Gate 4: Product Reassembly

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Gate Overview

After dis-assembling the Daiwa Baitcast Reel (Right Hand Retrieve), and performing a complete thorough analysis of its internal workings, our next task remains to be the re-assembly of the reel. We also identified and described the main mechanism involved in the workings of the reel system and suggested three possible system level revisions for the reel. Lastly we also looked into our team management once more to evaluate its efficiency in working as a single entity.

Project Management

Evaluation of Group Management

During the previous Gate (Gate 3), our team encountered problems related to the planning of group meetings. The issue mainly came from a lack of communication between members of the group. Group meetings were scheduled with very poor notice and without the agreement of every member in the team. There was in the end no option to move those meeting and members were forced to miss them. To correct this, at the end of Gate 3 our group decided to focus on communication improvements. Therefore, it was decided that the scheduling of the meetings would be discussed with all members, and that meetings would be advertised with more than 3 or 4 days notice. Meetings were also made shorter and more efficient, and started to focus more on advancement-checks. Group members were therefore given more take-home tasks, helping the team to deal more easily with the incompatibly of our schedules. Group meetings were finally made more regular, with 2 or 3 one-hour-meet-ups a week.

In the end, those changes helped us improve the overall productivity and implication of the group members. Group members managed to attend meetings more often and with more focus. Their respective deadlines were more strictly met, due to the ease of dealing with take-home tasks.

Product Archeology


As was seen in Gate 2, the Daiwa Baitcast Reel (Right Hand Retrieve) was easy to disassemble. However, re-assembling the product required more caution. As the pieces are fairly small in size with the smallest having a diameter of less than 1 cm, it was rather difficult when putting them in place. Thus, it can be seen in the reassembly table that the average difficulty rating for each task is higher than when dis-assembling the product.

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.

Re-assembly Procedure

For the re-assembly procedure, refer to the following catalog for the piece index:

Catalog 2.png

Procedure for Re-assembly
Step Number Description Difficulty Rating Tools Required Pictures
1 • Place springs 25 and 29 into clutch cam (piece 26).
\'\'\'Caution:\'\'\' While holding the springs inside the clutch cam,
squeeze the springs so that they will also fit inside their designated wholes.
5 • Hand
2 • Slide in piece 28 between 26 and the frame. 5 • Hand
3 • Place piece 51 back onto the frame assembly. 2 • Hand
4 • Screw piece 27 back in to lock down piece 51.
• Screw piece 42 in to lock down clutch cam.
• Place gear 49 back onto the worm shaft and lock it down with the clip, piece 50.
• Place gear 52 as denoted by the picture and place the gear retainer (piece 53) on top of it.
• Then place piece 54 back on top of the gear and screw it down with screws 55.
3 • Phillips Head Screw Driver
5 • Now slide pieces onto the shaft (piece 56). Piece 57 goes on first.
There are 2 piece 58\'s and they will be placed on either side of anti-reverse ratchet (piece 59).

• Then slide 61, 62, 63, and 64 onto the shaft in that order
(piece 65 may still be located in piece 36; if not, slide 65 onto the shaft too).
3 • Hand
6 • Part 60 fits in the teeth of the ratchet (piece 59).
The hole of piece 60 fits on a raised area of plastic of the frame assembly.
• Place the yoke (piece 30) on the 2 cylindrical piece of plastic sticking out of the frame assembly.

• The yoke should be oriented so that the removed circular section of the yoke can fit around
the pinion gear (piece 33) as you slide the pinion gear onto the frame assembly.

• Piece 32 will fit into one of the holes of the yoke, then place springs 31 into the yoke\'s holes.
Pieces 34 and 35 should still be in 36, if not, place them on top of the pinion gear (piece 33).
3 • Hand
7 • Place piece 36, the right side plate on top.

