Group 13 - Kawasaki 1/2 in Electric Impact Wrench (12 V) - Revision history

MAE 277 2012 - Group 13 at 18:00, 14 December 2012

2012-12-14T18:00:52Z

MAE 277 2012 - Group 13 at 18:58, 7 December 2012

2012-12-07T18:58:35Z

MAE 277 2012 - Group 13 at 18:56, 7 December 2012

2012-12-07T18:56:13Z

MAE 277 2012 - Group 13 at 18:54, 7 December 2012

2012-12-07T18:54:34Z

MAE 277 2012 - Group 13 at 20:44, 30 November 2012

2012-11-30T20:44:22Z

MAE 277 2012 - Group 13 at 20:43, 30 November 2012

2012-11-30T20:43:08Z

MAE 277 2012 - Group 13 at 20:40, 30 November 2012

2012-11-30T20:40:39Z

MAE 277 2012 - Group 13 at 20:39, 16 November 2012

2012-11-16T20:39:05Z

MAE 277 2012 - Group 13 at 20:37, 16 November 2012

2012-11-16T20:37:51Z

MAE 277 2012 - Group 13 at 20:32, 16 November 2012

2012-11-16T20:32:33Z

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 =Technical Report=
-===Project Summary===
+:The following technical report contains detailed information about the 12 volt, ½ inch Kawasaki Drive Roadside Impact Wrench kit. This product takes the high-speed output from an electric motor and converts it into a low speed, high torque impact wrench. This impact wrench is used mostly on basic automobile wheels. An interesting aspect of the wrench’s component setup is that the hammer and anvil subsystems are opposite of what one might think, with the smaller output component being the anvil and the larger component being the hammer. The clutch setup is also very interesting. By using a type of centrifugal clutch it can disengage after initial impact, which then creates the desired high toque.
-:In this project we dissected a Kawasaki 12V impact wrench. We used the analysis process to document our findings. This process consists of analyzing each part and sub-system individually, and using a seven step process to document them. The disassembly was relatively simple. The only tools we used were a Philips head screw driver and needle nose pliers. Upon opening the casing we found a motor, hammer, trigger, and anvil. We dissected each individual part and found several sub-systems. After documenting each of these parts and subsystems, we began taking note of any design revisions that we saw fit. We found three major design revisions that we looked into further. These included a flashlight, battery pack, and a 3 position switch (in the trigger). We then looked into the advantages and disadvantages of each of these revisions. Finally, we reassembled the impact wrench and finished documenting our project.
+:To analyze the impact wrench the entire product was taken apart piece-by-piece, documenting our analysis using both pictures and in a technical paper. Viewing the layout of the subsystems and doing further research on the product itself, we were able to understand how the product worked. Using these methods we were able to figure out how the switch and motor work, what the hammer and anvil components are and how they work and how it all fit together. We were able to track the flow of energy through the wrench and determine how the hammer and anvil setup creates the low speed and high torque required for the device.
 == Product Archaeology ==

@@ Line 1: / Line 1: @@
 == Project Management ==
 === Work Proposal ===
@@ Line 77: / Line 74: @@
 =Technical Report=
 == Product Archaeology ==

@@ Line 75: / Line 75: @@
 :*We managed to fix all of the kinks in our group management. We now meet regularly 3 times a week which lessens the burden on all members. While we were hit with a major change (one of our group members dropping the class and not notifying us until one day prior to the gate 3 due date), we managed to pull together and finish this member's part.
 == Product Archaeology ==
 [[File:Impact_Wrench_Pic.jpg‎]]

← Older revision		Revision as of 18:54, 7 December 2012
Line 1:		Line 1:
	== Project Management ==		== Project Management ==
		+
		+	===Project Summary===
		+	:In this project we dissected a Kawasaki 12V impact wrench. We used the analysis process to document our findings. This process consists of analyzing each part and sub-system individually, and using a seven step process to document them. The disassembly was relatively simple. The only tools we used were a Philips head screw driver and needle nose pliers. Upon opening the casing we found a motor, hammer, trigger, and anvil. We dissected each individual part and found several sub-systems. After documenting each of these parts and subsystems, we began taking note of any design revisions that we saw fit. We found three major design revisions that we looked into further. These included a flashlight, battery pack, and a 3 position switch (in the trigger). We then looked into the advantages and disadvantages of each of these revisions. Finally, we reassembled the impact wrench and finished documenting our project.

