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−	==Complications==	+	==Cause For Corrective Action==
	1. '''Contribution'''		1. '''Contribution'''

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Revision as of 23:39, 15 November 2012

Contents 1 Gate Overview 2 Project Management 2.1 Revision of Team Roles 2.2 Cause For Corrective Action 3 Product Archaeology 3.1 Component Catalog 3.2 Product Analysis 3.2.1 Complexity 3.2.2 Components 3.2.2.1 1. Handle Assembly 3.2.2.2 2. Star Drag 3.2.2.3 3. Pinion Gear 3.2.2.4 4. Yoke 3.2.2.5 5. Clutch Lever 3.3 Engineering Analysis 3.4 Design Revisions 3.4.1 “Mono-handle” Handle assembly 3.4.2 Fully metallic gear system 3.4.3 Full Waterproof Casing

Gate Overview

Following the complete dissection of the Daiwa Baitcast Reel (Right Hand Retrieve), we moved on into a more detailed analysis of the various parts of the reel, both internal and external emphasizing our analysis mainly on four specific parts as can be seen below. We also had to re-assess our project management in order to maximize the team efficiency and co-operation.

Project Management

Revision of Team Roles

After observing the various roles that each individual in the team have undertaken, the team leader, Md. Fahad Hossain, re-appointed the management of the team so as to make the team more efficient in order to meet the necessary deadlines and to ensure all the goals are met. Thus, he proposed the following changes to the management:

• Connor McCafferty was made the new co-project manager.

Cause For Corrective Action

1. Contribution

At the beginning of the project, it was already made aware that the leading photo-editor of the team, Paul Tabellion, will not be able to provide 100% dedication to the project as he is also playing crucial roles in other projects appointed by the senior classes. Although special consideration was made with regard to his dilemma, his lack of contribution to the project did start to become an issue when it resulted in lowering the morality of the team, which may have lead to future conflicts in the group.

To eliminate such a possible obstacle, Paul was given more take home tasks while remaining absent for most of the meetings. Furthermore, he was asked to assist team leader, Fahad, and project co-manager, Connor, in compiling the data from the other members in and after meeting hours.

2. Dedication

Throughout the project and the various meetings, one recurring trait that was observed in Kevin Dailey was his absence in most meetings and his lack of any interest in the project whatsoever. His technical knowledge of the internal workings of the reel is unparalleled in the group, however, the remaining members wished to see more contribution from our technical expert.

To resolve this, he was frequently consulted with whenever it came to issues regarding the mechanism of the reel and he was also given more take home tasks unlike the remainder of the team. He has since, proved his worth as he completed all of his work with the required amount of detailed information. Although he has yet to exceed his expectations, he has proved his worth to the rest of the team.

3. Update

As various members of the group have various other duties just as compelling as the project, the number of group meetings had to be increased so as to allow for each member of the group to contribute efficiently to the project and remain up-to-date. Three new meetings were conducted in the following times:

New Meetings

Monday	12:00 p.m. - 2:00 p.m.
Wednesday	12:00 p.m. - 2:00 p.m.
Friday	12:00 p.m. - 2:00 p.m.

Product Archaeology

Component Catalog

Here is a complete catalog of all the parts that were present in the Daiwa Baitcast Reel (Right Hand Retrieve).

Note: As the internal braking system was exempted from our analysis of the reel to retain the proper functionality of out product during and after its usage in the project, any parts associated with that system were excluded from the catalog. The fields associated with these parts have an N/A and the part names have a '*' beside them.

