Gate 1 - Group 15 - 2012

Work Proposal

In order to reverse engineer the circular saw, there are several important factors and requirements that must take into consideration. First and foremost, we must have a decisive plan of action to determine exactly how we approach each problem. In order to provide a solid foundation for the rest of the project, this proposal will aim to create a general outline for the procedures we will follow throughout the reverse engineering process.

• Disassembly

The dis-assembly of the circular saw will be difficult and our group must proceed with caution in order to make sure that everything goes as planned without any problems. In not, several issues may arise which could jeopardize the success of our project and prevent us from having the capacity to reassemble the saw. Overall, the major steps we will take during the reverse engineering process of our circular saw are as follows:

1. Determine which component to disassemble

Within the outer and inner workings of a circular saw are many different pieces that compose the main structure. Looking from the outside in, we will analyze the structure to determine which parts are the easiest to access. From there, we will decide as a group which piece to remove from the structure. Our decision will be based off an evaluation of the difficulty it will take to remove the part, and how its removal will affect the rest of the system.

2. Remove the part with the appropriate tool

Although removing a component of a circular saw may sound like a simple task, there are many complications that are involved. In the interest of correctly removing each piece, the proper tool must also be selected to complete the job. After researching the structure of a circular saw, it has become apparent that a variety of wrenches and screwdrivers will be sufficient. Until we actually begin to take apart the circular saw, we can’t be certain of exactly what types we will need. However some popular versions that are often used include

3. Document any vital information

At this point, all that is left is to catalog the part that has been removed. This step is extremely important, because without an accurate account of the part’s characteristics and its relationship with the rest of the circular saw, the assembly stage would be near impossible. Some examples of important documentation are a brief description of the component’s purpose along with pictures that show exactly where it was used. Information such as this will allow us to document exactly how each part is used in a clear and logical manner. As every component is removed, all of this information will be recorded in chronological order and the component will be labeled to ensure optimum organization.

• Assembly

For the most part, the assembly process will follow the reverse order of the process for the disassembly of the circular saw.

1. Examine all documented information

The group will make sure that all of our information from the disassembly is organized in the reverse order so that we can begin to reassemble the circular saw.

2. Connect the part with the rest of the assembly

As we piece the saw back together part by part, it is important to make sure that each part is placed back in its proper position. Using the same tools we used to take the circular saw apart, our group will begin to re-build the structure.

3. Continuously compare system to the original documentation

This final step is basically the solution check to our assembly. Without references back to our original notes and pictures there would be no definitive way to tell whether or not the circular saw has been assembled correctly.

• Challenges

Due to the immense complexity of this project, there are many challenges that we will face throughout our project. Unfortunately, there is no way to tell exactly what problems we will face so this will have to serve as a general statement to improve our awareness of potential hazards. One of the most obvious limitations every group will face is time. After analyzing the amount of work and extensive detail required throughout every step, it has become clear that there is no way to set a specific time limit on any aspect of the project. As a group, our best bet is to determine certain time windows within which different aspects must be completed to maintain our punctuality.

It is very important to create a schedule in order to meet all of our deadlines with ease. Furthermore, a circular saw can become very complicated very quickly as the amount of parts being removed builds up. Keeping all of these small components organized and accounted for will certainly be difficult. In addition, there will be a large amount of data to manage and organize considering each part will need a description as well as a photo to sufficiently describe it. Lastly, the fact that our group’s product is a circular saw poses immediate safety risks. This machine is designed to cut through several dense materials with ease and we must not take our safety precautions lightly. Although the power will not be on while we are examining the structure, it is still vital to keep in mind that the blade is very sharp and that we must demonstrate extreme caution as we proceed.

• Group Personnel Evaluation

• Timeline Plan

Management Proposal

• Work Division

Each week the group work will be divided based on a point system. Higher priority and more involved tasks will receive more points than less demanding assignments. A single task can receive no more than five points, with one point being the minimum. The total number of assignment points for the week are summed and divided by five. This gives the approximate number of points that each person will receive for that week. Group members are allowed to volunteer for any task. Priority is given to those that have knowledge in that particular field or are willing to put in the time to learn and do it correctly. Also each week a compiler will be assigned based on a rotating schedule. The compiler for that week/assignment is in charge of collecting all of the individual assignments from the other group members and putting them together. The compiler is also in charge of the initial quality control check by making sure that each assignment is followed correctly. Any minor mistakes the compiler is obligated to fix themselves, however major errors allow the compiler to return the assignment to the corresponding group member for a redo. A pre-deadline for every assignment will be set a few days before the actual due date so that any errors can be properly fixed. Conflicts will be resolved by discussing them as a group and deciding on an appropriate course of action.

• Meeting Times

Every group member is free at 5:00 p.m. (directly after class) Monday and Wednesday. General/emergency meetings will be held in the government documents section of Lockwood Library. Technical/work sessions will be held in the dissection lab. Each group member has been assigned a specific title to help with the ease of communication and lessen confusion throughout the course of the project. If you need to get in contact with our group please contact the Manager, Nicholas Grieco, at nlgrieco@buffalo.edu.