	=== Work Proposal ===		=== Work Proposal ===

@@ Line 69: / Line 69: @@
 ::*Meeting efficiency. While in a meeting, we must immediately get to work to use our time as efficiently as possible. We must ensure that everyone is participating, for maximum efficiency and accuracy of the material. This will result in a less stressful, ideally shorter meeting in which we get a significant amount of work done.
-===Coordination Review===
+===Critical Project Review===
 :*We managed to fix all of the kinks in our group management. We now meet regularly 3 times a week which lessens the burden on all members. While we were hit with a major change (one of our group members dropping the class and not notifying us until one day prior to the gate 3 due date), we managed to pull together and finish this member's part.
@@ Line 509: / Line 509: @@
 ==Design Revisions==
-:1)One thing we noticed in was that the trigger assembly seemed overly complicated. It looked like it could be simplified by using a 3-position switch instead of having these little components that if they break would be hard to replace. This could save money for the manufacturer because it would be easier to manufacture and get parts for.
+:1) One thing we noticed in was that the trigger assembly seemed overly complicated. It looked like it could be simplified by using a 3-position switch instead of having these little components that if they break would be hard to replace. This could save money for the manufacturer because it would be easier to manufacture and get parts for.
-:2)The option of a battery pack should be included with the wrench. Since it runs of a 12 volt car jack, it is implied that it is supposed to be used with your car. If the cord is not long enough to get from the inside of your car to wherever you need it, the tool is useless. By giving it a battery pack the tools mobility is increased making it more appealing to consumers.
+:2) The option of a battery pack should be included with the wrench. Since it runs of a 12 volt car jack, it is implied that it is supposed to be used with your car. If the cord is not long enough to get from the inside of your car to wherever you need it, the tool is useless. By giving it a battery pack the tools mobility is increased making it more appealing to consumers.
-:3)With all the torque that will be applied to this tool it seems that the thin plastic casing would wear out quickly and wouldn’t last too long. Making the case completely out of metal also isn’t a viable option. Putting in metal supports at certain locations to absorb and disperse some of that energy would increase the tools life and efficiency. These supports, mostly around the motor, could help eliminate wear on the plastic that repeated impact would create by creating a firmer hold on the specific part and dispersing the energy over a larger area so one location isn’t constantly taking all the force.
+:3) With all the torque that will be applied to this tool it seems that the thin plastic casing would wear out quickly and wouldn’t last too long. Making the case completely out of metal also isn’t a viable option. Putting in metal supports at certain locations to absorb and disperse some of that energy would increase the tools life and efficiency. These supports, mostly around the motor, could help eliminate wear on the plastic that repeated impact would create by creating a firmer hold on the specific part and dispersing the energy over a larger area so one location isn’t constantly taking all the force.

← Older revision		Revision as of 20:43, 30 November 2012
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	While there is numerous mechanisms working in conjunction with each other within this wrench, for this section we will only be considering the ball-locking mechanism (US Patent 4480497) that holds the socket head in place. This is the mechanism that when you push the head onto the shaft with sufficient force, snaps it in place and holds it there securely. If we look at the drawing below, we can see the inner workings of this simple yet effective mechanism.		While there is numerous mechanisms working in conjunction with each other within this wrench, for this section we will only be considering the ball-locking mechanism (US Patent 4480497) that holds the socket head in place. This is the mechanism that when you push the head onto the shaft with sufficient force, snaps it in place and holds it there securely. If we look at the drawing below, we can see the inner workings of this simple yet effective mechanism.

