Group 6 - Black and Decker Power Drill - Gate 1

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Work Proposal

Disassembly Procedure:

1. Unscrew the front section of the drill by removing the screws that hold it in place.
2. Remove the top half of the drill.
3. Lift inner components our of the drill housing.
4. Remove any screws on the inside of the drill.
5. Separate by hand, any of the remaining inner components, including the motor.

Tools Required:

We will need the following tools to disassemble the Black & Decker DR202:
  • Flat head screwdriver
  • Phillips screwdriver
  • Star screwdriver bits
We believe that the entire dissection process should take no longer than one hour to complete. However, with proper documentation, this process will take closer to two to three hours. The documentation process will include photographs, sketches, and 3D models of the inner components.

Potential Challenges:

Based on the initial inspection of the Black & Decker DR202 power drill there are a few challenges we feel we might face during disassembly. Since the main tools we are using to dissect our product are screwdrivers there is a chance that the screw heads may be stripped and become useless. In addition, it will be challenging to reassemble the inner components of the drill. It is necessary that they fit snuggly together so that the drill works efficiently. Since there are a several small components within the drill it will be necessary to properly document during the disassembly process to ensure that the parts are replaced in the proper location.

Group Abilities:

Our group has discussed its abilities as a group and as individuals and feel quite confident in our general set of skills. We do, however, realize that some members are more qualified than others when it comes to certain responsibilities. Table 1 summarizes the abilities of our group members.
Table 1 Group Member Abilities
Skill Laura Sarah Eric Tim Adam
Technical Writing X X
Management X X X X X
Software X X X X X
Presentation X X X X
Labor X X X X

Laura Ziegler

Skills: Laura has a great deal of leadership experience. She is very diligent and always completes tasks in a timely fashion. She is also good at technical writing and public speaking. She does not, however, have as much experience with manual labor. The knowledge and abilities of the other group members can help her improve this skill.

Sarah Griebner

Skills: Sarah is also a strong leader and skilled in technical writing. She will assure everyone does their share of the project. Compared to the other group members, Sarah is not as confident with her public speaking abilities. As a result of this, Sarah will most likely not be chosen to present for our group since only two people are required to present.

Eric Barone

Skills: Eric has a good deal of experience with computer programming. He can quickly pick up different programming languages. While Eric has already learned the basic formatting for the Wiki page, he still needs to further develop his skills so he can format more advanced tables and add videos. He is also good at presenting information in a professional manner and will most likely answer questions during our presentation at the conclusion of the project. He is not, however, as good with technical writing as the other group members.

Tim Osborne

Skills: Tim's main strength is with the manual labor portion of the project. He is very interested in disassembling and reassembling the drill. His knowledge of how the different components interact will aid in the dissection process. Tim needs to further develop his technical writing skills. This can be achieved through practice, and by having the other group members proof read and offer suggestions for improvement.

Adam Tschinkel

Skills: Adam is also highly skilled in the disassembly of products. His knowledge will be quite useful in this portion of the project. He also has a strong background in CAD software, and is willing to learn the solid modeling program. This will, however, take time to learn the program and will involve an understanding of component geometry. Adam also needs to advance his technical writing skills which can again be improved with practice.

Based on this information we are able to assign certain tasks to the team member that we feel would do the best job.

Management Proposal

Project Timeline
Chart 1 Project Timeline

The project is broken up into five separate gates. Each gate comprises a series of subtasks that must be completed within each gate window. Chart 1 is our project timeline that shows the breakdown of all the tasks. For each gate, several tasks must be in progress at the same time in order to ensure that they are completed in a timely fashion.

Based on the skill set of our group members we collectively decided to assign the positions as followed to ensure optimal group functionality.

Laura: leader, compiler
Sarah: documentation, compiler
Eric: dissection/reassembly, wiki-master
Adam: dissection/reassembly (main)
Tim: dissection/reassembly (main)

All group members will potentially take part in the dissection and assembly but the three listed will be the main dissectors

Group Member Responsibilities

Leader: As the leader Laura will make sure tasks are done efficiently and on time. This will require constant communication with all group members to ensure that work is being completed. In addition it will be necessary for her to check the group email to monitor group progress.
Documenter: As the main documenter and compiler, Sarah will have the following responsibilities. She will act as a photographer and take a high quality photo of each part. She will also be in charge of sketching individual components when deemed necessary. Sarah will also act as a recorder and document all the data and part information found during dissection.
Dissector: Tim and Adam will be in charge of the removal of screws, disassembly of gears and motor box, and all other components. They will also be in charge of reassembly and are responsible for putting the drill back together in the way that it was originally.
Compilers: Sarah and Laura will be the compilers for this group project. They will take all of the parts of the assignments and information found and put it into a technical report. They will ensure that the information is presented in a professional manner. It will be necessary to compile the report in a timely fashion so that Eric has sufficient time to create the wiki page.
Wiki Developer: Eric will be in charge of updating the wiki page. He will take all of the information compiled by Sarah and Laura and format it properly.

