Difference between revisions of "Group 1 2012 Gate 4"

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(Product Reassembly)
(Product Reassembly)
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|rowspan="2"|[[File:2012_Group_1_Picture_36.jpeg|200px]]
 
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|colspan="4"|The sustain pedal bar runs under the mutes. After the hinges are removed, the sustain pedal bar simply slides out from under the mutes.
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|colspan="4"|Place the sustain bar axles into their respective hinges, and temporarily remove the mutes covering the screw holes before attaching.
 
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|colspan="4"|Lifting up the very top panel of the piano exposes parts of the action and two hinges held on with screws that secure the top of the panel. Remove them to allow for easier access to the rest of the piano.
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|align="center"|''’2'''
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|align="center"|''2'''
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|Rescrew the hinges of the sustain pedal bar  
 
|Rescrew the hinges of the sustain pedal bar  
 
|Screwdriver
 
|Screwdriver
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|rowspan="2"|[[File:2012_Group_1_Picture_33.jpeg|200px]]
 
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|colspan="4"|These hinges are held by screws to the action bracket. Remove the screws and slide the hinges off the axles on the sustain pedal bar.
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|colspan="4"|Realign the hinges over the screw holes and tighten screws to fasten down the sustain bar.
 
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|align="center"|'''3'''
 
|align="center"|'''3'''
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|colspan="4"|The metal sustain pedal bar runs behind all the mutes. Its hinges are also behind the mutes. To access the hinges of the sustain pedal bar, four mutes that cover the hinges' screws must be removed. Unscrew as in step 15.
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|colspan="4"|Reattach the temporarily removed mutes over the hinge holes to complete the mute assembly.
 
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|rowspan="2"|[[File:2012_Group_1_Picture_29.jpeg|200px]]
 
|rowspan="2"|[[File:2012_Group_1_Picture_29.jpeg|200px]]
 
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|colspan="4"|A bar with  thin springs to return the hammers to rest position runs between the mutes and hammers. Remove the four screws that secure it and slide it out of the action.
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|colspan="4"|Slide the spring bar back in between the hammer and mute assemblies, then mount it to the rest of the action via the four screws.  After attaching the spring bar, carefully realign the springs into their respective slots on the base of each hammer, and be sure not to cross any.
 
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|colspan="4"|The una corda bar which runs behind the hammers pivots on the cast iron brackets in step 16. It is visible just above the bracket screws in the image at left. Once the brackets are loose, the una corda bar is free to drop from the action.
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|colspan="4"|Before screwing on the hinges to the una corda pedal bar, ensure that the axes are correctly seated to that they will fit into the cutouts in the action. Then proceed with inserting the screws through the holes in the hinges and tightening them down.
 
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|colspan="4"|The action’s structure is held together and attached to the piano body with cast iron brackets at its ends and center. This is also held on by screws that are removed with screwdrivers.  
+
|colspan="4"|First, make sure that the felt pads are around the holes, then screw on the iron bracket to the action frame.
 
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|rowspan="2"|[[File:2012_Group_1_Picture_35.jpeg|200px]]
 
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|colspan="4"|The mute pivot is screwed to the action bracket by a single screw. After the screw is removed, take the mute off the action bracket.
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|colspan="4"|With the mute pivot at an angle, fasten it to the mute assembly with the swivel screw, then turn it into place, ensuring it connects with the mutes and lines up with the respective holes.
 
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|rowspan="2"|[[File:2012_Group_1_Picture_37.jpeg|200px]]
 
|rowspan="2"|[[File:2012_Group_1_Picture_37.jpeg|200px]]
 
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|colspan="4"|The hammer pivot is screwed to the action bracket with one screw. It is also joined to the pull-rod lever by a cloth strap. Once both the pull-rod lever and the hammer are loose, they can be removed from the action bracket.
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|colspan="4"|Screw the hammer onto the action frame.
 
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|rowspan="2"|[[File:2012_Group_1_Picture_35.jpeg|200px]]
 
|rowspan="2"|[[File:2012_Group_1_Picture_35.jpeg|200px]]
 
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|colspan="4"|With the action removed, the pull rod and the lever it activates can now be removed. It is joined to the action bracket with one screw and joined to the hammer by a cloth strap.
+
|colspan="4"|Reattach the pull rod and lever to the action frame, then reconnect it to the respective hammer using the leather strap.
 