		+	[[File:Sketch2.png]]

−	While this is an abstract drawing, the same principles and equations apply. Picture the rectangular piece (#3) as the shaft of the wrench with the locking mechanism, and the oval shape (#1 & 2) as the socket head with a small cavity (#9)being pushed into place. Originally, the ball (#11) is in the outer position and the spring and block (#7) is extended with no force being applied to it within a chamber (#4). When the socket head is first put on, the ball and the head walls are pressing against each other with no movement. The spring has a critical point when applied force reaches a numerical value high enough, the spring compresses. Pushing on the socket head applies a force to the ball, which in turn applies an equivalent force to the block and spring system. When the applied pushing force reaches the critical point, the spring compresses, and allows the ball to retract a small amount into the chamber. When this happens, the socket head slides freely into the shaft until the cavity is aligned with the ball. Because the cavity is an open space, it applies no force to the ball (or to the spring), which allows the spring to extend to its original position pushing the ball back to into the cavity. Due to the limited movement of	+	While this is an abstract drawing, the same principles and equations apply. Picture the rectangular piece (#3) as the shaft of the wrench with the locking mechanism, and the oval shape (#1 & 2) as the socket head with a small cavity (#9)being pushed into place. Originally, the ball (#11) is in the outer position and the spring and block (#7) is extended with no force being applied to it within a chamber (#4). When the socket head is first put on, the ball and the head walls are pressing against each other with no movement. The spring has a critical point when applied force reaches a numerical value high enough, the spring compresses. Pushing on the socket head applies a force to the ball, which in turn applies an equivalent force to the block and spring system. When the applied pushing force reaches the critical point, the spring compresses, and allows the ball to retract a small amount into the chamber. When this happens, the socket head slides freely into the shaft until the cavity is aligned with the ball. Because the cavity is an open space, it applies no force to the ball (or to the spring), which allows the spring to extend to its original position pushing the ball back to into the cavity. Due to the limited movement of the socket head to the left, it is now locked in place and will not slide off the shaft. Removal is a reversal of the process in which a pulling force is applied until the critical point is reached.
		+	For this mechanism to work successfully, the following equations must be considered:
		+	F=ma
		+
		+	==Design Revisions==
		+
		+	:1)One thing we noticed in was that the trigger assembly seemed overly complicated. It looked like it could be simplified by using a 3-position switch instead of having these little components that if they break would be hard to replace. This could save money for the manufacturer because it would be easier to manufacture and get parts for.
		+	:2)The option of a battery pack should be included with the wrench. Since it runs of a 12 volt car jack, it is implied that it is supposed to be used with your car. If the cord is not long enough to get from the inside of your car to wherever you need it, the tool is useless. By giving it a battery pack the tools mobility is increased making it more appealing to consumers.
		+	:3)With all the torque that will be applied to this tool it seems that the thin plastic casing would wear out quickly and wouldn’t last too long. Making the case completely out of metal also isn’t a viable option. Putting in metal supports at certain locations to absorb and disperse some of that energy would increase the tools life and efficiency. These supports, mostly around the motor, could help eliminate wear on the plastic that repeated impact would create by creating a firmer hold on the specific part and dispersing the energy over a larger area so one location isn’t constantly taking all the force.

