Group 16 - DeWalt 4 1/2 in Angle Grinder Gate 3 - Revision history

MAE 277 2012 - Group 16: /* Interpretation of Solution */

2012-12-14T19:08:35Z

Interpretation of Solution

MAE 277 2012 - Group 16: /* Introduction */

2012-11-28T14:49:35Z

Introduction

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

2012-11-28T14:29:29Z

Links to Other Gates

MAE 277 2012 - Group 16: /* Handle */

2012-11-16T21:11:59Z

Handle

MAE 277 2012 - Group 16: /* Electromagnet */

2012-11-16T21:04:52Z

Electromagnet

MAE 277 2012 - Group 16: /* Brushes */

2012-11-16T20:55:13Z

Brushes

MAE 277 2012 - Group 16: /* Guard */

2012-11-16T20:24:50Z

Guard

MAE 277 2012 - Group 16: /* Guard */

2012-11-16T20:23:15Z

Guard

MAE 277 2012 - Group 16: /* Guard */

2012-11-16T20:21:27Z

Guard

MAE 277 2012 - Group 16: /* Battery */

2012-11-16T20:19:19Z

Battery

@@ Line 702: / Line 702: @@
 ====Interpretation of Solution====
-This solution would allow an engineer to decide how many wire loops need to be used in the motor armature. In addition, if magnetic field, desired torque, and maximum current are all known, as they were assumed to be, this equation is then a direct relationship between the radius and length of any given wire loop and the number of loops required, which will allow the engineer to fully design the armature.
+This solution would allow an engineer to decide how many wire loops need to be used in the motor armature. In addition, if magnetic field, desired torque, and maximum current are all known, as they were assumed to be, this equation is then a direct relationship between the radius and length of any given wire loop and the number of loops required, which will allow the engineer to fully design the armature. This analysis could be done numerically, but creating a computer program that could process the combinations of each variable and then analyze for other desirable characteristics (i.e. material used, max speed) would allow the engineer to decide on the dimensions of the armature coil with consideration of design requirements. We would therefore recommend using this equation as the basis for a computer analysis.
 This result is most sensitive to the assumptions that the wire coil has a constant resistance (this will actually vary as the length of wire in the coil increases) and that the magnetic field is constant (if an electromagnet is used, the field will fluctuate). The fluctuating magnetic field can be accounted for by multiplying the max magnetic field by the square root of 2 (this will yield BRMS). If the increases in resistance are non-negligible, the equation can be modified by adjusting the calculation of Imax (V/R) to account for variable resistance. Moreover, this Imax could be expressed in terms of wire length, which would allow this formula to still be used to solve for the necessary number of turns in the coil.

@@ Line 1: / Line 1: @@
 [[File:121113_0000.jpg|360px|thumb|right|View of Dissected Angle Grinder]]
 ==Introduction==
-In this phase of the project our group analyzed the components of our now dissected angle grinder. Before we could begin with this step of the reverse engineering process we first had to assess how our group has changed since Gate 2. We implemented several changes to address our problems at the time but still must address one new issue that has arisen. This analysis of our group can be found under '''Project Management'''. The next stew we took was forming a catalog of all of the parts in our product, along with a brief description of each. Our group then performed an in-depth analysis of several parts, created solid model assemblies for important system interactions, and considered how an engineer would have gone about designing the motor armature. All of these things can be found under '''Product Archaeology'''. Lastly, our group proposed three design revisions that would improve the overall design of the angle grinder. These revisions can be found under the '''Design Revisions''' section.
+In this phase of the project our group analyzed the components of our now dissected angle grinder. Before we could begin with this step of the reverse engineering process we first had to assess how our group has changed since Gate 2. We implemented several changes to address our problems at the time but still must address one new issue that has arisen. This analysis of our group can be found under '''Project Management'''. The next step we took was forming a catalog of all of the parts in our product, along with a brief description of each. Our group then performed an in-depth analysis of several parts, created solid model assemblies for important system interactions, and considered how an engineer would have gone about designing the motor armature. All of these things can be found under '''Product Archaeology'''. Lastly, our group proposed three design revisions that would improve the overall design of the angle grinder. These revisions can be found under the '''Design Revisions''' section.
 ==Project Management==

← Older revision		Revision as of 14:29, 28 November 2012
Line 764:		Line 764:

	[[Group_16_-_DeWalt_4_1/2_in_Angle_Grinder_Gate_2\|Gate 2]]		[[Group_16_-_DeWalt_4_1/2_in_Angle_Grinder_Gate_2\|Gate 2]]
		+
		+	[[Group_16_-_DeWalt_4_1/2_in_Angle_Grinder_Gate_4\|Gate 4]]

