Gate 1 - Group 4

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Contents

Gate 1: Project Planning

Purpose

The main purpose of this gate is to establish a planning stage. All the work we do here is before any product dissection actually takes place. The key points targeted are the work proposal, management proposal, and initial assessment.

DeWalt 1/2 in Hammerdrill (Corded)

Product Management: Request for Proposal

Work Proposal

The drill will be disassembled in an organized matter. Each part removed will be bagged and numbered. All parts will be recorded with their corresponding number and the parts function. After any major part removal (ex. drill housing) a picture will be taken to help aid in future reassembly. Each picture will also have parts clearly numbered. The group will make our own exploded view drawing of the drill. The group does not believe there will be any challenges faced during the dis-assembly and reassembly of this product due to its fairly simple complexity.

Based on initial observation of the drill, our group is expecting many complex components inside the drill including:

  • Motor
  • Gearbox
  • Anvil hammering mechanism
  • Trigger system
  • Shafts
  • Switches
  • Ball bearings

Tools Required

  • Philips and Flathead Screwdriver's
  • Allen Wrench (1/8",1/4")
  • Knife

Time Required

  • 2 hours

Group Capabilities

  • Mechanically inclined
  • Extensive CAD experience with programs such as AutoCAD, Solidworks, NX, and Autodesk Inventor
  • Computer literate
  • Some electrical experience

Group Shortcomings

  • No previous Wiki or technical communication experience
  • With only some electrical experience it may be hard to understand all of the drill's electrical components
  • Conflicting schedules in and outside of UB

Skills To Be Developed

  • Skills making Wiki pages
  • Skills communicating and working in a group
  • Skills using basic hand tools

Management Proposal

Meetings

We plan to manage our work by meeting twice a week on Mondays and Fridays in Knox lecture hall at 3:30 pm. During these meetings, group members will communicate which parts of the gates and which parts of the Wiki page they will be completing. Most of the work on the Wiki will be done by the group members on their own time. However during meetings, if a group member is confused or needs help on their part of the Wiki, other group members will assist them with their question. Group meeting time will also be used to schedule our time in order to make sure deadlines are met. A separate meeting time must be scheduled in order to dissect the drill.

Group Member Contact Info Title Responsibilities and Tasks
Joshua Kasprzyk joshuaka@buffalo.edu Project Manager, Documenter Responsible for keeping the project on track and delegating tasks that need to be completed. Also has the authority to make final decisions to resolve any conflicts. Responsible for a fair share of the wiki page.
Josh Gonas joshgona@buffalo.edu Communication Liaison, Documenter Responsible for contacting group members with details on meeting times and locations. Also in charge of recording each step of the dis-assembly. Responsible for a fair share of wiki page.
Justin Hromowyk justinhr@buffalo.edu Technical Expert, CAD Lead dis-assembler, In charge of all technical drawings and diagrams. Responsible for fair share of wiki page.
Peter Fornasiero peterfor@buffalo.edu Technical Expert, Documenter, CAD Responsible for aiding in the dis-assembly of the drill and creating technical drawings and diagrams to help layout all of the parts. Also in charge of taking pictures at all major part removals. Responsible for fair share of wiki page.

Conflicts

In the case of a meeting conflict due to an exam or some extenuating circumstance, the project manager Josh Kaspryzk will decide a new time and place to meet. This will then be sent via text message by the communication liaison Josh Gonas to make sure that all group members are aware of the change.In the event of an argument or confrontation the project manager will make a decision for the better of the group. If the project manager is involved in said argument or confrontation the group members will meet and vote on the best decision for the group.

Product Archaeology: Preparation and Initial Assessment

Development Profile

  • The specific DeWALT DW511 Hammerdrill we chose for dissection was manufactured in 2011. However, its original copyright date was established in 2008. DeWALT is a company whose domain lies in the United States, and therefore bases its safety requirements on American standards.
  • This product was certainly designed to be consumer-friendly. Provided with a 360° rotatable/removable handle, it's built for stability and versatility. It's overall light weight (3.85 pounds) provides for extended use and less user fatigue. This hammerdrill's comfortable grip handle shows ergonomical consideration with its rubber material. Also, its relatively low, economy-friendly price offers a great opportunity for the average private consumer to purchase a hammerdrill. DeWALT offers a 3-year limited warranty for the DW511, expecting there to potentially be required maintenance throughout the product's life cycle. The length of life cycle will depend on how much use the product sees, and the environmental conditions surrounding it (e.g. temperature, moisture, cleanliness, etc.)
  • The DW511 can be purchased online from DeWALT's website, or typical hardware stores such as Lowes, Home Depot, or Sears.

