Gate 2 - Product Dissection (Group 24) - Revision history

MAE 277 2012 - Group 24: /* Assessment Questions */

2012-12-12T01:48:14Z

Assessment Questions

MAE 277 2012 - Group 24 at 23:08, 6 December 2012

2012-12-06T23:08:11Z

MAE 277 2012 - Group 24: /* Product Archeology: Product Dissection Step-By-Step Process */

2012-12-06T23:03:54Z

Product Archeology: Product Dissection Step-By-Step Process

MAE 277 2012 - Group 24 at 22:45, 6 December 2012

2012-12-06T22:45:32Z

MAE 277 2012 - Group 24 at 22:44, 6 December 2012

2012-12-06T22:44:41Z

MAE 277 2012 - Group 24 at 22:44, 6 December 2012

2012-12-06T22:44:07Z

MAE 277 2012 - Group 24 at 22:31, 6 December 2012

2012-12-06T22:31:34Z

MAE 277 2012 - Group 24: /* Work Plan Assessment */

2012-12-06T22:20:58Z

Work Plan Assessment

MAE 277 2012 - Group 24: /* Introduction */

2012-12-06T22:11:02Z

Introduction

MAE 277 2012 - Group 24 at 22:05, 6 December 2012

2012-12-06T22:05:20Z

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 [[File:Presentation1-22.jpg|550px]]
-==Assessment Questions==
+==Subsystems==
-−
-Our CycloHBB contains 3 subsystems that are necessary for our module to function. It contains a reducer, a pinion attached to a shaft, and a gear that is attached to the output slot.
-−
 '''Physical:'''
+The SMCyclo HBB contains 3 subsystems that are necessary for our module to function. The reducer, which transfers the high rotational speed with a low torque to a low rotational speed with a higher torque. The pinion shaft which transmits the newly provided energy from the reducer and transmits it through the helical teeth located on the pinion to the helical teeth located  on the diameter of the gear. This rotational energy provided to the gear is then transmitted to a shaft that has been key slotted and fit on the inner diameter of the helical gear. This shaft is hollow to allow different modular fittings depending on the application.
 All three components work in unison to convert high speeds to torque and provide the transmitted energy to and output slot that can be modified for numerous uses.  The pinion shaft and the gear are lined up adjacent to one and other so that they lock together.  This way, when the pinion shaft rotates it also rotates the gear.
 '''Mass:'''
+Due to the amount of components moving within the gearbox and the reducer, the energy that is transferred through the unit loses efficiency. This loss of energy is due to the friction of that each mechanical part has on another. To minimize this loss of efficiency, the gear box and the reducer are filled with oil. The oil adds mass to the system but decreases the amount of thermal energy that is released from contact between the moving parts. The oil helps maximize the amount of energy provided by the system by minimizing the energy lost within the system, thus making it an essential part of all the subsystems.
-The Cyclo HBB was filled with oil adding to the efficiency of the physical connections.  The oil lubricated the steel on steel contact between the pinion shaft and the gear.  This reduced the mechanical energy lost due to friction and increased the efficiency of the process.
 '''Connections:'''
-The connections between the different components were carefully designed by SMCyclo simply for economic reasons. There patented design allows them to easily modify different parts to drastically change the function of their products. For example, the Taper Bushing can be easily removed to modify the type of output by inserting a drive shaft down the centrally located gear shaft inside of the gear. This can easily be done by the customer as well, thus attracting the consumer to buy SMCyclo products over others because there modules can be used for multiple applications. All other GSEE factors are not applicable and were not considered when designing this product.
+The connections between the different components were carefully designed by SMCyclo simply for economic reasons. There patented design allows them to easily modify different parts to drastically change the function of their products. For example, the Taper Bushing can be easily removed to modify the type of output by inserting a drive shaft down the centrally located gear shaft inside of the gear. This can easily be done by the customer as well, thus attracting the consumer to buy SMCyclo products over others because there modules can be used for multiple applications.
+The teeth of the pinion and the gear are helical, that is, at an angle. When geared teeth form an angle with one another the run quitter than traditional spurred gears. This is a major societal factor in the functionality of the gear box. For large operations the number of these units running at any given time can be quite high. If these machines are constantly running indoors the quieter the run the better. This is necessary for the work force behind the operation. Employees need to be able to communicate with each other and concentrate on the task at hand. Loud machines just add to distraction and effect the way employees communicate different objectives, especially if the work environment is fast paced, such as a package distribution company.
 <center>[[File:flowchartz.jpg|900px|]]</center>
 '''Subsystems:'''
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-<center>[[File:Capture2.jpg]]</center>
+<center>[[File:Capture2.jpg]]</

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 |Somewhat Difficult
 | Simple household tools/Little tool knowledge necessary
 |[[File:2 Star.png|125px]]
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 |Very Difficult
+|Non-household tools necessary
 |[[File:4 Star.png|125px]]
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 |Extremely Difficult
 |[[File:5 Star.png|125px]]

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 ! scope="col" | Difficulty
 ! scope="col" | Stars
 |-
 |Easy
 |[[File:1 Star.png|125px]]
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 |Somewhat Difficult
 |[[File:2 Star.png|125px]]
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 |Difficult
 |[[File:3 Star.png|125px]]
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 |Very Difficult
 |[[File:4 Star.png|125px]]

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 =Product Dissection=
 We dissected a Cyclo HBB Helical Gear Box.  During the dissection we took apart each component of gear box and carefully documented the process as we went forward.   The purpose of the dissection was to expose the internal mechanisms of the gear box, allowing us to analyze them later.
 ==Project Management: Preliminary Project Review==

