Gate 3 - Group 4 - Revision history

MAE 277 2012 - Group 4: /* Design Revisions */

2012-11-16T20:12:18Z

Design Revisions

MAE 277 2012 - Group 4: /* 7th Component: Gears Assembly */

2012-11-16T20:08:26Z

7th Component: Gears Assembly

MAE 277 2012 - Group 4: /* 6th Component: Armature */

2012-11-16T19:58:58Z

6th Component: Armature

MAE 277 2012 - Group 4: /* 5th Component: Chuck Assembly */

2012-11-16T19:48:36Z

5th Component: Chuck Assembly

MAE 277 2012 - Group 4: /* Solid Modeled Assembly */

2012-11-16T19:41:55Z

Solid Modeled Assembly

MAE 277 2012 - Group 4: /* Design Revisions */

2012-11-16T19:34:41Z

Design Revisions

MAE 277 2012 - Group 4: /* Solid Modeled Assembly */

2012-11-16T19:32:58Z

Solid Modeled Assembly

MAE 277 2012 - Group 4: /* 4th Component: Handle Clamp */

2012-11-16T19:28:08Z

4th Component: Handle Clamp

MAE 277 2012 - Group 4: /* 3rd Component: Side Handle */

2012-11-16T19:21:31Z

3rd Component: Side Handle

MAE 277 2012 - Group 4: /* 2nd Component: Power Cord */

2012-11-16T19:11:07Z

2nd Component: Power Cord

@@ Line 537: / Line 537: @@
-[[File:Wireless_example_g4.JPG|thumb|150px|A wireless hammerdrill]]
+[[File:Wireless_example_g4.JPG|thumb|150px|A cordless hammerdrill]]
 *'''Revision 1:'''
 :'''Remove cord '''

@@ Line 400: / Line 400: @@
 *'''Manufacturing Methods'''<br/>
+:The gear assembly consists of two gears and a shaft.  The cylindrical shape of the gears is formed through cold forging.  This technique is often chosen because it strengthens the material by aligning it on a molecular level.  The teeth of the gears are then machined out by using a broaching machine.  Evidence of this can be seen in the tool marking left behind on the inside wall of each gear tooth.  Finally the gears are drilled out though the middle to create a hole for the shaft. The shaft is produce through turning and cut to length on a metal lathe.  The ends of the shaft are then drilled out while still on the lathe to produce a pocket to hold the ball bearing. Tooling marks are left on the shaft but it also has produced a semi smooth finish.  The gears are then forced onto the shaft by using a press.  The gears are the most critical part of the drill. They are going to be put through a lot of stress and need to be durable.  The cold forging produces a strong metal resistant to wear.
 *'''Component Complexity:'''<br/>

@@ Line 379: / Line 379: @@
 *'''Manufacturing Methods'''<br/>
+:The armature has several different components and subsequently required several different manufacturing methods including metal casting, injection molding, turning, stamping, adhesion and annealing.  The main shaft of the armature is produced through turning, reducing its diameter till desired diameter is reached.  Metal plates are stamped out and adhered together using a high temperature resistant epoxy.  Copper wire is then drawn to a desired thickness and put through an annealing process to reduce brittleness and increase the flexibility of the wire.  This wire is then wrapped around the metal plates producing an electric motor armature. A plastic fan is then produced through injection molding and added to the end of the shaft of the armature to help maintain cool temperatures inside of motor.  The armature assembly is then attached to the rear of the gear box housing.  The gear box housing was produced through metal casting.  Evidence of the metal casting can be seen in the rough edges left where the two dies came together.
 *'''Component Complexity:'''<br/>

@@ Line 358: / Line 358: @@
 *'''Manufacturing Methods'''<br/>
+:Due to the many components of the chuck assembly several manufacturing methods have been used to produce all of its parts.  The black gear housing is produced through injection molding.  Evidence of this can be seen in the gate marks left on the inside of it.  The Chuck is produced though turning, machining, broaching, vulcanizing and adhesion joining.  Metal rod is cut to length and put in a lathe.  The rod is then turned down to the desired diameter and the end of the barrel is cut at an angle to make a chamfer. Evidence of this can be seen in the tool markings left on the barrel of the chuck.  After turning the end of the rod is drilled out while still on the lathe.  The rod is then removed and placed on a drill press where the 3 key holes are drilled into the side of the barrel.  The end of the barrel is given its edging with a broaching machine.  The textured rubber grip around the barrel is produced through vulcanization and attached to the barrel with an adhesive such as an epoxy.  Due to the chuck assemblies intricate design and several materials, different manufacturing methods were needed.
 *'''Component Complexity:'''<br/>

