Gate 3: Product Assessment and In-depth Analysis

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Contents

Gate Overview

Following the complete dissection of the Daiwa Baitcast Reel (Right Hand Retrieve), we moved on into a more detailed analysis of the various parts of the reel, both internal and external emphasizing our analysis mainly on four specific parts as can be seen below. We also had to re-assess our project management in order to maximize the team efficiency and co-operation.

Project Management

Revision of Team Roles

After observing the various roles that each individual in the team have undertaken, the team leader, Md. Fahad Hossain, re-appointed the management of the team so as to make the team more efficient in order to meet the necessary deadlines and to ensure all the goals are met. Thus, he proposed the following changes to the management:


  • Change Made: Connor McCafferty was made the new co-project manager.
  • Reason: Connor has been able to be present in nearly all the meetings. He has shown adequate enthusiasm and interest in taking part in the project. But most importantly, he is up-to-date with each individuals progress and can help group leader Fahad in maintaining a good co-ordination between each member.


Cause For Corrective Action

During Gate 3, a few problems were encountered up in terms of group management. Mainly, we encountered issues in the planning of the group meetings. Members of the group started to often be absent, and had a low attendance record. After discussing the issue, we realized that the problem was coming from the time notice given for the meetings. The scheduling of those meetings wasn’t discussed properly enough so that all group members could actually say if they would be available. Additionally, the time notice was too short for group members to make adjustments to their schedules, as they have many prior appointments and other group meetings throughout the week.

Accepting this fact, arrangements were made so that every meeting could be schedule with a minimum of 4 days notice. It has also been agreed that the scheduling of the meetings would be discussed with all members, to make sure that the time chosen suits everyone in the team.

Additionally, the work method of the group has been updated so that more of the work could be done as home-work. This was decided because of the difficulty the schedule long period meetings where every member would work on their assignments; the disparities in everyone schedules was making it impossible to find a time that could suit every member of the team.

Meetings' Update

As various members of the group have various other duties just as compelling as the project, the number of group meetings had to be increased so as to allow for each member of the group to contribute efficiently to the project and remain up-to-date. Three new meetings were added during the following times:

New Meetings
Monday 12:00 p.m. - 2:00 p.m.
Wednesday 12:00 p.m. - 2:00 p.m.
Friday 12:00 p.m. - 2:00 p.m.

Product Archaeology

Component Catalog

Here is a complete catalog of all the parts that were present in the Daiwa Baitcast Reel (Right Hand Retrieve).

Note: As the internal braking system was exempted from our analysis of the reel to retain the proper functionality of out product during and after its usage in the project, any parts associated with that system were excluded from the catalog. The fields associated with these parts have an N/A and the part names have a * beside them. Also a few parts were too small to be photographed, thus their photo has a 'N/A' on them.

