Gate 4 - Product Explanation (Group 24)
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|Difficulty:[[File:5 Star.png|125px]] | |Difficulty:[[File:5 Star.png|125px]] | ||
| − | ''This step received a difficulty of five because it is very hard to | + | ''This step received a difficulty of five because it is very hard to suspend the gear while placing the bearings into the track. None of the bearings were secure until most of them were put back into place. While we were adding more bearings, the previous bearings would fall out of the track.'' |
|Insert Ball Bearings into the track made between the shaft and the casing. These bearings prevent the gear and the shaft from shifting in the casing while still allowing rotation. | |Insert Ball Bearings into the track made between the shaft and the casing. These bearings prevent the gear and the shaft from shifting in the casing while still allowing rotation. | ||
Revision as of 01:08, 30 November 2012
Group 24 - Cyclo HBB Parallel Shaft Helical Gearbox with Cyclo Reducer Input
Contents |
Project Management: Coordination Review
Cause for Corrective Action
Group Challenges
Intergroup Challenges
Resolved Challenges:
Unresolved Challenges:
Product Archeology: Product Explanation
Product Reassembly
Upon dissecting and reassembly the Cyclo HBB Buddy Box it is clear that it was originally assembled by a machine. Many of the parts require a press, and the ones that do not still require very precise fits. Also, the difficulty level of some of the steps indicates that it would be too time consuming, too costly, and too frustrating to be assembled by hand. Finally, while we were assembling the HBB Buddy Box we noticed that there were many areas in which it would be far too easy to damage the product while assembling it by hand. Using robotics and machinery to assemble this product would allow for very precise and extremely challenging steps to be done quickly and more cost effectively. The utter weight of this product alone is an indicator that machines were used to assemble this product. It would be dangerous and extremely cumbersome for employees to be moving, flipping, and otherwise handling this product during the assembly.
- The assembly was exactly the same as the disassembly in reverse order.
| Difficulty | Stars |
|---|---|
| Easy | 
|
| Somewhat Difficult | 
|
| Difficult | 
|
| Very Difficult | 
|
| Extremely Difficult | 
|
| Step | Difficulty | Description | Picture |
|---|---|---|---|
| 1 | Difficulty:
|
Screw in one oil plug and one breather into the two oil plug holes on the casing. | 300px |
| 2 | Difficulty:
|
Screw in the other two breathers into the two breather holes on the casing. | 300px |
| 3 | Difficulty:
|
Slide the gear into the gear box. | 300px |
| 4 | Difficulty:
|
Attach the Face Plate to the casing. | 300px |
| 5 | Difficulty:
This step received a difficulty of two because it was tedious. |
Thread each of the eight screws through the Face Plate into the Casing, securing the Face Plate to the Casing. | 300px |
| 6 | Difficulty:
This step received a difficulty of four because it required a press. |
Press the shaft and the shaft key into the gear slot. | 300px |
| 7 | Difficulty:
This step received a difficulty of four because it required a press. |
Press the Ball Bearing Casing onto the Shaft. | 300px |
| 8 | Difficulty:
This step received a difficulty of five because it is very hard to suspend the gear while placing the bearings into the track. None of the bearings were secure until most of them were put back into place. While we were adding more bearings, the previous bearings would fall out of the track. |
Insert Ball Bearings into the track made between the shaft and the casing. These bearings prevent the gear and the shaft from shifting in the casing while still allowing rotation.
|
300px |
| 9 | Difficulty:
This step received a difficulty level of two because of the precise fit of the seals. |
Insert two rubber seals around the exposed part of the top side of the shaft. | 300px |
| 10 | Difficulty:
This step received a difficulty level of two because of the precise fit of the seals. |
Insert two rubber seals around the exposed part of the bottom side of the shaft. | 300px |
| 11 | Difficulty:
|
Slide the Thrust Plate over shaft of the Taper Bushing. | 300px |
| 12 | Difficulty:
This step received a difficulty level of three because it took quite a bit of force to screw the Taper Bushing back into the Shaft. |
Screw the Taper Bushing into the threaded slot of the Shaft. | 300px |
| 13 | Difficulty:
This step received a difficulty of two just because it was tedious. |
Screw the six Bushing Screws into the Taper Bushing, expanding the gap between the Thrust Plate and the head of the Taper Bushing. | 300px |
| 14 | Difficulty:
|
Slide the two seals onto the shaft of the pinion. | 300px |
| 15 | Difficulty:
This step received a difficulty of four because it required a press. |
Press the pinion onto the Taper Grip Bushing. Make sure to align the teeth of the Pinion with the grooves on the Taper Grip Bushing. | 300px |
| 16 | Difficulty:
This step received a difficulty of four because it required a press. |
Press the High Speed Shaft Ball Bearing A onto the High Speed Shaft. | 300px |
| 17 | Difficulty:
|
Slide the High Speed Shaft into the High Speed End Shield. | 300px |
| 18 | Difficulty:
|
Slide the spacer onto High Speed Shaft. | 300px |
| 19 | Difficulty: N/A
The difficulty here is not applicable because we were unable to complete this step. |
Clip the snap ring onto the High Speed Shaft to secure bearing and the spacer. This step makes sure that the assembly remains secure to the High Speed End Shield.
