HSC Engineered Products Research Task

.

21 06

Engineering Studies

2013

11.3-11ESJason Ho

Engineered Products Research Task

0621Engineered Products Research Task

Engineering Studies

2013

11.3—11ESJason Ho

Due: 21 June 2013

Engineering Studies | Jason Ho

John Edmondson High School Engineered Products Analysis Report- DC Cordless Drill

Teacher: Ms Johnston

Figure 1- The RYOBI ONE+ Drill - RYOBI/TECHTRONIC INDUSTRIES

Engineered Products Analysis Report- DC Cordless Drill

Abstract:This report was made to complete a research task set in year 11 engineering studies. To fulfil this requirement in the course I have chosen a product to analyse and evaluate. This product is the DC cordless drill. In this report I will cover the materials, manufacturing process, electronic and recyclability. I approached this report by going to many secondary resources and finding relevant information and calling the relevant companies or their suppliers about their products. During this task I have found that most of the information I required is proprietary knowledge which the manufacturer was unwilling to divulge but by combining many resources I managed to gather the required resources and complete the report.

Jason Ho 11 Engineering Studies Page 1 of 18 Engineered Products Analysis Report


Table of ContentsAbstract:................................................................................................................................................1

Table of Contents..................................................................................................................................2

List of Figures.........................................................................................................................................3

List of Tables..........................................................................................................................................4

Introduction...........................................................................................................................................5

Section 1: Materials Used......................................................................................................................6

General Outline:................................................................................................................................6

Table 1- Table of Components, Functions, Materials and Processes.................................................6

Materials Properties and Suitability:.................................................................................................8

Table 2-Table of Materials, Properties and Suitability.......................................................................8

Manufacturing Processes and Properties Alteration:......................................................................10

Table 3- Table of Forming Processes and Alterations......................................................................10

Section 2: Electrical Systems................................................................................................................11

Description of Electrical System:.....................................................................................................11

Operational Electrical Specifications:..............................................................................................12

Electrical Motor Operation and Magnetic Induction:......................................................................13

Safety Procedures and Precautions of the DC Drill:.........................................................................14

Section 3: Disposal and Recyclability...................................................................................................15

Design Factors for Ease of Disassembly:..........................................................................................15

.............................................................................................................................................................15

Recycling and Disposal:....................................................................................................................16

Environmental Effects and Cost of Recycling:..................................................................................16

Conclusion...........................................................................................................................................17

References...........................................................................................................................................18



List of FiguresFigure 1- The RYOBI ONE+ Drill - RYOBI/TECHTRONIC INDUSTRIES.......................................................0Figure 2-Inside a RYOBI ONE+ Power Drill- DEWALTOWNERSGROUP.COM..........................................5Figure 3- Example of a Variable Speed Trigger- Jason Ho....................................................................11Figure 4- Example of a Forward/Reverse/Lock Switch- Jason Ho........................................................11Figure 5- Approximate Electronic Diagram of Drill-Jason Ho...............................................................11Figure 6- Surface Mount Components-Electronicstraders.com...........................................................12Figure 7- Slide Variable Resistor-pcmag.com.......................................................................................12Figure 8- DC Dual Chemistry Charger- RYOBI/TECHTRONIC INDUSTRIES............................................12Figure 9- Diagram of Electric Motor-Discovery Channel, howstuffworks.com....................................13Figure 10- Exploded View of the RYOBI ONE+ Cordless DC Power Drill- RYOBI/TECHTRONIC INDUSTRIES.........................................................................................................................................15Figure 11-RYOBI ONE+ Cordless Drill Opened Up-DEWALTOWNERSGROUP.COM..............................16



List of TablesTable 1- Table of Components, Functions, Materials and Processes.....................................................6Table 2-Table of Materials, Properties and Suitability...........................................................................8Table 3- Table of Forming Processes and Alterations..........................................................................10Table 4- Safety Procedures of the DC Drill...........................................................................................14



IntroductionThe human race has evolved over millions of years but within the last 3000 years we have made rapid progress because of one idea, the idea of tools. One of these tools is drills. This report focuses on the materials, electronics and recyclability of the DC Cordless Drill. The purpose of this report is to inform about the structure of the mechanical components and electrical components in the DC Electric drill. It also informs and evaluates the disposal and reusability of the materials used in the cordless DC drill. This report has been conducted by using secondary resources from the internet, school library and from the suppliers of the manufacturer’s product. It also contains first hand media and information discovered through electrical testing. This report did have many limitations due to the fact that most of the information is proprietary and classified, but even though information was limited, I could still complete this report by consolidating many pieces of information together.