Individual Catalog
Key Photo Part Number of Times Used Manufacturing Process Used Material Function
1 N/A Set Plate Screw (S)* N/A N/A N/A N/A
2 N/A Set Plate Spring* N/A N/A N/A N/A
3 N/A Brake adjusting knob (S)* N/A N/A N/A N/A
4 N/A Brake click spring* N/A N/A N/A N/A
5 N/A Brake dial retainer (A)* N/A N/A N/A N/A
6 N/A Left side plate* N/A N/A N/A N/A
7 N/A Brake dial retainer (B)* N/A N/A N/A N/A
8 N/A Set Plate* N/A N/A N/A N/A
9 N/A Screw 1 Rolling Metal Holds down the set plate (Part 8)
10 N/A Magnet Holder* N/A N/A N/A N/A
11 N/A Magnet Holder Retainer Ring* N/A N/A N/A N/A
12 N/A Spacer (A)* N/A N/A N/A N/A
13 N/A Ball Bearing (A)* N/A N/A N/A N/A
14 N/A Bearing Retainer* N/A N/A N/A N/A
15 N/A Spool Assembly (A)* 1 Machined/Milled Metal Holds the line and rotates
16 N/A Spool Assembly (B)* 1 Machined/Milled Metal Holds the line and rotates
17 N/A Spool Assembly (C)* 1 Machined/Milled Metal Holds the line and rotates
18 N/A Spacer (B) 1 Injection Molding Plastic Holds the clutch lever
19 Popolnikof19.jpg Clutch Lever 1 Injection Molding Plastic Moves Clutch Cam
20 N/A Spacer (C) 1 Injection Molding Plastic Holds the clutch lever
21 N/A Frame Assembly 1 Injection Molding Plastic Holds the clutch lever
22 N/A Worm Shaft Retainer* N/A N/A N/A N/A
23 N/A Spool Pin* N/A N/A N/A N/A
24 N/A Worm Shaft Washer* N/A N/A N/A N/A
25 Popolnikof25.jpg Clutch Cam Spring (A) 1 Drawing Meal Holds Clutch Cam
26 Popolnikof26AA.jpg Clutch Cam 1 Die-Casting Metal Moves the clutch trip plate
27 Popolnikof27.jpg Screw 1 Rolling Metal Holds pieces together
28 Popolnikof28AA.jpg Clutch Trip Plate 1 Die-Casting Metal Responds to when clutch cam moves and engages the ratchet
29 N/A Clutch Cam Spring (B) 1 Drawing Metal Holds Clutch Cam
30 Popolnikof30.jpg Yoke 1 Injection Molding Plastic When used, raises the pinion gear
31 Popolnikof31.jpg Yoke Spring 2 Drawing Metal Holds the yoke in place
32 N/A Washer (B) 1 Extrusion Metal Spacer
33 Popolnikof33.jpg Pinion Gear 1 Die-Casting/Machining Metal Translates motion from the shaft to the spool
34 N/A Bearing Retainer 1 Drawing Metal Hold the ball bearing
35 N/A Ball Bearing (B) 1 Machined Metal Reduces friction
36 Popolnikof36AA.jpg Right Side Plate 1 Injection Molding Plastic Protect internal components
37 Popolnikof37.jpg Screw 2 Rolling Metal Holds pieces together
38 Popolnikof38.jpg Screw 1 Rolling Metal Holds pieces together
39 N/A Spacer (D) 1 Injection Molding Plastic Spacer
40 N/A Spacer (E) 1 Injection Molding Plastic Spacer
41 Popolnikof41AA.jpg Cast Control Cap (S) 1 Injection Molding Plastic Applies force to the spool
42 N/A Long Screw 1 Rolling Metal Holds together both sides of the spool assembly and allows the line guide so slide along it without rotating about the level wind guard
43 N/A Line Guide 1 Injection Molding Plastic Guides the line and slides along the level wind guard along the worm shaft. Rotating the worm shaft slides the line guide
44 N/A Line Guide Pawl* N/A N/A N/A N/A
45 N/A Washer ( C )* N/A N/A N/A N/A
46 N/A Line Pawl Cap 1 Injection Molding Plastic Undefined
47 N/A Level Wind Guard 1 Injection Molding Plastic Protects the worm shaft
48 N/A Worm Shaft 1 Machined Metal Holds line
49 Popolnikof49AA.jpg Worm Shaft Gear 1 Injection Molding Plastic Translate motion to the worm shaft
50 Popolnikof50.jpg Gear Retainer 1 Extrusion Metal Holds worm shaft gear to worm shaft
51 Popolnikof51AA.jpg Clutch Lever 1 Injection Molding Plastic Aesthetic
52 Popolnikof52.jpg Ball Bearing ( C ) 1 Machined Metal Reduces friction
53 N/A Drive Gear Shaft Retainer (B) 1 Extrusion Metal Holds down drive gear shaft retainer (A) to shaft
54 Popolnikof54.jpg Drive Gear Shaft Retainer (A) 1 Die-Casting Metal Helps hold the shaft in place
55 Popolnikof55.jpg Screw 2 Rolling Metal Holds down drive gear shaft retainer (A)
56 Popolnikof56.jpg Drive Shaft 1 Die-Casting/Machined Metal Holds the gears and translates motion
57 Popolnikof57.jpg Oscillation Gear 1 Injection Molding Plastic Translates motion from the shaft to the worm drive
58 Popolnikof58.jpg Spacer (F) 2 Injection Molding Plastic Spacer
59 Popolnikof59.jpg Anti-reverse Ratchet 1 Machined Metal One-way rotation of the shaft when the clutch lever is engaged
60 Popolnikof60.jpg Anti-reverse Pawl 1 Machined Metal Assures ratchet can only rotate in one direction
61 Popolnikof61AA.jpg Drive Gear 1 Machined Metal Center gear of gear system
62 Popolnikof62.jpg Drag Washer 1 Machined Metal Creates friction
63 Popolnikof63.jpg Key Washer 1 Machined Metal Spacer/Grips shaft
64 Popolnikof64.jpg Gear Shaft Collar 1 Extrusion/Milled Metal Spacer between the gears and the casing
65 N/A Roller Clutch 1 Injection Molding/Machined Plastic Reduces friction
66 Popolnikof66AA.jpg Ball Bearing (D) 1 Machined Metal Reduces friction
67 Popolnikof67.jpg Spacing Washer 2 Extrusion Metal Spacer
68 Popolnikof68.jpg Plate 1 Extrusion Metal Holds the Leaf Spring
69 N/A Leaf Spring (A) 1 Drawing Metal Detects tension in the fishing line
70 Popolnikof70.jpg Drag Spring Washer 2 Extrusion Metal Spacer
71 Popolnikof71AA.jpg Star Drag 1 Injection Molding Plastic Change resistance of reel
72 Popolnikof72.jpg Leaf Spring (B) 1 N/A Aluminum ?
73 Popolnikof73.jpg Handle Assembly (S) 1 Machined (CNC) Plastic/Metal Apply torque
74 Popolnikof74.jpg Handle Nut 1 Die-Casting/Machined Metal Holds the handle on
75 Popolnikof75AA.jpg Handle Nut Plate (S) 1 Injection Molding Plastic Aesthetic
76 Popolnikof76.jpg Screw 1 Rolling Metal Holds down the Handle nut and plate to the handle
77 N/A O-ring 1 Injection Molding Rubber Seals the cap and right side plate together



