800\'s, the fishing reel was not much more than a storage place for excess line. The British claim to be the originators for the multiplying reel, but the fishing reels of George Snyder, of Kentucky, have become the most famous 19th century multipliers. Snyder\'s reels were developed in the 1820\'s, and are what you would think of as an "old fishing reel." From these reels is what came to what we think of today as a fishing reel. At the time, England was the center of most technological developments in the world.

In 1820, Kentucky native George Snyder invented the first fishing reel in America. It was a bait casting design that quickly became popular with American anglers. It was also able to double as a fly reel.

And today, fishing reels are made for both commercial and industrial purposes as they are used to catch fish for fun as well as for a means of living. The use of fishing reels have not been altered much since its introduction to the modern world, however, fishing itself has found new purposes in the human society.

Usage Profile

A fishing reel is used within the context of fishing activities. Although it can be used for commercial fishing, it is more commonly known for being used in the recreational sport of angling and competitive casting. A fishing reel is usually combined with a fishing rod, to which it is directly attached, and has the task of winding and stowing of the fishing line.

Energy Profile

The Daiwa bait-cast reel utilizes several types of energy to accomplish its task of casting and retrieving bait. In order to cast bait, the reel uses the inertia of the bait to spin the spool, unwinding the line. While the bait is projecting through the air, several centrifugal brakes engage, using pressure to slow the spool. The reel uses rotational energy applied at the handle, and transmitted through a system of gears to spin the spool, rewrapping the line.

Complexity Profile

There are eight critical allotments of the Daiwa bait-cast reel when considering the products fundamental components:

2.Spool / Spool control
3.Free-spool button / Thumb bar
5.Gear Assembly
7.Braking system
8.Drag / Drag control

One method of observing the complexity of each component is by the following chart, in which a complexity rating, based on a scale of 1 – 5, is assigned to each part; the rating is determined by the amount of interaction, or interdependency, that each component has with others.

Component Number 1 2 3 4 5 6 7 8
Complexity Rating
(Scale: 1-5)
1 3 1 1 5 3 3 4

1. The frame can be categorized as a ‘1’ since its primary purpose is to simply encompass the rest of the reel. Its functions include the provision of the two side plates, which are constrained to the skeleton of the reel by screws, nuts, and bushings. There are specific holes cut in the side plate such that the handle and drag control can be held in place.

2. The combination of the spool and spool control can be recognized as one essential part of the reel, and is categorized as a ‘3’. The main function of the spool is obviously to house the fishing line while a fisherman is either casting or retrieving his line, and although this may seem like an elementary principle, the spool becomes more complex as one considers the way the spools tension is manipulated. The spool tensioner is a knob located on the side plate; turning the knob clockwise yields more pressure applied to the spool, while turning it counterclockwise yields less pressure. This variation of spool pressure allows a fisherman to control how fast the spool is able to rotate.

3. The ‘free-spool’ button has the one simple function of allowing the line to be cast when released from grip, and is thus categorized as a ‘1’.

4. The handle is another component that is relatively less complex in that its purpose is intrinsic of its appearance. Although its importance is inherent, acting as the receptor for the kinetic energy delivered by the fisherman’s hand, it does not directly prompt any other individual functions within the reel, and is categorized as a ‘1’.

5. The gear assembly is categorized as a ‘5’ and can be recognized as the most complex component for two reasons. The first is that the presence of the gear assembly is depended upon by all of the translational parts, or the parts that move. The second is that the term ‘gear assembly’ includes the totality of the gears within the reel, which aren’t found at one central location, but rather spread throughout the reel. The removal of the side plate reveals the drive gear calibrated with a smaller gear which engages the spool upon rotation of the handle. Another crucial gear, the worm drive, runs the length of the spool and provides for the uniform motion of the line guide.

6. The line guide’s categorization of a ‘3’ is assigned based on its contribution to the continuous, smooth overall function of the reel. Although a relatively smaller component, the line guide interacts with the spool, frame, gear assembly, and the line itself. The worm drive causes the guide to move in an even, harmonic pattern back and forth across the frame in front of the spool. As line is retrieved, this motion allows for the line to be uniformly distributed back onto the spool, as to prevent line tangles.

7. The braking system is categorized as a ‘3’; the reliance of other components and their functions is minimal, but when utilized by fishermen, the braking system interacts with the spool in a function carried out by a centrifugal method of spool tension, mimicking the function of the spool control. This ‘system’, located in the side plate furthest from the handle, consists of six pins which can be adjusted to control the spool tension in an effort to prevent spool overrun, which causes line tangles.

8. Often referred to as the ‘star drag’, the drag system is categorized as a ‘4’. It is relatively complex due to its interactions and crucial purpose. First, the drag is manipulated by a star-shaped wheel located between the handle and the side plate, and is what allows the spool to ‘give’ when the line is under high tension. The system is a stack of drag washers of alternating materials, metal and fabric. The pressure applied to the stack of washers by the wheel is translated to the drive gear, which rests upon the same shaft. The drive gear meshes with the smaller gear which in turn engages the spool, hence the end-effect of the drag on the spool.