Individual Catalog

Key	Photo	Part	Number of Times Used	Manufacturing Process Used	Material	Function
1	N/A	Set Plate Screw (S)*	N/A	N/A	N/A	N/A
2	N/A	Set Plate Spring*	N/A	N/A	N/A	N/A
3	N/A	Brake adjusting knob (S)*	N/A	N/A	N/A	N/A
4	N/A	Brake click spring*	N/A	N/A	N/A	N/A
5	N/A	Brake dial retainer (A)*	N/A	N/A	N/A	N/A
6	N/A	Left side plate*	N/A	N/A	N/A	N/A
7	N/A	Brake dial retainer (B)*	N/A	N/A	N/A	N/A
8	N/A	Set Plate*	N/A	N/A	N/A	N/A
9		Screw	1	Rolling	Metal	Holds down the set plate (Part 8)
10	N/A	Magnet Holder*	N/A	N/A	N/A	N/A
11	N/A	Magnet Holder Retainer Ring*	N/A	N/A	N/A	N/A
12	N/A	Spacer (A)*	N/A	N/A	N/A	N/A
13	N/A	Ball Bearing (A)*	N/A	N/A	N/A	N/A
14	N/A	Bearing Retainer*	N/A	N/A	N/A	N/A
15		Spool Assembly	1	Machined/Milled	Metal	Holds the line and rotates
16		Spool Assembly	1	Machined/Milled	Metal	Holds the line and rotates
17		Spool Assembly	1	Machined/Milled	Metal	Holds the line and rotates
18		Spacer (B)	1	Injection Molding	Plastic	Holds the clutch lever
19		Clutch Lever	1	Injection Molding	Plastic	Moves Clutch Cam
20		Spacer ( C )	1	Injection Molding	Plastic	Holds the clutch lever
21		Frame Assembly	1	Injection Molding	Plastic	Holds the clutch lever
22	N/A	Worm Shaft Retainer*	N/A	N/A	N/A	N/A
23	N/A	Spool Pin*	N/A	N/A	N/A	N/A
24	N/A	Worm Shaft Washer*	N/A	N/A	N/A	N/A
25		Clutch Cam Spring (A)	1	Drawing	Meal	Holds Clutch Cam
26		Clutch Cam	1	Die-Casting	Metal	Moves the clutch trip plate
27		Screw	1	Rolling	Metal	Holds pieces together
28		Clutch Trip Plate	1	Die-Casting	Metal	Responds to when clutch cam moves and engages the ratchet
29		Clutch Cam Spring (B)	1	Drawing	Metal	Holds Clutch Cam
30		Yoke	1	Injection Molding	Plastic	When used, raises the pinion gear
31		Yoke Spring	2	Drawing	Metal	Holds the yoke in place
32		Washer (B)	1	Extrusion	Metal	Spacer
33		Pinion Gear	1	Die-Casting/Machining	Metal	Translates motion from the shaft to the spool
34		Bearing Retainer	1	Drawing	Metal	Hold the ball bearing
35		Ball Bearing (B)	1	Machined	Metal	Reduces friction
36		Right Side Plate	1	Injection Molding	Plastic	Protect internal components
37		Screw	2	Rolling	Metal	Holds pieces together
38		Screw	1	Rolling	Metal	Holds pieces together
39		Spacer (D)	1	Injection Molding	Plastic	Spacer
40		Spacer (E)	1	Injection Molding	Plastic	Spacer
41		Cast Control Cap (S)	1	Injection Molding	Plastic	Applies force to the spool
42		Long Screw	1	Rolling	Metal	Holds together both sides of the spool assembly and allows the line guide so slide along it without rotating about the level wind guard
43		Line Guide	1	Injection Molding	Plastic	Guides the line and slides along the level wind guard along the worm shaft. Rotating the worm shaft slides the line guide
44	N/A	Line Guide Pawl*	N/A	N/A	N/A	N/A
45	N/A	Washer ( C )*	N/A	N/A	N/A	N/A
46		Line Pawl Cap	1	Injection Molding	Plastic	Undefined
47		Level Wind Guard	1	Injection Molding	Plastic	Protects the worm shaft
48		Worm Shaft	1	Machined	Metal	Holds line
49		Worm Shaft Gear	1	Injection Molding	Plastic	Translate motion to the worm shaft
50		Gear Retainer	1	Extrusion	Metal	Holds worm shaft gear to worm shaft
51		Clutch Lever	1	Injection Molding	Plastic	Aesthetic
52		Ball Bearing ( C )	1	Machined	Metal	Reduces friction
53		Drive Gear Shaft Retainer (B)	1	Extrusion	Metal	Holds down drive gear shaft retainer (A) to shaft
54		Drive Gear Shaft Retainer (A)	1	Die-Casting	Metal	Helps hold the shaft in place
55		Screw	2	Rolling	Metal	Holds down drive gear shaft retainer (A)
56		Drive Shaft	1	Die-Casting/Machined	Metal	Holds the gears and translates motion
57		Oscillation Gear	1	Injection Molding	Plastic	Translates motion from the shaft to the worm drive
58		Spacer (F)	2	Injection Molding	Plastic	Spacer
59		Anti-reverse Ratchet	1	Machined	Metal	One-way rotation of the shaft when the clutch lever is engaged
60		Anti-reverse Pawl	1	Machined	Metal	Assures ratchet can only rotate in one direction
61		Drive Gear	1	Machined	Metal	Center gear of gear system
62		Drag Washer	1	Machined	Metal	Creates friction
63		Key Washer	1	Machined	Metal	Spacer/Grips shaft
64		Gear Shaft Collar	1	Extrusion/Milled	Metal	Spacer between the gears and the casing
65		Roller Clutch	1	Injection Molding/Machined	Plastic	Reduces friction
66		Ball Bearing (D)	1	Machined	Metal	Reduces friction
67		Spacing Washer	2	Extrusion	Metal	Spacer
68		Plate	1	Extrusion	Metal	Holds the Leaf Spring
69		Leaf Spring (A)	1	Drawing	Metal	Detects tension in the fishing line
70		Drag Spring Washer	2	Extrusion	Metal	Spacer
71		Star Drag	1	Injection Molding	Plastic	Change resistance of reel
72		Leaf Spring (B)	1	?	Aluminum	?
73		Handle Assembly (S)	1	Machined (CNC)	Plastic/Metal	Apply torque
74		Handle Nut	1	Die-Casting/Machined	Metal	Holds the handle on
75		Handle Nut Plate (S)	1	Injection Molding	Plastic	Aesthetic
76		Screw	1	Rolling	Metal	Holds down the Handle nut and plate to the handle
77		O-ring	1	Injection Molding	Rubber	Seals the cap and right side plate together