Product Analysis

After documenting the basic detailed information about all of the components associated with the reel, we moved on to perform a thorough analysis of seven parts of the reel. Also, please refer to the above catalog for any numbered parts mentioned in the following analysis.

Handle Assembly (73): The handle assembly was chosen because it is the first part that the user interacts with. It is the first step in the mechanical energy flow through the systems of the reel.

Star Drag (71): The star drag was chosen because it is an external component that interacts with internal components, meaning that both aesthetic and functional value are placed on this part.

Pinion Gear (33): The pinion gear was chosen because it performs a relatively complex function, and is made from a material scarcely found within the reel.

Yoke (30): The yoke was chosen because it has a unique shape, and is a step in a flow of energy that performs a complex task.

Clutch Lever (19): The clutch lever was chosen because it is an external part that is the first step in a flow of mechanical energy within the reel. Much aesthetic value was placed on the design of this part.

Clutch Cam (26): The clutch cam was chosen because it is the next step in the flow of mechanical energy that starts with the push of the clutch lever (19). The clutch cam is also one of the few metallic components of the reel.

Right Side Plate (36): The right side plate was chosen because it is the external covering of the entire right side of the reel. Much aesthetic and functional value was placed on the design of this part.


Manufacturing/Interaction Complexity scales

To help with the in-depth analysis, we decided on a complexity scale for both interactions and manufacturing. The manufacturing complexity scale is based on how many process were needed to manufacture the part, and how difficult these processes were. The interaction complexity scale is based on how many interactions the part is involved with. Thus the following two tables will be referred to during the analysis:


Manufacturing Complexity Scale

Value Description
1 Any part that was created using a single manufacturing process. Including but not limited to: die-casting, injection molding, forging.
2 Any part that required 2 simple manufacturing processes.
3 Any part that required a difficult process such as turning.
4 Any part that required a difficult process and other processes, such as: forging then milling.


Interaction Complexity Scale

Value Description
0 Any part that performs no contribution to function. Including parts that serve

for purely aesthetic value.

1 A part that has one simple interaction with neighboring parts, such as a spacer,

bearing, or washer.

