Component Summary

RYOBI Battery-Powered Corner Sander (Table 3.1)

Part	Qty.	Function	Material	Manufacturing Process	Part Number	Picture
Sand Paper Punch	1	Punches holes into the sand paper for a perfect fit onto the sander.	ABS Plastic	Injection Molding	N/A	Sand Paper Punch
4 x 8 mm Phillips head screws	5	Used to attach the sand paper velcro pad and the velcro pad housing	410 hardened stainless steel & zinc plated steel	Thread Rolling	19001001015	Base Screws
Sand Paper Velcro Pad	1	Holds the sand paper in place	Velcro	Die Casting	19001001017	Sand Paper Velcro Pad
Velcro Pad Housing	1	Holds the Velcro pad	ABS Plastic	Injection Molding	19001001016	Velcro Pad Housing
External Screws	11	Holds together the two outer casings of the power sander	410 hardened stainless steel & zinc plated steel	Thread Rolling	N/A	External Screws
Cushion Support (front)	1	Connects the sander and the sand paper velcro housing	Malleable Plastic	injection molding	N/A	Cushion Support (front)
Cushion Support (rear)	1	Connects the sander and the sand paper velcro housing	Malleable Plastic	Injection molding	N/A	Cushion Support (rear)
Bearing with counterweight	1	Helps to reduce the vibrations	Metal and ABS Plastic	Injection Molding, Caste ironing, and Machining	N/A	Gears and bearing with counterweight
On/Off button	1	Used to turn the switch on and off	ABS Plastic	Injection Molding	N/A	On/Off button
Gear (motor)	1	Uses the power of the motor and turns it into an oscillating motion	ABS Plastic	Injection molding	N/A	Gear (Motor)
Gear (counterweight)	1	Uses the motion of the gear attached to the motor to drive the counterweight	ABS Plastic	Injection Molding	N/A	Gear (Counterweight)
Leads	1	Connects to the battery to draw electrical power from the battery	Metal	Forging	N/A	Leads
Switch	1	Opens and closes the circuit connecting the leads and the motor	ABS Plastic/Copper/Rubber	Hand Assembly	N/A	Switch
Motor	1	Runs the gears so that the system will run	Metal	Machining	N/A	Motor
Casing	2	Holds together the internal components of the sander	Polystyrene Plastic	Injection molding	N/A	Casing

RYOBI Corner Sander (Table 3.2)

Part	Qty	Function	Material	Manufacturing Process	Model no.	Picture
Screw (M4.2 x 8 mm)	5	Hold together the Velcro pad and the Velcro pad housing	steel	thread rolling	cfs1501-01	Velcro pad Screws Velcro pad Screws
Screw (M4.2 x 8 mm)	4	Hold together the Velcro pad housing to the outer casing of the sander	steel	thread rolling	cfs1501-01	Velcro pad housing screws
Sand Paper Velcro Pad	1	holds the sand paper in place	Plastic & Velcro	Die Casting	cfs1501-02	Sand Paper Velcro Pad
Velcro Pad Housing	1	Holds the sand paper Velcro pad in place	Plastic	Die Casting	cfs1501-03	Velcro Pad Housing
Cushion Support (front)	1	Connects the sander and the sand paper Velcro housing	Malleable Plastic	Injection Molding	cfs1501-05	Cushion Support (front)
Cushion Support (rear)	1	Connects the sander and the sand paper Velcro housing	Malleable Plastic	Injection Molding	cfs1501-06	Cushion Support (rear)
Fan Baffle Screws (M3 x 8mm pan HD.)	2	Holds the fan baffle in place	steel	Thread Rolling	cfs1501-07	Fan baffle screws
Fan Baffle	1	Protective plate around the fan	ABS Plastic	Investment Casting	cfs1501-08	Fan Baffle
Ball Bearing	1	Helps to prevent vibration	Steel	Machining	cfs1501-10	Ball Bearing
Fan	1	Moves the dust particles around	Steel	Forging	cfs1501-11	Fan
External Screws (M4.2 x 20 mm Pan HD.)	4	Holds the outer casing of the sander together	Steel	Thread Rolling	cfs1501-16	External Screws
External Screws (M4.2 x 16mm Pan HD.)	2	Holds the outer body casing of the sander together	Steel	Thread Rolling	cfs1501-17	External Screws
Housing Assembly	1 (2 pieces)	Holds the internal components together	Polystyrene Plastic	Die Casting	cfs1501-18	Casing
Armature Assembly	1	Works with the field assembly to convert the electrical power to mechanical power	Steel/Copper/Plastic/etc.	Hand Assembled and Machined	cfs1501-12	Motor/Fan
Field Assembly	1	Works with the armature assembly to convert the electrical power to mechanical power	Steel/Plastic/Iron	Hand Assembled and Machined	cfs1501-21	Field Assembly
Switch	1	Closes and opens the switch for the	Plastic/Copper/Rubber	Cast and Hand Assembled	cfs1501-22	Switch
On/Off Switch	1	turns the switch on and off	ABS Plastic	Injection Molding	cfs1501-23	On/Off Switch
Brush Holder/Brush assembly	2	Helps the connection between the field assembly and the armature assembly	Plastic	Hand Assembled and Injection Molding	cfs1501-24	Brush Holder/Brush Assembly
Cord Clamp	1	Helps to support the power cord assembly so that it will stay in place	ABS Plastic	Injection Molding	cfs1501-26	Cord clamp
Cord Clamp Screw (M4.2 x 12mm Pan HD.)	2	Holds in the cord clamp and keeps the two outer casings together	Steel	Thread Rolling	cfs1501-27	Cord clamp screws
Power Cord Assembly	1	Provides the power to the motor	Rubber/Copper/Solder	Hand Assembled	cfs1501-28	Power cord assembly
Top Cover w/ Overmold	1	Provides a grip for the user and covers up the internal components of the sander	Rubber	Injection Molding	39110006002	Rubber Grip
Top Cover Screw (M4.2 x 14mm Pan HD.)	4	Holds in the Top cover w/ overmold	Steel	Thread Rolling	cfs1501-30	Top cover screws
Dust Bag	1	Collects the dust particles from the sanded surface	plastic/nylon	Injection Molding and Sewing	cfs1501-31	Dust Bag
Paper Punch	1	Punches holes into the sand paper for a perfect fit onto the sander	ABS Plastic	Die Casting	cfs1501-32	Sand Paper Punch

