Group 22 Gate 2

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Product Dissection

Project Management: Preliminary Review

Causes For Corrective Action:

Group 22’s work proposal for the dissection of the Barbie Jammin’ Jeep was very close to how the actual dissection went except for the time accountability. We originally estimated the dissection and rebuilding of the Jeep would take approximately 2 to 3 hours when the dissection and documentation took over 4 hours alone and spanned 3 or 4 lab sessions. Other than this factor, our plan to dismantle and our presumed method for physically taking it apart was quite accurate. In the lab, our group used the instruction manual along with cunning ingenuity, as well as assistance from the instructor and teaching assistant to step by step remove attachments and subsystems from the Jeep in the reverse order it is required to assemble. Methodology was also adopted from other groups, with their consent.

Our management proposal for the dissection of the Jeep has been accurate to follow for time management purposes and to gather order in our group. We originally planned to use text messages, emails and wiki along with group meetings before class outside the classroom and in the Capen library to discuss our advancements and check up on every member’s progress. During some of the meetings, we planned who will perform which parts of the dissection and who will be responsible for which sections of the write-up. In the lab for the actual dissection, each member added their input that corresponded to their initial strength characteristics from the management proposal (as seen below). In fact, the only problem with the original management plan was conflicts with each member’s schedules and showing up at the lab at slightly different times. We solved this problem by using our mornings and hour breaks between classes to meet up. The only thing our group can improve on is managing our time (though we followed our gantt chart nicely), planning lab times and possibly planning writing sections more to each member’s strength/ weakness characteristics.

Overall our project plan is working, and everything had been coming together. we get our work done on time and try to meet every requirement as best as possible. As for future challenges we plan on conflicting each other if we ever feel anything needs to be fixed.

Product Archaeology

Product Dissection

The figures below show the step by step process of our products’ dissection, tools we used to complete the each steps and difficulty level of each steps. The figures also details how long each step took to complete. These photographs are supporting evidence for the products dissection. In addition, scale of difficulty which is as follows:

1 = Easy: meaning this step required little effort, no tools needed and very little thinking.

2 = Medium: meaning this step required thinking, longer assessment and the use of tools.

3 = Hard: meaning this step required more thinking, rather assessment and attempts, and possibly two people.

• Disassembly of Barbie Jammin' Jeep Wrangler
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  Step 1: Take out the battery: raise the hood and unplug the motor harness connector from the battery. Then lift and pull the battery out. Tools Required: Hands Difficulty: 2 Time:0:40

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  Step 2: Remove doors: by removing 3 screws, separates each door from groove on the side of the jeep. Tools Required: Hands, Slot–head screwdriver Difficulty: 2 Time: 0:50

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  Step 3: Separate lights, light covers and sports bar system: turn the jeep on its side and loosen four #10 x 3/4 screws from the hole. After, turn the vehicle upright and push up the sports bar support. Tools Required: Hands, Slot–head screwdriver Difficulty: 2Time: 1:30

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  Step 4: Removing seats: first remove a #10 x ¾ screw from the back side of the seat. Second, lift back part of the seat first and then hardly pull up and remove seat from the front side slots. Tools Required: Hands, Philips-head screwdriver Difficulty: 2Time: 0:50

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  Step 5: Removing brush guard: remove both light covers and two #8 x 3” screws from the brush guard. Then remove the two #10 x ¾” screws from the bottom of the brush guard and pull back it. Tools Required: Hands, Philips-head screwdriver. Difficulty: 2 Time: 1:00

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  Step 6: Remove windshield by pulling it up from the large slots in the dash. Tools Required: Hands Difficulty: 2 Time:0:10

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  Step 7: Pop out the hood by lifting up hood tab from front slots: once hood was removed, also remove the hood latch from the slot in the front. Tools Required: Hands Difficulty: 1Time:0:25

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  Step 8: Remove headlights: by removing 2 screws, and carefully pull out the headlights from grille. Tools Required: Hands, Philips-head screwdriver Difficulty: 2 Time: 0:20

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  Step 9: Removing front wheels and steering: first, turn the jeep on its side. Next, remove #8 x ¾” screw from the steering column cap. Then, remove the steering cap away and remove the front wheel set from the body. Take steering away from the body by pull it up. Tools Required: Hands, Flat-head screwdriver Difficulty: 3 Time: 1:50

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  Step 10: Removing motor from jeeps’ body: Using needle nose pliers, the right retention bushing was pried from the axle and broken/torn. The axel was slid out to the left, with the left rear wheel assembly intact. The motors remained in the body of the jeep. The motors were then rotated and pulled out of the body. Tools Required: Hands, pliers Difficulty: 3 Time: 2:10

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  Step 11: Disassembling motor housing: After removing the housings from the axel and body, the motors were then pulled from the housing. The tabs were pushed inward to allow the housing to split. Tools Required: Hands, Slot–headed screwdriver, Philips–head screwdriver Difficulty: 2 Time:0:30

Figures 2.1: Steps taken in Disassembly

As shown in the figures above, the total time taken to disassemble the Barbie Jammin' Jeep Wrangler was 16:10. The tools used were: Phillips Head Screwdriver, Flathead Screwdriver, and Needle nose pliers. Challenges Faced: Some pieces required a lot of force in order to be removed such as the tire caps but especially the bushings on the axial. These challenges were overcome by using the appropriate tool. Also removing certain pieces ultimately led to them being ruined so now the jeep cannot be reassembled unless they are replaced.