2 A simple interaction that influences more than one other part.
3 Any part which serves an important role in a complex interaction within the product. Includes parts such as: gears, worm drive.

Components Analysis

1. Handle Assembly

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Handle AssemblyGate 3: Product Assessment and In-depth Analysis
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Popolnikof73.jpg {{#if:Manufacturing Complexity: 2
Interaction Complexity: 1
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Manufacturing Complexity: 2
Interaction Complexity: 1
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 [[[|v]]  [[|d]]] 

Component Function

  • To provide a platform for the user through which he may introduce the mechanical energy needed to operate the reel.
  • It helps to translate the energy into the drive shaft (56) that is connected to the internal systems.

Component Form

  • It is 'U' shaped with the two handles connected via an arm.
  • It has a smooth, ergonomic outer finishing with smooth edges.
  • It is axis-symmetrical with 2 holes on each side of the arm.
  • It has a 3 dimensional shape.
  • The overall size of the handle plus arm is 9 cm x 4 cm (approx.)
  • The symmetrical property allows equal translation of mechanical energy no matter which handle is used during rotation.
  • The arm is made of steel, probably plated due to the smooth and shiny finish.
  • The two handles at each end were plastic/rubber.
  • Steel was used in the arm because the material needs to be strong and durable as it undergoes heavy strain during its translation of energy. Yet, it also has to be light so as not to add extra strain on the user.
  • The handles are which come into direct contact with the user ( that is via the fingers when grasped ). Thus the material should provide adequate grip while not applying too much stress on the fingers. (societal)
  • The whole arm and handle system is only made up of two different materials so as to best recycle the product with ease. (Environmental)
  • Thus, mass production is easier with lower unit costs. (Economical)
  • It is part of the outer systems of the reel, thus is made as aesthetic as possible.
  • The arm is silver while the two handles are gray. The colors go well together forming a good contrast and as only the arm is shiny, it is easy to distinguish the handle from the rest of the system.

Manufacturing Methods

  • Arm was forged while the handles were injection molded.
  • This can be easily seen as the overall shape of the arm was horizontal with slight level changes throughout the thick metal. The overall geometry of the arm is quite simple and it can be easily attained from a single mold. The metallic arm could be made through various methods, however, forging seems to be the most cost effective in this case.
  • The handles have a parting line and drafts are present as well. Plastic is nearly always made through injection molding through which complex shapes can be achieved with ease.
  • For this piece, of this size and shape, forging is the most economical. Any other method would probably yield a higher unit cost. (Economical)

Component Complexity

  • The manufacturing complexity for this part was given a 2 as the process used to make the handles and that for the arm were two different types.
  • The interaction complexity level for this would be 1 as all it does is rotate the drive shaft of the reel system.


2. Star Drag

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Star DragGate 3: Product Assessment and In-depth Analysis
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NIST Functional Basis Elements
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 [[[|v]]  [[|d]]] 

Component Function

  • Spinning the star drag either increases or decreases the drag on the spool (15), in turn increasing or decreasing the drag on the line.
  • Friction is the force that the star drag relies on to perform its function.
  • The star drag is directly attached to the drive shaft (56).

Component Form

  • Like it's name suggests, the Star Drag is shaped much like a pointed start, symmetric about its axis with 5 points.
  • It has a 3-dimensional shape.
  • The dimension of the Star Drag is roughly a cylinder with diameter 5 cm, height 1 cm.
  • The Star Drag is symmetric and ergonomic. The 5 pointed shape allows the user to easily grasp and spin it.
  • It is made from plastic, and has a circular metal nut glued inside.
  • It is much easier and cheaper to manufacture a part like this out of plastic rather than metal. This is why plastic was chosen for this part.
  • The company had economics in mind when manufacturing this part.
  • The Star Drag has a unique shape and a silver finish. This point to the fact that the part is meant to look good as it is on the outside of the fishing reel.

Manufacturing Methods

  • The Star Drag was made by the injection molding of plastic.
  • It is obvious that the Star Drag was injection molded because of the riser marks seen on the inside of the part.
  • Injection molding is the best manufacturing process to create a plastic part with complex geometry like the Star Drag.
  • The choice to mold the part out of plastic was influenced by global and economic factors. The part can be easily mass-produced anywhere since one standard mold exists for every Star Drag made for this reel.