Figure 2-Inside a RYOBI ONE+ Power Drill- DEWALTOWNERSGROUP.COM



Section 1: Materials UsedGeneral Outline:The cordless drill is made by combining many components into a shell. These components are made through various manufacturing processes such as injection moulding, extraction, casting and drop forging. Below is a table that contains the individual components of the DC cordless drill and their function with the materials and forming processes used to create them.

Table 1- Table of Components, Functions, Materials and Processes

Component Function Material Used Manufacturing Process18V Nickel Cadmium Battery Pack

To provide electrical power to drive an electronic circuit

Acrylonitrile Butadiene Styrene, Nickel, Cadmium, Iron 0%C, Copper

Injection Moulding, Extrusion, Manual Assembly

Drill Casing To house the components of the drill and to protect the user from electric shock and moving parts

Acrylonitrile Butadiene Styrene And Rubber

Injection Moulding

Wires To transport electric power through the drill

Rubber And Copper Cold Drawing or Extrusion

Electric Motor To drive the mechanical components of the drill

Below, in blue section Manual Assembly

Electric Motor Shell To hold the components that drives the mechanical components of the drill using DC electricity.

Cast Iron Extrusion, Casting, Cold Forming

Armature To hold the field coils in place and to act as a solenoid to generate the magnetic field.

Iron 0%C Casting

Commutator and Axel To supply the DC current to the field coils in an AC modulation and transfer the mechanical energy made to an external drive.

Copper Rolling, Extrusion

Field Coils To use the magnetic generation properties of electricity to create an opposing electric field to those of the permanent magnets

Copper Cold Drawing



Stationary Magnets To provide a stationary magnetic field for the field coils to act against.

Magnetised cast Iron Casting

Brushes To transfer electric current to the Commutator while remaining stationary

Carbon Casting

Gears To change the speed and strength (torque) of the drill

Teflon, Nylon, Brass or High carbon steel

Cold forming, Injection Moulding

Gearbox Assembly To hold the gears and drive shafts in place

Acrylonitrile Butadiene Styrene

Injection Moulding

Drive Shaft To transfer mechanical energy to the clutch and to the chuck.

High carbon steel Extrusion, forged

Ball Bearings To reduce friction against other components

Stainless Steel Cold Forming

Speed Lever and clutch

To change the current gear and speed while disconnecting the drive to protect the gears

Acrylonitrile Butadiene Styrene and Iron 0%C

Injection Moulding, Cold Forming

Keyless hand chuck To hold and drive the drill bit while allowing the user to change drill bits without having to use an external tool.

High carbon steel, Acrylonitrile Butadiene Styrene

Injection Moulding, and cold forming, forging

Screws To hold the whole assembly together while being able to be taken apart.

Medium Carbon Steel Casting and Cold Forming, forging

Washers To distribute the load from the chuck to the gear system

Rubber Injection Moulding

Variable resistor switch

To turn off/on the motor while controlling speed and torque

Carbon and Iron 0%C Manual assembly

Battery connector To transfer the power from the DC Battery to the main circuit.

Iron 0%C Rolling



Materials Properties and Suitability:There are many materials that are used in the design and manufacture of engineered products but specific materials should be used for specific components due to each materials properties. The table below shows each of the materials used in the cordless drill and why they are suitable for their respective components.

Table 2-Table of Materials, Properties and Suitability

Material Properties Components Made From This Material

Why is it suitable for these components

Iron 0%C Strong, Very Ductile, Very Malleable, Soft, Not Elastic, Conducts Electricity, High Plasticity

Battery Connector, Variable Resistor Switch, Armature, 18V Lithium Ion Battery Pack

Iron is fairly strong while being very workable which allows the manufacturer to make these components easily. Iron’s strong property also adds the strength that is needed for its operation by any rough user.