|
There is no photo available for this step. |
| 20 | Difficulty:
|
Slide the Eccentric Bearing Key into the slot onto the High Speed Shaft. | 300px |
| 21 | Difficulty:
This step received a difficulty of four because it required a press.;; |
Press the Eccentric Bearing onto the High Speed Shaft.
|
300px |
| 22 | Difficulty:
This step was difficult because of it was challenging to slide the Cycloid Disk around the offset bearings on the Eccentric Bearing. |
Slide the Cycloid Disk onto the lower part of the Eccentric Bearing.
|
300px |
| 23 | Difficulty:
|
Slide the Cycloid Disk Space around the Eccentric Bearing. | 300px |
| 24 | Difficulty:
This step received a difficulty of two simply because of the precise fit between the Cycloid Disk and the Eccentric Bearing. |
Slide the second Cycloid Disk onto the upper part of the Eccentric Bearing.
|
300px |
| 25 | Difficulty:
|
Make sure that the etchings of the Cycloid Disks are aligned as shown in the accompanying photo.
|
 |
| 26 | Difficulty:
|
Slide the spacer onto the High Speed Shaft. | 300px |
| 27 | Difficulty:
This step received a difficulty of four because it required a press. |
Press the High Speed Shaft Ball Bearing B onto the High Speed Shaft. | 300px |
| 28 | Difficulty: N/A
The difficulty is not applicable because we were unable to complete this step. |
Attach a snap ring onto the end of the high speed shaft, securing the entire assembly below.
|
There is no photo available for this step. |
| 29 | Difficulty:
|
Set the Ring Gear Housing onto the High Speed End Shield.
|
300px |
| 30 | Difficulty:
This is difficult because it is very hard to set each of the pins and rollers into the slots while simultaneously making sure that they sit nicely in the tracks, while also keeping the Ring Gear Housing Securely Attached to the High Speed End Shield. |
Insert the ring gear housing pins and rollers into the Ring Gear Housing.
|
300px |
| 31 | Difficulty:
This step received a difficulty of four because it required a press. |
Press the Pinion and the Taper Grip Busing Assembly into the Gear Box.
|
300px |
| 32 | Difficulty:
This step received a difficulty of four because it required a press. |
Press the Ball Bearing simultaneously around the end of the pinion shaft and the hole in the bottom of the gear box.
|
300px |
| 33 | Difficulty:
|
Slide the eight Slow Speed Rollers around the eight pins on the Taper Grip Bushing. | 300px |
| 34 | Difficulty:
This step received a difficulty of five because it is extremely challenging to pick up the entire reducer subsystem and slide it onto the pins of another subsystem while making sure that none of the components of the reducer subsystem move out of place. |
Slide the holes of both, offset, Cycloid disks around the Slow Speed Rollers, and the pins on the Taper Grip Bushing.
|
|
| 35 | Difficulty:
|
Slide the High Speed Shaft Oil Seal onto the High Speed Shaft. | 300px |
| 36 | Difficulty:
|
Slide the key into the key slot on the expose part of the High Speed Shaft. | 300px |
| 37 | Difficulty:
This step received a difficulty of four because it required a press. |
Press the Lovejoi Connector onto the end of the High Speed Shaft.
|
300px |
| 38 | Difficulty:
|
Slide the eight bolts on the Input HUB through the eight holes of the High Speed End Shield and the Ring Gear Housing. | 300px |
| 39 | Difficulty:
|
Slide the eight spring washers onto the eight exposed bolts from the Input HUB. | 300px |
| 40 | Difficulty:
This step received a difficulty level of two just because it was tedious. |
Secure the assembly by threading the eight nuts onto the exposed part of the eight bolts from the Input HUB | 300px |