• Screws 37 and 38 will now be screwed back into piece 36 to lock it down in place.
2 • Phillips Head Screw Driver
8 • Slide pieces 66-70 onto the plate in the order: 66-67-68-69-70(2). 4 • Hand
Unscrew 1.0.png
9 • The star drag can now be placed back on top. Gently screw the star drag (piece 71) back on.
Place pieces 72, 73, 74, and 75 back on at the same time, and screw piece 76 into the hole located
on piece 75.
2 • Phillips Head Screw Driver
10 • The O-ring may still be located on piece 36. If not, slide the O-ring, piece 39, and piece 40 back on.
Then screw cap 41 back onto the top.

\'\'\'Reassembly completed!\'\'\'
1 • Phillips Head Screw Driver




The Daiwa Baitcasting Reel uses a system of gears to translate rotational energy of the user’s hand, into kinetic energy of the spool.

When the user rotates the handle, this rotational energy is transmitted to the drive gear, which rotates the pinion gear. The pinion gear has a smaller radius than the drive gear, thus spinning much faster than the handle. The pinion gear is directly attached to the drum. The drum spins as fast as the pinion gear, and winds the line.

Two gears: A and B. N = number of teeth


Suggested System Revisions

1. Braking System Revision:

After dissecting and analyzing the inner workings of the reel, a feature that was an obvious candidate for design revision was the braking system, which is currently categorized as a ‘conventional magnetic’ braking system. The systems current interface is a knob on the side opposite the handle, consisting of several braking presets which are represented by numbers 1 – 10. The system utilizes magnetic forces between the magnets and the moving metal spool, in which the brake force is proportional to the spool speed. This specific system yields an ineffective braking process while the spool is rotating at low speeds. Our revision yields the conversion of the system to a ‘pitch centrifugal’ braking system. A centrifugal system enables the fisherman to customize the amount of tension produced by the system through a series of pins, which are usually oriented in a circular pattern. The pins can either be pushed into or remain out; while ‘in’, the pins push up against an internal brake ring. The pitch centrifugal system is actually a specific subset of centrifugal systems that consist of springs which forbid the pins from contacting the brake ring while the spool is rotating at low speeds. The standard setting for a centrifugal braking system consists of the pins alternating between ‘in’ and ‘out’ around the circular pattern.

2. Free-Spool Button Location:

The ‘Free-Spool’ button is currently mounted on the front of the reel, above the spool. This positioning requires the user to either stretch their thumb or use both hands in order to utilize this function. Our design revision proposes that the button be relocated to the side of the reel on which the handle is also located. While this revision does not alter the function of the system, it renders the button easier to reach while the reel is being used. Since the function of the ‘Free-Spool’ button is mostly required during the process of casting, this revision yields less errors committed by the user while casting. Since it is comprehensive that the process of casting is the most hazardous activity in which the user engages while fishing, the overall safety of the product is increased relative to the potential hazards of casting.

3. Twin Drag System:

The reel currently has a drag system consisting of different rings on one side of the spool. The star drag is twisted up and down, adding or releasing pressure on the drive gear. If a twin drag system were implemented, in which drag disks are located on both sides of the spool, the reel would be much more versatile. With the drag friction dispersed over two systems instead of one, the pressure would be kept more constant. Also, the reel would be able to handle larger fish, and longer fights.

Affecting GSEE Factors

\'\'\'Design Revision\GSEE Factor\'\'\' \'\'\'Societal\'\'\' \'\'\'Economical\'\'\' \'\'\'Environmental\'\'\' \'\'\'Global\'\'\'
\'\'\'Centrifugal Braking System\'\'\' Expands market to more advanced fishermen. Increased range of tension control, hence wider variety of fishing capabilities.
\'\'\'Free-Spool Button\'\'\' Decrease in casting mishaps will lead to a safer overall usage in the product’s life New location of button decreases the amount of required effort to utilize, thus allowing for a wider range of dexterity in the target market.
\'\'\'Twin Drag System\'\'\' Increased, and more balanced drag allows the reel to be used in more situations, and with bigger fish.