Gate 2 (group 8)
CAUSES FOR CORRECTIVE ACTION
Group eight’s final project is to dissect a Black and Decker Jigsaw, and so far the execution is going as planned. All five group members met on the weekend of the 16th of October and the product was disassembled. As planned, Chris Fernandes was the lead for the dissection and a Phillips head P2-418wpr screwdriver was used to complete the disassembly. As Chris took apart the Jigsaw, Pramit used a video camera to record the whole process while Ajmer, Agnelo and Seungkuk made further, individual observations. The Black and Decker Jigsaw was relatively simple to take apart and thus every member had the same perspective that the drill was easy to disassemble. In the end, every aspect of the disassembly was successful because each group member contributed equally to the completion of Gate 2. Teamwork is the key for these projects so once a group of individuals works as a collective unit, a project will be completed as planned. Also four of the five members of group eight are Juniors in the field of Mechanical Engineering, who all took Physics 108 and Electrical Engineering 202, so are well aware of how to dissect an electrical product.
The only challenge that lies ahead of group eight is that one of its members is not fluent in English language. This problem as already been addressed by having the rest of the members proof read that individual’s work. For the future Gates, group eight will continue to divide the project into equal portions in order to complete the required assignments.
The next time the group meets will be on the weekend of the 13th of November in order to complete the ‘Production Documentation and Analysis’ assignment, which is due on the 30th of November. This assignment would be split equally between all members with Chris Fernandes being the head of the CAD drawings. Ajmer Samaroo, who is the project leader, will continue to send emails to the group members about upcoming meetings. He is also the lead in proof reading and organizing the assignments before submission. If we come across any problems, Seungkuk will be the main person conducting research for solutions to problems mainly because he is very effective at it. The group will then meet the following weekend of the 20th of November in order to polish up this part of the assignment and discuss the tasks for the ‘Critical project Review’ assignment due on the 12th of December. Since our Jigsaw was broken from the start our main goal with the assembly is to get the product working again. Again all members will work collectively in trying to find a solution for this part of the assignment. The group will then meet on the weekend of the 4th of December in order to complete this and start on the ‘Final Report Submission and Oral Presentation’ assignment. At the end of this weekend, the group is hoping to completely finish the entire final project so all that would be needed is a review and submission. With this outline, and every member doing his portion of the assignment, group#8 will be very successful in completing the final project.
PRODUCT DISSECTION PLAN
The product js501g Jigsaw from Black and Decker has an outer plastic that acts as a casing for the inner motor and components as well as a grip for using the jigsaw. The casing is basically hard plastic molded into an elliptical shape that is held together with six metal screws. As the only other external part are the electrical cable and the base plate, which attaches to the body with the help of a single screw, it can be said that the product is intended to be taken apart easily from its external casing.
After opening the product it is noted that the internal components are more complex than the outer body as it has several different part, like the motor, several wires and gears that are interconnected to each other. The inner components were not screwed or attached to the outer body but neatly held in place by the several molded grooves of the outer casing. After careful study of these parts they were taken out of their grooves and properly separated. The various steps of the product disassembly are listed below along with their ease of disassembly:
|Step||Part Dissembled||Description||Ease of step|
|1||Metal base plate
|The base plate was attached to the
bottom of the outer plastic body with the metal screw.
The screw was easily taken off by hand
|2||Six metal screws||The outer body was held together with
six screws fastened deep into it.
A Phillips screw driver had to be used here.
The screws were tight and required a Phillips head screwdriver
|3||The outer body||After taking the screws off, the outer
body had to be opened carefully, as it
contained all the inner parts. The two
halves were separated by hand
|4||Plastic gears and trigger
|There were two plastic gears and a trigger
that were placed in the grooves of the body.
They were easily taken apart by hand.
|5||Electric motor and metal gears||The electric motor is the biggest internal
part and the most complicated to take
apart, it was attached firmly to the outer body and had many components such as
wires, metal gears, and an electromagnetic inducer
our group used a screw driver to
take it out of the casing and the gear was
separated from the axial rod.
|6||Metal blade clamp and
|A clamp is used to attach the blade to
the body. Our group used pliers to pull
the edges of the clamp and then took it
out by hand. The parts were tightly
attached and took time to understand
how to get them apart.