Component Complexity

  • The Star Drag was created by first the injection molding of plastic, and then the inlaying of the metal washer. Based on the scale defined for component complexity, the Star Drag has a complexity of 2.
  • The complexity scale is defined by the manufacturing methods used to create the product. The Star Drag is a relatively simple component that can be injection molded on a mass scale, therefore defining its complexity.
  • The Star Drag’s function is to compress the gears and washers along the drive shaft, in turn putting more or less drag on the spool. The Star Drag performs a simple function, but influences multiple parts within the reel. This interaction warrants a 3 based on our interaction complexity scale.


3. Pinion Gear

{{#if:Pinion Gear||}} {{#if:|}}{{#if:|}}{{#if:|}}{{#if:Popolnikof33.jpg |}}{{#if: |}}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | |{{#if: | }}}}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | |}}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if: | }}{{#if:|}}{{#if:|}}
Pinion GearGate 3: Product Assessment and In-depth Analysis
{{{above}}}
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Popolnikof33.jpg {{#if:Manufacturing Complexity: 3
Interaction Complexity: 3
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Manufacturing Complexity: 3
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 [[[|v]]  [[|d]]] 

Component Function

  • Translates motion from the drive gear (68) to the spool (15).
  • When the handle (73) is rotated, the spool (15) will rotate; the pinion gear provides that connection.
  • Energy flow is associated with the pinion gear, specifically mechanical energy.

Component Form

  • The pinion gear is most similar to that of a cylinder, but has a groove near the middle where the yoke (30) fits in, and the bottom is closer to that of the bottom half of a cone. It is specifically a helical gear, denoted by the non-parallel structure of its teeth.
  • It is a 3-dimensional piece with a diameter of 0.6cm on the top and 0.7cm on the bottom. Its height is 1.5cm.
  • Its cylindrical shape allows it to rotate smoothly, and the grooves allow it to fit into the grooves of other gears, translating mechanical energy. It weighs about 5 grams.
  • It is made of some type of metal. Perhaps because it is such an important gear, it was made of metal. This gear will rotate very fast depending on the speed the spool (15) or handle (73) rotates. As one of the gears that will have the most force applied to it, its durability is very important.
  • The only aesthetic property is the metal makes the part shiny and smooth. The smoothness of the bottom part of the pinion gear is very noticeable and allows it to lose very little energy to friction. The finishing helps to keep the helical gears running smoothly.

Manufacturing Methods

  • The part was Die-Cast, and the details were CNC machined. The gears body was most likely die-cast because it is made of metal. The teeth were CNC machined as the smooth finishing with a few key marks are evidence of machining.
  • Economically, die-casting is the most efficient way of creating gears. The machining then allows for the accuracy needed for the creation of the gear’s teeth.

Component Complexity

  • The manufacturing complexity should be 3 because it is produced by two fairly simple processes; die casting and machining. There are two different gear ratios for the two ends.
  • The interaction complexity should be 3. The first interaction is fairly simple where it is being raised/lowered by the yolk. Then 2 more complicated reactions takes place where energy is being translated from gear 68 to the pinion gear to the spool.


4. Yoke

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YokeGate 3: Product Assessment and In-depth Analysis
{{{above}}}
{{{subheader2}}}
Popolnikof30.jpg {{#if:Manufacturing Complexity: 1
Interaction Complexity: 2
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[[Image:|{{#if:|px|125px}}|]] {{#if: |
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 [[[|v]]  [[|d]]] 

Component Function

  • When lifted by the clutch cam (26) it disengages the pinion gear (33) from the spool assembly allowing the spool to rotate freely.
  • Flow of Mechanical Energy
  • Internal environment as in part of the internal machinery.