Meeting Plan:

Our group plans to meet every Thursday at 3:30 PM to 5:30 PM with tentative meetings on Tuesdays at 5:00 PM to 7:00 PM in the Lockwood Library or in Ellicott (main dissection area). We plan to use these meetings as general meetings to keep everyone informed and on track with their assignment. During these meetings we will discuss the project, determine the action items, develop a clear understanding on the state of the project, and leave making sure everyone knows their responsibilities. While we plan to have group meetings once or twice a week, additional work must be done individually outside of this dedicated work time. As a group, we have decided that only a majority of the group members need to be present for decisions to be made effectively. We feel like our group leader, Laura, should be present whenever decisions are made along with any two group members.


Main Contact for Group 6: Laura Ziegler
For communication, we have decided to set up a gmail account that every group member had access to: We have exchanged phone numbers, but due to the absence of a group member's cell phone we are also relying heavily on email and in-person communication before or after classes together.

Conflict Resolution:

As with all projects, we know there is the potential for conflicts. We plan on dealing with these by discussing it openly as a group. Since we have an odd number, if a vote needs to occur we can do so and reach a resolution. Any major conflicts we plan on going to the instructor about. If a group member is not doing their work, they will be informed and if they continue to slack off without a reasonable, proper excuse then the instructor will be informed so that person does not unfairly get credit where credit is not due.

Product Archaeology: Preparation and Initial Assessment

Development Profile

The Black and Decker DR202 Type 2 was designed with the intention of providing the consumer with a durable, hardworking, cost friendly power drill. Made by Black and Decker Inc. in China the DR202 was designed to first be available for purchase worldwide in late 2007, excluding Third World countries. Any industrialized country, including the United States, China, Japan and other European countries would have a market for household power drills. The electrical cord would have to be modified to fit the appropriate electrical outlets. Utilizing a 5 amp motor capable of producing 150 in/lbs of torque, a soft grip handle, keyless chuck, and variable/reversible speed, the DR202 is the perfect drill for the everyday ‘do-it-yourselfer’ [1]. The DR202 corded power drill was to be sold at the retail price of approximately $40 [4] and is capable of performing moderate drill and driving tasks through an array of materials [1]. During the product's development cheaper materials such as plastic and steel were chosen to keep the cost of the drill to a minimum. This would allow Black & Decker to sell the drill to a wider audience. Global concerns were also considered during the design process for the drill. The interfaces on the drill were designed to make the drill easy to use. Universal symbols such as arrows near the reverse lever were used to prevent a language barrier from developing. Together these characteristics show us why the Black and Decker DR202 was a great selection for an inexpensive corded power drill in a competitive marketplace.

Usage Profile

The Black and Decker DR202 drill is intended to be a fast and easy way to drill holes or screw in screws in wood and some metals. This is done by putting drill bits into the chuck and proceeding to drill a hole or fasten in a screw. The drill can also be set in a reverse rotation making it possible to take out screws. It can be used to help make hundreds of different things. The drill has the capability to help make tables, chairs, and even homes. The drill also has as a level which is commonly used around the house to level picture frames, shelves, etc. A bit holder on the top of the drill allows easy access to frequently used drill bits. The drill was made for home use [2]. It can be used as a level and a bit holder which makes it ideal for homeowners. It is a multipurpose tool which many homeowners look for in their power tools. The drill is a quality tool that is also inexpensive. The drill is only 5 volts which is big enough for home use, but not suitable for commercial use.

Energy Profile

Kinetic, magnetic, rotational mechanical, electrical, and human energy are all used in the drill. The drill requires electrical energy to make the motor move which is imported through the electrical cord via the electrical outlet. The drill must be plugged into an outlet for the drill to work since our drill does not include a rechargeable battery. This electrical energy is then converted into magnetic energy because of the current that is flowing through the wires in the field. The current in the armature opposes the current in the field, causing the armature to rotate. This completes the transformation of magnetic energy into rotational kinetic energy. Once the armature starts rotating it turns the gears which ultimately rotates the drill bit. Human energy is also inputted into the drill, allowing for the transformation of energy to begin. Plugging in the drill, pulling the trigger, and keeping the drill level all require human energy. When the trigger is pulled, the electrical circuit is completed. This allows the electricity to flow from the outlet to the field which initiates the energy transformation process from electrical to rotational mechanical energy of the bit.

