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| | [[Image:PowerDrill.jpg]] | | [[Image:PowerDrill.jpg]] |
| | + | == Executive Summary == |
| | + | The Black and Decker DR-202 power drill is a drill intended for home use. The quality of the drill was established to be quite high for home use as each component was evaluated once the entire drill was dissected. Each component of the power drill was made using different materials and manufacturing processes. The most common materials in the drill are rubber, steel, copper, and plastic. Once disassembled and evaluated the drill was reassembled and possible alternatives to make the drill better were established. Through all evaluations the drill had proved to be a sturdy power tool for the average consumer.<br/> |
| | == Group Members == | | == Group Members == |
| | '''Leader & Main Contact''': Eric Kieffer<br/> | | '''Leader & Main Contact''': Eric Kieffer<br/> |
| Line 8: |
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| | If there are any questions or concerns please contact Eric Kieffer at ''kieffer7@buffalo.edu'' | | If there are any questions or concerns please contact Eric Kieffer at ''kieffer7@buffalo.edu'' |
| | | | |
| | + | == Introduction == |
| | + | Group 16 consists of five group members; Eric Kieffer, Jonathan Lottes, Alexis Wong, Kyle Lynch, and Sanket Chavan. The group was assigned a Black and Decker DR-202 power drill. All information regarding the drill and what the group did with it can be found by clicking one of the links below. |
| | | | |
| − | == Gate 1 == | + | == Gate 1: Request for Proposal == |
| − | | + | The '''Work Proposal''', '''Management Proposal''' and '''Initial Product Assessment''' can be found by clicking on the link below.<br/> |
| | [http://gicl.cs.drexel.edu/wiki/Group_16_-_Black_%26_Decker_Drill/Gate_1 Link to Gate 1] | | [http://gicl.cs.drexel.edu/wiki/Group_16_-_Black_%26_Decker_Drill/Gate_1 Link to Gate 1] |
| | | | |
| − | == Gate 2 == | + | == Gate 2: Preliminary Project Review == |
| | + | The '''Causes for Corrective Action''', and '''Product Dissection Plan''' can be found by clicking on the link below.<br/> |
| | + | [http://gicl.cs.drexel.edu/wiki/Group_16_-_Black_%26_Decker_Drill/Gate_2 Link to Gate 2] |
| | | | |
| − | === Causes for Corrective Action === | + | == Gate 3: Coordination Review == |
| − | <blockquote>
| + | The '''Component Summary''', '''Design Revisions''', '''Solid Modeled Assembly''', and '''Engineering Analysis''' can be found by clicking on the link below.<br/> |
| − | The work and management plans have been followed perfectly by the entire team. Following these plans has made the project very manageable for everyone in the group, as all of the work has been split up evenly and fairly.<br/> | + | [http://gicl.cs.drexel.edu/wiki/Group_16_-_Black_%26_Decker_Drill/Gate_3 Link to Gate 3] |
| − | <br/>In the work assessment, all work required for each stage was intended to be completed a few days early to avoid last minute stress. Everything has been accomplished in the designated time frames with time to spare<br/>
| + | |
| − | <br/>Each member has followed the management proposal and everyone has fulfilled the duties that their respective position entails. Every member has embraced their responsibilities and is ready for the challenge of the workload ahead.<br/>
| + | == Gate 4: Critical Project Review == |
| − | <br/>In order for the team to continue to work as effectively and efficiently as it has thus far, there are a few essential things the group must continue to do. The group must stick to the management and work proposals diligently. The group must also continue to maintain strong communication with one another, keeping up to date with the individual sections being worked on.<br/>
| + | The '''Product Reassembly Plan''' can be found by clicking on the link below.<br/> |
| − | <br/>Everyone in the group plans on sticking to the management and work proposals for the upcoming parts of the project, and each will strive for it to go as smoothly as the previous stage has gone.<br/>
| + | [http://gicl.cs.drexel.edu/wiki/Group_16_-_Black_%26_Decker_Drill/Gate_4 Link to Gate 4] |
| − | </blockquote>
| + | <br/><br/> |
| − | <br/> | + | |