High Carbon Steel Strong, Brittle, Very Low Elasticity; Very Low Malleability, Very Hard.

Drive Shaft, Keyless Hand Chuck, Gears

High carbon steel is effective for these components because these components require a strong hard material due to their high kinetic force that they have to endure

Medium Carbon Steel

Strong, Medium Elasticity, Medium Malleability, Mild Hardness

Screws Medium Carbon Steel is effective for screws because the manufacturer can easily form them due to its malleability. It is also strong and can withstand tensile force which is paramount for its purpose.

Cast Iron Strong, Brittle, Low Elasticity, Low Malleability, Mild Hardness, Stiff

Electric Motor Shell Cast iron is effective for the motor casing because it is extremely strong and stiff. This is important because

Acrylonitrile Butadiene Styrene

Strong, Increased Hardness, Medium Malleability, Low Weather Resistance, Low Elasticity, Stiff, Insulator

Keyless Hand Chuck, Speed Lever And Clutch, Drill Casing, 18V Lithium Ion Battery Pack, Gearbox Assembly

The components are subjected to dropping and high impact forces so they must be made of an extremely strong material but at the same time it MUST insulate the user against electric surges. ABS is extremely suitable for these components because it is extremely strong and insulates from electricity.



Graphite Carbon Weak, Brittle, No malleability, no elasticity, low hardness, conductor,

Brushes The brushes are made from this material because of its low hardness property. If the brushes were made from another material, there is a chance that they could scratch the Commutator thus damaging the motor permanently.

Rubber Strong, very elastic, soft, no malleability, high friction, insulator, shock absorbing

Drill Casing, Wires Rubber is excellent for the grip on the casing because it allows the user to hold the drill without it falling out of the hand. This is because of its high friction property. It also insulates electricity which makes it great for wires.

Teflon Low friction, strong

Gears This material is extremely suitable for the gears because it allows them to move without causing too much friction that can slow down the drill. It also is rust-proof which means a water based lubricant can be used

Copper Conducts electricity well, ductile, High Plasticity

Wires, field coils This material is extremely suitable for the wire and field coils because it can be drawn into wires and it can efficiently conduct electricity.

Brass Low friction, strong, malleable

Gears This material is extremely suitable for the gears because it allows them to move without causing too much friction that can slow down the drill. It also is rust-proof which means a water based lubricant can be used

Stainless steel Strong, Brittle, low elasticity, low malleability, mild hardness

Ball bearings This material is extremely suitable for the bearings because it allows them to move without causing too much friction that can slow down the drill. It also is rust-proof which means a water based lubricant can be used

Nylon Low friction, strong

Gears This material is extremely suitable for the gears because it allows them to move without causing too much friction that can slow down the drill.



Manufacturing Processes and Properties Alteration:During the production of the cordless drill, many manufacturing processes are used such as Injection moulding, Rolling, Cold Forming, Cold drawing, Casting, Extrusion, forging and manual assembly. Some of these processes alter the properties of material and thus component. This alteration usually benefits it attractive properties. Below is a table listing all of the manufacturing process used for each component and (if any) alterations that the process makes.

Table 3- Table of Forming Processes and Alterations

Process Description Components Alterations MadeInjection moulding A polymer is fed from a

tube and forced into a mould by injection. It is then left to cool and removed from the mould.

18V Nickel Cadmium Battery Pack, Gears, Gearbox Assembly, Drill Casing, Speed Lever and clutch, Keyless hand chuck, Washers

NA

Rolling An ingot is fed into two high pressure rollers until it is thin.

Commutator, Battery Connector

Grains become elongated and the material becomes stronger and stiffer

Cold Forming Multiple tools are used such as a magna-bend and hammer to make the desired shape.

Electric Motor Shell, Gears, Ball Bearings, Keyless hand chuck, Screws

The material undergoes work hardening to make it stiffer and harder but increased risk of fracture.

Cold drawing A metal ingot is forced into a small die until a wire is produced

Wires, Field Coils Grains become elongated and the material becomes stronger in tension

Casting The molten metal is poured into a casting mould and allowed to cool. It is then taken out of the mould

Electric Motor Shell, Armature, Magnets, Brushes, Screws

NA

Forging The metal is heated until red-hot and hit with a hammer on an anvil until the desired shape is made.