Complexity Profile

Though the drill has only about ten visual components, there are many more components inside the machine. Besides the ten components outside the drill, our group estimated that there are about twenty components inside the drill, making the total number of components about thirty. The complexity of the individual components ranges from simple to moderately complex. For example, the trigger is just a solid piece of plastic that looks like it was molded very easily using injection molding. The bit holder on top of the drill is also a simple component of the drill made through the same manufacturing process. Some of the more complex components include the drill housing and the electric motor because of the way they had to be produced. The housing was made by injection molding, but is composed of two different materials. The housing has many grooves and holes in it to cool the drill and give it aesthetic appeal, which takes longer to make and increases the amount of money that is used to make the mold. The motor is also complex because the copper wire has to be run around an independent magnet to make the rotation possible. These copper wires are manufactured during a shaping and forming process called drawing. The component interactions are simple to moderately complex as well. The trigger system and the transmission switch (the switch between forward and reverse) would be examples of simple component interactions. The trigger just closes a circuit in the drill that lets current flow to the motor to make it rotate. The transmission switch reverses the current flow so the rotation will switch. In these interactions only one form of energy is used. The trigger and reversal switch use only human energy. A more complex component interaction involves the transformation of energy from one form to another. An example for the DR202 is the entire motor and gear system. The motor drives the rotor shaft, which turns a gear system to make the bit rotate. This involves the transformation of electrical to magnetic to rotational energy. The gear system has to be in the right ratio to output a sufficient amount of torque to the screw.

Material Profile

The drill housing is made out of plastic and rubberized parts for the handle. Most of the outside components are made of metal, besides the bit holder, which is made of stainless steel. The wires are made out of copper. Without looking on the inside, the materials are most likely made mostly out of steel, copper, and plastic. The gears are made of steel and the fan is made out of plastic. Most of the other inside components are made of steel, including the gears and the rotor shaft.

User Interaction Profile

This powered hand drill was certainly designed with the consumer in mind. A series of unique capabilities allow the user to have more control and expend less energy. In order to operate the drill, the user must simply pull the trigger and then apply a force to the screw they wish to remove or insert. This trigger is easy to pull and is located in its traditional spot on the handle. For screw removal the user must set the drill forward/reverse switch to reverse. For all other functions, this switch is set to forward [9]. The fact that this drill makes use of a double gear reduction, results in a greater torque applied to the screw. This means that less energy is required on behalf of the user. The handle of the drill is also molded in such a way that enhances comfort and allows for a more natural grip. This helps to reduce stress on the user during more demanding projects. In addition to these features, a variable speed option gives the consumer greater control and flexibility, adding to the ease of use. Other interfaces on the drill were designed in such a way to facilitate the drilling process. A keyless chuck allows the user to change the drill bits easily and efficiently by simply rotating the chuck counterclockwise to loosen, or clockwise to tighten. The hassle of using a key is no longer an issue. The arrows on the tool head also line up with the arrows on the drill when the tool is aligned properly. When inserted completely, the user will hear a click. In addition, a compartment is conveniently located on the top of the drill for bit storage. This means that a drill bit is always at hand. A bubble level located on the upper back side of the drill can be used to ensure that a screw is being inserted level. Arrows are also located on the drill casing by the reverse switch. The use of symbols on the drill makes the interfaces easy to understand. It also eliminates any language barrier that could be generated through words as interfaces. Since the drill is mainly used for simple household projects, major wear is not expected. Regular maintenance is, therefore, not required. Only when a component inside the drill breaks should the drill be opened. These parts can be easily replaced using parts on the Black & Decker website. If there are any breakages or binding of parts, however, it is recommended that the drill be serviced by a professional or someone with experience to avoid injury [2]. Black & Decker offers product warranties on its drills as well, which increases the trust of its buyers.