Product Analysis

After documenting the basic detailed information about all of the components associated with the reel, we moved on to perform a thorough analysis of seven parts of the reel.

Handle Assembly (73): The handle assembly was chosen because it is the first part that the user interacts with. It is the first step in the mechanical energy flow through the systems of the reel.

Star Drag (71): The star drag was chosen because it is an external component that interacts with internal components, meaning that both aesthetic and functional value are placed on this part.

Pinion Gear (33): The pinion gear was chosen because it performs a relatively complex function, and is made from a material scarcely found within the reel.

Yoke (30): The yoke was chosen because it has a unique shape, and is a step in a flow of energy that performs a complex task.

Clutch Lever (19): The clutch lever was chosen because it is an external part that is the first step in a flow of mechanical energy within the reel. Much aesthetic value was placed on the design of this part.

Complexity

To help with the in-depth analysis, we came up with a complexity scale. The complexity of each part was decided by observing two different aspects of the parts, namely, how difficult was it to manufacture and how complex were it's interaction with its neighboring components. Thus the following two tables will be referred to during the analysis:

Manufacturing Complexity Scale

Value	Description
1	Any part that was created using a single manufacturing process. Including but not limited to: die-casting, injection molding, forging.
2	Any part that required 2 simple manufacturing processes.
3	Any part that required a difficult process such as turning.
4	Any part that required a difficult process and other processes, such as: forging then milling.

Interaction Complexity Scale

Value	Description
0	Any part that performs no contribution to function. Including parts that serve for purely aesthetic value.
1	A part that has one simple interaction with neighboring parts, such as a spacer, bearing, or washer.
2	A simple interaction that influences more than one other part.
3	Any part which serves an important role in a complex interaction within the product. Includes parts such as: gears, worm drive.

Components

1. Handle Assembly

Component	Image	Manufacturing Complexity	Interaction Complexity
Handle Assembly		2	1

Component Function

• To provide a platform for the user through which he may introduce the mechanical energy needed to operate the reel.
• It helps to translate the energy into the drive shaft (56) that is connected to the internal systems.