@@ Line 627: / Line 627: @@
 *The component takes  the shape and dimensions it does to make it roughly the same dimensions of a human hand that is gripping something. The dimensions are intended to make the grip comfortable, while still giving the user enough material to apply force when they need to.
 *The component weighs 0.44 lb.
-*The component is made from rubber and steel.
+*The component is made from plastic and steel.
-*Steel was chosen because it is a very strong and durable material that the user should not break during normal use. This allows the handle to best perform its function. The rubber is also used for functional reasons, as it gives a better grip than most metals and is also comfortable because of its elasticity. Manufacturing methods probably did not directly affect the material chosen, though the fact that steel and rubber had the aforementioned functional properties AND were easy to manufacture did confirm the material choice.
+*Steel was chosen because it is a very strong and durable material that the user should not break during normal use. This allows the handle to best perform its function. The plastic is also used for functional reasons, as it gives a better grip than most metals and is also comfortable because of its elasticity. Manufacturing methods probably did not directly affect the material chosen, though the fact that steel and plastic had the aforementioned functional properties AND were easy to manufacture did confirm the material choice.
 Four Factors:
-*Global Factors: The rubber exterior of this part was chosen to prevent corrosion of the steel in very wet working environments.
+*Global Factors: The plastic exterior of this part was chosen to prevent corrosion of the steel in very wet working environments.
 *Societal: This part was designed to be ergonomic and allow the user to comfortably use the overall product for extended periods of time.
 *Economic: This handle was designed to work in all DeWalt angle grinders, which reduces the production cost for all models.
 *Environmental: This part has no energy or material flow, meaning it will have no environmental impact over its working life.
-The product is black purely for aesthetic purposes. This is not the natural color of the rubber, and it does not aid the functional purpose of the product, but making it black does provide a nice contrast with the overall yellow of the angle grinder.
+The product is black purely for aesthetic purposes. This is not the natural color of the plastic, and it does not aid the functional purpose of the product, but making it black does provide a nice contrast with the overall yellow of the angle grinder.
 This product has a rough surface finish because it does not need a fine finish to perform its function, and the rubber will probably deform somewhat during use anyway.
 '''Manufacturing Methods'''
-*The steel core was most likely done by die  casting based on the simple geometry of the part, surface finish, and material used. The threads on the end are done by turning based on the increased shininess of the threads, greater precision, and axis-symmetry. The rubber grip was injection molded based on the material used, parting line, and presence of a gate on the end.
+*The steel core was most likely done by die  casting based on the simple geometry of the part, surface finish, and material used. The threads on the end are done by turning based on the increased shininess of the threads, greater precision, and axis-symmetry. The plastic grip was injection molded based on the material used, parting line, and presence of a gate on the end.
 *The choice to use steel and rubber respectively made die casting and injection molding ideal processes, as they would allow the manufacturer to reuse the die and molds and make very large production runs.
 *The shape probably did not impact the manufacturing methods other than to allow turning for the threads on the end.

