Group 26 - Craftsman 1/2 in Impact Wrench - Gate 3
From GICLWiki
(Difference between revisions)
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|Light weight Composite plastic | |Light weight Composite plastic | ||
|The impact wrench case was made through a plastic injection molding process. There is an evident seam line along the outside rim from where the two molds met. Extrusion marks were also found on the bottom and top edges. The inside was milled after production to ensure perfect fitment of internal components. | |The impact wrench case was made through a plastic injection molding process. There is an evident seam line along the outside rim from where the two molds met. Extrusion marks were also found on the bottom and top edges. The inside was milled after production to ensure perfect fitment of internal components. | ||
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|F19982-01N | |F19982-01N | ||
|[[File:housingassembly2012.jpg|200px|thumb|center]] | |[[File:housingassembly2012.jpg|200px|thumb|center]] | ||
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|Stainless steel | |Stainless steel | ||
|The hammer cage was assumed to be produced by a metal forging process. The outside was then polished for aesthetic purposes. The inside was milled to ensure close tolerance where achieved. The screw holes were drilled and threaded. | |The hammer cage was assumed to be produced by a metal forging process. The outside was then polished for aesthetic purposes. The inside was milled to ensure close tolerance where achieved. The screw holes were drilled and threaded. | ||
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|FS2147R-47 | |FS2147R-47 | ||
|[[File:hammercase.jpg|200px|thumb|center]] | |[[File:hammercase.jpg|200px|thumb|center]] | ||
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|Lightweight composite plastic | |Lightweight composite plastic | ||
|The rear case endplate was made by an injection molding process. This was concluded from mold seam lines along the matting surface. The composite plastic part was then drilled so four screw could be placed to hold the entire unit together. | |The rear case endplate was made by an injection molding process. This was concluded from mold seam lines along the matting surface. The composite plastic part was then drilled so four screw could be placed to hold the entire unit together. | ||
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|FS2147R-22 | |FS2147R-22 | ||
|[[File:endcap2012.jpg|200px|thumb|center]] | |[[File:endcap2012.jpg|200px|thumb|center]] | ||
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|High strength carbon steel | |High strength carbon steel | ||
|The hammer cage is thick in nature and has a textured finish. It was made from a metal forging process. The part was then drilled and reamed to fit the hammer pin and anvil through the center body. | |The hammer cage is thick in nature and has a textured finish. It was made from a metal forging process. The part was then drilled and reamed to fit the hammer pin and anvil through the center body. | ||
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|312-248-19B | |312-248-19B | ||
|[[File:hammercage2012.jpg|200px|thumb|center]] | |[[File:hammercage2012.jpg|200px|thumb|center]] | ||
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|High strength carbon steel | |High strength carbon steel | ||
|The hammer cam is assumed to produce from a milling process due to its evident smooth and sharp surface finishes and edges. The part was then drilled out to fit a hammer pin holding it inside the hammer cage while rotating. | |The hammer cam is assumed to produce from a milling process due to its evident smooth and sharp surface finishes and edges. The part was then drilled out to fit a hammer pin holding it inside the hammer cage while rotating. | ||
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|9287163 | |9287163 | ||
|[[File:cam2012.jpg|200px|thumb|center]] | |[[File:cam2012.jpg|200px|thumb|center]] | ||
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|High strength carbon steel | |High strength carbon steel | ||
|The hammer dog was produced by horizontal lathe that turned the part on one axis while removing excess metal to achieve proper dimensions. The impact slot was presumed to be milled out since a lathe cannot achieve this multi axial cut. This part may also receive thermal heat treatment to ensure optimum microstructure. | |The hammer dog was produced by horizontal lathe that turned the part on one axis while removing excess metal to achieve proper dimensions. The impact slot was presumed to be milled out since a lathe cannot achieve this multi axial cut. This part may also receive thermal heat treatment to ensure optimum microstructure. | ||
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|9287162 | |9287162 | ||
|[[File:hammerdog2012.jpg|200px|thumb|center]] | |[[File:hammerdog2012.jpg|200px|thumb|center]] | ||
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|High strength carbon steel | |High strength carbon steel | ||
|The hammer pin is made from a common metal rolling process. The steel ingots are heated to a malleable state passed between grooved rolls to reduce in size. The metals dowels are then cut to a specified length. This part may also receive thermal heat treatment to ensure necessary strength and optimum hardness. | |The hammer pin is made from a common metal rolling process. The steel ingots are heated to a malleable state passed between grooved rolls to reduce in size. The metals dowels are then cut to a specified length. This part may also receive thermal heat treatment to ensure necessary strength and optimum hardness. | ||
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|312-248-20B | |312-248-20B | ||
|[[File:hammerpin2012.jpg|200px|thumb|center]] | |[[File:hammerpin2012.jpg|200px|thumb|center]] | ||
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|High strength carbon steel | |High strength carbon steel | ||
|In order to achieve this unique shape the anvil was milled on a horizontal lathe. The cam edge and square socket attachment points were then CNC milled. | |In order to achieve this unique shape the anvil was milled on a horizontal lathe. The cam edge and square socket attachment points were then CNC milled. | ||
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|9287159 | |9287159 | ||