| | ---- | | ---- |
| | | | |
| − | === Product Dissection Plan: === | + | == References == |
| − | <br/> | + | '''Gate 1'''<blockquote> |
| − | === Overview ===
| + | [1] http://www.amazon.com/Black-Decker-DR202-8-Inch-Keyless/product-reviews/B0000C6DX3/ref=cm_cr_dp_all_summary?ie=UTF8&showViewpoints=1&sortBy=bySubmissionDateDescending<br/> |
| − | The Black and Decker hand drill is a sturdy tool. It has been built to ensure that all parts in the product remain in place and do not cause a safety hazard. Although built to last, it is fairly easy to disassemble. To rate the difficulty of disassembly, a scale from ‘1’ to ‘5’, with ‘1’ being the easiest and ‘5’ being the hardest, is used. To give meaning to the scale, a ‘1’ is defined as a simple disassembly, requiring few tools and little time, while a ‘5’ would be a complex process, requiring multiple tools, numerous attempts, and a large amount of time. The disassembly of the Black and Decker hand drill is around a ‘2’ on the scale. Disassembly is not very difficult, as it may become necessary to repair or replace broken and faulty parts.<br/>
| + | [2] http://www.lowes.com/lowes/lkn?action=productDetail&productId=92896-70-DP350&lpage=none<br/> |
| − | <br/>During pre-disassembly, it was assumed the following would be needed:<br/>
| + | [3] http://www.lowes.com/lowes/lkn?action=productDetail&productId=219608-70-DWD110K&lpage=none<br/> |
| − | <blockquote>
| + | |
| − | 1. 3/16 flathead screwdriver <br/> | + | |
| − | 2. Small pick <br/> | + | |
| − | 3. Large pick <br/> | + | |
| − | 4. Needle nose pliers <br/>
| + | |
| − | 5. Small wire cutter <br/>
| + | |
| − | 6. Torx driver set <br/>
| + | |
| − | 7. Vice <br/>
| + | |
| − | 8. Soldering iron <br/>
| + | |
| | </blockquote> | | </blockquote> |
| − | During disassembly, it was found that the following was required:
| |
| − | <blockquote>
| |
| − | 1. #12 Torx screwdriver <br/>
| |
| − | 1. Needle nose pliers <br/>
| |
| − | 3. Allen key <br/>
| |
| − | </blockquote>
| |
| − | <br/>
| |
| − | === Step-by-Step Process ===
| |
| − | Each step will be rated in terms of difficulty on a scale from ‘1’ to ‘5’. This is with a ‘1’ being a simple task such as unscrewing something and a ‘5’ being taking apart a piece that is breakable and not easy to get at without care.<br/>
| |
| − | <blockquote>
| |
| − | 1. Place the drill on the table, check that it is unplugged and the drill is flat and steady with the Black and Decker label side down.<br/>
| |
| − | ''Difficulty: 1''<br/><br/>
| |
| − | 2. Remove the 9 screws that keep the housing intact using a #12 Torx screwdriver.<br/>
| |
| − | ''Difficulty: 1''<br/><br/>
| |
| − | 3. Remove the top shell of the housing by hand and set it aside.<br/>
| |
| − | ''Difficulty: 1''<br/><br/>
| |
| − | 4. Remove the level cap and rubber drill bit from the inside of the housing. This may require force.<br/>
| |
| − | ''Difficulty: 1''<br/><br/>
| |
| − | 5. Remove the level from the top right corner and the bit holder from the upper middle area. Both components are black in color making them easy to identify against the red shell.<br/>
| |
| − | ''Difficulty: 1''<br/><br/>
| |
| − | 6. Remove the two screws holding the cord clamp using a #12 Torx screwdriver. This clamp is in the central region of the handle. The clamp easily comes off once the screws are taken off.<br/>
| |
| − | ''Difficulty: 1''<br/><br/>
| |
| − | 7. There are two wires connected to the reverse ring on the top right corner. These wires connect the directional switch to the external 120V power supply. The main cord is fastened by compression from the housing at the bottom of the handle. Remove the cord from the slots at the bottom of the handle and remove the two cables inside the housing. Note: Removing the cable is simple, but care must be taken while removing the wires from the reverse ring.<br/>
| |
| − | ''Difficulty: 2''<br/><br/>
| |
| − | 8. Remove the trigger from the shell. '''Take note of the assembly of the reverse ring and its positioning with the toggle switch and trigger.'''<br/>
| |
| − | ''Difficulty: 1''<br/><br/>
| |
| − | 9. Remove the directional switch. Be sure to take the left end of the switch out of the lower side of the reverse ring. Once the switch is out, there are no parts held by compression from the housing.<br/>