Reference: http://dewalt.com/tools/hammerdrills--hammers-hammerdrills-dw511.aspx

Usage Profile

Example of a hammerdrill in use
  • What is a hammerdrill and what can this product do for the consumer? As its name suggests, this tool is a rotary hand drill which performs with a hammering action. Often times while trying to drill a hole through a rather hard and dense material, there is not enough force from the operator's hands alone to break the surface. The hammerdrill provides short rapid bursts of hammering force to help push the screw into the material while simultaneously drilling it in. This results in quicker drilling with less effort. Once the tougher material has been penetrated and the hammering motion is no longer needed, a simple switch on top of the drill allows for a quick change between a hammerdrill and plain drill setting.
  • The DeWALT DW511 is mostly intended for private consumer home use. Although it could be used for professional work, its design quality was not specifically targeted towards large-scale production factories. Its ergonomic and economic design provide a satisfactory level performance for home projects and side jobs, but would face alot of 'wear and tear' in commercial use, requiring more frequent maintenance.

Reference:http://www.ehow.com/facts_5946664_rotary-hammer-drill-information.html


Energy Profile

Power cord and trigger system
  • The DeWalt DW 511 that we chose for dissection and analysis requires electrical, human and rotational energy for operation. Energy is imported into the drill by the cord being plugged into the wall outlet.The drill must be plugged in to operate since this model does not include a rechargeable battery. In order for the drill to work, the user must use mechanical energy by squeezing the trigger to complete the electric circuit and power the system. Once this happens, electricity is allowed to flow from the outlet in the wall, through the cord and into the components of the drill. The electric energy is converted into rotational energy which causes the bit of the drill to spin.

Reference: http://dewalt.com/tool-categories/Hammers-and-Hammer-Drills.aspx



Complexity Profile

  • From the outside of the DeWalt DW 511, the key components that can be seen are the drills casing, a trigger, chuck, the power cord and 3 switches. On the inside of the hammer drill, we have estimated there to be many other components including a motor, shaft, wiring, gearbox, and an anvil hammering system. In order for the drill to work, the user must insert a drill bit into the drill bit holder and pull the trigger. When this happens, electricity then flows from the wall outlet through the power cord and to the motor. The motor then uses the electricity to spin the shaft which is connected to the drill bit holder and bit. When the user flips the reverse switch, the transmission inside the drill switches into reverse. The clutch switches the gear in the gearbox into the opposite direction.
Complexity Scale
Complexity Level Complexity Description
1 The component or interaction is simple, consisting of one part or one interaction connection.
2 The component or interaction is basic, consisting of a couple parts, or a couple interaction connections.
3 The component or interaction is complex, consisting of a few parts or a few interaction connections.
4 The component or interaction is very complex, consisting of multiple parts or multiple interaction connections.
Product Components
Assumed Component Component Complexity Level Connection Interaction Complexity Level
Drill Casing 2 - The casing has an intricate shape. 1 - The casing surrounds the overall components of the system.
Trigger 3 - Several parts connect to make up a trigger system. 2 - The trigger connects to the power cord by a couple wires.
Chuck 4 - A large number of parts consist within the chuck. 2 - Shafts between the chuck and gearbox connect to rotate the drill bit.
Switches 3 - Several parts make up the overall switch mechanism. 2 - The switches connect to the trigger by a couple wires.
Power Cord 2 - The power cord consists of a couple wires. 2 - The power cord connects to the trigger system by a couple wires.
Motor 4 - A large number of parts consist within the motor. 4 - A couple wires connect to the motor to convert electrical energy, outputting it into a rotating shaft connected to the gearbox.
Shaft 1 - The shafts are one solid piece. 2 - The shafts in the system connect to the gears and subsequent subsystems.
Wiring 2 - The wiring consists of a couple wiring usually for positive and negative terminals. 2 - The wiring connects to positive and negative terminals in the trigger and motor.
Gearbox 3 - The gearbox consists of several gears and shafts. 2 - The gearbox connects to the motor and chuck by shafts.
Anvil hammering system 3 - The anvil must consist of several parts. 4 - The anvil is connected to the motor and the chuck by shafts and other components.

