Gate 2: Dissection of the Reel

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Contents

Gate overview

In this gate, the overall purpose was the physical dissection of the Daiwa Baitcast Reel (Right Hand Retrieve). This was done so as to better understand the internal workings and mechanisms involved with the day-to-day usage of the reel, along with the identification of the internal subsystems. As we took apart the reel, the initial planning proposed in Gate 1 was revised and amendments were made where and when needed.

Revision and Assessment of Gate 1

As stated in Gate 1, the disassembly of the reel took no more than around 40 minutes, leaving aside the time needed for documentation of the dissection process. The only obstacle that we faced was the incomplete disassembly of the reel, namely, failure to access the internal braking system (which will be discussed with more depth later in this gate).

Temporary Group Management

As a new task was at hand, new roles were appointed for each group member for the duration of the dissection process:


\'\'\'Md. Fahad Hossain\'\'\' (Supervisor):

  • Supervised the dissection of the reel.
  • Performed the step-by-step initial draft documentation.


\'\'\'Paul Tabellion\'\'\' (Pictorial Documenter):

  • In charge of photo-documentation.
  • Took the necessary photographs, edited and labelled them.


\'\'\'Connor McCafferty\'\'\' (Dissection Engineer):

  • Selected the necessary tools and supplied them as well.
  • Lead the hands-on dissection of the reel.


\'\'\'Kevin Dailey\'\'\' (Assistant Dissection Engineer and Consultant):

  • Assisted Connor during the actual dissection.
  • Helped identify the subsystems and the internal mechanisms.


\'\'\'Mike Persic\'\'\' (Documenter and Part Identification):

  • Revised and edited the initial draft.
  • Created and maintained disassembly sheet and held on to the dissected parts for future re-assembly.

Other Complications

Due to the higher work load required by this gate, a new weekly meeting was introduced: \'\'\'Every Sunday, noon, Capen Ground Floor\'\'\' so that we may complete the gate by the given deadline. As no individual in the group had any prior knowledge or experience regrading wiki editing, group leader, Fahad, took it upon himself to make the necessary appointments with the Teaching Assistant for the course and acquire the necessary skills for wiki editing and will henceforth, be in charge with the updating of the group wiki page. Although, no true even distribution was possible, every attempt was made to keep the work load equal for each member of the group.

Product Dissection

Difficulty

The difficulty of performing each step was decided by the amount of caution needed to undertake that task. This is because the disassembly does not require much plain force rather, it is the presence of numerous small parts that poses real difficulty. Keeping track of the individual parts is very important for which we used the labeling sheet.


Catalog Sheet.png


The difficulty rating ( 1 - 5 ) was decided upon by the amount of tools, time, and caution required by each step:

  • 1 being the easiest-where little tools and caution was required.
  • 5 being the hardest-which required much caution, and tools.

Dissection Procedure

For the dissection procedure, refer to the following catalog for the piece index.


Catalog 2.png


Procedure for Disassembly
Step Number Description Difficulty Rating Tools Required Pictures
1 • Take your reel.
Reel
2 • Unscrew screw number 76.
• Remove the cap (piece 75)
1 • Phillips Head Screw Driver
3 • Unscrew piece 74. 3 • Socket Wrench
4 • Then slide the handle out (piece 73).
\'\'\'Caution:\'\'\' There is a washer attached (piece 72).
2
Slide Out Handle
5 • Gently unscrew star drag wheel (piece 71).
• Take apart pieces 66-70 which lie directly under the star drag (piece 71).
\'\'\'Use Caution\'\'\' when taking these pieces off as there are several very small pieces involved.
• Then firmly unscrew piece 41 which is the cap still visible on piece 36.
• Unscrew the screws 37 and 38 using a Phillips head screw driver which can be seen on the picture to the left denoted by black arrows.
4 • Phillips Head Screw Driver
Unscrew Star Drag Wheel
6 • Pull apart the outer casing (part 36) and keep aside.
1
Remove Casing
7 • Gently slide off these pieces from the shaft (piece 56).
The pieces come off in the following order
(\'\'\'Use Caution\'\'\' as they are small and stuck together due to lubrication):
64 (Outer)
63 (Out)
62 (Out)
61 (Outermost Gear) 58 (Inside)
59(Middle gear)
58 (Inside)
57 (Innermost Gear)
3
Shaft 1.1