| |
| − | ''Difficulty: 2''<br/><br/>
| |
| − | 10. Carefully take out the entire arrangement of the reverse ring, motor, fan, gearbox assembly, and keyless chuck from the housing together. As the assembly is held in place by built-in slots in the housing, the assembly should be lifted straight out applying equal force across the each member of the assembly. '''Note: Perform this step slowly and carefully to ensure the brushes do not fall out or break.'''<br/>
| |
| − | ''Difficulty: 4''<br/><br/>
| |
| − | 11. Place the assembly on the table and separate the gearbox from the motor; it will pull out with ease.<br/>
| |
| − | '''Video Demonstration:''' http://www.youtube.com/watch?v=HHbZ2U3iodE<br/>
| |
| − | ''Difficulty: 2''<br/><br/>
| |
| − | 12. Separate the reverse ring from the end on the motor. It is held on by plastic clamps and snaps off easily; care must be taken as the brushes are held in place by the ring with a spring mechanism that pushes them against the motor. Remove the ring and take out the brushes and set them aside.<br/>
| |
| − | ''Difficulty: 3''<br/><br/>
| |
| − | 13. The reverse ring bracket is fastened to the motor by two long screws. Use a #12 Torx screwdriver to remove the screws. The bracket pulls out.<br/>
| |
| − | ''Difficulty: 2''<br/><br/>
| |
| − | 14. The gearbox assembly is made up of four parts: the rear bearing plate, the gear and pinion, front bearing plate, and the spindle attached to the keyless chuck. The four components come off once the gearbox assembly is twisted. This requires little force. After twisting just pull the assembly apart.<br/>
| |
| − | ''Difficulty: 4''<br/><br/>
| |
| − | 15. After step 14 the disassembly is complete. Be sure to take notes on all the parts and label the direction of insertion for the parts. It is suggested to put all small parts such as the screws and the brushes in a bag.<br/>
| |
| − | <br/>'''Total Time: 45 minutes'''
| |
| − | </blockquote>
| |
| − | <br/>
| |
| | | | |
| − | === Analysis ===
| + | |
| − | '''''If you faced challenges during dissection outline those challenges and describe how they were overcome.''''' | + | [4] http://www.dewaltservicenet.com/Products/DocumentViewPDF.aspx?productid=33258&typeId=8795&documentId=21976 |
| − | <blockquote>There were very few problems during the disassembly. The following challenges were faced:<br/> | + | |
| − | <blockquote>
| + | |
| − | '''1'''. The chuck could not be taken apart from the spindle. In the attempt to remove the chuck, the chuck was clamped down while an Allen key was inserted and twisted with as much torque as could be produced. After numerous attempts, the chuck could not be successfully removed.<br/>
| + | |
| − | '''2'''. The drill was in a non-working condition when handed over to the group. The group believes it has successfully identified the problem in the drill. It was not working due to the broken reverse ring. The group tried to fix it temporarily using insulating tape to hold the two pieces of the reverse ring together. The insulating tape did not work; as soon as it was put back in the assembly, the two pieces broke off again. This problem will try to be resolved in the future by using duct tape or a better option if available. Until then the drill is still in non-working condition.<br/>
| + | |
| | </blockquote> | | </blockquote> |
| − | '''''Is the product intended to be taken apart easily?'''''
| |
| − | <blockquote>
| |
| − | As mentioned earlier, the drill is supposed to have a very sturdy build but, as it is a power tool, it is made to be disassembled. Even with the sturdiness it can be disassembled fairly easily which makes repairing/replacing the parts convenient.</blockquote>
| |
| − | '''''What fasteners are used and why?'''''
| |
| − | <blockquote>Fasteners used:<br/>
| |
| − | <br/>1. 9 Screws for the housing.<br/>
| |
| − | 2. 2 screws and a clamp for the cable inside the handle.<br/>
| |
| − | 3. The whole housing is designed with grooves and slots such that the internal mechanical assembly is secured and in place once the two shells of the housing are screwed together.<br/>
| |
| − | </blockquote>
| |
| − | '''''Are special tools required?'''''