|[[File:anvil2012.jpg|200px|thumb|center]] | |[[File:anvil2012.jpg|200px|thumb|center]] | ||
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|Aluminum | |Aluminum | ||
|The rear rotator plate was spun on a vertical lathe. The part was then cut to size. There are groves on the inside surface edge that were vertically milled to allow airflow between rotator blades. | |The rear rotator plate was spun on a vertical lathe. The part was then cut to size. There are groves on the inside surface edge that were vertically milled to allow airflow between rotator blades. | ||
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|9287172 | |9287172 | ||
|[[File:rearendplate2012.jpg|200px|thumb|center]] | |[[File:rearendplate2012.jpg|200px|thumb|center]] | ||
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|Steel | |Steel | ||
|The rotator wheel was manufactured from a horizontal lathe. This method turns and cuts the object on a single axis. The six blade slots and connection spline where CNC milled after to achieve a multi-axial dimension cut. | |The rotator wheel was manufactured from a horizontal lathe. This method turns and cuts the object on a single axis. The six blade slots and connection spline where CNC milled after to achieve a multi-axial dimension cut. | ||
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|9287168 | |9287168 | ||
|[[File:rotor2012.jpg|200px|thumb|center]] | |[[File:rotor2012.jpg|200px|thumb|center]] | ||
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|Composite polycarbonate plastic | |Composite polycarbonate plastic | ||
|These six rotator blades area CNC milled from a composite polycarbonate plastic | |These six rotator blades area CNC milled from a composite polycarbonate plastic | ||
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|9287169 | |9287169 | ||
|[[File:rotorblade2012.jpg|200px|thumb|center]] | |[[File:rotorblade2012.jpg|200px|thumb|center]] | ||
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|Aluminum | |Aluminum | ||
|The rotator cylinder is made from a casting process. This was assumed from evident seam marks on the outside edges and textured finish. The internal cylinder walls were finish cut from a lathe to produce a very smooth surface. The intake/exhaust ports were vertically drilled out. | |The rotator cylinder is made from a casting process. This was assumed from evident seam marks on the outside edges and textured finish. The internal cylinder walls were finish cut from a lathe to produce a very smooth surface. The intake/exhaust ports were vertically drilled out. | ||
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|9287176 | |9287176 | ||
|[[File:cylinder2012.jpg|200px|thumb|center]] | |[[File:cylinder2012.jpg|200px|thumb|center]] | ||
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|Aluminum | |Aluminum | ||
|The rear rotator plate was spun on a vertical lathe. The part was then cut to size. There are groves on the inside surface edge that were vertically milled to allow airflow between rotator blades. | |The rear rotator plate was spun on a vertical lathe. The part was then cut to size. There are groves on the inside surface edge that were vertically milled to allow airflow between rotator blades. | ||
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|9287166 | |9287166 | ||
|[[File:frontendplate2012.jpg|200px|thumb|center]] | |[[File:frontendplate2012.jpg|200px|thumb|center]] | ||
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*The springs is made from a cold winding process | *The springs is made from a cold winding process | ||
*The steel pin is made from a rolling process that reduces ingot size to desired dimensions and cut to proper length. | *The steel pin is made from a rolling process that reduces ingot size to desired dimensions and cut to proper length. | ||
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| | | | ||
*FS2147R-03 | *FS2147R-03 | ||
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|Aluminum | |Aluminum | ||
|This part was produced from a horizontal lathe which achieved in circular figure. There are slotted flat groves that were milled into the part after being turned. | |This part was produced from a horizontal lathe which achieved in circular figure. There are slotted flat groves that were milled into the part after being turned. | ||
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|9106136 | |9106136 | ||
|[[File:reversevalve.jpg|200px|thumb|center]] | |[[File:reversevalve.jpg|200px|thumb|center]] | ||
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|Plastic | |Plastic | ||
|The regulator switch was manufactured from an injection molding process. This was determined from evident seam marks and extrusion points on backside. | |The regulator switch was manufactured from an injection molding process. This was determined from evident seam marks and extrusion points on backside. | ||
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|9106133 | |9106133 | ||
|[[File:reverseswitch.jpg|200px|thumb|center]] | |[[File:reverseswitch.jpg|200px|thumb|center]] | ||
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|Brushed Steel | |Brushed Steel | ||
|This small part was die cast manufactured | |This small part was die cast manufactured | ||
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|9287185 | |9287185 | ||
|[[File:throttlevalve.jpg|200px|thumb|center]] | |[[File:throttlevalve.jpg|200px|thumb|center]] | ||
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|Spring Steel | |Spring Steel | ||
|The throttle spring is made from a cold rolled from a spring winding machine. A central navigation computed is used to roll the spring to a correct ‘k’ constant for mass production | |The throttle spring is made from a cold rolled from a spring winding machine. A central navigation computed is used to roll the spring to a correct ‘k’ constant for mass production | ||
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|9287186 | |9287186 | ||
|[[File:throttlespring.jpg|200px|thumb|center]] | |[[File:throttlespring.jpg|200px|thumb|center]] | ||
|} | |} | ||
Revision as of 15:45, 11 November 2012
Component Summary
This section list all the components that make up the impact wrench. The table below explains the various functions of these parts as well as their material make up, appearance, and the manufacturing processes used to produce them. A complexity scale is used to assign the components and rank based on their intricacy.