@@ Line 454: / Line 454: @@
 [[File:ShaftsBallBearingGroup4.jpg|thumb|center|900px|Individual Part Drawings]]
 [[File:GearsGroup4.3.jpg|thumb|center|1000px|Individual Part Drawings]]
-[[File:AssemblyGroup4.3.jpg|thumb|center|1000px|Assembly Drawings]]
+[[File:AssemblyGroup4.4.jpg|thumb|center|1000px|Assembly Drawings]]
 [[File:AssemblyExplodedGroup4.2.jpg|thumb|center|950px|Assembly Drawings]]

@@ Line 537: / Line 537: @@
-[[File:Wireless_example_g4.JPG|thumb|150px|Gear Assembly]]
+[[File:Wireless_example_g4.JPG|thumb|150px|A wireless hammerdrill]]
 *'''Revision 1:'''
 :'''Remove cord '''
@@ Line 549: / Line 549: @@
-[[File:Light_example_g4.JPG|thumb|150px|Gear Assembly]]
+[[File:Light_example_g4.JPG|thumb|150px|A hammerdrill with an LED]]
 *'''Revision 2: '''
 :'''Add LED Light'''

@@ Line 412: / Line 412: @@
 ==='''Solid Modeled Assembly'''===
-*For our solid modeled components and assembly, we decided it would be best to show the interactions between the shafts and gears which allow for the product to work correctly. The assembly we formed consists of the motor shaft, the helical gear, the gear shaft, and it's ball bearing, the shaft gear, the chuck gear, the chuck shaft, and it's ball bearing. The ball bearings are what lie in between the connections of the shafts to the drill base and chuck base. Since the motor powers the drill, it was important to show the motor shaft interacting with the gear assembly. The gear assembly connects to the chuck shaft and therefore the drill bit. The motor shaft extends underneath the helical gear on the gear shaft, which also has a shaft gear on the other end. This shaft gear connects to the chuck gear above it which is held in place by the chuck shaft extending to the drill bit. The overall rotational motion in the drill bit is transferred from the motor through the shaft and gear components thus our reasoning to reveal this assembly; it is basic assembly which allows the hammer drill to function.
+*For our solid modeled components and assembly, we decided it would be best to show the interactions between the shafts and gears which allow for the product to work correctly. The assembly we formed consists of the motor shaft, the helical gear, the gear shaft, and it's ball bearing, the shaft gear, the chuck gear, the chuck shaft, and it's ball bearing. The ball bearings are what lie in between the connections of the shafts to the drill base and chuck base. Since the motor powers the drill, it was important to show the motor shaft interacting with the gear assembly. The gear assembly connects to the chuck shaft and therefore the drill bit. The motor shaft extends underneath the helical gear on the gear shaft, which also has a shaft gear on the other end. This shaft gear connects to the chuck gear above it which is held in place by the chuck shaft extending to the drill bit. The overall rotational motion in the drill bit is transferred from the motor through the shaft and gear components thus our reasoning to reveal this assembly; it is the most bare-bone assembly which allows for the hammer drill to function.
 {| border="4" cellspacing="0" cellpadding="3" align="center"
 |+