Component Form

• It is 'U' shaped with the two handles connected via an arm.
• It has a smooth, ergonomic outer finishing with smooth edges.
• It is axis-symmetrical with 2 holes on each side of the arm.
• It has a 3 dimensional shape.
• The overall size of the handle plus arm is 9 cm x 4 cm (approx.)
• The symmetrical property allows equal translation of mechanical energy no matter which handle is used during rotation.
• The arm is made of steel, probably plated due to the smooth and shiny finish.
• The two handles at each end were plastic/rubber.
• Steel was used in the arm because the material needs to be strong and durable as it undergoes heavy strain during its translation of energy. Yet, it also has to be light so as not to add extra strain on the user.
• The handles are which come into direct contact with the user ( that is via the fingers when grasped ). Thus the material should provide adequate grip while not applying too much stress on the fingers. (societal)
• The whole arm and handle system is only made up of two different materials so as to best recycle the product with ease. (Environmental)
• Thus, mass production is easier with lower unit costs. (Economical)
• It is part of the outer systems of the reel, thus is made as aesthetic as possible.
• The arm is silver while the two handles are gray. The colors go well together forming a good contrast and as only the arm is shiny, it is easy to distinguish the handle from the rest of the system.

Manufacturing Methods

• Arm was forged while the handles were injection molded.
• This can be easily seen as the overall shape of the arm was horizontal with slight level changes throughout the thick metal. The overall geometry of the arm is quite simple and it can be easily attained from a single mold. The metallic arm could be made through various methods, however, forging seems to be the most cost effective in this case.
• The handles have a parting line and drafts are present as well. Plastic is nearly always made through injection molding through which complex shapes can be achieved with ease.
• For this piece, of this size and shape, forging is the most economical. Any other method would probably yield a higher unit cost. (Economical)

Complexity

• The manufacturing complexity for this part was given a 2 as the process used to make the handles and that for the arm were two different types.
• The interaction complexity level for this would be 1 as all it does is rotate the drive shaft of the reel system.

2. Star Drag

Component	Image	Manufacturing Complexity	Interaction Complexity
Star Drag		2	3

Component Function

• Spinning the star drag either increases or decreases the drag on the spool (15), in turn increasing or decreasing the drag on the line.
• Friction is the force that the star drag relies on to perform its function.
• The star drag is directly attached to the drive shaft (56).

Component Form

• Like it's name suggests, the Star Drag is shaped much like a pointed start, symmetric about its axis with 5 points.
• It has a 3-dimensional shape.
• The dimension of the Star Drag is roughly a cylinder with diameter 5 cm, height 1 cm.
• The Star Drag is symmetric and ergonomic. The 5 pointed shape allows the user to easily grasp and spin it.
• It is made from plastic, and has a circular metal nut glued inside.
• It is much easier and cheaper to manufacture a part like this out of plastic rather than metal. This is why plastic was chosen for this part.
• The company had economics in mind when manufacturing this part.
• The Star Drag has a unique shape and a silver finish. This point to the fact that the part is meant to look good as it is on the outside of the fishing reel.

Manufacturing Methods

• The Star Drag was made by the injection molding of plastic.
• It is obvious that the Star Drag was injection molded because of the riser marks seen on the inside of the part.
• Injection molding is the best manufacturing process to create a plastic part with complex geometry like the Star Drag.
• The choice to mold the part out of plastic was influenced by global and economic factors. The part can be easily mass-produced anywhere since one standard mold exists for every Star Drag made for this reel.

Complexity

• The Star Drag was created by first the injection molding of plastic, and then the inlaying of the metal washer. Based on the scale defined for component complexity, the Star Drag has a complexity of 2.
• The complexity scale is defined by the manufacturing methods used to create the product. The Star Drag is a relatively simple component that can be injection molded on a mass scale, therefore defining its complexity.
• The Star Drag’s function is to compress the gears and washers along the drive shaft, in turn putting more or less drag on the spool. The Star Drag performs a simple function, but influences multiple parts within the reel. This interaction warrants a 3 based on our interaction complexity scale.

3. Pinion Gear

Component	Image	Manufacturing Complexity	Interaction Complexity
Pinion Gear		3	3

Component Function

• Translates motion from the drive gear (68) to the spool (15).
• When the handle (73) is rotated, the spool (15) will rotate; the pinion gear provides that connection.
• Energy flow is associated with the pinion gear, specifically mechanical energy.