Component Form

  • A slightly bent rectangle, bent about the middle.
  • Symmetrical about its axis where the bend is.
  • Primarily 2-dimensional
  • Length – 3.5cm. Width (average) – 0.6cm
  • In the center, there is a radial area where the pinion gear (33) slides in. It allows the pinion gear to rotate without translating this rotational motion to the yoke. The bottom of the yoke has 2 grooves that fit onto protruding parts of the clutch cam (26). When the clutch cam (26) is engaged, it slides along the grooves of the yoke, pushing the yoke up, which pushes the pinion gear and disengages it from the spool.
  • It is made of plastic.
  • The material chosen is not important because it is only moving up and down/lowering raising another part. Therefore plastic can be used to keep the part cheap. (Economic Factor).
  • There are no aesthetic properties; it is purely a functional part because it is an internal part

Manufacturing Methods

  • Injection molding was used, evidenced because it is made of plastic, and by some marks that indicate a mold was used.
  • This method is cost efficient and allows the part to be produced. (Economic)

Component Complexity

  • The manufacturing complexity is 1 as injection molding is cheap and simple.
  • Interaction complexity is 2 because it has 2 simple interactions: gets raised/lowered by clutch cam (26) and raises/lowers pinion gear (33).


5. Clutch Lever

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Clutch LeverGate 3: Product Assessment and In-depth Analysis
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NIST Functional Basis Elements
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Component Function

  • The clutch lever is operated by a push of the user’s thumb. When pushed, the clutch lever rotates the clutch cam (26) which then raises the pinion gear (33), disengaging the drive gear (61) allowing the spool (15) to spin freely.
  • The clutch lever is the first step in a series of mechanical energy flow which end results in the free rotation of the spool (15).
  • Being on the outside part of our product, this component is directly going to interact with the external environment. Therefore, it will be functioning in a fresh or salt water environment.

Component Form

  • It has a complex shape with multiple curves.
  • It is three dimensional and symmetric in nature.
  • length: 28mm x Width: 23 mm x height: 10 mm.
  • The lever needs to be accessible easily and quickly. Thus it was designed to be broad and one of the surfaces resembles a human thumb for better access.
  • The Clutch lever of our fishing reel is made of plastic.
  • This part is going to function in a fresh or salt water environment. Thus the material should be such that it is not affected by the external materials while still retaining some strength for functionality. Thus plastic was used instead of the steel due to its corrosive resistant property. (Global)
  • The parts that are interacting with the user were smoothed out with no sharp edges. Also, it should be easily distinguished from the other parts, thus the shiny finish. (Societal)
  • The whole part is made of just plastic and so, it is easily recycled. (Environmental)
  • The overall finish is smooth, shiny and ergonomic mainly for ease of access.

Manufacturing Methods

  • This part was made through injection molding which can be easily understood due to the presence of the parting lines. Plastic can only be injection molded or CNC machined, however, the later method would prove to be more cost inefficient to use. (Economical)
  • There is a lot less material wastage in injection molding when compared with CNC machining. (Environmental)

Component Complexity

  • Manufacturing complexity would be of level 1 as only one simple method was used in the production of this part.
  • The interaction level would be 2 as although it interacts with only one part, it results in a chain reaction.


6. Clutch Cam

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Clutch CamGate 3: Product Assessment and In-depth Analysis
{{{above}}}
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Interaction Complexity: 3
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Manufacturing Complexity: 2
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 [[[|v]]  [[|d]]] 

Component Function

  • The clutch cam is engaged when the clutch lever is pushed. The clutch cam then rotates the yoke, disengaging the drive gear. The function of the clutch cam is to allow the spool to spin freely while casting.
  • The clutch cam relies on mechanical energy to perform its function.
  • The clutch cam operates on the inside of the reel.

Component Form

  • The clutch cam is shaped like a circle with an added lever arm perpendicular to the plane of the circle.
  • The clutch cam is roughly 3 cm x 3 cm x 2 cm (approx.).
  • The clutch cam’s shape is specific to the function it performs. It consists mainly of a lever arm used to rotate the part, and a sloped outcrop that raises the yoke.
  • The clutch cam is made from smooth, cheap metal.
  • The clutch cam is a complexly shaped part that also needs to be relatively strong. The manufacturing process used to make the part was chosen based off these facts.
  • The clutch cam’s main function is to rotate against plastic. It is made from a smooth metal that aids in this process.
  • Because the clutch cam operates internally, no thought was given to the aesthetics of the part.
  • It is metallic silver in color.
  • The surface finish of the clutch cam makes it very smooth. This aids only in the function of the part, not the aesthetics.

