HSC Engineered Products Research Task

.
Jason Ho 11.311ES
2013
Engineering Studies
Engineered Products Research Task
21 06
Engineered Products Research Task
Jason Ho
11.3-11ES
2013
Engineering Studies
06 21

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

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

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


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


Introduction
The 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 manufacturers 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 Used
General 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 Process
18V 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
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
Below, in blue section Manual Assembly
Electric Motor Shell To hold the
components that
drives the mechanical
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
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
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,
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. Irons 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
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
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 Made
Injection 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
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,
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 Precaution
Flying pieces from drill bit When operating this machine always wear
safety glasses.
Chemical leaks from battery Do not overcharge or overheat battery
Electric shock and burns Make sure all insulation is intact and look for
any electrical short circuits
Fire Look for any electrical short circuits and
dont place near flammables.
Burns from drill bit Dont 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.

The drills connector mainly consists of Philips head screws which the everyday consumer has, which
makes it easy for disassembly.
Figure 10- Exploded View of the RYOBI ONE+ Cordless DC Power Drill- RYOBI/TECHTRONIC INDUSTRIES


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 tips 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 dont have disposal program due to it not being cost effective most people will have
to recycle their old power tools.

Conclusion
After thoroughly analysing this product I have found that:
a) The DC Cordless Drill is made from many suitable materials such as ABS and iron
b) The electrical systems are effective for this device and is fairly safe is precautions are
followed
c) That most of the manufactures 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.


References
1. Engineering Fundamentals Course Notes. 2013. John Edmondson High School. Australia
2. Engineered Products Course Notes. 2013. John Edmondson High School. Australia
3. 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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