Although the complexity of the interactions within the reel can be derived from the above descriptions of the components’ functions, certain interactions can be highlighted to render an overall explanation of how the reel works in a segmented display of the steps taken when fishing:

\'\'\'Interaction\'\'\' Before casting, a fisherman calibrates his drag control by turning the drag wheel to the right, which compresses a stack of material-alternating drag washers that rest on the same shaft as the drive gear. The drive gear translates the pressure generated by this to the spool, so that when the line tension becomes too high, the lubricated washers will ‘give’ as to prevent the breaking of the line or rod.
The fisherman casts the line by releasing the free-spool button. After hooking a fish, the fisherman turns the handle of the reel, turning the drive gear which in turn rotates the smaller gear and worm drive. The smaller gear engages the spool, which receives the line from the line guide. The line guide’s motion is caused by the worm drive.
The fisherman decreases the speed of the spool by adjusting the spool tensioner knob, which increases pressure on the spool. If the fisherman prefers to further prevent the chance of spool overrun, he will push the appropriate pins inward on the centrifugal braking system, which also increases pressure on the spool.
\'\'\'Components Involved\'\'\' a. Drag Control
b. Gear Assembly
a. Gear Assembly
b. Line Guide
c. Handle
d. Free-spool Button
a. Spool/Spool Control
b. Braking System
  • Sources cited on last page

Material Profile

Based on simple observation of the external aspect of the product, we figure that there are at least 3 different materials present:

1. The first thing we noticed was that the fishing reel is very light. Based on this, we assume that most of the metal pieces, especially the external ones, are made of aluminum:

― The frame and the right and left plates of the product

― The handle, which is used to retrieve the fishing line

― The start drag, located next to the handle

― The clutch lever and the side plate

― The worm drive and the spool assembly

2. The second material obviously present in our product is plastic. The parts made of plastic are the following:

― The grips on the handle assembly

― The level wind guard and the line guide, although the line guide has a small portion of metal used to contact the fishing line.

3. The last main material present in our product is steel. The parts probably made of steel are the following:

― Most of the screws used to assemble the parts together (although some might be made of aluminum)

― The gears located inside the product

― All the washers, springs, ball bearings and roller clutch

Other materials might be present inside our product. They could be other types of metallic materials. However, we will need to wait until we actually open the product to find out more about those materials.

User Interaction Profile

The main interface of the user with our product is the handle. This part of the reel is pretty intuitive to use. The main task is to “reel” the handle backwards to bring the fishes up to the surface.

The other main interface is the bail (or “pick up”) which is used to lock or unlock the fishing line in the fishing reel. This is what allows anglers to unlock the line so that they can cast it far away, and lock it so that they can “reel it” backwards to bring back fishes. This part of the product is a little more complicated to use and requires a minimum of knowledge and experience with fishing reels. With that being said, this device is not that complex and it gets quickly easier to handle with a minimum of practice.

With fishing reels, maintenance is delicate. Fishing reels require to be oiled frequently. Maintenance can also involve changing the fishing line. In any case, maintenance involves disassembling the product and opening it; a task which requires experience with fishing reels.

Product Alternative Profile

Alternative Types of Reels
Type Advantages Disadvantages Average Cost
\'\'\'Fly Reel\'\'\' •good for catching smaller fish
•not very good for catching larger fish
•earlier models had to use palming the reel methods to slow a fish
$30 - $750
\'\'\'Centre pin\'\'\' •drag free drifts (natural bait movements)
•palming the reel needed for drag
$30 - $200
\'\'\'Bait Casting\'\'\' •more accuracy than most other reels
•handle larger tackle and lures better
•powerful in casting and retrieving line
$20 - $500
\'\'\'Spinning\'\'\' •easy to use
•can use light line effectively
•easy to care for
•older models couldn’t handle heavier line
$20 - $500
\'\'\'Spin Cast\'\'\' •easy to use
•can catch most types of fish
$20 - $150
\'\'\'Underspin\'\'\' •easy to use (good for kids and beginners)
•intended for light line and smaller fish (can be used for larger fish as a challenge)
$15 - $40

When casting a fly reel, the rod is held in the dominant hand, and the line would be stripped off the reel and manipulated by the other hand. This is much different than a bait casting reel because the line would remain on the spool of the reel.

It is easier to adjust the line tension and drag with a spinning reel than with a bait casting reel. Overall, bait casting and spinning reels are very similar. The spin cast reel and underspin use a button to release the line.

Some people consider spin cast reels to be the beginner reels, and fisherman steadily “graduate” to spinning reels and eventually move on to bait casting. The difficulty levels and effectiveness of each reel is open to interpretation as all are very similar and recent improvements to all types put them on similar levels.