Manufacturing Methods

  • The clutch cam is made from die-casting metal. The obvious riser marks on the part indicate the manufacturing method used.
  • Being a very complexly shaped part, the clutch cam could have been manufactured either by die-casting or injection molding. Because the clutch cam needs to be a strong part, die-casting of metal was chosen to make it.
  • Creating a complex part like the clutch cam from a method other than injection molding or die-casting would be very expensive and impractical. Economically it makes the most sense to die-cast a part like this.
  • Globally speaking, the mass production of the product would be much easier if complex pieces like the clutch cam were made from cheap, labor minimal processes.


Component Complexity

  • The clutch cam was manufactured from the die-casting of metal. Because one simple manufacturing process was used to make the part, it earns a component complexity rating of 1.
  • The complexity of the clutch cam is based off the fact that the part operates internally, so there are no aesthetic concerns, and the complex shape required a process like die-casting to be made.
  • he clutch cam is the second step in a flow of mechanical energy that influences multiple parts within the reel. Because of this, the clutch cam earns a interaction complexity rating of 2.


7. Right side plate

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Right side plateGate 3: Product Assessment and In-depth Analysis
{{{above}}}
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Popolnikof36.jpg {{#if:Manufacturing Complexity: 1
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Manufacturing Complexity: 1
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Component Function

  • To contain the internal systems of the reel as well as acting as a protective shell for the internal parts.
  • It is subject to external weather and/or environmental conditions.

Component Form

  • It has a very complex shape with irregular curves, extrusions, beveled edges and holes.
  • It is three dimensional with dimensions: 68 mm x 52 mm x 25 mm.
  • The component has been designed so as to best fit the internal parts with minimum spacing between them.
  • The plate is made up of plastic with some metallic sub-components glued around the axis of the system.
  • The part is one with probably the highest amount of exposure to external conditions and as the external environment is usually water related, it needs to be corrosion resistant to enhance its durability.(Global)
  • As it is an outer part, it has the highest likelihood of coming into contact with the user, thus, the outer layer is free of any sharp edges due to safety precautions. (Societal)
  • The overall shape is aerodynamic and smooth, which is because this is probably the biggest external part of the real and holds a high aesthetic requirement.
  • The color here is gray so as to remain discrete as it does not perform any major function which requires much interaction with the user.


Manufacturing Methods

  • As the material is plastic, there are only two possibilities for its manufacturing process: CNC Machining or Injection Molding. However, as CNC Machining would result with a higher unit cost for the product, injection molding was used here. Also the markings on the internal side of the plate provide further evidence of injection molding.
  • Using Injection Molding resulted in a lower unit cost. (Economical)
  • Injection Molding and the use of plastic suggests easier recycling prospects with low wastage. (Environmental and Economical)

Complexity

  • The manufacturing complexity of the plate would gain a value of 1 as only one method was used with a uniform, albeit, complex shape.
  • The interaction complexity is 0 as it does not interact with any other parts per say, but rather holds them together.

Assembly Drawings

We decided to focus on the particular function of the ‘Drag Control’ system within the reel; the model consists of the following parts: drive shaft (56), drive gear (61), drag washer (62), and key washer (63). While in use, the drag control system follows a certain drag setting which has been predetermined by the fisherman, and it dictates the amount of tension allowed in the line. For instance, if the fisherman catches a bass that weighs too much for him to reel in on his first try, the lubricated washers will ‘slip’ according the drag setting and allow for some of the line to be given to the bass as it attempts to escape. This is a crucial aspect to any bait-casting reel since it lets the fisherman engage in a ‘fight’ for his catch. Once an arbitrary amount of line is admitted back out to sea, the fisherman’s fight will continue until the fish tires out, making it easier for him to reel the bass in.

To create the following diagrams, Autodesk Inventer Fusion was used, as it was the CAD software that we were most familiar with. It allowed us to create individual parts and then bring them altogether in an assembly drawing.


