Group 16 - DeWalt 4 1/2 in Angle Grinder Gate 2 - Revision history

MAE 277 2012 - Group 16: /* Implementation of Connections */

2012-12-10T02:23:14Z

Implementation of Connections

MAE 277 2012 - Group 16 at 02:05, 10 December 2012

2012-12-10T02:05:20Z

MAE 277 2012 - Group 16: /* Implementation of Connections */

2012-12-10T02:04:20Z

Implementation of Connections

MAE 277 2012 - Group 16: /* Implementation of Connections */

2012-12-10T00:07:24Z

Implementation of Connections

MAE 277 2012 - Group 16: /* Challenges of Dissection */

2012-12-09T23:47:11Z

Challenges of Dissection

MAE 277 2012 - Group 16: /* Product Archaeology */

2012-12-09T23:43:28Z

Product Archaeology

MAE 277 2012 - Group 16: /* Difficulty Scale */

2012-12-09T23:41:38Z

Difficulty Scale

MAE 277 2012 - Group 16: /* Links to Other Gates */

2012-12-05T16:55:56Z

Links to Other Gates

MAE 277 2012 - Group 16 at 16:55, 5 December 2012

2012-12-05T16:55:37Z

MAE 277 2012 - Group 16: /* Links to Other Gates */

2012-11-28T14:30:07Z

Links to Other Gates

@@ Line 234: / Line 234: @@
 '''Environmental''': Because the pinion is small and made of metal, it can be easily recycled at the end of the part's life</td>
 <td>The pinion is very good for performance as it enables the system to be rattled and dropped without losing the alignment of the gear grooves . A simple Bevel Gear would not be as robust (1800 Mechanical Movements)</td>
 </tr>
 </table>
 Note: *All factors may not apply to each connection
 ==Reasons for Subsystem Arrangement==

@@ Line 258: / Line 258: @@
 *The grinder head cannot be located near the control system (switch) because the operator would be in danger of being hit with debris when trying to turn the grinder off.
 =Links to Other Gates=
 [[Group_16_-_DeWalt_4_1/2_in_Angle_Grinder|Home]]

@@ Line 203: / Line 203: @@
 The connections between the different sub-systems of the angle grinder were each affected by GSEE factors. Even if a different design would achieve the same overall function, the angle grinder had to be designed to balance these concerns with overall performance and longevity. A summary of how the major connections were implemented along with the GSEE and performance factors for that implementation can be found in Table 3 below:
+<table border=1>
+<caption>'''Table 3''': Connection Implementations and Factors</caption>
 The connection between the power system and the motor system are very economical. The biggest concerns when designing a product and determining the connection of subsystems are cost and safety, and the economic and societal factors. The DeWalt 4 1/2 in Angle Grinder was designed with the intention of providing a product of high quality and performance at a low price for consumers. To achieve this, the connections used over the entire product and within specific systems are simple and uniform. As a result, the parts and systems are mainly connected together by same types of screws which saves time with assembly and repairing. This is a cheap yet durable way to connect the parts together. The system that has the greatest effect on keeping the cost of the product down is the cutting head. This part is designed to be cheap, degradable, and easily replaceable. Rather than using more expensive materials or manufacturing processes to make the heads last longer, they are made to be replaced regularly, but at a low cost to the consumer.