Our group measured the ease of product disassembly in the following manner-
Easy –The part did not take much time to disassemble and did not require any tool.
Difficult – The part may have required tool like screwdrivers but was very easy to understand the disassembly and took some time, about 10-15 minutes.
Extremely difficult-The part required several tools such as pliers and screwdrivers. The part was Difficult, complex, and had a lot of components. It also took time to study the part before it’s disassembly. About 15-20 minutes.
Pictures taken during disassembly
Figure 1- Fasteners, Base plate, Blade Support and Casing removed
Figure 2- Armature assembly with field assembly, Variable Speed Switch, Guard, Locking Gears, Shaft assembly removed from casing
Figure 3- Parts labeled
Jigsaw JS510G type 2 parts
|Reference #||Part #||Part Name||Description|
|1||583824-01||ARMATURE ASSY.||The motor and its components.|
|2||583820-02||FIELD ASSY.||Component providing power for the motor to rotate.|
|3||585794-00||SWITCH ASSY.||Control switch for moving the blade|
|4||487525-00||CLAMSHELL SET||Used as a housing for the motor and wiring inside.|
|5||582761-01||BRUSH & SPRING||Used to transmit power to Field Assembly.|
|6||582696-00||BRUSH BOX||Brush and spring Holder.|
|7||582585-00||THRUST PLATE||A component of the motor.|
|8||582586-00||COUNTERWEIGHT||Helps the ¼ inch plate keep the parts in place|
|9||583825-00||GEAR ASSY.||Attached to the rotor to help move the saw.|
|12||582768-00||GEAR ASSY.||Used for tightening the locking screw.|
|13||582596-00||SHOE ASSEMBLY||A plate for the user to push down on to keep the tool steady.|
|14||582594-00||BLADE SUPPORT||A support for the blade.|
|15||582600-00||LOCKING SCREW||Used to hold the shoe plate in place.|
|16||582603-00||GUARD||A safety feature for the blade.|
|17||582606-00||BUTTON, LOCK||A handy component to lock on speed of the blade.|
|18||582599-00||ELBOW||Shoe plate support.|
|20||583826-00||SHAFT ASSY.||Attached to motor for movement.|
|21||582593-00||BLADE CLAMP||Blade holder|
|22||583173-00||SCREW||Fastener for shaft assembly.|
|23||810893-00||BEARING,SLEEVE||Cylindrical shaped support.|
|24||770235-00||PROTECTOR,CORD||A support for the cord.|
|25||330073-98||CORD/8 FT/18-2||Electricity supply|
|26||583353-00||LEAD ASSY.||Power transmitter|
|27||583353-01||LEADWIRE ASSY.||Wire connection to field assembly.|
|28||370748-00||SCREW||Fastener used in switch component.|
|29||380414-00||CLAMP,CORD||Component for the switch.|
|30||582613-07||NAMEPLATE||Description of product.|
|31||809961-00||SCREW||Screws used to hold the two pieces of casing together|
|33||582697-00||LEAD||Wiring for the motor|
|34||582697-01||LEAD||Wiring for the motor|
|35||478314-00||GEL INSERT||Used for providing grip and comfort.|
|36||478317-00||BASEPLATE||Base support for the Gel insert.|
Photographs of individual components:
Photograph 1- armature assembly without Field assembly
Photograph 2- thrust plate
Photograph 3- Gear
Photograph 4- shaft assembly
Photograph 5- Casing
Photograph 6- base plate and blade support
Photograph 7- Fasteners
Photograph 8-Variable speed switch
Photograph 9- Locking gears
Photograph 10- Field assembly
The only fasteners used for this product are the Phillips P2 head screws in order to hold the product together.
All the components inside the product had their own fitting space on the inside of the casing.
There were seven screws altogether and no snap on locks were included unlike some of the other products/components.
No special tools are required for the process of dissection although we used pliers to pull out a small
metal piece which was tight fitted to the inside of the plastic covering. The main tool required for this
product dissection was the P2 screwdriver.