Component Form

• The pinion gear is most similar to that of a cylinder, but has a groove near the middle where the yoke (30) fits in, and the bottom is closer to that of the bottom half of a cone. It is specifically a helical gear, denoted by the non-parallel structure of its teeth.
• It is a 3-dimensional piece with a diameter of 0.6cm on the top and 0.7cm on the bottom. Its height is 1.5cm.
• Its cylindrical shape allows it to rotate smoothly, and the grooves allow it to fit into the grooves of other gears, translating mechanical energy. It weighs about 5 grams.
• It is made of some type of metal. Perhaps because it is such an important gear, it was made of metal. This gear will rotate very fast depending on the speed the spool (15) or handle (73) rotates. As one of the gears that will have the most force applied to it, its durability is very important.
• The only aesthetic property is the metal makes the part shiny and smooth. The smoothness of the bottom part of the pinion gear is very noticeable and allows it to lose very little energy to friction. The finishing helps to keep the helical gears running smoothly.

Manufacturing Methods

• The part was Die-Cast, and the details were CNC machined. The gears body was most likely die-cast because it is made of metal. The teeth were CNC machined as the smooth finishing with a few key marks are evidence of machining.
• Economically, die-casting is the most efficient way of creating gears. The machining then allows for the accuracy needed for the creation of the gear’s teeth.

Complexity

• The manufacturing complexity should be 3 because it is produced by two fairly simple processes; die casting and machining. There are two different gear ratios for the two ends.

• The interaction complexity should be 3. The first interaction is fairly simple where it is being raised/lowered by the yolk. Then 2 more complicated reactions takes place where energy is being translated from gear 68 to the pinion gear to the spool.

4. Yoke

Component	Image	Manufacturing Complexity	Interaction Complexity
Yoke		1	2

Component Function

• When lifted by the clutch cam (26) it disengages the pinion gear (33) from the spool assembly allowing the spool to rotate freely.
• Flow of Mechanical Energy
• Internal environment as in part of the internal machinery.

Component Form

• A slightly bent rectangle, bent about the middle.
• Symmetrical about its axis where the bend is.
• Primarily 2-dimensional
• Length – 3.5cm. Width (average) – 0.6cm
• In the center, there is a radial area where the pinion gear (33) slides in. It allows the pinion gear to rotate without translating this rotational motion to the yoke. The bottom of the yoke has 2 grooves that fit onto protruding parts of the clutch cam (26). When the clutch cam (26) is engaged, it slides along the grooves of the yoke, pushing the yoke up, which pushes the pinion gear and disengages it from the spool.
• It is made of plastic.
• The material chosen is not important because it is only moving up and down/lowering raising another part. Therefore plastic can be used to keep the part cheap. (Economic Factor).
• There are no aesthetic properties; it is purely a functional part because it is an internal part

Manufacturing Methods

• Injection molding was used, evidenced because it is made of plastic, and by some marks that indicate a mold was used.
• This method is cost efficient and allows the part to be produced. (Economic)

Complexity

• The manufacturing complexity is 1 as injection molding is cheap and simple.
• Interaction complexity is 2 because it has 2 simple interactions: gets raised/lowered by clutch cam (26) and raises/lowers pinion gear (33).

5. Clutch Lever

Component	Image	Manufacturing Complexity	Interaction Complexity
Clutch Lever		1	2

Component Function

• The clutch lever is operated by a push of the user’s thumb. When pushed, the clutch lever rotates the clutch cam (26) which then raises the pinion gear (33), disengaging the drive gear (61) allowing the spool (15) to spin freely.
• The clutch lever is the first step in a series of mechanical energy flow which end results in the free rotation of the spool (15).
• Being on the outside part of our product, this component is directly going to interact with the external environment. Therefore, it will be functioning in a fresh or salt water environment.

Component Form

• It has a complex shape with multiple curves.
• It is three dimensional and symmetric in nature.
• length: 28mm x Width: 23 mm x height: 10 mm.
• The lever needs to be accessible easily and quickly. Thus it was designed to be broad and one of the surfaces resembles a human thumb for better access.
• The Clutch lever of our fishing reel is made of plastic.
• This part is going to function in a fresh or salt water environment. Thus the material should be such that it is not affected by the external materials while still retaining some strength for functionality. Thus plastic was used instead of the steel due to its corrosive resistant property. (Global)
• The parts that are interacting with the user were smoothed out with no sharp edges. Also, it should be easily distinguished from the other parts, thus the shiny finish. (Societal)
• The whole part is made of just plastic and so, it is easily recycled. (Environmental)
• The overall finish is smooth, shiny and ergonomic mainly for ease of access.