It should also be noted, while the total time of disassembly is quite low, the actual disassembly time was roughly ten times that of the time given above. This is due to the process of noting the disassembly actions, documenting the process of each aspect of disassembly, and in some cases idling time when the next action was unclear.

Subsystems

The Barbie Jammin Jeep is composed of four independent systems. They can be classified as Electrical System, Control System, Power System, and Chassis. Each system could be divided into smaller subsystems as shown below.

Figure 2.3: Diagram of major subsystems

The Connection of Subsystems:

Each component of subsystems in Fig.1 cooperates systematically in order to allow the jeep to operate properly. The energy generated from the battery provides the power to the wheels through each subsystem. Fig.1 shows that which subsystems are passed by during power supply from battery to rear wheels. In the process, mutual connection between components are very important. Most of components are connected by wires and screws. Figure 2.4 below shows more detail how each subsystem is connected on the body. It is described by four different factors in relation to its connection.

Figure 2.4: Chart of major subsystems

Why are they connected?

Subsystems of the Barbie Jammin Jeep are not only connected on the body of the car, but also connected to each other to supply energy from battery to the rear wheels. The mutual connection between those components is the primary source to activate the Barbie Jammin Jeep. The Motor Harness Connector which connect the battery is linked to under the footboard to transfer the energy from battery to pedal. The energy which is imported from the battery is gathered at the footboard, and then it is transmitted to the motor by operating the foot pedal. The pedal acts like Switch here which is regulating the energy flow by pressing it or release it. When the pedal is pressed, the energy flow continues to run toward the other components, and when the pedal is released, the energy is cut off. The energy which passed the pedal now ready to go to the motor to generate power to move the jeep. However, before the energy can be transferred to the motor, it should be be given a designated speed and direction first. That is why the transmission is connected with motor. After the transmission confirmed its direction or speed, then motor finally convert the electrical energy to rotational kinetic energy. A coil inside motors create magnetic field as the electrical energy is delivered into the motor. That cause the rod to spin, and a gear becomes to rotate as the rod spins. Finally, the spinning gear produce a torque on the rear axle, and the rear wheel which is connected to the rear axle begin to move. Like this, the mutual connection between subsystems make it possible to move the Barbie Jammin Jeep forward or backward. Moreover, the door increase a safety when children are placed in the vehicle as well as seat belts on the seats; also, Brush Guard and Roll Bar provide a sporty looking for the jeep while the radio provides entertainment.

How are the Different Connections Implemented?

To show excellent performance during the Jeep’s operation, each part is required to maintain good connection. Most of subsystems of Barbie Jammin Jeep are connected with wires and screws, especially metal screws were used to connect almost every components. The door is connected to the side of dashboard with ¾” metal screws, and the gear assembly is connected to the seats with two Phillips Head Screws. However, these components could be connected with plastic screws as well metal screws. There are four factors which considered when metal screws were chosen at the time of connection. The influence of factors such as global, societal, economical, and environmental concerns is described below in Figure 2.5.

Figure 2.5: Chart of major Influences on Design

As a matter of scarcity of nature resources, plastic screw could be a good substitution for metal screw. Nevertheless, plastic has less clamping force than metal screw, and it is not friendly material in nature . Moreover, it takes much environmental cost than recycling metal. This is why metal screws are commonly used more place in today. Providing such a good connection force and cost-effectiveness, the metal screws are used to connect subsystems of Barbie Jammin Jeep.

Arrangement of Subsystems:

The battery is placed under the hood and locked with hood latch. The motor also covered under the seat where children cannot reach. The primary reason for this is safety. The battery is heavy and contain sulfuric acid. If children drop it or expose the internals of a damaged battery, it could result in serious injury. The heat from the motors also could be a cause of burning, and the exposed contacts are a source for electrocution.

In addition to the safety, motors and battery are covered to protect them from their operational environment. The Barbie Jammin Jeep is designed to play outside, so operating the vehicle in harsh condition such as sand and gravel could be damage those parts and cause them to fail. Therefore, the aforementioned components are placed in a manner that protects them and keeps the operator from major harm.

Furthermore, the radio and battery should be apart to improve FM reception signal. Any obstacles or electrical interferences around the radio could result in poor reception on the radio. Thus, the placement of the radio is towards the top of the product, and the antenna is stretched underneath the dashboard to provide optimal reception.

References

1. “Plastic and the Environment.” PlasticIndustry.com(2010). 10.21.2010. http://www.plasticsindustry.com/plastics-environment.asp

2. "Wrangler, Barbie Jammin’ Jeep." Owner’s Manual with Assembly Instruction(2005). 10.21.2010 http://www.fisher-price.com/inst_sheets/T8396pr-0920.pdf

3. “What Is a Plastic Screw?” Wise Geek.(2010).10.21.2010 http://www.wisegeek.com/what-is-a-plastic-screw.htm

4. “Power Wheels Fisher-Price Barbie Jammin' Jeep” 10.21.2010 http://www.toysrus.com/product/index.jsp?productId=2647264