Black and Decker Grinder

Figure 1: Fully dissected product

Description

This product is a produced by Black and Decker. The product is used to grind down metal.

How It Works

Inside the grinder there is an electric motor that spins a shaft connected to a bevel gear. The bevel gear is then attached to another driving shaft. A grinding wheel is clamped onto the driving shaft, causing the grinding wheel to spin.

Because of constant friction and the forces acting on each component there is a certain life expency. This varries for individual parts based on the force acting on the part and the design of the part.

For the bearing, an assumed torque of 0.315 Nm was applied to the shaft. Assuming the grinder is being used constantly the bearing would last 1.83 years before failure. If the grinder was being used six hours every day, 365 days a year then the bearing would last 7.33 years. If the grinder was being used six hours a day, five days a week, the bearing would last 10.26 years.

For the force requirement on the gears to rotate the grind wheel at 10,000 RPM, the power consumption of the grinder was looked up. From the power consumption the torque was calculated to be 0.315 Nm, which equates to about 2.61 lbs of force on the workpeice from the grind wheel. This calculates to 12.4626 N of force at the gears to rotate the grind wheel at 10,000 RPM.

To calculate the stress in the gears, a stress equation was used from the Fundamentals of Machine Compoents Design by Robert C. Juvinall. The velocity factor was caluated with the assumption that the gears were precision shaved and ground. The overload factor was calculated with the assumption that the source of power is uniform and the driven machinery is assumed to have moderate shock. Both gears were overhung, which gave a mounting factor of 1.25. The calculated stress in the smaller gear was 613.601 PSI and the stress in the larger gear was 442.438 PSI.

Parts

The table belows lists the Bill of Materials for the disposable camera:

Table 3.1: Disposable Camera Bill of Materials

Part #	Part Name	# Req'd	Mat'l	Manufacturing Process	Image
1	Back Interior	1	ABS Plastic	Injection Molding
2	Back Plastic Cover	1	ABS Plastic	Injection Molding
3	Camshaft	1	ABS Plastic	Injection Molding
4	Eyehole for Shutter	1	ABS Plastic	Injection Molding
5	Film Advance Gear	1	ABS Plastic	Injection Molding
6	Film Advance Lock	1	ABS Plastic	Injection Molding
7	Film Canister	1	Varied	Varied
8	Film Spindle	1	ABS Plastic	Injection Molding
9	Frame Counter	1	ABS Plastic	Injection Molding
10	Front Interior	1	ABS Plastic	Injection Molding
11	Front Plastic Cover	1	ABS Plastic and Rubber	Injection Molding and Molding
12	Inner Lens	1	ABS Plastic	Injection Molding
13	Interior Body	1	ABS Plastic	Injection Molding
14	Lens Holder	1	ABS Plastic	Injection Molding
15	Outer Lens	1	ABS Plastic	Injection Molding
16	Outside Film Advance	1	ABS Plastic	Injection Molding
17	Shutter	1	1040 Steel	Stamping
18	Shutter Lever	1	ABS Plastic	Injection Molding
19	Shutter Spring	1	1040 Steel	Forming
20	Spring for Shutter Lever	1	1040 Steel	Forming
21	Sprocket	1	ABS Plastic	Injection Molding
22	Viewfinder	1	ABS Plastic	Injection Molding
23	Washer	1	Rubber	Molding

Disassembly

The ease of disassembly (ranked on a scale of 1 - 5 with five being the most difficult) is ranked at 2. No tools are required for disassembly but a flathead screwdriver or knife helps.

The following table lists the steps and procedures for disassembly:

Table 4.1: Disassembly of a Disposable Camera

Step	Procedure	Image
1	Pop film advance wheel up and out from body; separate covers	Figure 5.1: Exterior Disassembly
2	Remove film canister and film spindle	Figure 5.2: Large Component Removal
3	Remove lens holder, outer lens, shutter cap, shutter spring, shutter, eyehole, and inner lens	Figure 5.3: Lens Assembly Dissection Figure 5.4: Lens Assembly Dissection View 2
4	Remove viewfinder, frame counter, internal film advance wheel, shutter lever, advance lock, camshaft, lever spring, and sprocket	Figure 5.5: Final Component Removal

<embed src="http://www.youtube.com/v/-KtdLcgpb2I" type="application/x-shockwave-flash" width="425" height="350"></embed>

Right-click here and select "Save Link As" if you want to download the video of the animated disassembly of the camera (.wmv)

<embed src="http://www.youtube.com/v/yfjMW4G0INM" type="application/x-shockwave-flash" width="425" height="350"></embed>

Right-click here and select "Save Link As" to download the video of the disassembly of the camera (.wmv)

Files

3D Models

3D Models as Alibre Design AD_PRT

3D Models in STEP Format

3D Models in ACIS Format

3D Models in IGS Format

3D Models in STL Format

2D Drawings

2D Alibre Drawings (.AD_DRW)

2D Drawings in STP Format

Camera Assembly

Camera Assembly as ACIS, STL, STP, and Alibre

Table 5.1: List of Models for Download
(Zipped ACIS, IGS, STL, STP, AD_PRT Files)

Part #	Part Name	Image	3D Models	2D Drawings
1	Back Interior		3D Package	2D Package
2	Back Plastic Cover		3D Package	2D Package
3	Camshaft		3D Package	2D Package
4	Eyehole for Shutter		3D Package	2D Package
5	Film Advance Gear		3D Package	2D Package
6	Film Advance Lock		3D Package	2D Package
7	Film Canister		3D Package	2D Package
8	Film Spindle		3D Package	2D Package
9	Frame Counter		3D Package	2D Package
10	Front Interior		3D Package	2D Package
11	Front Plastic Cover		3D Package	2D Package
12	Inner Lens		3D Package	2D Package
13	Interior Body		3D Package	2D Package
14	Lens Holder		3D Package	2D Package
15	Outer Lens		3D Package	2D Package
16	Outside Film Advance		3D Package	2D Package
17	Shutter		3D Package	2D Package
18	Shutter Lever		3D Package	2D Package
19	Shutter Spring		3D Package	2D Package
20	Spring for Shutter Lever		3D Package	2D Package
21	Sprocket		3D Package	2D Package
22	Viewfinder		3D Package	2D Package
23	Washer		3D Package	2D Package

Table 5.2: Point and Mesh Clouds Available for Download
(Zipped .wrp format)

Image	Link
Figure 5.1 Front Exterior Scan	Gave to Dave
Figure 5.2 Front Interior Scan	Gave to Dave
Figure 5.3 Rear Exterior Scan (Front View) Figure 5.4 Rear Exterior Scan (Back View)	Gave to Dave
Figure 5.4 Rear Interior Scan	WRP Scan Files

Links

Other Kodak One-Time-Use Cameras