• Group Roles

Group Manager/Supervisor: Nicholas Grieco (nlgrieco@buffalo.edu)

• In charge of final quality check for all assignments

• Will assign tasks to those that do not show up to class/meetings

• Regularly check progress with all group members

• Emergency point of contact for all group members if they encounter any problems

Modeling Expert/Co-manager: Theodore Nalesnik (trnalesn@buffalo.edu)

• Responsible for the majority of the CAD modeling assignments

• Can take responsibility for one or all of the Manager’s tasks if needed for whatever reason (like an illness)

Group Documenter: Joshua Beres (jjberes2@buffalo.edu)

• Will document and outline the group’s progress and findings during the project (in depth).

• Will be responsible for a larger percentage of the writing assignments.

• Log group ideas and activity during meetings for future reference

Dissection Technician: James Pullano (jamespul@buffalo.edu)

• In charge of proper storage/dissection of the hand saw. Including any research that might be needed for complete dissection (how to access welded or permanently molded seems)

• Required to document non text progress during the dissection process. (Making quick sketch models, pictures, videos, animations, flow charts, etc)

Communication Director: Colin Mutton (colinmut@buffalo.edu)

• First point of contact for all group members

• Responsible for group wide email communication

• Will facilitate the distribution of important documents to other group members, via hardcopy or electronically.

• Checks to make sure everyone will be on time for group meetings/ any auxiliary problems.

Product Archaeology

• Development Profile

The Skilsaw is a handheld circular saw manufactured by Skilsaw Inc. Its design is similar to that of the first worm-drive portable circular saw which was developed in 1923 by Edmond Michel, who later went on to form Skilsaw Inc. During this time, the key economic concerns were being able to offer an affordable, yet powerful tool with a long product life. In addition, the global concerns at the time were being able to find materials to construct the Skilsaw and finding a region to distribute in where many consumers could have access to it. The Skilsaw was intended to be sold in the United States and Canada. Its development and distribution impacted the consumer by allowing the everyday person to have access to a powerful tool that could make precision cuts at different angles. The size of the Skilsaw also enabled the home owner to be able to use a powerful saw in a location such as a garage without having to need access to a machine shop. In addition, it impacted society by offering an ergonomic power saw as an alternative to a handsaw. The Skilsaw also features a guard to protect the user from its blade and a trigger that will cancel power in the event that the user loses control of it.

• Usage Profile

The intended use of the Skilsaw is to make precision cuts at various angles in different materials. It may be used in a home setting or for professional use. The common person may find this tool to be invaluable because it is a small, affordable, and maneuverable tool that can make powerful cuts. It may also be used professionally by users such as construction workers because it is designed to make cuts with better precision than another product such as a handsaw. In addition, both home and professional users may benefit from the portable nature of the saw. It only requires that the user have an outlet nearby to draw power from and may be displaced as far the power cord will reach.

• Energy Profile

The Skilsaw runs on 120V AC power and has a 13 amp motor that generates 2.3HP. Electrical energy is imported into the system by a cord which connects from an electrical outlet to the back of the Skilsaw. The electrical energy is converted into mechanical energy through the motor, which is used to rotate the blade.

• Complexity Profile

• Material Profile

Plastic and various metals are clearly visible, as noted in the component table. There are likely more metal parts inside of the motor including a magnet and fluids used such as oil or lubrication. Electrical components may be plastic or rubber coated for insulation purposes.

• User Interaction Profile

To use the product one adjusts the plane to the type of cutting necessary, holds down the safety lock button and depresses the lever to turn on the saw. The interfaces on the saw are intuitive, easy to use, manipulate, and understand. The product is, with basic knowledge of intended purpose, very easy to use. The product only requires that the user keep the trigger pressed to allow power to be delivered to the saw and that they guide it correctly alone the cutting path. Regular maintenance is required for safety reasons. A majority of the maintenance concerns making sure the saw blade is regularly replaced (as teeth fade, making for poor and dangerous cutting potential) that all electrical cords are functional and without short (to avoid saw uncontrollably starting or stopping) and to make sure the safety measures (safety lock, as well as guards) are functional and in place. Maintenance is, again, very easy with basic knowledge of the products intended purpose. If the saw becomes dull, the user will need to replace it or take it to be sharpened. In the event that a power cord becomes damaged, the user will either need to patch the breach or have the manufacturer replace it. In addition, lubrication may be needed to be added to the point where the saw rotates in order to keep it operating with minimal friction.

• Product Alternative Profile

Alternatives to the Skilsaw include, but aren't limited to, hand saws (hack saws primarily), table saws, and miter saws. These are all rough alternatives, as a circular saw is designed for a specific range of utility. The aforementioned other saws can do some of the things circular saws are intended for, but none do all. The advantages are, relating to the previously stipulated point, based on what sort of utility you expect out of the saw. Miter and table saws offer more precision in the sense of straight cuts but at the drawback of mobility. Advantages of a hand saw would be increased precision in sharp angled cuts with a severe drawback in cutting time. Disadvantages of miter and table saws include large size, lack of mobility, and the inability to do curved or angled cuts easily. The main disadvantage of handsaws includes time consumption as well as less clean cuts. The alternatives are not worth it as a circular saw is designed for a specific range of cutting utility, and excels in doing so, while other saws are meant for other ranges of use. Table and miter saws tend to be significantly more expensive than a circular saw. Hand saws are purchasable for less than the cost of a circular saw.