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|rowspan="2"|[[File:2012_Group_1_Picture_21.jpeg|200px]]
 
|rowspan="2"|[[File:2012_Group_1_Picture_21.jpeg|200px]]
 
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|colspan="4"|The pivot for the pedal is screwed into the floor. The axles are press-fit into these and the pedal. Once the pivot block is loose, the axle pulls out.
+
|colspan="4"|Put the pedal axle through the pedals and the pedal hinges before screwing them into the floor of the piano frame.
 
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|rowspan="2"|[[File:2012_Group_1_Picture_38.jpeg|200px|]]
 
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|colspan="4"|The pedal lever is attached to the piano floor by a flat spring. This spring is connected directly to the floor by two screws.
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|colspan="4"|Line up the pedal levers with the holes in the piano frame floor then screw them back into place.
 
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|rowspan="2"|[[File:2012_Group_1_Picture_19.jpeg|200px|]]
 
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|colspan="4"|The pedal dowels connect the pedal lever to the action. A simple vertical pin protruding from the bottom of the dowel is the only mounting hardware. With the action removed, the pedal dowels simply lift out of the pedal levers.
+
|colspan="4"|Simply attach the pedal dowels to the pedal levers using the metal pin protruding from the end and place the tops under the mute and una corda bars.
 
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|rowspan="2"|[[File:2012_Group_1_Picture_20.jpeg|200px]]
 
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|colspan="4"|Release the pedal levers from pedals by unscrewing the threaded connector. These may be finger-tight or may require a wrench and pliers.
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|colspan="4"|Reattach the pedal levers to the pedals using the nuts and threaded rods.
 
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|rowspan="2"|[[File:2012_Group_1_Picture_23.jpeg|200px]]
 
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|colspan="4"|The board the keys were attached to was secured to the frame of the piano with screws placed along its length. Unscrew them.  
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|colspan="4"|Place the key pin board into the front of the piano frame and reinsert the screws down its length, and secure it to the frame.
 
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|rowspan="2"|[[File:2012_Group_1_Picture_13.jpeg|200px|]]
 
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|colspan="3"|All of the keys are only attached by vertical pins on the pull rod board. The keys are easily removed using our hands, and their numbers are inscribed in their body, so order was easily maintained. We took the extra step of storing the keys taped together in numerical order to facilitate reattaching them.
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|colspan="3"|Ensuring the correct order, put the keys onto the right pins, and ensure that they pivot easily.
 
|[[File:2012_Group_1_Picture_17.jpeg|200px]]
 
|[[File:2012_Group_1_Picture_17.jpeg|200px]]
 
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|rowspan="2"|[[File:2012_Group_1_Picture_8.jpeg|200px]]
 
|rowspan="2"|[[File:2012_Group_1_Picture_8.jpeg|200px]]
 
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|colspan="4"|With the action disjoined from the keys, the only thing left holding it into the piano are screws on either side that attach to the piano body and screws to the back wall. These are unscrewed, and the action is carefully lifted out as to not disrupt the fragile members. Be sure to have at least one person holding up the unscrewed parts of the action.
+
|colspan="4"|Replace the action by lining up the action brackets with the threaded holes in the piano frame and replace each screw.
 
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|rowspan="2"|[[File:2012_Group_1_Picture_9cropped.jpeg|200px]]
 
|rowspan="2"|[[File:2012_Group_1_Picture_9cropped.jpeg|200px]]
 
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|colspan="4"|Upon initial inspection, it appears that the action can be removed at this step. This is not the case. The action is connected to the keys by a series of long metal rods capped with dowels that will prevent movement unless they are disconnected. To remove, slightly depress the key and pull the dowel off the key towards the action. Note the bright orange felt underneath the removed pull-rods at right.  
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|colspan="4"|Reattach the correct pull rods with their respective key on the key pin board.
 
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|rowspan="2"|[[File:2012_Group_1_Picture_6.jpeg|200px|]]
 
|rowspan="2"|[[File:2012_Group_1_Picture_6.jpeg|200px|]]
 
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|colspan="4"|This bar holds the keys in place, and must be taken off next. It was held in by evenly spaced screws along its length.
+
|colspan="4"|This bar holds the keys in place, so ensure it is tightened down so that they stay in place, but are still able to pivot smoothly.
 
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|colspan="4"|The keyboard cover was attached to a hinge that allowed it to slide over the keys. Remove the screws holding it in to the side of the piano and lift out.  
+
|colspan="4"|Reattach the keyboard cover to the sliding hinges via screws.
 