Material Profile

From this photo, you can clearly see the materials present on the exterior of the drill
  • The housing of the drill is made of mostly plastic. There is rubber around the handle to help it from slipping from your hand. The drill bit holder is made of all metal. Due to the components our group believes to be housed inside the drill, it is safe to say that the materials on the inside of drill would be steel for the motor, shafts and gears, copper in wires, and plastic for various parts due to their functions and strengths required. However, we can only speculate on what materials are in fact on the inside of the drill.

Reference: http://www.ehow.com/facts_5946664_​rotary-hammer-drill-information.html




User Interaction Profile

  • User Interface:
    Example of a hammerdrill in use
    • The user interacts with the hammer drill, by lining up the drill bit in the desired location where they want the hole, and then by pressing on the trigger and the switch for the hammering motion the hole is drilled with little force. There is also a removable handle included with the drill that can be used to give the user added stability.





  • Intuition:
    Hammer drill with handle attached for extra stability
    • Overall the interface is very intuitive, by inspection the user can easily see that the trigger is used to spin the drill, while the switch is used for the hammering motion and the forward/reverse settings. The drill also comes with a specialized tool to switch out drill bits for different hole shapes.





  • Difficulty:
    • This model hammer drill is quite simple to use. The specialized tool makes it easy to switch out the drill bits and lock them into place quickly. Since it is corded as well, there is no time wasted charging batteries like other models. In order to operate the drill, the user must simply plug the cord into the wall and squeeze the trigger to get the drill to run.
DeWalt 1/2 in Hammerdrill bit changing tool





  • Maintenance:
    • Besides switching out drill bits depending on what the user is trying to do, there is not much maintenance required for this tool other than cleaning off any excess material left on the drill and the bits from drilling.

Reference: http://www.Dewalt.com

Product Alternative Profile

Overall alternative drills get the same job done in terms of drilling holes, but the hammerdrill allows for less force required by the user due to the hammering motion. Other household power drills do not have this motion so they require more force. Where drill presses do not require nearly any force at all, they are not mobile; the items to be drilled must be placed on the press. Hand drills do not require electricity, but as a result the drilling is completely done by the user which is hard work.

Alternates

Power Drills
Cordless Power Drill
  • Advantages:
    • If corded, no battery charging dock is required.
    • If cordless, they are more mobile than the corded drills as extension cords and outlets are not required.
    • They are compact.
    • Bits are easy and quick to change.
  • Disadvantages:
    • If corded, extension cords or close outlets may be required depending on where the work is being done.
    • If cordless, the battery will have to be charged often which is time consuming.
    • They require a decent amount of force to drill since there is no hammering motion.
Drill Presses
Drill Press
  • Advantages:
    • They are very durable.
    • The drill bits are simple to change out.
    • They are great for drilling holes into individual parts and pieces.
    • They require barely any force by the user to drill the holes.
    • Very accurate placement and straight holes can be drilled since the press uses a downwards motion (easy to line up the piece).
  • Disadvantages:
    • They are not mobile or compact.
    • They can only drill holes into materials that can be removed and placed on the press.
Hand Drills
Aged Hand Drill
  • Advantages:
    • They are small and compact.
    • Drill bits are easy enough to exchange.
    • No electricity or battery is required.
  • Disadvantages:
    • A large force is required by the user to drill the holes.
    • They are not as accurate since the user must spin the handle to drill; this movement may shake the piece or the drill itself, moving the focal point.

Average Costs

  • Power Drills ~ $30-$250
  • Drill Presses ~ $80-$800
  • Hand Drills ~ $10-$50
  • Hammerdrills ~ $60-$350

Reference: http://www.Amazon.com