@@ Line 387: / Line 387: @@
 Materials the Component is Made From
-*The exterior of the component is made of aluminum. The wire loops are made of copper, and insulated in plastic.
+*The exterior of the component is made of steel. The wire loops are made of copper, and insulated in plastic.
-*Aluminum is chosen for the exterior because sheet metals would be ideal to provide strength while still being cheap. Aluminum allowed die casting to be used for manufacture. Copper and plastic were NOT chosen primarily for manufacturing purposes.
+*Steel is chosen for the exterior because sheet metals would be ideal to provide strength while still being cheap. Copper and plastic were NOT chosen primarily for manufacturing purposes.
 *Copper and plastic were chosen because their properties are essential to the proper functioning of this component. Copper was chosen for wires because of its high conductivity, which was essential to the functioning of the electromagnet without overheating or wasting power. Plastic was chosen for the necessary function of insulating the wires. If they had not been insulated, the entire magnet exterior would carry current, significantly reducing the effectiveness of the magnet.
-*Aluminum was chosen because of societal factors affecting this product. The angle grinder as a whole is a hand held tool, so using a lightweight metal was essential to making the product usable for extended periods of time.  Also as previously mentioned, using a metal would be ideal because it would keep production and initial cost down, which is an economic factor.
+*Steel was chosen because of societal factors affecting this product. The angle grinder as a whole is a hand held tool, so using a strong metal was essential to making the product last for extended periods of time.  Also as previously mentioned, using a metal would be ideal because it would keep production and initial cost down, which is an economic factor.
 The necessity of using insulated copper wires was a global issue, as a skilled workers were needed to manufacture the raw materials and then assemble them in the exterior.
@@ Line 396: / Line 396: @@
 *This component has no aesthetic purpose because it is inside of the product and should not be seen by the consumer during normal operation.
 *The component is grey, brown, and green because those are the natural colors of the materials, and no aesthetics were considered. The plastic may have been made green to identify the type/quality of insulator used.
-*The surface finish is rough on the aluminum just because a good surface finish was not necessary for this component’s function and it has no aesthetic purpose. The wires and plastic are unfinished as well for the same reasons.
+*The surface finish is rough on the steel just because a good surface finish was not necessary for this component’s function and it has no aesthetic purpose. The wires and plastic are unfinished as well for the same reasons.
 '''Manufacturing Methods'''
-*The aluminum exterior is cast. This can be deduced from the draft on the interior (intended to help the mold separate) and parting line. The copper was probably drawn, as this is the most common method of making wire. The plastic would have been drawn along with the copper.
+*The steel exterior is stamped and then stacked to make a cylindrical case. The copper was probably drawn, as this is the most common method of making wire. The plastic would have been drawn along with the copper.
 *The aforementioned need for a metal to provide support made die casting a good manufacturing method for the exterior. The use of drawing was not really affected by the choice of copper and plastic, though these materials did make drawing a viable process.
 *The desired shape of the exterior had no impact on the manufacturing method chosen, given the desired shape was already feasible. The desired shape of the wires (very long, very thin) made drawing the ideal method for manufacture.
-*Global Factors: The need for technologies to die cast the aluminum exterior meant that the part would have to be manufactured in a somewhat developed country just to use the power and water infrastructure.
+*Global Factors: The need for technologies to die cast the steel exterior meant that the part would have to be manufactured in a somewhat developed country just to use the power and water infrastructure.
 *Societal Factors: This part does not interact with the user during normal use, nor is it expected to fail over the life of the product. Therefore, the manufacturing methods were not significantly impacted by societal factors.
 *Environmental Factors: The part is made entirely of recyclable materials, which allows it to be easily disposed of at the end of the part’s life. The part should last for the life of the product without being serviced, which means it will not have a detrimental impact on the environment during the product’s working life. There is no material flow for this product, and the only pollution is therefore the indirect pollution from making the electricity to power this part.
-*Economic Factors: Die casting was chosen for the exterior because after an upfront initial cost this part could be mass produced for only the material cost. Aluminum was a more expensive than steel, but provides aforementioned advantages to the consumer. This product would be quite expensive to assemble because interlocking the wires and exterior would require human assembly. However, this is a necessary cost in order to manufacture the product properly, and cannot be avoided without even more expensive machinery.
+*Economic Factors: Steel is cheaper than aluminum and easy to work with, provides aforementioned advantages to the consumer. This product would be quite expensive to assemble because interlocking the wires and exterior would require human assembly. However, this is a necessary cost in order to manufacture the product properly, and cannot be avoided without even more expensive machinery.
 '''Component Complexity'''

← Older revision		Revision as of 20:55, 16 November 2012
Line 654:		Line 654:

	The only component this part interacts with is the gearbox. This interaction is simple, as there is no energy or material flow between the two. One just supports the other and neither component's function is essential to the function of the other.		The only component this part interacts with is the gearbox. This interaction is simple, as there is no energy or material flow between the two. One just supports the other and neither component's function is essential to the function of the other.
−
−	~~====Brushes====~~
−	~~[[File:Group_16_Brush.JPG\|250px\|thumb\|right]]~~
−
−	~~start text here.~~

	===Solid Modeled Assembly===		===Solid Modeled Assembly===

@@ Line 723: / Line 723: @@
 *''Economic''
 will cost slightly more than previous design(almost negligable)
 ===Battery===

@@ Line 721: / Line 721: @@
 *''Societal''
 The adjustment method is more intuitive and is easier for the user to perform and use.
 ===Battery===

@@ Line 718: / Line 718: @@
 '''GSEE Factors'''
 *''Global''
 ===Battery===

@@ Line 727: / Line 727: @@
 Global
-*The battery pack will always provide the same energy source to the product. While chargers may need to account for different frequencies in the country of sale, the same grinder can be sold worldwide.
+*The battery pack will always provide the same energy source to the product. While chargers may need to account for different voltages in the country of sale, the same grinder can be sold worldwide.
 Societal
 *The battery pack will increase the product's range of use and allow the consumer to use it in all working environments.