Gate 1 - Group 6 2012
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The goal of the dissection will be to provide the team with insight into how each component works in conjunction with the others as well as the inner workings of each individual component. With this context in mind, the dissection will start with the removal of part of the outside cover with an aim toward providing the team with a cross-sectional view. This will hopefully provide an opportunity to diagram the impact wrench with all of its components intact and in place. Then, the team will identify and remove the complex parts in order to dissect those as well. Tools required for dissection include an Allen wrench and a screw driver, primarily to take apart the casing. The anticipated time required to dissect the wrench is thirty minutes to an hour. The major concern of the group is regarding whether the components will stay in place after removing the cover, as this would greatly impact the team’s ability to diagram and understand the interaction of the components. As far as skills are concerned no one in the group has ever tried to dissect an impact wrench or any similar tool before, but this is not a big concern for the group. Some members have experience dissecting other instruments, communication and analytical skills are strong among all members, and one member is able to do solid modeling.
The group has decided to manage its work by utilizing well defined roles for its members, regular meetings and designated deadlines for communication via E-mail.
Roles have been split up among group members as follows:
Communication Liaison-Amie Vuong
- Serve as a point of contact for instructors - email@example.com
- Compose and disseminate communication between group and instructors
- Compile group input for Gates and prepare preliminary drafts to be reviewed and edited by group members
- Respond to editing comments and sends out second draft, repeating process until satisfactory
Project Manager and Intra-group Communications Coordinator - John Pfalzer
- Set timeline for work to be done, including internal group due dates for work leading up to class due dates
- Since each Gate has two Fridays between due dates, the group has tentatively planned to meet on the first Friday to discuss the tasks to be completed by each member in the following week. The second Friday will be the intra-group due date for the written portion of the Gate, and the week leading up to the class due date will be used to edit and re-edit the Gate according to group input via E-mail and occasional contact in person since many members attend the same classes.
- Arrange group meetings, including coordinating group member availability and booking learning space in campus libraries as necessary
- Currently, group availability has been Fridays between 12pm and 1pm, and most recently, the group has met in a study room in Lockwood to discuss this particular Gate. Future meetings will be similarly planned.
- Preside over group discussions and mediate group conflicts
- Should a conflict arise and the project manager be unable to mediate alone, a democratic process including a majority vote on the issue at hand will result. Ramifications for poor behavior in the group will result in a poor evaluation from members at the end of the project
These roles have been defined in light of the skills and experience that these members have in accomplishing the tasks required for the Gates to be completed.
Computer Technology Expert - Kyle Schmidt
- Solid model components as necessary
- Manage wiki page
- Research any media which can be used and suggest additions to written materials as appropriate
- Organize and format any multimedia resources used by the group, including any video, photos and animation as needed.
Dis-assembly Technicians - Spencer Heyden and Michael Wrona
- Research product for the purposes of dissection strategy
- Develop an order of operations and communicate plan to members before dissection
- Lead the dissection process by delegating tasks to members and making sure that procedure is followed
In order to understand the development of the impact wrench it is necessary to begin with the advances that were made in compressed air technology. Compressed air was first used in pneumatic devices in the 17th century by Otto von Guericke for ideal environments for his science experiments. The pneumatic hammer and the pneumatic drill, which are both very similar to the impact wrench, were invented in the late 1800’s.
Market Influences and Impact
Impact wrenches in general were initially intended to be sold all over the world for industrial and commercial use. Advantages over other sources of torque have provided a market for the impact wrench and have driven many improvements in the design as well as research on how to increase efficiency in pneumatic devices and systems in general.
- Various materials and housing now used to optimize weight for the tool
- Improvements in the clutches to be manually changed to different settings and to provide higher torque
Solutions to Challenges
- Meets demand for more precision and accuracy in applied torque in manufacturing processes
- Automotive Repair
- Industry utilizes the large amount of torque applied by the impact wrench and its portability daily in the removal of tires and difficult bolts as well as in its assistance to stranded drivers
- Major demand for such a powerful and portable device created through increased use of automobiles and mass transit due to urban sprawl, longer commutes and thus greater wear on tires and need for efficient repairs
- Safety Needs
- Safe for work in areas of high risk of fire or electrocution to user
Market Expansion to Home Use
The impact wrench that will be dissected by the group is designed for home use. Households use the impact wrench for “Do-It-Yourselfers” who are working on projects that often require torque issues such as project cars, lower level racing circuits, and mechanics who work out of their garages.
The intended use for the product is the quick and efficient removal of bolts and other projects which require a wrench mechanism with either a powerful torque or a very precise torque. Although many impact wrenches on the market are for the automotive repair sector and other industry level usage, the impact wrench that is being dissected is for home use. Possible home uses include quick removal of tire bolts on the household’s automobiles as well as home improvement and construction projects which require a great amount of torque to fasten or remove nuts, bolts or screws.
Energy Profile: Air Compressor vs Electric Motor
Tradeoffs for Energy Efficiency: Advantages of Pneumatic Motors over Electric Motors
- Greater control over speed and greater power
- Ability to release pressure as a great amount of torque at once rather than maintain a lower torque through a less powerful electric motor over time
- Ability to store energy in the form of compressed air
- Financially advantageous when costs of electricity vary during peak and off peak times
- Useful when energy availability is inconsistent or unavailable
- Safety advantages
- No risk posed to user for electric shock
- Safe for use around highly flammable materials due to no risk of spark
- Possible to use in wet and some underwater conditions - compressed air prevents water from entering the air motor
- Air motors do not overheat when overloaded
A great part of the appeal of the device is its simplicity. The most complex interface will likely be the hammer and clutch interface.
- compressor inlet
|Compressor Inlet||combination of metal to prevent kinking of hose and rubber or plastic to create a better seal|
User Interaction Profile
The tool is very simple and intuitive to operate:
The tool is first attached to an air supply
- The tool is held in the user’s hands like a gun (hence impact gun)
- A switch is used to switch between tightening and loosening bolts
- Once bolt/nut is secured in the socket, a trigger is pulled
Maintenance of the product is also quite simple:
- Oil should be applied through the air inlet daily
Checking the tools performance :
- Output can be checked by tightening a nut onto a stud and then using a torque wrench to see if the working torque is achieved.
- If the working torque is not achieved, a rebuild is most likely necessary.