Group 27 - Weed Wacker

Latest revision as of 04:34, 7 December 2008

Executive Summary

Our reverse engineering team project product was a Weed Eater gas-powered line trimmer. We were asked to document our disassembly, analysis, and reassembly of the product.

Introduction

Disassembly Product

Our product was a 1989 Weed Eater gas-powered line trimmer, model LT7000. It is powered by a single cylinder two stroke engine, and is used to trim off unwanted weeds and plants. We were unable to test it prior to disassembly because of regulations and safety concerns with fuel.

Group Members

Our team consists of five people:

• Joe Herman (Group Leader): Disassembly / Presentation / Reassembly / Wiki Editing
• Clyric Ng: Disassembly / Presentation / Reassembly / Wiki Editing
• Blaine Reeher: Disassembly / Reassembly / Wiki Editing
• Konrad Sontag: Disassembly / Reassembly / Wiki Editing
• Neil Taras: Disassembly / CAD / Presentation / Reassembly / Wiki Editing

Before Disassembly

Purpose

The purpose of a gas-line trimmer is to cut, trim, and shear different types of grass, weeds, and small plants using a flexible line. This line is rotated about a reel/head powered by an internal motor. Connected to a shaft, the motor creates enough torque to make the line functional. The line then rotates and the purpose of the gas-line trimmer is performed. Both potential and kinetic energies are used here. More specifically, elastic potential energy and rotational kinetic energy drive the trimmer. A coil spring contains elastic potential energy, which is then transformed into rotational kinetic energy in the reel.

Operation

Because the trimmer requires gas, we were unable to operate and test the product. However, from prior knowledge, a typical gas-line trimmer has a small engine that spins a shaft. Ours appears to spin a flexible one, which connects to the head. The head contains three slots for cutting "fingers" that flare out when subjected to rotation. These fingers are responsible for trimming lawns, weeds, etc.

Components/Material

Without disassembling the product, the gas-line trimmer appears to be made up of 30-35 components. Because it is gas-powered, it will contain more parts than an electric trimmer. These components are all made up of a variety of different materials. The most visible and most common material is molded plastic. This material can be found in components such as the housing, head guard, trigger, handle, gas tank and smaller plastic components located inside the housing. The trimmer also contains a shaft made of aluminum. The line used is made of nylon but contains three individual lines, each thick in diameter to provide more strength and durability. All screws, nuts, and fasteners, along with a coil spring, are made of metal, most likely steel. Assuming the trimmer contains a piston-cylinder device to drive the motor along with the motor itself, we can assume the two to be made of steel as well. The startup rope is most likely made from nylon or polyester. Knowing several of the components and the materials they are made from, we can now begin the disassembly portion and compare what we saw with what we predicted.

Gas Trimmer Pictures From Different Angle

Disassembly Procedure

Step #	Procedure/Difficulty	Time Spent	Tools Used	Pictures
Start	The whole gas trimmer	0	0
1	Disconnect reel guard from shaft via two screws Easy	<1 minute	Phillips Head Screwdriver
2	Disconnect reel head from shaft via hex bolt Easy	<1 minute	Pliers
3	Remove trigger handle from shaft via four screws Easy	<1 minute	Phillips Head Screwdriver
4	Remove throttle cable from trigger handle Easy	<1 minute	No tools
5	View of throttle cable attached to choke N/A	N/A	N/A
6	Remove choke housing from main housing Easy	<1 minute	Phillips Head Screwdriver
7	Remove air filter to expose choke cover Easy	<1 minute	No tools
8	Remove interior choke cover and selector Easy	<1 minute	Allen Key Set
9	View of interior choke cover and selector N/A	N/A	N/A
10	Remove choke from engine via Allen screws Easy	<1 minute	Allen Key Set
11	Disconnect throttle cable from choke Easy	<1 minute	No Tools
12	View of choke cover connected via screws N/A	N/A	N/A
13	Remove top choke cover Easy	<1 minute	Phillips Head Screwdriver
14	Remove idle adjustment screw and spring Easy	<1 minute	Phillips Head Screwdriver
15	Remove lower choke cap Easy	<1 minute	Phillips Head Screwdriver
16	Removing the throttle disc Easy	<1 minute	Phillips Head Screwdriver and Needle-Nose Pliers
17	Removing a governing screw from the choke Easy	<1 minute	No tools
18	Assembled Side View of choke N/A	N/A	N/A
19	Assembled view of trigger and throttle cable N/A	N/A	N/A
20	View of internal end of the throttle cable N/A	N/A	N/A
21	Remove the plastic engine housing via 4 Allen screws Easy	2 Minutes	Allen Key Set
22	Remove Engine from housing via several Allen screws and bolts Easy	2 Minutes	Allen Key Set
23	View of the top of the engine with upper housing removed N/A	N/A	N/A
24	View of engine showing wire to be disconnected N/A	N/A	N/A
25	Second view of engine showing wire to be disconnected N/A	N/A	N/A
26	Remove cable covering spark plug and disconnect spark generator from engine via connecting bar/2 Allen screws Easy	<1 minute	Allen Key Set
27	View of disconnected spark generator N/A	N/A	N/A
28	View of connecting rod and 2 Allen screws N/A	N/A	N/A
29	Remove gas tank housing from other exterior housing via several Allen screws Easy	<1 minute	Allen Key Set
30	Remove engine from housing via 4 Allen screws Easy	<1 minute	Allen Key Set
31	Underside view of detached engine, showing flywheel, muffler, cylinder, and gasket N/A	N/A	N/A
32	Remove spark plug and detach cylinder/muffler assembly from flywheel via 2 Allen screws Easy	<1 minute	Allen Key Set
33	Disassembled view of cylinder/muffler, showing spark plug, spark plug ring, and two Allan screws N/A	N/A	N/A
34	View of two Allen screws connecting cylinder to flywheel N/A	N/A	N/A
35	Remove INSULATOR? from cylinder via 2 Allen screws Easy	<1 minute	Allen Key Set
36	View of detached cylinder/muffler assembly N/A	N/A	N/A
37	View of piston connected to crankshaft N/A	N/A	N/A
38	Alternate view of piston/crankshaft along with gasket N/A	N/A	N/A
39	Underside view of crankshaft N/A	N/A	N/A
40	Remove piston from crankshaft Easy	<1 minute	No Tools
41	View of housing/components after engine was removed N/A	N/A	N/A
42	Closer view of reel/rope to be removed N/A	N/A	N/A
43	Remove reel via 2 bolts and rope via small screw/nut Easy	<1 minute	Phillips Head Screwdriver
44	View of detached reel/rope from housing N/A	N/A	N/A
45	After reel is detached, remove coil spring cover to reveal coil spring Easy	<1 minute	No Tools
46	View of housing where coil spring/reel rested N/A	N/A	N/A
47	Finally, remove shaft/cable line from housing Easy	<1 minute	No tools

