Group 16 - Black & Decker Drill/Gate 4

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Gate 4

Causes For Corrective Action

The group has worked very well together since gate three. All group members have made it to the meetings for gate four and plan on continuing to make all of the rest of the meetings until the project is complete. All work distributed for gate four was accomplished by everyone on time and to the standards of the group. The group plans to have gate five go as smoothly as gate four has.

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Product Reassembly Plan

Reassembly Process

Each step will be rated in terms of difficulty on a scale from ‘1’ to ‘5’. This is with a ‘1’ being a simple task such as screwing something together and a ‘5’ being fitting together pieces that are breakable and not easy to put together without care.

1.) Place the housing with the Black and Decker side down on the table.
Difficulty: 1

2.) Reassemble the gearbox by fist holding the rear bearing plate and fitting the gear and pinion into the smaller raised slot. The next step is to place the spindle which is attached to the keyless chuck, front bearing plate, and gear with pressure fittings into the higher raised slot.
Difficulty: 4

3.) Attach the reverse ring bracket to the field using the long screws and a #12 Torx screwdriver.
Difficulty: 2

4.) Put the brushes into the reverse ring by sliding them into the rectangular slots.
Difficulty: 3

5.) Attach the reverse ring carefully to the reverse ring bracket by placing it into the clamps on the reverse ring bracket. This must be done carefully as both parts are very delicate.
Difficulty: 4

6.) Slide the armature into the now attached field and reverse ring with the heat sync end of the armature being closest to the reverse ring once inserted.
Difficulty: 3

Video Demonstration of Steps 5 to 6: http://www.youtube.com/watch?v=3ZXej4DC0Ek

7.) Attach the assembled gear box to the field and armature by sliding the armature into the center hole of the rear bearing plate. Set this assembly aside.
Difficulty: 2

8.) Slide the level into the cap and then slide the cap into the back slots in the top of the housing.
Difficulty: 2

9.) Slide the drill bit holder into the front slots in the top of the housing.
Difficulty: 1

10.) Put the VS-switch and trigger into the slot in the housing making sure the triangular button is able to be pushed through the hole in the housing.
Difficulty: 2

11.) Keeping the field and gearbox assembly already fit together as one piece fit the assembly into the housing. Be sure to have each piece in the assembly facing the proper directions so it will slide directly into the housing.
Difficulty: 5 (due to the fact that getting the directions of all of the parts correctly so it fits into the housing is difficult)

12.) Put the reverse lever into the slots in the housing directly above the VS-switch. Also, make sure to slide the reverse lever into the hole in the reverse ring carefully when sliding the part into the housing. This must be done carefully as the reverse ring is very delicate.
Difficulty: 3

13.) Place the cord protector with the cord running though it into the slots in the bottom of the housing.
Difficulty: 1

14.) Attach wires from the power cord to the VS-switch. This must be done carefully in order to not bend the tips of the wires.
Difficulty: 3

15.) Attach wires from the VS-switch to the reverse ring. This must be done carefully in order to not bend the tips of the wires.
Difficulty: 3

16.) Clamp the cord into the housing using two small screws and the bracket using a #12 Torx screw.
Difficulty: 2

17.) Place the cover onto the housing and make sure it is fitted over all pieces properly. There should be no gap in between the housing that the cover.
Difficulty: 3

18.) Screw the housing and the cover together using nine short screws with a #12 Torx screwdriver.
Difficulty: 2

Overall Video Demonstration: http://www.youtube.com/watch?v=klSekYjhh-c

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Additional Information

1. The Black and Decker Drill functions the same as it was before it was disassembled. The product was not working when received. Upon disassembly it was found that the reverse ring was cracked in half. This prevented the brushes from contacting the armature to allow it to function properly. Also, one half of the reverse ring was jammed in between the field and armature preventing the keyless chuck from spinning freely. The other half held the reverse lever to one side. The product still does not work, but the two halves of the reverse ring was taped back together allowing the keyless chuck to spin freely; which prevented the jamming in the keyless chuck and reverse lever. However, this small fix does not allow the current to flow from the brushes to the armature.

2. The processes for assembly and disassembly are the same except for one small difference. The only difference in assembly is that one has to make sure that the internal assembly lines up with its proper slots in the housing.

3. An additional desirable feature for the Black and Decker Power Drill would be to add a rechargeable battery pack to increase portability. The negative side of this feature would be the additional cost and limited operation time. However, the negatives would be outweighed by increased portability of the drill which is desired by most users.