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|rowspan="2"|[[File:2012_Group_1_Picture_4.jpeg|200px|]]
 
|rowspan="2"|[[File:2012_Group_1_Picture_4.jpeg|200px|]]
 
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|colspan="4"|Now that the the top hatch and base board are removed, remove the horizontal bar that the top hatch rested on. The bar is held up with two screws on each side, so a screwdriver was used for the disassembly.
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|colspan="4"|Reattach the bar by using the respective screws and ensure that the sliding cover can rest upon it.
 
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|colspan="4"|There is a latch near the baseboard of the piano on the underside of the keys that holds the baseboard of the piano in. Flip it, and remove the baseboard.
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|colspan="4"|Simply place the baseboard into the front of the piano and twist the latch to lock it closed.
 
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|rowspan="2"|[[File:2012_Group_1_Picture_3.jpeg|200px]]
 
|rowspan="2"|[[File:2012_Group_1_Picture_3.jpeg|200px]]
 
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|colspan="4"|Lifting up the very top panel of the piano exposes parts of the action and two hinges held on with screws that secure the top of the panel. Remove them to allow for easier access to the rest of the piano.  
+
|colspan="4"|First, screw on the hinges attaching the top hatch to the rest of the piano frame and close the hatch.  
 
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|colspan="5"|
 
|colspan="5"|

Revision as of 04:07, 29 November 2012

Blabbity blab blab we put the piano back together an' shit.


Contents

Project Management

Cause for Corrective Action

The decision to decentralize the work involved in completing Gate 3 by assigning each group member a specific task and having no group meetings proved to be highly effective in minimizing the total amount of time spent on the project while still providing an acceptable degree of quality. Given the fractured and busied nature of everyone in the group's schedule during this project gate, we will continue to use this method to complete Gate 4.


Product Explanation

Product Reassembly

Chris, Sam, and I will finish this out, but for now just flip all the entries in this table.

In the end we need to answer these: How difficult is each step? How can you define a meaningful scale to rate the difficulty? How was the product originally assembled (by hand, robot, etc.)? Is the assembly the same as the disassembly?