Product Alternative Profile

Table 2 Product Alternatives
Screwdriver Power Screwdriver Power Drill
Craftsman 8 pc. Screwdriver Set Black & Decker LI3100 3.6V Lithium-Ion CompactFit Screwdriver DeWalt DW222 3/8" (10mm) VSR Drill with Keyless Chuck
Craftsman 11779 7.2-volt Ni-Cd Cordless Screwdriver with Bit Set Black & Decker 5.2 Amp 3/8" VSR Drill/Driver Model # DR250B

Advantages and Disadvantages

The Black & Decker DR202 comes with a screw bit. Therefore, the screwdriver set is the most basic tool you can derive from the DR202 drill. Screwdrivers have the ability to fit into tight areas that are not accessible with a power drill. In the Craftsman 8 pc. Screwdriver Set, the different size options allow users to have whatever screwdriver is needed for the job readily available [6]. However, screwdrivers also require a lot more hard work because all the torque comes from the arm rather than the motor. So, even though they are a staple in toolboxes, they simply do not compare to a power drill.
Power screwdrivers make regular tasks very simple and painless. The compact design of the Black & Decker LI3100 3.6V Lithium-Ion CompactFit Screwdriver allows it to fit into smaller spaces while still providing more power than a regular screwdriver can produce. Another advantage to this product is that the Lithium-Ion battery stays charged for up to 18 months, leaving more time for usage and less time for hassling with a charger or a cord. It also contains a work light, allowing users to see in tight, dark spaces. However, it is still only a power screwdriver, not a drill [3]. The drill, although it does not come with the necessary tools, can drill holes, while the screwdrivers cannot. Another power screwdriver, the Craftsman 11779 7.2-volt Ni-Cd Cordless Screwdriver, comes with more accessories, which makes it a widely popular power tool. A unique advantage of the Craftsman screwdriver is that it can lock so that it can be used as a manual screwdriver, no matter what the battery level. It has three different locking positions so the user can achieve maximum comfort and control. As with the compact screwdriver, the worklight illuminates dark areas to allow for more efficient work. A very important advantage to this particular power screwdriver is that it has 24 torque settings, which allows for maximum control and efficiency to accomplish the job as quickly as possible. One disadvantage to the Craftsman screwdriver is that it weighs 3.15 lb, which is heavier than the Black & Decker screwdriver. However, it is lighter than the power drill. Since it is only a power screwdriver though, it does not have nearly the same capabilities as the Black & Decker DR202 [5].
Power drills are very handy household tools to own. They can fasten objects with screws or drill holes in a wide range of materials, from wood to plastic to metal. The Black & Decker DR202 is one of the basic models. The DeWalt DW222 has some of the same features as the DR202 along with a higher level of performance. The DW222 has higher amperage, which gives it more power. It also weighs less than the DR202, which is a huge advantage considering the fact it has more power. One disadvantage of the DW222 is that is has an extremely high level of torque for a 3/8”. This high torque is not suited for all types of work, making the DW222 a less all-around consumer-friendly drill. Like the DR202, the DW222 has a keyless chuck. However, it has a spindle lock which can be finicky at times. This detracts from the ease of the keyless chuck [8]. Another Black & Decker drill, the DR250B, is essentially an updated version of the DR202. It is a VSR drill, which allows for more control and is a convenient power tool. For the price, it is an efficient drill that has a surprising amount of power. It also has the convenient onboard storage of the screwdriver bits, allowing for quick, easy changing of bits [10]. One disadvantage of this drill, though, is the keyless chuck. For most applications, it works as it should. For heavier duty projects, though, the chuck will pose some issues. It will slip and not always hold the bit. This problem can be fixed, but it takes some adjusting, time, and patience [7].

Cost Differences

Black and Decker Drill DR250B
Figure 1 Black and Decker Drill DR250B
Table 3 shows the prices of the different tools at a glance. The Black & Decker DR250B has a MSRP of $59.00 but is normally sold for about half of that. That would bring it down to around the price of the DR202, which causes it to become a popular household tool. This updated version of the DR202, seen in Figure 1, is the best value in terms of price and performance.
Table 3 Price Comparison
Product Price
Black & Decker DR202 around $30.00
Craftsman 5 pc. Screwdriver Set $12.99
Black & Decker LI3100 3.6V Lithium-Ion CompactFit Screwdriver $29.97
Craftsman 11779 7.2-volt Ni-Cd Cordless Screwdriver with Bit Set $34.99
DeWalt DW222 3/8" (10mm) VSR Drill with Keyless Chuck Around $100
Black & Decker 5.2 Amp 3/8" VSR Drill/Driver MODEL # DR250B $59.00 (MSRP)


Main Page


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