After Disassembly

Part Table, including:

Part #	Part	Quantity	Material	Manufacturing Process	Picture	CAD file
1	Gas Tank/Housing	1	Plastic	Injection Molding
2	Choke Assembly	1	Steel and Aluminum	Stamping/Machining
3	Engine Housing	1	Plastic	Injection Molding
4	Spark Plug Line and Assembly	1	Plastic	Injection Molding
5	Coil Spring/Housing	1	Steel/Plastic	Coil Spring: Rolling/Bending Housing: Injection Molding
6	Handle	1	Plastic	Injection Molding
7	Inner choke housing	1	Plastic	Injection molding
8	Reel Guard	1	Plastic	Injection Molding
9	Choke Housing	1	Plastic	Injection Molding
10	Trigger Handle	1	Plastic	Injection Molding
11	Motor Assembly	1	Steel	Casting and Machining
12	Piston Assembly (Piston, Connecting Rod, Compression Rings, Pin)	1	Steel	Casting and Machining
13	Engine mounting screws	2	Steel	Metal casting
14	Spark Plug	1	Various(Ceramic, steel, aluminum, copper)	Combination of Machining and Stamping
15	Air Filter	1	Some form of Plastic/PVC	Nontraditional Form of Injection Molding
16	Cutting Head	1	Plastic	Injection Molding
17	Choke Selector Lever	1	Aluminum	Stamped
18	Coil Spring housing	1	Sheet-Steel	Stamped
19	Throttle cable and casing	1	Steel and Plastic	Cover Injection Molded, Cable is Woven
20	Throttle Trigger	1	Plastic	Injection Molding
21	Choke end Cap and screws	5	Steel	Metal Stamping and Casting
22	Choke cap (2) and Mounting screw	2	Steel	Metal Casting
23	Small Engine Casing screw	1	Steel	Metal Casting and Machining
24	Large Engine Casing screw	1	Steel	Metal Casting and Machining
25	Choke governor screw and spring	2	Steel	Metal Casting and Machining
26	Cutting head attachment nut	2	Steel	Metal Casting and Machining
27	Internal Choke valve and screw	2	Brass Alloy and Steel	Metal Stamping and Casting
28	Air Filter Support	1	Aluminum	Stamped
29	Restrictor Plate	1	Aluminum	Metal Stamping
30	Blade guard attachment with screws	3	Steel	Metal Stamping and Casting
31	Handle attachment with bolt and wing nut	3	Steel	Metal Casting
32	Idle tuning screw and spring	2	Steel	Metal Casting and Machining
33	Outer choke casing screws	2	Steel	Metal Casting and Machining
34	Engine Bracket	3	Iron	Metal Casting and Machining
35	External Housing screws and bolts	9	Steel	Metal Casting and Machining
36	External screws with rubber gaskets	4	Steel	Metal Casting
37	Pull Start Reel	1	Plastic	Injection Molded
38	Pull Start Line and Handle	1	Plastic	Injection Molded
39	Reel Attachment Hardware	1	Steel	Machined and Stamped
40	Internal Choke mount and screws	3	Plastic and steel	Injection Molded and Metal Casting

Total Number of Parts: 70 Note: CAD drawings pertaining to parts are limited on site since several of the parts could not be broken down into base components due to rust, press fit etc. See list given in CAD Assembly Video for a total list of the parts rendered with software.