Complexity Scale
To define a practical measure of complexity for a part, the component's shape, function, and material composition must be taken into account. Multiple indentations as well as asymmetrical structure are typically strong indicators the original stock material had to be greatly modified to achieve the desired shape of the component. How a part connects and functions with the other components in a system is also a factor of complexity because more functions and connections involved with a certain component usually call more accuracy with the dimensions of the part thus making the manufacturing more elaborate. Level 1
- function is limited to fastening, securing, or housing other components
- simple manufacturing process; i.e. few indentations or cuts, simple finished
- non-complex figure which can be described by a few geometric forms
Level 2
- function may involve housing moving parts or regulating energy flow
- semi-complex manufacturing that requires few incisions or steps; i.e. castings, lathe
- form is a simple form with some gaps, indentations, or other modifications
Level 3
- has two or more functions involved with the transfer or regulation of force
- was made using multiple manufacturing processes and has a finished surface
- has many complex and elaborate indentations and grooves that would call for a significant amount of dimensional accuracy
Table of Components
| Component Function | Material Composition | Manufacturing Processes Implemented | Dimensions | Part # | Visual Representation |
| Impact wrench external case- holds together all of the internal components of the impact wrench. Must be strong enough to endure the physical interactions and internal forces of parts reacting against each other during operation. | Light weight Composite plastic | The impact wrench case was made through a plastic injection molding process. There is an evident seam line along the outside rim from where the two molds met. Extrusion marks were also found on the bottom and top edges. The inside was milled after production to ensure perfect fitment of internal components. | 2 | F19982-01N |  |
| Hammer Case-contains the impact system of the wrench which include the hammer cage, dog, pin and anvil. These parts interact with high amount of kinetic energy and force. The encasement is very thick to ensure these parts do not fail. The matting surface was horizontally milled so a rubber gasket could be placed in between. This acts as a barrier to keep tool oil in and dirt out. | Stainless steel | The hammer cage was assumed to be produced by a metal forging process. The outside was then polished for aesthetic purposes. The inside was milled to ensure close tolerance where achieved. The screw holes were drilled and threaded. | 2 | FS2147R-47 |  |
| Rear case end plate- encloses the rotational assembled of the impact gun by four long screws . This plate also contains the regulator switch and direction valve. A rubber gasket is used between the matting surface to keep tool oil in and dirt/water out during use. | Lightweight composite plastic | The rear case endplate was made by an injection molding process. This was concluded from mold seam lines along the matting surface. The composite plastic part was then drilled so four screw could be placed to hold the entire unit together. | 3 | FS2147R-22 |  |
| Hammer cage- is a part of the impact system which contains the hammer dog, cam, pin and anvil. When this system Is loaded, it converts rotational energy to a quick succession of impact force. This cage has to be strong enough to endure such energy and force during operation. | High strength carbon steel | The hammer cage is thick in nature and has a textured finish. It was made from a metal forging process. The part was then drilled and reamed to fit the hammer pin and anvil through the center body. | 2 | 312-248-19B |  |
| Hammer Cam-converts rotational energy to an impulse force when external loaded during operation. The cam is held in the hammer cage through a pin and rests on the anvil. This part is strong enough to endure a rapid succession of impulses between itself and the rotating anvil. | High strength carbon steel | The hammer cam is assumed to produce from a milling process due to its evident smooth and sharp surface finishes and edges. The part was then drilled out to fit a hammer pin holding it inside the hammer cage while rotating. | 2 | 9287163 |  |
| Hammer Dog- is contained within the hammer cage. This part is held in place by the anvil. The hammer dog causes the anvil and cam to lock and release 1 impulse per revolution. The grooved slot on the outside allows this action to happen against the anvil while rotating. | High strength carbon steel | The hammer dog was produced by horizontal lathe that turned the part on one axis while removing excess metal to achieve proper dimensions. The impact slot was presumed to be milled out since a lathe cannot achieve this multi axial cut. This part may also receive thermal heat treatment to ensure optimum microstructure. | 2 | 9287162 |  |
