Group 5 - Two Power Sanders

Ryobi Corner Sander

Battery Powered Ryobi Corner Sander

Introduction

For the MAE 277 reverse engineering project, our group was given two electric powered RYOBI corner sanders (Model #’s P400 & CFS1502). One of the sanders is powered by an electric cord and the other is battery-powered. Throughout the semester, we will be dissecting and analyzing the components that make these two products work. We will then compare the different results for the two sanders to figure out which one is more efficient than the other.

Gate 4

Difficulty Scale

The difficulty scale is based on a 1 through 5 scale:

1. only use of hands needed requires little/no* technical ability (no tools required)
2. only use of hands needed, requires some* technical ability (no tools required)
3. Only use of hands needed, requires high* technical ability (no tools required
4. Requires use of single tool, but requires little/no* technical ability.
5. Requires use of single tool, but requires some* technical ability.

Notes

• little/no technical ability- requires less than 5 minutes to complete
• some technical ability- requires between 5-10 minutes to complete
• high technical ability- requires more than 10 minutes to complete

RYOBI Battery-Powered Corner Sander

Step	Description	Easiness	Tools Used	Pictures
1	Place the electric motor and switch assembly into the housing so that the spindle is placed into the lube. This part is fitted into the casing. The wires should be tucked into the outer parts of the housing so they will not be pinched when it is put together.	1	Hands	Casing and Motor
2	Place the black switch in it\'s fitted housing next to the motor. Then place the yellow on/off switch over the black one.	1	Hands	Switch and On/Off Button
3	Place the small metal clip against the yellow switch to stabilize the switch.	3	Hands	Metal Clip
4	Place the gears and bearing with counterweight into its fitted spot in the housing. The gears should be able to now spin the spindle.	1	Hands	Gears and Ball Bearing
5	Place the two white connectors (cushion supports) into the housing. The smaller one fits in below the switch assembly. If looking at the sander with the motor to the top right, the larger connector will be placed about an inch to the left of the gears in it\'s fitted spot.	1	Hands	Cushion Supports
6	Slide the other casing onto the casing with the motor, gears, and switch assembly. It should match up so that connectors go into their fitted spots. The connectors should now be seen on the bottom of the sander.	2	Hands	Second Half of Casing
7	There are eleven Phillips head #2 screws that need to be screwed onto the outer casing. There are designated holes for the screws, and they are the only holes on the sander.	2	Phillips head #2 screw-driver	External Screws
8	Snap the Velcro pad housing onto the bottom of the sander. It snaps on using the connectors.	1	Hands	Velcro Pad Housing
9	There are five Phillips head #2 screws that need to screw the sand-paper Velcro pad onto the sander.	2	Phillips head #2 screw-driver	Velcro Pad

RYOBI Corner Sander

Step	Description	Easiness	Tools Used	Pictures
1	Slide the field assembly over the armature assembly. The wires for the switch should be on the opposite side of the vacuum fan as seen in the picture.	1	Hands	Field Assembly and Armature Assembly
2	Attach the switch to the field assembly. This is done by connecting it to the fitted connector of the red wire.	1	Hands	Switch and Field Assembly
3	Connect the black wire coming from the power supply cord to the switch.	1	Hands	Switch and Black Wire
4	Place one brush into the connector coming from the white cord of the power supply. Place the other brush into the connector coming from the black cord of the field assembly.	1	Hands	Brush Assembly
5	Everything assembled thus far will fit onto the casing. The field assembly has a fitted spot in the center of the casing, everything else attached will fall into it\'s fitted spot.	1	Hands	Field Assembly and Attachments Fitting
6	The orange on/off switch lays in next to the switch assembly	1	Hands	On/Off Switch
7	The black fan baffle fits in over the sand vacuum. The curved edges will fit onto the housing properly.	1	Hands	Fan Baffle
8	Place the two white connectors (cushion supports) into the housing. The smaller one fits in below the switch assembly. If looking at the sander with the motor to the top right, the larger connector will be placed about an half an inch to the left of the field assembly in it\'s fitted spot.	1	Hands	Cushion Supports
9	Place the second part of the housing onto the connectors. Wires must be placed in designated areas. There are teeth that will catch the wires to keep them in place.	4	Hands	Second Half of Casing
10	Screw the two cord clamp screws over the cord where it meets the sander.	2	Phillips Head #2 screw-driver	Cord Clamp Assembly
11	Screw in both of the internal screws to connect both casings. These screws are located underneath where the grip will be.	2	Phillips Head #2 screw-driver	Internal Screws
12	Place the grip on top of the sander. Fasten the three top cover screws.	2	Phillips Head #2 screw-driver	Grip and Grip Screws
13	Place the velcro pad housing onto the bottom of the sander and use the 4 velcro pad housing screws to fasten it.	2	Phillips Head #2 screw-driver	Velcro Pad Housing
14	Place the velcro pad onto the velcro pad housing and use 5 of the velcro pad housing screws to fasten it onto the velcro pad housing.	2	Phillips Head #2 screw-driver	Velcro Pad
15	Fit the dust bag over the vacuum exhaust coming out the back of the sander as seen in the picture.	1	Hands	Dust Bag

After reassembly of the sanders we ran into a couple difficulties that could be improved upon at the product level. When reassembling the corded sander we ran into fitment problems while trying to place all the components in together and fitting the housing on. We happen to break the brush tips while doing this maneuver. The tips were made of some sort of carbon material much like the tip of your pencil (possibly graphite) and were very brittle. If a stronger material like a type of metal was used this problem would be avoided and the tips wouldn’t break. Another improvement we would recommend is to make more room for the electric wire to be placed within the housing of the corded sander. It took many tries to get the fitment of this sander correct because the wires didn’t have much space to be placed. We would recommend that the housing have a little bit more “play” area for the wires so that reassembly and maintenance would be more strait forward (much like the battery powered sander). If more tolerance was allowed for the wires to fit in the sander the reassembly would have been much simpler. The only downside to adding this additional room would be that more material would be used and in turn a greater cost to the manufacture, but we feel that it is worth the small increase in price.

References

Ryobi Corner Cat Power Sander Parts (model #CFS1502)