# Step Description Tool Used Difficulty Rating
1 Put sustain pedal bar in None 1-1-1 2012 Group 1 Picture 36.jpeg
Place the sustain bar axles into their respective hinges, and temporarily remove the mutes covering the screw holes before attaching.
’2' Rescrew the hinges of the sustain pedal bar Screwdriver 1-1-1 2012 Group 1 Picture 33.jpeg
Realign the hinges over the screw holes and tighten screws to fasten down the sustain bar.
3 Rescrew the mutes above the hinges of the sustain pedal bar Screwdriver 1-3-3 2012 Group 1 Picture 32.jpeg
Reattach the temporarily removed mutes over the hinge holes to complete the mute assembly.
4 Replace spring bar Screwdriver 2-1-3 2012 Group 1 Picture 29.jpeg
Slide the spring bar back in between the hammer and mute assemblies, then mount it to the rest of the action via the four screws. After attaching the spring bar, carefully realign the springs into their respective slots on the base of each hammer, and be sure not to cross any.
5 Replace the una corda pedal bar None 2-1-2 2012 Group 1 Picture 30.jpeg
Before screwing on the hinges to the una corda pedal bar, ensure that the axes are correctly seated to that they will fit into the cutouts in the action. Then proceed with inserting the screws through the holes in the hinges and tightening them down.
6 Rescrew the iron bracket back on to the end of the action Screwdriver 2-2-2 2012 Group 1 Picture 30.jpeg
First, make sure that the felt pads are around the holes, then screw on the iron bracket to the action frame.
7 Rescrew mute back in Screwdriver 1-1-2 2012 Group 1 Picture 35.jpeg
With the mute pivot at an angle, fasten it to the mute assembly with the swivel screw, then turn it into place, ensuring it connects with the mutes and lines up with the respective holes.
8 Reattach hammer Screwdriver 1-1-3 2012 Group 1 Picture 37.jpeg
Screw the hammer onto the action frame.
9 Screw on pull-rod and associated lever Screwdriver 1-1-3 2012 Group 1 Picture 35.jpeg
Reattach the pull rod and lever to the action frame, then reconnect it to the respective hammer using the leather strap.
10 Replace pedal hinges and put axle back on to pedal Screwdriver 1-1-2 2012 Group 1 Picture 21.jpeg
Put the pedal axle through the pedals and the pedal hinges before screwing them into the floor of the piano frame.
11 Reattach pedal levers from piano floor Screwdriver 1-1-1 2012 Group 1 Picture 38.jpeg
Line up the pedal levers with the holes in the piano frame floor then screw them back into place.
12 Replace pedal dowels None 1-1-1 2012 Group 1 Picture 19.jpeg
Simply attach the pedal dowels to the pedal levers using the metal pin protruding from the end and place the tops under the mute and una corda bars.
13 Put pedal levers back on pedals Wrench, pliers 1-1-1 2012 Group 1 Picture 20.jpeg
Reattach the pedal levers to the pedals using the nuts and threaded rods.
14 Replace key pin board None 2-1-1 2012 Group 1 Picture 23.jpeg
Place the key pin board into the front of the piano frame and reinsert the screws down its length, and secure it to the frame.
15 Replace keys and key pin board None 3-2-2 2012 Group 1 Picture 13.jpeg
Ensuring the correct order, put the keys onto the right pins, and ensure that they pivot easily. 2012 Group 1 Picture 17.jpeg
16 Place back in action bracket and rescrew it Screwdriver 3-1-1 2012 Group 1 Picture 8.jpeg
Replace the action by lining up the action brackets with the threaded holes in the piano frame and replace each screw.
17 Replace the steel pull-rods on the key-levers None 2-2-2 2012 Group 1 Picture 9cropped.jpeg
Reattach the correct pull rods with their respective key on the key pin board.
18 Replace the horizontal bar on top of keys Screwdriver 1-1-1 2012 Group 1 Picture 6.jpeg
This bar holds the keys in place, so ensure it is tightened down so that they stay in place, but are still able to pivot smoothly.
19 Replace keyboard cover Screwdriver 2-1-1 2012 Group 1 Picture 5.jpeg
Reattach the keyboard cover to the sliding hinges via screws.
20 Replace horizontal bar on top of sliding keyboard cover Screwdriver 1-1-1 2012 Group 1 Picture 4.jpeg
Reattach the bar by using the respective screws and ensure that the sliding cover can rest upon it.
21 Replace bottom baseboard None 1-1-1 2012 Group 1 Picture 1.jpeg
Simply place the baseboard into the front of the piano and twist the latch to lock it closed.
22 Replace top hatch Screwdriver 2-1-1 2012 Group 1 Picture 3.jpeg
First, screw on the hinges attaching the top hatch to the rest of the piano frame and close the hatch.

Mechanisms

"Your group must identify one or more mechanisms that your device uses to generate specific motion, control system behavior, modify/condition energy, etc"

They say we only need one. I don't believe them.

First Mechanism

  • Technical Name
  • Purpose
  • "how the mechanism works"
  • Equations governing the design of the mechanism


Design Revisions

Based on our analysis of the piano so far, and our understanding of the GSEE factors, three different revisions to the traditional piano could be made that would modify its design on the system level. These revisions would address issues that we identified.

First Revision

One of the issues with the piano is that it is too large and heavy. This limits its mobility, as well as places where it can be used. A solution to this would to reduce the number of keys in the piano itself. By cutting the number of keys in half, this would greatly reduce the size of the piano and its overall weight. This would increase its overall mobility, and its smaller footprint would allow the piano to be placed in more locations. Taking note of societal factors, the keys that would be eliminated would be those at the two extremes of the note range. This would make sure that the piano could still play a large number of piano compositions, that hover around the notes near middle C.

Second Revision

A second solution could also address the issue of the size, weight, and mobility of a traditional piano. Most of the current piano's size and weight come from the soundboard. With enough experimentation and research, the soundboard could be modified so that the same sounds could be produced, while changing the strings length, orientation, and tension. By doing this, the overall structure of the piano could be much smaller and significantly lighter. This could be beneficial to the consumer from an economic standpoint, since less material would be needed to make it so the price would go down. This also would take note of global factors, as the piano could now be moved around much easier and be played in places that it could not be done before.

Third Revision

Another issue with the full size piano, is that it is difficult for children and people with small hands to extend their fingers far enough to consistently play certain chords. The solution for this would be to integrate auxiliary keys to the original piano set up, that would hit the notes of the chord with a single depressed key. This takes into account societal factors by increasing the number of people that can learn to play the piano, even before their have grown to the ideal playing size, or if they never will.