@@ Line 201: / Line 201: @@
 ==Implementation of Connections==
-:The connections between the different sub-systems of the angle grinder were each affected by global, environmental, economic, and societal factors. The connection between the power system and the motor system are very economical. The biggest concerns when designing a product and determining the connection of subsystems are cost and safety, and the economic and societal factors. The DeWalt 4 1/2 in Angle Grinder was designed with the intention of providing a product of high quality and performance at a low price for consumers. To achieve this, the connections used over the entire product and within specific systems are simple and uniform. As a result, the parts and systems are mainly connected together by same types of screws which saves time with assembly and repairing. This is a cheap yet durable way to connect the parts together. The system that has the greatest effect on keeping the cost of the product down is the cutting head. This part is designed to be cheap, degradable, and easily replaceable. Rather than using more expensive materials or manufacturing processes to make the heads last longer, they are made to be replaced regularly, but at a low cost to the consumer.
+The connections between the different sub-systems of the angle grinder were each affected by GSEE factors. Even if a different design would achieve the same overall function, the angle grinder had to be designed to balance these concerns with overall performance and longevity. A summary of how the major connections were implemented along with the GSEE and performance factors for that implementation can be found in Table 3 below:
-:They are joined by two wires which is black and white, to deliver the electrical energy to the motor. This type of connection is inexpensive. It is also a safe connection because of the plastic housing the wire is inside of. Environmentally, the wires and the plastic casing can be recycled. The wires were also influenced by global factors in that the power cord is one of the first parts that can be removed. This allows the quick changing of wires for use in countries with 240 v. The connection between the angle gearbox and the drive shaft is made completely of metal, which provides strength and durability both at the grinding surface and motor. This makes the product reliable, which satisfies the societal demand for a strong, reliable product. Environmentally, this metal can be recycled, meaning the connection between these two systems can be reused in a different system, reducing the end of life pollution of this product. Economically, the raw materials are relatively cheap for this connection, while the shape allows casting of these parts, meaning they can be manufactured cheaply and rapidly. The gears that connect the systems are cheap to make, but are also safe because of the way they are situated inside the grinder metal housing. This safety is a major societal factor when working with a product that could severely injure someone due to the high speeds parts are moving at. The steel used to make the gears can also be recycled to be used on other projects, and are easily made by an unskilled labor force. This is a global concern, as the making of these parts can be done cheaply in any part of the world.
+The connection between the power system and the motor system are very economical. The biggest concerns when designing a product and determining the connection of subsystems are cost and safety, and the economic and societal factors. The DeWalt 4 1/2 in Angle Grinder was designed with the intention of providing a product of high quality and performance at a low price for consumers. To achieve this, the connections used over the entire product and within specific systems are simple and uniform. As a result, the parts and systems are mainly connected together by same types of screws which saves time with assembly and repairing. This is a cheap yet durable way to connect the parts together. The system that has the greatest effect on keeping the cost of the product down is the cutting head. This part is designed to be cheap, degradable, and easily replaceable. Rather than using more expensive materials or manufacturing processes to make the heads last longer, they are made to be replaced regularly, but at a low cost to the consumer.
-:All of these connections are designed to allow the high transfer of energy from part to part with minimal loss. While the housing may be plastic, the connections between all major subsystems are made of steel so that the angle grinder will hold up, even when subjected to large forces. Because angle grinders do not have any one particular function, but instead will face many odd orientations and uses over their lifetime, this kind of universal strength and utility is an absolute essential for an angle grinder to have.
+The steel guard around the grinder wheel  is connected to the gear rod and is in a position that protects the operator from the high rotating speed of the grinder wheel  and from getting hit by any other objects that go through the spinning line. The product also has a side handle perpendicular to the body of the grinder which gives proper grip to make it easier and more convenient to hold and causes less strain on the user. This is a societal concern, as the primary users of this product will probably be using it for prolonged periods of time. The use of plastic for the outer casing and grip also reduces the effect of the vibration that is caused by the engine, which keeps the operator from getting tired. Using plastic for these different systems makes the DeWalt  Angle Grinder lighter in weight thus easier to hold.
 ==Reasons for Subsystem Arrangement==

@@ Line 178: / Line 178: @@
 ==Challenges of Dissection==
-The dissection went very smoothly with the only significant challenge being the removal of the two drive shaft bearings.
+The dissection went very smoothly with the only significant challenge being the removal of the drive shaft bearing and the pinion. As mentioned in dissection, both of these parts were shrink fitted on, and removing them required more force than one person could apply with the channel-lock
 ==Connections of Subsystems==
 The overall function of the DeWalt 4 1/2 in Angle Grinder is to grind materials by converting electrical energy into rotational mechanical energy. This occurs through a series of subsystems.

@@ Line 42: / Line 42: @@
 <tr>
 <td>Difficult</td>
-<td>This step required advanced planning and analysis of the product to determine how to do it. While it may have involved the same tools as a moderate step, it was a challenge to use them on the part that was to be removed, or a large amount of force may have been required. Executing these steps was very challenging and may have required multiple attempts or assistance from another person.</td>
+<td>This step required inspection of several parts in order to determine how to do it. While it may have involved the same tools as a moderate step, it was a challenge to use them on the part that was to be removed, or a large amount of force may have been required. Executing these steps was very challenging and may have required multiple attempts or assistance from another person.</td>
 <td>Removing a bearing that is shrunk fit onto a shaft</td>
 </tr>