| |
| − | <blockquote>The only special tools that are needed to disassemble the drill were the #12 torx screwdriver and the Allen key.</blockquote></blockquote>
| |
| − | <br/>
| |
| − |
| |
| − | === Parts List ===
| |
| − | <table border="1">
| |
| − | <tr valign="middle">
| |
| − | <td width="40" align="center">'''Item No.'''</td>
| |
| − | <td width="300" align="center">'''Part Description'''</td>
| |
| − | <td width="40" align="center">'''Item No.'''</td>
| |
| − | <td width="300" align="center">'''Part Description'''</td>
| |
| − | </tr>
| |
| − |
| |
| − | <tr>
| |
| − | <td align="center">1</td>
| |
| − | <td align="center">Housing and cover</td>
| |
| − | <td align="center">15</td>
| |
| − | <td align="center">Reverse Ring</td>
| |
| − | </tr>
| |
| − |
| |
| − | <tr>
| |
| − | <td align="center">2</td>
| |
| − | <td align="center">Spindle</td>
| |
| − | <td align="center">16</td>
| |
| − | <td align="center">Reverse lever</td>
| |
| − | </tr>
| |
| − |
| |
| − | <tr>
| |
| − | <td align="center">3</td>
| |
| − | <td align="center">Gear</td>
| |
| − | <td align="center">17</td>
| |
| − | <td align="center">VS Switch</td>
| |
| − | </tr>
| |
| − |
| |
| − | <tr>
| |
| − | <td align="center">4</td>
| |
| − | <td align="center">Washer</td>
| |
| − | <td align="center">18</td>
| |
| − | <td align="center">Cord – 8ft</td>
| |
| − | </tr>
| |
| − |
| |
| − | <tr>
| |
| − | <td align="center">5</td>
| |
| − | <td align="center">Front Bearing plate</td>
| |
| − | <td align="center">19</td>
| |
| − | <td align="center">Cord protector</td>
| |
| − | </tr>
| |
| − |
| |
| − | <tr>
| |
| − | <td align="center">6</td>
| |
| − | <td align="center">Keyless chuck</td>
| |
| − | <td align="center">20</td>
| |
| − | <td align="center">Clamp, cord</td>
| |
| − | </tr>
| |
| − |
| |
| − | <tr>
| |
| − | <td align="center">7</td>
| |
| − | <td align="center">Rear bearing plate assembly</td>
| |
| − | <td align="center">21</td>
| |
| − | <td align="center">Screw </td>
| |
| − | </tr>
| |
| − |
| |
| − | <tr>
| |
| − | <td align="center">8</td>
| |
| − | <td align="center">Gear and Pinion</td>
| |
| − | <td align="center">22</td>
| |
| − | <td align="center">Screw</td>
| |
| − | </tr>
| |
| − |
| |
| − | <tr>
| |
| − | <td align="center">9</td>
| |
| − | <td align="center">Armature</td>
| |
| − | <td align="center">23</td>
| |
| − | <td align="center">Name Plate</td>
| |
| − | </tr>
| |
| − |
| |
| − | <tr>
| |
| − | <td align="center">10</td>
| |
| − | <td align="center">Retaining Ring</td>
| |
| − | <td align="center">24</td>
| |
| − | <td align="center">Brush</td>
| |
| − | </tr>
| |
| − |
| |
| − | <tr>
| |
| − | <td align="center">11</td>
| |
| − | <td align="center">Washer, Plain</td>
| |
| − | <td align="center">25</td>
| |
| − | <td align="center">Felt washer</td>
| |
| − | </tr>
| |
| − |
| |
| − | <tr>
| |
| − | <td align="center">12</td>
| |
| − | <td align="center">Heat sink </td>
| |
| − | <td align="center">26</td>
| |
| − | <td align="center">Cap</td>
| |
| − | </tr>
| |
| − |
| |
| − | <tr>
| |
| − | <td align="center">13</td>
| |
| − | <td align="center">Washer</td>
| |
| − | <td align="center">27</td>
| |
| − | <td align="center">Level</td>
| |
| − | </tr>
| |
| − |
| |
| − | <tr>
| |
| − | <td align="center">14</td>
| |
| − | <td align="center">Field</td>
| |
| − | <td align="center">28</td>
| |
| − | <td align="center">Bit holder</td>
| |
| − | </tr>
| |
| − |
| |
| − | </table>
| |
| − | <br/>
| |
| − | '''Video of Parts:'''http://www.youtube.com/watch?v=vF1B7a0WoYE<br/><br/>
| |
| − | [[Image:Drill1.jpg | 800px | 544py]]
| |
| − |
| |
| − | === Sources ===
| |
| − | DeWalt Service Net - http://www.dewaltservicenet.com/Products/DocumentViewPDF.aspx?productid=33258&typeId=8795&documentId=21976
| |
The Black and Decker DR-202 power drill is a drill intended for home use. The quality of the drill was established to be quite high for home use as each component was evaluated once the entire drill was dissected. Each component of the power drill was made using different materials and manufacturing processes. The most common materials in the drill are rubber, steel, copper, and plastic. Once disassembled and evaluated the drill was reassembled and possible alternatives to make the drill better were established. Through all evaluations the drill had proved to be a sturdy power tool for the average consumer.
Group 16 consists of five group members; Eric Kieffer, Jonathan Lottes, Alexis Wong, Kyle Lynch, and Sanket Chavan. The group was assigned a Black and Decker DR-202 power drill. All information regarding the drill and what the group did with it can be found by clicking one of the links below.