@@ Line 313: / Line 313: @@
 *'''Component Form'''<br/>
 [[File:Handle g4.JPG|thumb|250px|Handle]]
-:The side handle is made of a durable non flexible plastic. The handle is three dimensional, cylindrically shaped and it flares out at both ends. The handle is 7 inches long and an inch wide at the ends. The handles shape is ergonomically designed so it easily fits into a wide variety of hand sizes. The handle is solid plastic and weighs about a half pound. Economically, the manufacturers choose to make the handle out of plastic because it is very durable, cheap and recyclable. Also, not all drills include an extra removable handle. The manufacturers included it to improve the safety of the user and bystanders. Aesthetically, the handle is very basic. It is black and has grooves in it to help provide the user with more grip and less slippage. The handle also bears the Dewalt name on it. The handles finish is shiny, smooth and has the grooves to provide more grip.
+:The side handle is made of a durable non flexible plastic. The handle is three dimensional, cylindrically shaped and it flares out at both ends. The handle is 6 inches long and an inch wide at the ends. The handles shape is ergonomically designed so it easily fits into a wide variety of hand sizes. The handle is solid plastic and weighs about a half pound. Economically, the manufacturers choose to make the handle out of plastic because it is very durable, cheap and recyclable. Also, not all drills include an extra removable handle. The manufacturers included it to improve the safety of the user and bystanders. Aesthetically, the handle is very basic. It is black and has grooves in it to help provide the user with more grip and less slippage. The handle also bears the DeWALT name on it. The handles finish is shiny, smooth and has the grooves to provide more grip.
 *'''Manufacturing Methods'''<br/>
+:The handle is produced using injection molding and drilling.  Black plastic is forced into a mold producing the cylindrical shape and texture.  It is then drilled through the center to produce a hole running the length of the handle.  Evidence of the injection molding can be seen in the gate and runner marks on the side of the handle.  Evidence of the drilling can be seen in the tooling marks on the inside of the handle.  The choice to use a plastic allowed for a detailed texture to be manufactured on the handle.  If this handle was made out of metal a lathe would be used to produce the cylindrical shape and then the texture would also be applied through turning.  The handle would then be drilled out while still on the lathe.  Plastic allows the part to be produced in fewer manufacturing processes.
 *'''Component Complexity:'''<br/>
@@ Line 326: / Line 326: @@
 :'''Level:''' 1
 :*Human energy is imported onto the handle by the user to provide drill with more stability. The handle connects to the handle clamp and the handle clamp is attached to the drill.
 ====''4th Component: Handle Clamp''====

@@ Line 296: / Line 296: @@
 :The power cord is made of a flexible and durable rubber allowing it to be bent and folded into any shape. The cord is primarily cylindrical in shape. The cord is about one centimeter thick. At the end of the cord is a 3 prong wall adapter. Due to the flexibility of the cord, the drill can be used around any obstacle. The metal prongs on the wall adapter transfer electrical energy from the power outlet to the drill. The cord is very light. It weighs about a pound. The outer layer of the cord is made of rubber. This rubber protects the copper wire inside that transfers the electrical energy to the drill.The rubber outer layer acts as an insulater on the copper wire making it safe to touch the power cord while it is plugged into the wall.The inner wire had to be made of something conductive. Copper is an electrical conductor and is a relatively cheap metal. The plastic plug portion of the cord is made through injection molding which is cheap and very efficient. The plastic used can be recycled at the end of the drills life cycle. Aesthetically, the power cord is thin and black making it as unnoticeable as possible. The surface finish of the power cord is smooth and shiny making it able to slide against surfaces without damaging them.
 *'''Manufacturing Methods'''<br/>
+:Several methods are used to produce the power cord including drawing, vulcanizing and soldering.  The copper is first drawn to its desired thickness.  After drawing, the copper is somewhat brittle so the copper wired is put through an annealing process.  THe annealing process allows for the copper wire to bend without breaking.  The copper is then soldered to the prongs for the plug.  All of this is then loaded into an autoclave with black rubber and vulcanized to its final desired shape.  Vulcanizing is used to "set" raw rubber into a desired shape.  It heats the rubber to a specific temperature and pressure. When the rubber cools it retains the shape it was heated in.  The rubber provides a protective casing around the copper.  Evidence of vulcanizing can be seen in a cross section of the power cord.  The rubber has completely filled all voids between the copper wiring showing that it had been heated to a melting point under pressure.  The shape of the cord needed to be flexible so the copper needed to go through an annealing process and rubber was needed as a protective casing due to its flexibility.
 *'''Component Complexity:'''<br/>
@@ Line 305: / Line 305: @@
 :'''Level:''' 2
 :*The power cord provides electrical energy to the system. Without this electrical energy, the system is useless.
 ====''3rd Component: Side Handle''====