Gate 2 (group 8)

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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.


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:

Dissection Procedure

Step Part Dissembled Description Ease of step
1 Metal base plate

-blade pointer

-metal screws

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

-Two gears

-Grip 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.

Extremely difficult
6 Metal blade clamp and

plastic protector

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.

Extremely difficult

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.
10 813480-00 ROLLER Motor component.
11 582601-00 ACTUATOR Locking gear.
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

Fasteners used

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.

Special Tools

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.


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