Drive Shaft, Keyless hand chuck, Screws

Compresses the grain, producing a stronger, harder material

Manual Assembly Parts are put together by man or robots.

18V Nickel Cadmium Battery Pack, Electric Motor, Variable resistor switch

NA

Extrusion The metal is made into a billet and forced through a die creating the component.

18V Nickel Cadmium Battery Pack, Wires, Electric Motor Shell, Commutator, Drive Shaft

Grains become elongated and the material becomes stronger and stiffer



Section 2: Electrical Systems

Description of Electrical System:The DC Cordless drill has a basic electrical system with a high powered motor fitted for 18V DC but it does have a few features such as a reverse/forward/ lock switch and variable speed trigger.

The electrical system consists of an 18V DC Nickel Cadmium battery pack connected to a variable resistor switch which is then connected to an LED which then connects to a DPDT Switch which connects to the motor then back to the battery. Below is an approximate diagram of the electronic circuitry in the DC Drill.


Figure 3- Example of a Variable Speed Trigger- Jason Ho Figure 4- Example of a Forward/Reverse/Lock Switch- Jason Ho

Figure 5- Approximate Electronic Diagram of Drill-Jason Ho


The Electrical system can be broken down into individual components such as the capacitors, resistors and diodes. Most of these components are now installed by means of surface mounting.

The circuit contains a variable resistor switch which controls the speed of the motor by controlling the rate of flow of electricity. It does this by sliding a conductor that is connected to the circuit over increasing carbon content surface resistor that is connected to the other side of the circuit.

Operational Electrical Specifications:The DC Drill Uses 18V DC current at 1.5-4 Amps and uses 27-72 Watts which is supplied from a nickel-cadmium or lithium-ion battery

The battery is charged by a charging station which is power by a 220-240V AC Current.


Figure 6- Surface Mount Components-Electronicstraders.com

Figure 7- Slide Variable Resistor-pcmag.com

Figure 8- DC Dual Chemistry Charger- RYOBI/TECHTRONIC INDUSTRIES


Electrical Motor Operation and Magnetic Induction:An electric motor operates by using magnetic induction and opposing magnetic field. These magnetic fields work hand in hand because of magnetic induction. Magnetic induction is when a magnetic field perpendicular to a coiled wire causes free electrons to move in that wire, creating current. The reverse is also true. When an electric current flows through a coiled wire, it creates a magnetic field perpendicular to the flow of electrons.

The electric motor uses this phenomenon by creating an EM field around a solenoid (Armature) connected to a spinning axel which concentrates the magnetic fields outwards, which opposes a stationary permanent magnet on the outside of the axel causing the magnetic attraction to drive the electromagnet towards it. This drive spins the axel which alternates the current going through it (Commutator and stationary brushes) which in turn inverts the magnetic field thus causing it to be attracted to the other side which turns the magnet and in turn causing the current to alternate and the whole process to repeat countless of times.


Figure 9- Diagram of Electric Motor-Discovery Channel, howstuffworks.com


Safety Procedures and Precautions of the DC Drill: When using this product there are many safety precautions that must be observed. These precautions are listed on the following table. Also observe all stickers on the drill itself and do not disassemble unless you understand the circuitry.

Table 4- Safety Procedures of the DC Drill

Danger PrecautionFlying pieces from drill bit When operating this machine always wear

safety glasses.Chemical leaks from battery Do not overcharge or overheat batteryElectric shock and burns Make sure all insulation is intact and look for

any electrical short circuitsFire Look for any electrical short circuits and

don’t place near flammables.Burns from drill bit Don’t touch bit after drilling.Jammed body parts Keep body parts away from moving parts



Section 3: Disposal and Recyclability

Design Factors for Ease of Disassembly:The DC drill is a tool that can disassemble many things, but can it be disassembled itself? The RYOBI ONE+ drill can be disassembled with ease because its internal and external connectors are easy to separate and the manufacturer has an exploded view of the insides of the drill. Below is the exploded view of the RYOBI drill.


