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Gate 3: Product Examination

Purpose:

With the product dissected, you can now complete a detailed analysis of it. In this stage you will examine the product at the component and subsystem level, gathering detailed information. Present the information in your technical report on your wiki page. Project Management: Coordination Review

Cause for Corrective Action

The group should now be working together well. For unresolved challenges propose how your group is going to address these problems. For challenges that have been addressed describe how your group dealt with the problems. Be very specific in all cases. Product Archaeology: Product Evaluation

Component Summary

Component Summary Table
Part Name	Description	Manufacturing	Reason for Materials	Reason for Shape	Forces Applied	Functional/Cosmetic	Quantity	Complexity	Picture
Washer	Holds the torque adjuster to the rest of the drill, separates the ball bearings from the falling out of their bearing holes, separates the gear assemblies	Sheet metal stamping	Steel because of its availability and to keep down cost	Standard	Normal forces applied from the materials that the washer is separating	Functional	3	1
Ball Bearings	Allows the chuck to gear assemblies spin almost frictionaly from the clutch	Cold forged in dies	Steel because of demand for strength and durability	Standard	None	Functional	6	1
Gear Shifter	Shifts a gear between a lower gear ratio for high torque, and a higher gear ratio for higher speed	Machined	Steel because of demand for rigidness	Allows for easy shifting back and forth in linear direction	Normal force to slide the shifter between gears	Functional	1	1
Spring	Applies tension towards the gear shifter to keep it form moving freely	Coiling	Steel because its common and has a consistent elastic modulus with life cycle	Coil shape because of the principles of a spring	Mostly compressive forces in design	Functional as it keeps the spring in place	1	1
Motor Cage	Holds the motor to direct power into the gear assemblies	Plastic injection molding	Plastic because it is easy to mold, inexpensive, and also absorbs any motor vibrations	Circular to form to the shape of the motor	None	Functional as it holds the motor in place	1	1
Sliding Gear	Gear that slides between the higher and lower gear	Plastic injection molding	Plastic possible for easier shifting with lighter weight than metal gear	Circular so that it can easily switch between the gear assemblies	None	Functional as it is the gear that changes between the low and high gear speeds	1	1

Product Analysis

Analyze the engineering decisions that were made during the design of the product, considering the questions in Table 1 at a minimum for seven or more components. These components should be important to the user’s experience, product functionality, product failure, etc.; components which are heavily influenced by one or more GSEE factors are also good candidates for analysis. Justification of your component selection should be provided in the component’s introduction. You should reflect on the information gathered in the previous stages (e.g., the development profile) to help inform your analysis.

Solid Modeled Assembly

The reasons for choosing these three components are because they are one of if not the most important components that the drill uses to perform its function. These three gears form one gear assembly which is used and appears three times in the drill in conjunction with each other and the motor of the drill. The motor of the drill spins these sets of gears depending on which torque setting is selected and this makes these three components vital in the operation of the drill.

We used AutoDesk Inventor for our CAD package. The reason we chose this is because one of our group members has a fair amount of experience in Inventor. He took classes three separate years in high school and has a good understanding of how Inventor works.

Your group should provide solid models of 3-5 individual components using the CAD package of your choice. These components should physically interact, and you must provide an assembly drawing that represents the interaction. Briefly explain your choice of components and CAD package; in this explanation, you may wish to consider previous work.

Engineering Analysis

Choose a key component or function and explain how engineering analysis would be used in the design or testing stages of the design process. Provide a detailed description including MAE 277: Introduction to Mechanical Engineering Practice Fall 2012 Instructors: Phil Cormier and Andrew Olewnik relevant equations and processes that would allow an engineer to easily perform this analysis. This analysis could also be used to help inform your proposed revisions. Table 1: Component Assessment Questions

Design Revisions