CAD Assembly Video

CAD Assembly Description

These parts represent the engine block of the weed eater. What you are seeing is the muffler, piston, connecting rod, bushings, and block come together with their attachment hardware. Assembly is simple with tension or friction providing the forces needed to keep the system together. The piston fits tightly within the cylinder and all that needs to be done is make sure the muffler is on straight. For further reference of the CAD block see the "Gas Trimmer Pictures From Different Angles" section of the page. The last few images of the block at different angles should answer any other questions you have.

Assembly

Assembly was fairly straightforward, though some of the steps had varying levels of difficulty. The assembly steps were as follows:

1. Re-house the coil spring into the front plastic housing
   • Very difficult to correctly position spring. The housing process took more than a dozen trials.
   • Tools used:
     • Needle-nose pliers
     • Pliers
     • Flathead screwdriver
     • Small butterfly binder clips
   • Time spent: approximately 12+ man hours.
2. Fit the reel with nylon string into place.
   • Difficult to correctly align with internal coil spring.
   • Tools used:
     • Phillips-head screwdriver
     • Needle-nose pliers
   • Time spent: roughly 15 minutes on successful trial.
3. Piece engine together, attach to reel
   • Fairly easy to fit together from spark plug to piston, some lubrication lacking.
   • Grease applied where needed, engine needs two-stroke fuel priming.
   • Tools required:
     • Hex key
     • Adjustable wrench
   • Time spent: 20 minutes after some trial and error with confusing bolts.
4. Piece together choke
   • Moderately difficult due to small parts and spring-loaded assembly, but quick to fix small errors.
   • Tools required:
     • Hex key
     • Needle-nose pliers
     • Phillips-head screwdriver
   • Time spent: 30 minutes
5. Assemble housing
   • Very easy once we identified bolt/screw positions.
   • Tools required:
     • Hex key
     • Phillips-head screwdriver
   • Time spent: 15 minutes
6. Attach guard, reel and handle to pole
   • Easy to piece together and adjust.
   • Tools required:
     • Wrench
     • Pliers
     • Phillips-head screwdriver
   • Time spent: 10 minutes
7. Attach pole to housing, and throttle cable to choke.
   • Easy to piece together.
   • Tool required:
     • Hex key
   • Time spent: 5 minutes

After Assembly

Final Function

We were once again unable to secure a source of fuel for testing our Weed Eater, thus we were unable to fully test its function. In comparison to its initial state, the only notable change is the length of the retracted pull cord: it remains about six inches shy of complete retraction. This is because of slight damage to the coil spring that caused a different coiling pattern than the original design.

Concluding Remarks

After more than 30 man hours of work, we were successful in reassembling our Weed Eater. In retrospect, this project was straightforward in theory, though difficult in practice. Disassembly was not very complicated, and we were able to finish within two hour-long sessions. There were a large number of parts, some of which we grouped together for ease of differentiation among their types. The most hazardous part of disassembly was removing the coil spring, which released tension on us very suddenly. Aside from that, it was a smooth process.

Reassembly, however, was a different story. It was easy to understand what we needed to do by simply reversing the process according to the extensive pictures we took. The initial steps proved to be a challenge for us. We spent far too much time trying to re-coil the coil spring: three meetings with four people per meeting, dozens of successful re-coils but unsuccessful placements, many minor fixed damages, a call to Weed Eater support, and much frustration later, we were able to re-seat the coil spring where it was supposed to go.

Beyond this major reassembly setback, the rest of our operation went smoothly. We decided to add a touch of grease to let the flywheel spin more freely. Cosmetically, the Weed Eater looks markedly similar to its initial state, with the same two missing fingers as it had when we began. Functionally, the Weed Eater seems to behave the same way as far as we know. Perhaps the only noticeable difference is the pull cord's incomplete retraction, our final penalty for our extended troubles with the coil spring. Assuming one can pull fast enough, the cord will still work, at least in theory. The single cylinder will need fuel/oil priming before its first reassembled run-- we were not able to add any sort of oil or gas to the product as stated previously. The pull string retracts and spins the flywheel, and upon a pull, one can feel and hear the piston compressing the cylinder's air.

In retrospect, this project was much more difficult and time consuming than we initially imagined. For future disassembly projects, we would not recommend this product without a simpler way to safely re-house and re-coil the coil spring.

References

Weed Eater Customer Support: 1-800-554-6723