1. Drive Shaft (Part 56)

DrawingAA.png


2.Fabric Washer (Part 62)

DrawingAB.png


3.Drag Washer (Part 63)

DrawingAC.png


4.Drive Gear (Part 61)

DrawingAD.png


5.Complete Assembly

DrawingAE.png

Engineering Analysis

Problem Statement

Engineering analysis would be used in the design process of the handle to determine the mechanical energy translated due to a predetermined expected applied force. A force would be applied to the handle but will this force be enough to reel in fish? By assuming no force or energy lost to friction. We can determine energy translated from handle to drive gear, from drive gear to pinion gear and from pinion gear to the spool.

Assumptions

  • The force applied on the handle by the user remains constant throughout the process.
  • The loss of energy due to friction is negligible.
  • All force applied is translated to drive shaft
  • Line is not stretched
  • Force of fish is constant

Governing Equations

1. EquationsAA.png

2. EquationsAB.png

3. EquationsAC.png

4. EquationsAD.png


Discussions

With this analysis a prediction of the performance of the product can be made before testing starts, saving time and money.

Design Revisions

While the Daiwa Baitcast Reel is well designed and engineered, it is not perfect. There are a multitude of design revisions that could be implemented to make it more efficient and economic.

“Mono-handle” Handle assembly

Currently, the Daiwa Baitcast Reel is equipped with a “double-handle” handle assembly. This is obviously to make the handle easier to reach for in a moment of struggle. However, this design choice is cause for usage discomfort and, even moderate extra weight. The usage discomfort comes from the position of the Star drag. This component is located directly behind the Handle assembly. As a consequence, a “double-handle” handle assembly makes it difficult to reach for. Also, this type of assembly doesn’t allow the user to reel the handle back and forth as freely as possible. While holding one of the handles, the other one always ends up being in contact with the user’s wrist.

An extended “mono-handle” assembly would prevent all of this. It would make the Star drag easier to reach for, offer a more comfortable user experience, and increase torque on the drive shaft. It would however make it less easy to reach for quickly. Additionally, this would make the whole system more weight, energy, and cost-effective.

Summary of Four Factors improvements

  • Societal: Star drag easier to reach for
  • Societal: Torque on the drive shaft increased
  • Societal: Handle assembly easier to operate
  • Economical/Societal: Assembly more weight-effective
  • Economical: Assembly composed of less parts and material, resulting in more cost effectiveness


Fully metallic gear system

Currently, our Daiwa Baitcast Reel is composed of both metallic and plastic gears. Although plastic gears are cost and weight effective, they do not perform as well over their life. The lifecycle of a plastic gear assembly is much shorter than that of a metallic system because the material itself is much weaker. A plastic assembly is less likely to survive repeated stresses in the long run. As a result, plastic gear components may need to be replaced often.

The primary user for this product is professional anglers which will most likely perform maintenance operations themselves. Therefore, maintenance is a big issue. Having a product which is more likely to last in the long run is a primary requirement. Having a fully metallic gear system would offer a much more robust product. The gears would be less likely to fail over time, and there would be less need for maintenance and part replacement. The reel would also be able to reach higher performances, allowing anglers to work on bigger fish without any risk of material failure.

Summary of Four Factors improvements

  • Societal: More robust product; less risk of material failure
  • Societal: Less frequent maintenance operations
  • Societal: Higher range of performances; ability to work on bigger fish


Fully Waterproof Casing

A fishing reel is used close to water for its entire life cycle. The Daiwa Baitcast Reel currently has no means of waterproofing. Many of the internal components are made of metal, so they may easily rust–permanently damaging the function of the reel. We propose fully waterproofing the outer casing to prevent water from affecting the internal components. This waterproofing system would consist of rubber seals along the edge of the outer casing. O-ring seals would also be used anywhere external components enter the inner casing, such as around the drive shaft (56) and around the clutch lever (19). This system would increase the cost of the reel, but improve the overall life cycle and performance.

Summary of Four Factors improvements

  • Environmental: The implementation of a waterproofing system would increase the overall life cycle of the reel, meaning less reels would be thrown away.
  • Societal: Because moisture would no longer be able to affect the internal components of the reel, performance would be improved.