Product Decomposition- NERF Maverick

So for today we had to prepare a presentation for mechanics on the mechanical workings of a simple. The idea was in groups of five to take a simple product, take it apart, documenting the stages and each individual component, and then demonstrating how these pieces interact, facilitate the flow of energy and contribute to the overall function. We were in a three, and the product was surprising complicated.

 This was the item in question, one NERF Maverick toy gun. The gun is designed to shoot small foam darts and then have the barrel rotate a new chamber into position. So we set about disassembling it, removing the multitude of screws from it to reveal....

 A very complicated interior mechanism. We had chosen this because we knew it was completely mechanical, with no electronics so we knew it would be complicated, but still we were somewhat surprise when this jumped out at us (literally with some of the springs). 

 

 So as we deconstructed it we recorded our progress, neatly laying out all the parts and photographing them with their corresponding components, till it was completely apart, as shown above and below.

 Once it was in pieces we then set about photographing the different components, 35 varieties in total with some multiples.

Disassembling the mechanism.

From this procedure and the photos we had taken, we were then able to create a Product Decomposition Report. This involves labeling, and providing information such as how it was manufactured, on each component, detailing how each component interacts with other components and other objects, detailing the overall function, the flow of energy, information and materials and flowcharts on the function and subfunctions. Some pages from the report are below.

 

 Then from this report we (well...I) made this presentation (again only some pages shown below), presenting the information from the report with a mood board at the end, to be presented in class today.

 The presentation session was scheduled from 4pm-6pm, but ended up taking until 7pm, as groups required more time. Other objects chosen included two identical staple guns, four corkscrews, a stapler, a lighter, a garlic slicer and two tape measures, all with less than 20 parts total. So yeah ours was overly complicated. But the presentation still went well, and the lecturer seemed happy with our efforts, so a success, I think.
Anyway I now need to get on adding the finishing touches to the foam models as they are due tomorrow so better crack on.

Metal Workshop- Tremmel (4)

A quick update of my process at the moment with the tremmel, with half a day to go till it is marked, and progress is good.

The main body of the tremmel

With the extension above it.

Some closeups of the completed components in place.

My initials stamped onto the side of the pin holders.

And finally some extras, on the left is the first part of a components to hold a lead, the right is a pen/pencil extension to the tremmel however because I made a slight mistake, it is now also optimized for holding a scalpel as well. So anyway, the final making day is tomorrow, and all looks well.

Metal Workshop- Tremmel (3) and a pencil......pen.......thing

Sorry but more work on the tremmel today. I finished my preliminary work on the lathe, more to be done later though, and started work on the milling machines

The milling machines are the linear response to the rotation of the lathe, namely a way to make precise and automated vertical and horizontal cuts and holes, and as such I was able to add the required holes to the extension adjustment component. This was all I was able to do as the milling machine is very confusing and has some very complicated processes using strange things such as wobblers, datums, reamers, digital readouts and leather hammers (called hammers of Thor), at least complicated to all of us beginners.

 The milling machine

 

 However, while waiting for a chance to use the milling machine, there are only six in the workshop, I was given a bonus challenge on the lathe in the form of a tremmel style pencil/pen.

 The pencil is made from two parts of the same 8mm rod, and uses the techniques we have used already, but to a greater extent.

 I was also given an option of how I wanted the end of the pencil finished, choosing an angled end. I do still need to finish and polish it, but that can be done in the general polishing session that will inevitably come later. So more work tomorrow and more greasy hands, what fun.

Deconstructivism Mug 3

With the deadline for the object assignment drawing closer, and the final foam workshop over, today I decided to get on with adding and improving the Deconstructivism Mug I am working on.

So after a few hours work I have advanced my model closer to completion. I have now refined and attached the handle made earlier and I have been cleaning up all the surfaces and edges with some fine grade sandpaper (600) and some needle files. I got a lot done today, but of course there is still more to do.

 Close ups of the faces and edges.

I did also do some more work on the other part of the assignment, the mystery object, however I will show that later on, when I have done some more work on it.

Product Description 2- Partner's Product; & Remembrance

So after a day full of lectures yesterday, the only change being a switch in Mechanics from Statics to Dynamics, today I got on with the second part of the Design Process assignment, making a model of a product, purely from a description by my partner. The description, given to me earlier goes like this:

The product which I am describing centres around a flat disk which has teeth around the outside set at a distance apart of about 5mm. The disk rotates and has a diameter of the 80mm. Beneath the disk is a moulded plastic component which is designed to support the disk and form a handle to the product. The handle has a very basic ergonomic shape which fits the hand in a pistol type grip with a big trigger component designed for all four fingers. Where the palm rests there’s a section which opens up allowing the product to be reloaded.

Above the rotating ring there is a 25mm width raised 5mm section which acts to stop the ring coming off from the top. It runs in the same direction as the pistol grip directly above it and at the end there is a rectangular hole (4mm x 11mm) where the product produces its completed product.

Surrounding the ring there are a series of letters and symbols all with different processes. Beneath the rotating ring  there is also a small button which sticks out 5mm with a diameter of 4mm.

The product is entirely plastic external components in very basic primary colours.

From this description I was able to create this rough sketch of how it may look. This is only rough as it gives me a starting point for the actual construction of the model out of the pink foam.

 At this stage I am unsure of exactly what it's function is, I have a guess that it is an old tool for making raised labels, but I could not say for certain.

From this sketch, and with the description close to hand, I was able to start work on the model in the foam workshop today.

As I hope you can see, I got the major shapes blocked out and roughly sanded into shape using both the hot wire cutter and some 60 grade sandpaper. During the next week I will focus on the details of the model, and sand down the surface to a high quality finish, the same as needs to be done with the other part of this assignment, the mug. Some more photos of the work are below.

Of course I cannot finish this post today without a reference to the fact that it is Remembrance Day. As a person I believe it is my obligation to improve the world, and as a designer I am well placed to do that. But we cannot do that without remembering the tragedy of the sacrifices of those who have fought and fallen to enable everyone to have an equal opportunity to improve the world, no matter how small that improvement may be. So I will remember and reflect on all those who have fought, and their families, who must live with their worries, concerns and losses, today and everyday, and I hope you will too. Thank you.

Metal Workshop- Tremmel (2)

 So I've had two more days of work in the metal workshop since I last showed my work, and it has advanced considerably.

I have now advanced from just the metal working lathe, I have now used both a milling machine (for straight machined cuts) and a Collet (a highly accurate lathe). So above are all my components so far, all of them are at the furthest stage I can take them at the moment, so in my mind I have done pretty well. The individual components are below.

 Bolt x6                                        Tremmel Head x2

Extension Cap x1                                 Wheel holder? x1

 Adjustment Wheel x1                                  Collet Cap x2

M5 threaded rod x1                              Steel Point x2

Measureing Rod x1                                 Extension Rod x1

While all of the components will fit together to create a single tool, some of them are already made to fit and below are the different attachments so far.

 Extention Rod and Cap and the Tremmel head, collet cap and Steel point

And the adjustment wheel and wheel holder.

So thats where I am at the moment, no more work on this till next week where we will be doing much more work on the milling machines.