Manufacturing Methods

• This part was made through injection molding which can be easily understood due to the presence of the parting lines. Plastic can only be injection molded or CNC machined, however, the later method would prove to be more cost inefficient to use. (Economical)
• There is a lot less material wastage in injection molding when compared with CNC machining. (Environmental)

Complexity

• Manufacturing complexity would be of level 1 as only one simple method was used in the production of this part.
• The interaction level would be 2 as although it interacts with only one part, it results in a chain reaction.

Engineering Analysis

• Assumptions:

• Governing Equations:

• Discussions:

Design Revisions

The product we are dissecting this semester is a Daiwa Baitcast Reel developed for right-handed people. The main purpose of this product is to be easy to use as well as light-weight. Efficiency and reliability are also obvious requirements that have been taken into account to make it meet its performances.

While this product is well designed and engineered, it is not perfect; there are a multitude of design revisions that could be addressed to make it meet more adequately its requirements and be more effective and economical.

“Mono-handle” Handle assembly

Currently, our Daiwa Baitcast Reel is equipped with a “double-handle” Handle assembly. This is obviously a design choice made to have a Handle assembly easier to reach for. However, this design choice is cause for usage discomfort and, even if it’s moderate, extra weight. The usage discomfort comes from the position of the Star drag. This component is located directly behind the Handle assembly. As a consequence, a “double-handle” Handle assembly makes it very difficult to reach for. Also, this type of assembly doesn’t allow the user to reel the handle back and forth as freely as possible. While holding one of the handles, the other one always ends up being in contact with the user’s hand.

A “mono-handle” assembly would prevent all of this. It would make the Star drag easier to reach for and the Handle assembly easier to operate. It would however make it less easy to reach for. Additionally, this would make the whole system more weight and cost-effective.

Summary of Four Factors improvements

• Societal: Star drag easier to reach for
• Societal: Handle assembly easier to operate
• Economical/Societal: Assembly more weight-effective
• Economical: Assembly composed of less parts and material, resulting in more cost effectiveness

Fully metallic gear system

Currently, our Daiwa Baitcast Reel is composed of both metallic and plastic gears. Although plastic gears are a great deal in terms of cost and weight, they fallow up as well when looking at performances. The lifecycle of a plastic gear assembly is a lot shorter than the one of a metallic system because the material itself is much more damageable. A plastic assembly is less likely to survive repeated stresses and constraints on the long run. As a result, plastic gear components may require more maintenance operations and parts replacement.

The primary target for our product is professional anglers which will most likely perform maintenance operations themselves. Therefore, maintenance is a big issue. Having a product which is more likely to last on the long run is a primary requirement. Having a fully metallic gear system would offer a more robust product. The gears would be less likely to fail over time, and there would be less need for maintenance and par replacement. The reel would also be able to reach higher performances, allowing anglers to work on bigger fish without any risk of material failure.

Summary of Four Factors improvements

• Societal: More robust product; less risk of material failure
• Societal: Lower need for maintenance operations
• Societal: Higher range of performances; ability to work on bigger fish

Full Waterproof Casing

A fishing reel is used close to water for its entire life cycle. The Daiwa Baitcast Reel currently has no means of waterproofing. Many of the internal components are made of metal, so they may easily rust–permanently damaging the function of the reel. We propose fully waterproofing the outer casing to prevent water from affecting the internal components. This waterproofing system would consist of rubber seals along the edge of the outer casing. O-ring seals would also be used anywhere external components enter the inner casing, such as around the drive shaft (56) and around the clutch lever (19). This system would increase the cost of the reel, but improve the overall life cycle and performance.

Summary of Four Factors improvements

• Environmental: The implementation of a waterproofing system would increase the overall life cycle of the reel, meaning less reels would be thrown away.
• Societal: Because moisture would no longer be able to affect the internal components of the reel, performance would be improved.