@@ Line 1: / Line 1: @@
 [[File:Angle_Grinder_snapshot.jpeg|420px|thumb|right|Dewalt 4 1/2" Angle Grinder]]
-=Gate 2=
+=Introduction=
 For this gate our group dissected our product and considered what its assembly revealed about the design factors that went into this product. Before we could do this, our group first had to analyze how our original plans outlined in Gate 1 had gone, and what changes needed to be made in order to make our group perform better. This group assessment is provided under the '''Project Management''' section below. We then proceeded to dissect our part, and have provided step-by-step instructions on how to do this. Under the '''Product Archaeology''' section we describe our scale of difficulty for disassembling each part and then provide the aforementioned step-by-step instructions, along with a rating of the difficulty of each step. Finally, under '''Connection of Subsystems''' our group documents the connections of the subsystems and considers the factors behind these design decisions.
-==Project Management==
+=Project Management=
 '''Summary'''
 *At the start of the first gate our group had gotten together and divided the work load amongst most of our group. Each individual that was present was given a task to perform so the work load was on every one (we thought). Michael Halloran was appointed our communication liaison and none of us had ever used wiki before. The other group members could not figure out the wiki so we sent email to the communication liaison to put it up on the wiki. He put all of our information together and posted it to our wiki, but Gate 1 was posted to our user page, not the main page, or a specific Gate 1 page.
@@ Line 18: / Line 18: @@
 *We have discussed and redistributed the work load so that the communication liaison will have an appropriate amount of research and analysis given that he also has to form tables and upload images, which the rest of the group does not.
-==Product Archaeology==
+=Product Archaeology=
-===Difficulty Scale===
+==Difficulty Scale==
 In order to describe the difficulty of each step, we will use the categories outlined in Table 1. When assessing the difficulty of each step, it was important not just to assess the time a step took, but rather the aspects that would make the task challenging for the average user. We therefore considered the tools required for a task, the intuitiveness of the step, and any difficulties that may have arose from inaccessibility of a part or the amount of force that must be applied.
@@ Line 48: / Line 48: @@
 </table>
-===Dissection Instructions===
+==Dissection Instructions==
 The instructions given in Table 2 are intended to provide a thorough and complete description of the dissection process such that an individual with no prior knowledge of the product could disassemble it in the same manner our group did. Pictures are provided for clarity and to specify which component of the product is being dealt with at any particular point.
 *Before beginning dissection, the following tools will be required:
@@ Line 151: / Line 151: @@
-===Intent of Disassembly===
+==Intent of Disassembly==
 *'''Gaurd, Handle, and Axle nuts'''
 :-They are intended to be adjusted by the user. The gaurd can be removed or re positioned to accommodate various attachments. Axle nuts slip off.
@@ Line 179: / Line 179: @@
 ==Connections of Subsystems==
 The overall function of the DeWalt 4 1/2 in Angle Grinder is to grind materials by converting electrical energy into rotational mechanical energy. This occurs through a series of subsystems.
-=====First Level of Subfunctions=====
+===First Level of Subfunctions===
 [[File:AngleGrinderFunctionalModel001.jpg |center||700x700px|]]
-=====Second Level of Subfunctions=====
+===Second Level of Subfunctions===
 [[File:AngleGrinderFunctionalModel002.jpg |center||700x700px|]]
 [[File:AngleGrinderFunctionalModel003.jpg |center||700x700px|]]
-===How the Subsystems are Connected===
+==How the Subsystems are Connected==
-====Physically====
+===Physically===
 To achieve the overall function, the subsystems must be physically connected. The power switch is connected to a plastic bar that slides back and forth and allows electricity into the electric motor. The electric motor is connected to the drive shaft. When the electric motor spins, the drive shaft rotates. The drive shaft then connects to the gearbox and to the gears inside. The rotation of the drive shaft causes the gears to turn. The gears are connected to the head, causing it to rotate and thus giving the operator the ability to grind materials.
-====Signals====
+===Signals===
 For the angle grinder to run, the operator must send a signal to it. This is done using the power switch. The power switch can signal the angle grinder to turn on or shut off, depending on what the operator wants. The power switch is connected to a plastic bar that slides back and forth. When the operator turns the switch on, the bar slides sending a signal to allow electricity into the electric motor, thus activating the angle grinder.  When the operator turns the switch off, the bar slides back into its original position sending a signal to stop sending electricity to the electric motor, thus deactivating the angle grinder.
-====Mass====
+===Mass===
 There is no mass flowing through the angle grinder.
-====Energy====
+===Energy===
 Electrical energy from an outlet enters the angle grinder through a cord. The electrical energy is then sent to the electric motor. The electric motor spins, converting the electrical energy into mechanical energy. The mechanical energy is then sent to the drive shaft where it becomes rotational mechanical energy. The drive shaft channels the rotational mechanical energy to the gear box and into the gears.  The gears take this rotational mechanical energy to the head where it can be used to grind materials.
-===Why They are Connected===
+==Why They are Connected==
 The subsystems must be connected in order for the angle grinder to work properly. The power switch is connected to the plastic bar in order for the on/off signal to be received. The power switch is not located at the bottom of the angle grinder where the electricity comes in so the plastic bar is used to send the on/off signal to the correct location. Once the signal is received, the electric motor can beginning converting electrical energy into mechanical energy. The drive shaft connects the electric motor to the gear box. The drive shaft must be connected to the electric motor to be able to rotate, allowing the rotational mechanical energy to be channeled to the gearbox and the gears. The gears must be connected to the drive shaft so they can turn, otherwise the gears won't do anything. The gears then take the rotational mechanical energy to the head, thus allowing the operator to grind materials.
 ==Implementation of Connections==

← Older revision		Revision as of 14:30, 28 November 2012
Line 223:		Line 223:

	[[Group_16_-_DeWalt_4_1/2_in_Angle_Grinder_Gate_3\|Gate 3]]		[[Group_16_-_DeWalt_4_1/2_in_Angle_Grinder_Gate_3\|Gate 3]]
		+
		+	[[Group_16_-_DeWalt_4_1/2_in_Angle_Grinder_Gate_4\|Gate 4]]