Figure 10- Exploded View of the RYOBI ONE+ Cordless DC Power Drill- RYOBI/TECHTRONIC INDUSTRIES


The drill’s connector mainly consists of Philips head screws which the everyday consumer has, which makes it easy for disassembly.

Figure 11-RYOBI ONE+ Cordless Drill Opened Up-DEWALTOWNERSGROUP.COM

Recycling and Disposal:The company does NOT have any arrangements for the disposal of their tools after consumer purchase. Even though there is no return program, the drill can still be recycled at the appropriate recycling centre. Most of the drill can easily be recycled because it is mainly made from recyclable plastics such as ABS and recyclable metals such as iron/steel. The polymers in the drill all fit in the 7 (OTHER) recycle code which means that they all can be placed into the household recycling bin. The metal in the drill can be given to scrap metal collection centres for a profit or can be placed at the local tip’s metal collection area. The only component which is not recyclable is the Lithium/Ni-CAD metal in the battery. These must be given to specialised collection centres which can treat these materials. Unfortunately there are no alternatives to these metals so it is paramount that they are given to the proper centres for treatment.

Environmental Effects and Cost of Recycling: Recycling the individual components of the drill is estimated to be cheaper that creating new materials. Also through recycling we can decrease the amount of greenhouse gas emission produced in the manufacture of new polymers. Recycling also decreases the amount of landfill in our tips



which in turn decreases the amount of pollution in the atmosphere and on land. Since most manufacturers don’t have disposal program due to it not being cost effective most people will have to recycle their old power tools.

ConclusionAfter thoroughly analysing this product I have found that:

a) The DC Cordless Drill is made from many suitable materials such as ABS and ironb) The electrical systems are effective for this device and is fairly safe is precautions are

followedc) That most of the manufacture’s details are classified because of trade secrets

In conclusion the DC Cordless Drill is a well-engineered product due to its effectiveness for it purpose and well-chosen electrics and materials. It is strong and can withstand most work conditions.



References1. Engineering Fundamentals Course Notes. 2013. John Edmondson High School. Australia2. Engineered Products Course Notes. 2013. John Edmondson High School. Australia3. HowStuffWorks, Discovery Channel. 2013. HowStuffWorks "How Electric Motors Work".

[ONLINE] Available at: http://electronics.howstuffworks.com/motor1.htm. [Accessed 20 June 2013].

4. PC Magazine . 2013. variable resistor Definition from PC Magazine Encyclopedia. [ONLINE] Available at: http://www.pcmag.com/encyclopedia/term/59623/variable-resistor. [Accessed 20 June 2013].

5. National Geographic. 2013. Effects of Recycling on Humans | National Geographic. [ONLINE] Available at: http://greenliving.nationalgeographic.com/effects-recycling-humans-20310.html. [Accessed 20 June 2013].

6. NDT. 2013. Electromagnetic Induction. [ONLINE] Available at: http://www.ndt-ed.org/EducationResources/HighSchool/Electricity/electroinduction.htm. [Accessed 20 June 2013].

7. NSW Government . 2013. Environmental Benefits of Recycling Study | NSW Environment & Heritage . [ONLINE] Available at: http://www.environment.nsw.gov.au/warr/BenefitRecycling.htm. [Accessed 20 June 2013].

8. SITA Australia. 2013. Plastic Recycling Service - Recycled Plastic Collections - Plastic Disposal Services - SITA Australia | SITA Australia. [ONLINE] Available at: http://www.sita.com.au/commercial-solutions/resource-recovery-recycling/plastic-polystyrene/?gclid=CIa4tpHD8rcCFURcpQodXTMAcQ. [Accessed 20 June 2013].

9. RYOBI AUSTRALIA. 2013. RYOBI AUSTRALIA: Power Tools & Power Garden Equipment . [ONLINE] Available at: http://www.ryobi.com.au/Home. [Accessed 20 June 2013].

10. Techtronic Industries. 2013. TTi Service Management Portal. [ONLINE] Available at: http://service.ttibrands.com.au/. [Accessed 20 June 2013].

11. Techtronic Industries. 2013. Subsidiary RYOBI representative. [INTERVIEW]. June 18


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