← Older revision		Revision as of 20:40, 30 November 2012
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	:One component of the impact wrench that could undergo engineering analysis is the anvil. Since the anvil is one of the main components of the impact wrench and it is continually hitting and getting hit by the hammer, it must undergo a lot of testing to make sure that it complies with all of the specifications it must achieve. First, the engineers analyzing the anvil will come up with a problem that must solve. That may be what material to make the anvil out of, what size, what length, what shape, what kind of surface finish, how heavy it must be, its life expectancy, and how strong and sturdy the anvil must be to be able to perform its job. The second step would be to draw diagrams (either by hand or by using an online application) of all of the different kinds of designs that were created, and compare and contrast them until a final design is agreed upon. Next the engineers will state all of the assumptions that they should make, such as the weight and density of the material chosen. These assumptions will help the engineers with their equations as well as with solving the problem at hand. Next they will list any governing equations relevant to solving the problem at hand. These equations can include τ = F/A which measures stress on the anvil, τ = rFsinθ which measures the anvils torque output, and P= τω which measures power. Next the engineers would use these equations, and possibly more, to figure out the max torque, speed, and power that the anvil would need to perform its role. After these calculations are done, the anvil will go for testing to see if it complies with specifications and to see if the anvil fulfills all of its requirements and is safe and durable. Some tests that it will go for are tests to see if the anvil fits along with the rest of the components as well as within the casing of the product. They can test to see the strength and durability of the anvil. They can also test to see how smoothly the anvil operates. Lastly, the engineers will discuss and interpret the results of the solution, checking back to see if they are satisfied with that they have done and checking to see if what they have done satisfies the problem they were originally faced with.		:One component of the impact wrench that could undergo engineering analysis is the anvil. Since the anvil is one of the main components of the impact wrench and it is continually hitting and getting hit by the hammer, it must undergo a lot of testing to make sure that it complies with all of the specifications it must achieve. First, the engineers analyzing the anvil will come up with a problem that must solve. That may be what material to make the anvil out of, what size, what length, what shape, what kind of surface finish, how heavy it must be, its life expectancy, and how strong and sturdy the anvil must be to be able to perform its job. The second step would be to draw diagrams (either by hand or by using an online application) of all of the different kinds of designs that were created, and compare and contrast them until a final design is agreed upon. Next the engineers will state all of the assumptions that they should make, such as the weight and density of the material chosen. These assumptions will help the engineers with their equations as well as with solving the problem at hand. Next they will list any governing equations relevant to solving the problem at hand. These equations can include τ = F/A which measures stress on the anvil, τ = rFsinθ which measures the anvils torque output, and P= τω which measures power. Next the engineers would use these equations, and possibly more, to figure out the max torque, speed, and power that the anvil would need to perform its role. After these calculations are done, the anvil will go for testing to see if it complies with specifications and to see if the anvil fulfills all of its requirements and is safe and durable. Some tests that it will go for are tests to see if the anvil fits along with the rest of the components as well as within the casing of the product. They can test to see the strength and durability of the anvil. They can also test to see how smoothly the anvil operates. Lastly, the engineers will discuss and interpret the results of the solution, checking back to see if they are satisfied with that they have done and checking to see if what they have done satisfies the problem they were originally faced with.
		+
		+	==Product Reassembly==
		+
		+	The reassembly of the impact wrench was relatively simple. There are not many parts involved in the reassembly process, which makes the entire process very quick and easy. The only tool used in the reassembly process was a Philips head screwdriver. Due to the different size in the screws, two different sized Phillips head screwdrivers were used, one for the big screws and one for the small screws. The only challenge to reassembling the impact wrench was remembering where each of the parts belonged. However, the casing of the impact wrench clearly outlined where each part would fit, and using simple deduction it was fairly easy to reassemble the impact wrench by putting the parts into their respective places. Throughout the reassembling stages, there was only a single, slightly difficult step. This step would be the reassembling of the electromagnet because in order to reassemble it you must force the parts into place against a strong magnetic force. On a scale of one to ten, one being easy and ten being difficult, I would rate this assembly process a four out of ten. I would give it a low rating because the impact wrench has very few parts and where the parts belong is clearly indicated by looking at the casing. The few parts and clear locations make the entire assembly process quick and easy. The only tool necessary for the reassembly is a Phillips head screwdriver, which is easy to operate. The only challenging part was the reconstruction of the electromagnet. Any person with average strength, knowledge of screwdriver use, and simple deduction can easily reconstruct this impact wrench. The reassembly process was identical to the disassembly process in every way. The same steps taken to disassemble the impact wrench were just reversed to reassemble it. Seeing how easy and simple the impact wrench is assembled, it could be possible that the original assembly was done by hand. The first step in the reassembly process is reconstruction the electromagnet (motor). The only reconstruction necessary for this part is placing the motor shaft and copper coil into the center of the electromagnet, fighting the magnetic force as it is inserted. Then screw the back of the electromagnet (motor) closed. The motor is then placed at the very back of the impact wrench casing. The next part for reassembly is the trigger. This reassembly is very straightforward as a majority of the triggers electrical components are already connected. The only necessary step is pushing the triggers electrical components together and then placing them near the top of the handle of the impact wrench casing. Next the reverse switch is placed into the reverse switch socket and connected to the top of the trigger. The hammer assembly is very straightforward as well. Taking the bearing, you simply place the spring into the spring slot, slide the counter weight under the thick black bracket, then screw in the skinny bracket (using the small Phillips head screwdriver) on top of the area where the spring resides and the end of the counter weight is placed. The anvil does not require any reassembly of its own. The cylindrical end of the anvil is then connected to the hammers bottom and the entire combination is placed in the remaining spot in the impact wrench casing, with the head of the anvil protruding out of the casing. The leveler is also placed in its respective place. The power jack connected to the trigger is placed in its slot, allowing for the extension cord to be free and be placed into the power source. When all parts are in place, put the other half of the impact wrench casing on top of the half containing all of the parts. Using the big Phillips head screwdriver, screw the two casing parts together. When all of the screws have been screwed into the casing, the impact wrench reassembly has been finished.
		+
		+	==Mechanisms==
		+
		+	While there is numerous mechanisms working in conjunction with each other within this wrench, for this section we will only be considering the ball-locking mechanism (US Patent 4480497) that holds the socket head in place. This is the mechanism that when you push the head onto the shaft with sufficient force, snaps it in place and holds it there securely. If we look at the drawing below, we can see the inner workings of this simple yet effective mechanism.
		+
		+
		+	While this is an abstract drawing, the same principles and equations apply. Picture the rectangular piece (#3) as the shaft of the wrench with the locking mechanism, and the oval shape (#1 & 2) as the socket head with a small cavity (#9)being pushed into place. Originally, the ball (#11) is in the outer position and the spring and block (#7) is extended with no force being applied to it within a chamber (#4). When the socket head is first put on, the ball and the head walls are pressing against each other with no movement. The spring has a critical point when applied force reaches a numerical value high enough, the spring compresses. Pushing on the socket head applies a force to the ball, which in turn applies an equivalent force to the block and spring system. When the applied pushing force reaches the critical point, the spring compresses, and allows the ball to retract a small amount into the chamber. When this happens, the socket head slides freely into the shaft until the cavity is aligned with the ball. Because the cavity is an open space, it applies no force to the ball (or to the spring), which allows the spring to extend to its original position pushing the ball back to into the cavity. Due to the limited movement of