For both sanders, different materials were selected for different components. ABS plastics were used to provide durability and strength for internal components such as the on/off switch and the Velcro pad housing for the sanders. Various amounts of steel and metal were used for different purposes. Metal associated with electrical flow within the sanders helped to distribute electricity from the power source. This mainly involves the switch/motor assembly where electrical power is centralized. The composition of this assembly includes metal for the leads, metal for the motor, and a mixture of ABS plastic, copper and metal. Different types of steels were used for various screws to help retain the assembly of both sanders. Rubber-based materials were used mainly around areas of electrical power. The power cord was encased in a rubber-based material to provide safety from dangers such as electrical shock. Rubber was also used on the handle so that when using the sanders, there was proper control toward tasks at hand. Malleable plastics were used for the cushion supports which helped keep the Velcro pad housing attached to the base of the sanders. As for the Velcro pad, Velcro helps to ensure necessary adhesiveness to keep the sand paper firmly attached to the sander. Finally, Polystyrene Plastic was used for the body casings of both sanders. This type of plastic is needed to provide necessary durability and strength. This is needed so that the sanders can withstand excessive force as well as keeping a boundary between the user and the internal components.

The forces that are involved in this system are electrical forces and applied forces. The applied forces include compressive force from the force applied from the user and tensile force from the screws holding the casing together. There is also a frictional force acting on the system mainly at the base of the sander between the Velcro and the sand paper. Finally there is a centripetal force acting on counterweight that provides for the oscillating motion.

Material choice does affect the manufacturing process. Since different types of materials are used for different components, there is not just one simple manufacturing process. For example, various plastics of these sanders are processed through injection molding whereas thread rolling is used for screws. Each process is designed specifically to fit the needs of each part. While ABS plastics were used for internal components for each sander for slight flexibility, the Polystyrene Plastic was used for the outer body casing for no flexibility. Different types of manufacturing processes are necessary to build these sanders.

Shape is also affects the manufacturing processes of each sander. Each part needs to be able to fit within both sanders. The outer body casing needs to encase all the internal components as well as provide a handle and grip for each sander. The parts are made the way they are primarily because of size constraints. Parts can be functional but if they can’t fit into the product then the whole product is not functional. Shape is an important aspect for both of these sanders.

Basically, each internal component mainly serves a functional purpose. Only components that can be seen externally provide both functional and cosmetic purposes. The reason for these cosmetic purposes is most likely due to appeal to the consumer.

When considering different materials manufactured by different processes, shape and size constraints, and other actions involved, the complexity of each component is relatively difficult. Each component’s level of difficulty involves basically the same procedures. Obtaining the material leads to the planning and manufacturing of the material where size and shape constraints are taken into consideration.