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 [[Group 24 - Cyclo HBB Parallel Shaft Helical Gearbox with Cyclo Reducer Input]]
 =Introduction=
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-[[File:Banner.jpg|500px|thumb|Cyclo HBB Reducer Exploded View]]
 =Product Dissection=

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 ===Group Challenges===
-[[File:Vice Grips.jpg|500px|thumb|right|We decided this was dangerous.]]
+[[File:Vice Grips.jpg|500px|thumb|right|Here we are using two vice grips to generate more force to pull the Taper Bushing out of the shaft. We decided that this was dangerous and decided not to proceed.]]
 Our original work plan was not as effective as we thought. At the onset of the dissection we severely underestimated to complications that we would run into. Our plan was to all remove the external bolts in order to remove the casing cap that housed the love joy connection and the reducer and then simply slide the bushing out of the shaft. However, we were unaware that the bushing was threaded into the shaft. After applying quite a bit of force we determined that it must be threaded and we came up with a new plan of action. We did not have access to the proper tools in order to do this, so we improvised by clamping the bushing in place and spinning the reducer so that it would unscrew itself. (At that point in the project we were not aware that the machine shop was even an option at our disposal.) Our first attempt failed because we did not have enough force to clamp the bushing securely. We then clamped another vice grip onto the first one in order to generate more force. This looked very dangerous, so we decided against it and tried again to use one clamp. After a long, frustrating, and brutal hour we were able to unthread the bushing from the shaft.

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 Seeing as though our meetings were restricted to lab time, we needed to communicate regularly and discuss who could meet when.  We soon discovered that everybody would not always be available during lab openings.  This was one of the major issues that we faced   In order to resolve this, while getting the work done at the same time, we came to the conclusion that we would do a revolving dissection in which we would meet on alternating lab days to account for the days that different people could not show up.  This proved to be very effective because it made it easier for everybody to get involved without getting in the way of one and other.
-'''Unresolved:'''
+'''Future Challenges:'''
 Moving forward it is apparent that our schedules will continue to conflict with one and other.  We plan to lay out specific times that we can all meet to get work done, well in advance.  By doing this we hope to increase the transparency of the group thought process, decrease the amount of times that group members need to miss, and alleviate most of pressure put on group members during the scramble the night before a gate is due.  Our goal is to make sure that no one group member suffers unjustified workloads at any time, especially considering that we each have other pressures coming from different courses and outside sources.
 ==Product Archeology: Product Dissection Step-By-Step Process==

← Older revision		Revision as of 22:20, 6 December 2012
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	It was amazing how simple it was to finish taking apart the Helical Buddybox (HBB) once we started using the correct tools. As the dissection trudged forward it quickly became apparent that our original dissection plan underestimated the amount of time, the amount of work, and the overall complexity of the product. Our initial assessment didn’t even include the possibility of using a press or a bearing puller, both of which were integral to the products dissection. We credit our obstacles to our own ignorance about tools and our lack of knowledge about machinery. During the first gate we predicted that it would take about six hours to dissect our project. It turned out to take eleven hours in total, something that we were not expecting but we had enough for site to plan accordingly. This left us with ample room to take into account the error in our judgment. Furthermore, none of us had ever used a press or even heard of a bearing puller before we started work on this project. Without these tools we would never have been able to dissect the product.		It was amazing how simple it was to finish taking apart the Helical Buddybox (HBB) once we started using the correct tools. As the dissection trudged forward it quickly became apparent that our original dissection plan underestimated the amount of time, the amount of work, and the overall complexity of the product. Our initial assessment didn’t even include the possibility of using a press or a bearing puller, both of which were integral to the products dissection. We credit our obstacles to our own ignorance about tools and our lack of knowledge about machinery. During the first gate we predicted that it would take about six hours to dissect our project. It turned out to take eleven hours in total, something that we were not expecting but we had enough for site to plan accordingly. This left us with ample room to take into account the error in our judgment. Furthermore, none of us had ever used a press or even heard of a bearing puller before we started work on this project. Without these tools we would never have been able to dissect the product.
		+
		+	For all future challenges that may arise during the process of this course project we will setup meetings to productively brainstorm and derive solutions to effectively solve said challenges. It is a necessity that during this gate we are extremely organized and that every process is documented which will allow for an easy assembly process simply by following the disassembly process in reverse. Only if it is an absolute necessity will we consulte the manufacturers manual for more information to help us reassemble this complex product. We plan on moving forward as if we have no knowledge of the product and how it functions in order to properly reverse engineer the BuddyBox.

	===Intergroup Challenges===		===Intergroup Challenges===

← Older revision		Revision as of 22:05, 6 December 2012
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	In gate two our group dissected the Cyclo HBB Gearbox. The purpose of the dissection is to examine and later analyze the many different components inside of the gearbox. The following sections will allow any individual that may me unaware or unfamiliar with the SM Cyclo HBB Helical Gear Box to properly disassemble all mechanism and components.		In gate two our group dissected the Cyclo HBB Gearbox. The purpose of the dissection is to examine and later analyze the many different components inside of the gearbox. The following sections will allow any individual that may me unaware or unfamiliar with the SM Cyclo HBB Helical Gear Box to properly disassemble all mechanism and components.

−	""Warning: Normal household tools will not be sufficient to successfully dissect the Buddy Box.""	+	'''Warning: Normal household tools will not be sufficient to successfully dissect the Buddy Box.'''