@@ Line 483: / Line 483: @@
 [[File:Assembly2.png]]
-==Engineering Analysis==
+==Engineering Analysis/Design Revisions==
 :A design revision that can be made to the impact wrench would be dual functionality. Instead of being used as only an impact wrench, certain tweaks can be made to the subsystems to allow for it to be used as a screwdriver as well. There can be a setting that reduces torque so that the screwdriver doesn't strip the screws and allows for the user to have more control over the product. The wrench can also come with interchangeable heads that will allow for the change from impact wrench to screwdriver. These changes will probably cost the consumer more money for this purchase, but it would save them money because they would not have to buy more then one power tool. The dual functionality would also attract more consumers to buy the product. The dual functionality complies with the societal concerns of GSEE because it is aimed more towards societies who enjoy high-tech gadgets and who have frequent construction products that call for then one tool.

@@ Line 69: / Line 69: @@
 ::*Meeting efficiency. While in a meeting, we must immediately get to work to use our time as efficiently as possible. We must ensure that everyone is participating, for maximum efficiency and accuracy of the material. This will result in a less stressful, ideally shorter meeting in which we get a significant amount of work done.
 == Product Archaeology ==
@@ Line 195: / Line 198: @@
 :*Environmentally it is designed to have a long life cycle, with lots of recyclable steel parts if one takes the time to separate them. Its carbon footprint is negligible as it runs off of 12v electricity power from your cars battery. The most harmful component of it is the plastic housing and wire insulation, as those are petroleum based and harm the environment in both formation and decomposition. Other than that it is made of earth metals that are easily recyclable and have little to no effect in formation or decomposition.
-==Product Analysis==
+==Product Analysis/Component Summary==
 ===Anvil===

← Older revision		Revision as of 20:32, 16 November 2012
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	==Solid Model Assembly==		==Solid Model Assembly==
		+
		+	:*We made a 3D model of the anvil, hammer, and bearing. This assembly plays a huge role in the functionality of the impact wrench.
		+	:*We used Autodesk Inventor 2012 to do said modeling.

	===Bearing===		===Bearing===