Shaft 1.2
8 • Part 60 was removed after Step 7.
• Piece 33 is located on the picture to the right as denoted by the red arrow, and is a cylindrical piece of metal.
\'\'\'Use Caution\'\'\' as pieces 34 and 35 lie on top of it,
while the yoke (piece 30) is attached to the bottom of piece 33 and holds 2 springs and a small washer (pieces 31 and 32).
4
Shaft 1.3
9 • Gently pull out the longer shaft system, which includes (Pieces 53-54-56-57) in order.
• Unscrew the 2 screws in piece 54 (pieces 55).
• Then put aside the small bearing (piece 52).
• Pry off clip 50 using flat head screw driver.
• Underneath it is a larger plastic gear (piece 49) that will come off easily after piece 50 is removed.
• Unscrew piece 42 denoted by a yellow arrow.
\'\'\'NOTE:\'\'\' The screw is longer than the other average screws unscrewed before.
3
Shaft 2.1
10 • Part 51 easily comes off. 1
Remove Handle
11 • Unscrew screw 27.
• Parts 19, 26 and 28 just fall out along with the two side springs 25 and spring 29 (smaller).
\'\'\'NOTE:\'\'\' Putting these pieces back into their place is very difficult.
2
11.1

11.2
12 • [Switch to the other side. Take a dime and unscrew piece 1.]
\'\'\'Caution:\'\'\' The remainder of this side is not meant to be disassembled as this will damage the reel, making it unusable in the future.

\'\'\'Any further dissection is no longer possible without damaging the reel.\'\'\'
1
Piece 1


Dissection Assessment

Is The Reel Meant To Be Disassembled?

The reel is clearly meant to be disassembled as the tools required were household items. The outer casing and inner case layers were held together by simple screws which can be easily removed by using an average philips-head screw driver. The inner gears and subsystems were kept together by nothing more than simple, semi-adhesive lubricating oil. All of this clearly indicates and points to one conclusion: The maintenance of the reel does not require any special skills, rather it is meant to be maintained by an average user, regardless of prior experience with even day-to-day household tools.

However, the internal braking system was inaccessible without permanently damaging the product. This part of the reel was clearly not meant to be disassembled. Given the fact that the reel used in our dissection was one of the relatively cheaper models available, it has restrictions to the number of parts that are accessible. A more expensive model would allow further dissection for complete maintenance and customization. Thus, we can conclude that most generic reels are meant to be disassembled only to a point, for general maintenance.

Subsystems and Function Chart

Function Chart.png


The subsystems associated with the reel are generally synonymous with the different groups of parts that make up its individual ‘essential components’. In other words, they are components of the reel that are trivially seen as ones which possess their own function. Assuming each of the eight previously mentioned components to be subsystems of the reel, it seems reasonable to associate each subsystem with the phases of the functional energy model. The following table displays the relations between the subsystems and the model:


\'\'\'Subsystem/Phase\'\'\' 1 2 3
\'\'\'Handle\'\'\' Receives shaft work produced by hand and translates it into kinetic energy.
\'\'\'Drag\'\'\' The predetermined magnitude of drag applies variant frictional force to the rotation of the shaft,
either increasing or decreasing the rotational velocity, and thus kinetic energy (KE=m(V^2)/2)
\'\'\'Gear Assembly\'\'\' Harnesses the kinetic energy according to its gear ratio (7.1:1) and engages spool in rotation. As the line is accelerating around the spool, the drive gear dictates the lines distribution speed through the worm gear.
\'\'\'Spool\'\'\' Engaged in rotational motion due to gear assembly. The cylindrically shaped component rotates and provides a means for a net tension in the line.
\'\'\'Line-guide\'\'\' Motion caused by the worm gear. Distributes the line in an even harmonic pattern as line is being retrieved.
\'\'\'Brakes\'\'\' The magnetic braking system applies additional friction in the direction opposite that of the spools motion.
\'\'\'Free-spool Button\'\'\' This ‘release’ button relieves the line of any tension so that it may be cast by a fisherman when ready.
\'\'\'Frame\'\'\' Acts as a sort of foundation such that the other components are attached in place and are only allowed certain degrees of freedom.


Four Factors

Global

  • Most gears within the reel are plastic or alloys so as to minimize any effects of rusting.
  • The gear system is contained within a housing, so no debris will jam the system.
  • Pieces are coated with lubricating oil, which minimizes friction and rusting.

Societal

  • The handle of the reel is meant to be as ergonomic as possible, making the reel comfortable to use for a long time.
  • The parts within the reel that would be subjected to the most strain/stress during average use were made of strong metallic alloys. Examples include: frame, handle, shafts, and internal breaking system.

Economic

  • Most parts in the reel were made of injection-molded plastic, making the overall cost of the reel relatively cheap.
  • The reel was easy to access with household tools; therefore broken parts can be replaced without throwing the whole reel away.