| Hammer Pin- is a vital component that holds the hammer in the external cage. This part experiences very strong internal forces between the cam, dog and anvil. This is a vital component that keeps all parts in place while operating. | High strength carbon steel | The hammer pin is made from a common metal rolling process. The steel ingots are heated to a malleable state passed between grooved rolls to reduce in size. The metals dowels are then cut to a specified length. This part may also receive thermal heat treatment to ensure necessary strength and optimum hardness. | 2 | 312-248-20B |  |
| Anvil-is a key component of the impact wrench. This part excerpts both rotational energy and impulse force to tighten and loosen hardware. The anvil is where impact desired size sockets and torque extensions are connected to. | High strength carbon steel | In order to achieve this unique shape the anvil was milled on a horizontal lathe. The cam edge and square socket attachment points were then CNC milled. | 3 | 9287159 |  |
| Rear rotator end plate- holds the rotator wheels and blades in place during operation. This plate contains a pressed in ball bearing where the rotational wheel seats and spins freely. Creates an air tight seal in the rotating cylinder. | Aluminum | The rear rotator plate was spun on a vertical lathe. The part was then cut to size. There are groves on the inside surface edge that were vertically milled to allow airflow between rotator blades. | 3 | 9287172 |  |
| Rotational wheel- is a key component that converts pressurized air to rotational energy. The wheels has six slots that hold the rotator blades. A sprocket end connects the wheel to impact cage. This transmits rotational energy from the wheel to impact cage system | Steel | The rotator wheel was manufactured from a horizontal lathe. This method turns and cuts the object on a single axis. The six blade slots and connection spline where CNC milled after to achieve a multi-axial dimension cut. | 3 | 9287168 |  |
| Rotor Blades- are housed in the rotator wheel slots. These blades move in and out because the wheel is of centered in rotator cylinder. This movement achieves a constant seal between blade ends and cylinder walls. Air passes between blades to convert pressurized gas to kinetic energy. | Composite polycarbonate plastic | These six rotator blades area CNC milled from a composite polycarbonate plastic | 2 | 9287169 |  |
| Rotator cylinder- contains the rotator wheel and blades. This is chamber is pressurized with air that spins the blades and wheel. Air enters from an intake port and exits through an exhaust port located on the bottom cylinder wall. | Aluminum | The rotator cylinder is made from a casting process. This was assumed from evident seam marks on the outside edges and textured finish. The internal cylinder walls were finish cut from a lathe to produce a very smooth surface. The intake/exhaust ports were vertically drilled out. | 2 | 9287176 |  |
| Front Rotator end plate- holds the rotator wheels and blades in place during operation. This plate contains a pressed in ball bearing where the rotational wheel seats and spins freely. Creates an air tight seal in the rotating cylinder. | Aluminum | The rear rotator plate was spun on a vertical lathe. The part was then cut to size. There are groves on the inside surface edge that were vertically milled to allow airflow between rotator blades. | 3 | 9287166 |  |
| Trigger/Spring/pin- the trigger allows user to engage/disengage tool. When a force is applied to the trigger the throttle valve is opened allowing air charge the regulator system. The spring returns trigger to original position when finger is removed. Trigger pin keeps trigger in place. | Trigger-plastic
Spring-steel Pin-steel |
|
2 |
|
 |
| Directional Valve- controls the direction of air flow into the rotator cylinder. This enables the wheel to spin clockwise or counter clockwise depending on user input. | Aluminum | This part was produced from a horizontal lathe which achieved in circular figure. There are slotted flat groves that were milled into the part after being turned. | 3 | 9106136 |  |
| Regulator Switch- enables user to turn the directional valve left or right to tighten/loosen hardware. The switch slides over a grooved slot on the valve and is held in place by a small set screw. | Plastic | The regulator switch was manufactured from an injection molding process. This was determined from evident seam marks and extrusion points on backside. | 1 | 9106133 |  |
| Throttle Valve- controls the air flow into the regulator system. When the trigger switch is engaged the throttle valve is pushed down allowing pressurized air to charge the impact gun and start operation. | Brushed Steel | This small part was die cast manufactured | 2 | 9287185 |  |
| Throttle Spring-exerts a kinetic force on the throttle spring to ensure it is closed when trigger is released. This also keeps the valve closed when impact gun is connected to an air source but not in use. | Spring Steel | The throttle spring is made from a cold rolled from a spring winding machine. A central navigation computed is used to roll the spring to a correct ‘k’ constant for mass production | 1 | 9287186 |  |
