Dismantling and Reassembly of a Toaster - Report Example

TOASTER ANALYSIS By Student’s name Course code and name Professor’s name University name City, State Date of submission Executive Summary This report covers reverse engineering experiment carried out with an aim of acquainting and establishing knowledge that shall be required in technological advancement. The experiment involved dismantling and reassembly of a toaster and analysis of materials utilised in its manufacture. Challenges are noted here and there during the dismantling process with breakages being prominent due to the nature of the manufacturers’ assembly processes. There are also notable challenges noted during the reassembling process in that some parts are left out for inability to recollect on where there should be fitted. The experiment also successfully indicates the reasons behind material type usage in various components. Self-acquaintance and critical analysis of the object prior to dismantling or even assembly is recommended in the long run for groups that might wish to undertake the same exercise. Table of Contents Executive Summary 2 This report covers reverse engineering experiment carried out with an aim of acquainting and establishing knowledge that shall be required in technological advancement. The experiment involved dismantling and reassembly of a toaster and analysis of materials utilised in its manufacture. Challenges are noted here and there during the dismantling process with breakages being prominent due to the nature of the manufacturers’ assembly processes. There are also notable challenges noted during the reassembling process in that some parts are left out for inability to recollect on where there should be fitted. The experiment also successfully indicates the reasons behind material type usage in various components. Self-acquaintance and critical analysis of the object prior to dismantling or even assembly is recommended in the long run for groups that might wish to undertake the same exercise. 2 Table of Contents 3 Introduction 4 Part 1: Dismantling the Toaster 4 Part 2: Reassembling the Toaster 10 Part 3: Materials Used in Production of the Toaster 12 Conclusion 13 Reference List 14 Introduction The technology behind objects that have already been engineered is very important for purpose of improvement and advancement or even introduction of market substitutes. In order to understand how an existing product functions reverse engineering sets in as a very important approach. This process usually involves disassembly and assembly of a product after which the parts are analysed through a non-destructive manner. This report aims at documenting the reverse engineering observations made on all components of a toaster. This shall include the time taken for the disassembly and assembly processes to be successfully undertaken, problems incurred and material analysis with suggestions of improvements. Part 1: Dismantling the Toaster Prior to the dismantling exercise it was noted from the data sheet that the toaster type and model number were Abode and KS-2000DS respectively. Other specifications of this China made toaster included 220 – 240V alternating current, operating frequency of 50/ 60 Hz and a rating of 850 –1000W. The photographs in figure 1 and 2 below show the general outlook and the datasheet of the toaster respectively. Figure 1: Toaster to be dismantled. Figure 2: Datasheet of the toaster indicating specifications. Once these specifications were noted down, the fastening points were identified for the dismantling exercise to commence. One of the noted difficulties at this point is the fact that the configuration of the locking mechanism of the shell and the inner assembly could not be well deciphered. Further, the regulating knobs were noted to be another stumbling block in this whole exercise as they required special attention in order to ensure their reusability on reassembly. Figure 3: Base of the toaster is made of thermosetting plastics. Note: The arrows indicate the fastening points of the aluminium shell which are made of stainless steel. The four sitting pads are made of rubbers which act as vibration dumpers. On opening up all the holding screws, the inner assembly was separated from the shell. This process was also challenging in a way that it had to be done carefully in order to avoid damaging of any of the components basically due to the orientation and uncertainties of assembly. This process which took a maximum of 5 minutes was carried out painstakingly to avoid damaging the thermoset base threads. Figure 4 shows the separation process in progress while figure 5 shows the already separated building blocks of the toaster. Figure 4: Separation of shell and inner assembly in progress. Figure 5: Toast loader top (green arrow) and toaster wall (blue arrow) are made of stainless steel. Bread holder support wires made of stainless steel were also posed difficulties in dismantling due to the nature of assembly done on it. The amount of time taken (10 minutes) was more compared to the other operations which took an average of up to two minutes each. Figure 5: The arrows indicate the bread loader made of aluminium. Once the components were separated, the controls were segregated and marked in order to ensure that they were assembled well during the finalization of this exercise. The process of dismantling these items took ten minutes and the material of these components identified. The figures 6, 7 and 8 indicate the items that were finally exposed for this study in accordance to the given instructions. Figure 6: Dismantled inner assembly. The dismantled inner assembly indicates the insulation (yellow arrow) holding the control mechanism (green arrow) for the heating element (blue arrow) and screws that were extracted from the holding clamp. This process was however a challenge when it came to withdrawing the clamp as it got damaged due to handling problems. The electrical heating element is made of Nichrome material which converts electricity energy to heat while at the same time resisting. Figure 7: Restoring springs made of steel (blue arrows) and electrical cables made of copper (green arrows). Figure 8: The adjustment knob alongside other control switches majorly composed of silicon. Part 2: Reassembling the Toaster Reassembling the toaster was quite an easy task that took approximately 20 minutes in total. The major challenges were regarding the structure itself rather than the functional components. The electrical functions such as the knobs (figure 9) were noted to be damaged due to application of force while dismantling. These were however not cause for alarm as the other parts that were required for the assembly exercise were still intact. The Figure 9: Broken heat control knob (left) and a broken electric cables holding clamp (right). During the assembly process it was observed that the metal strips are made up of a series of tabs that could be connected and disconnected with relative ease. The plates could connect to each other by folding without applying extreme efforts in achieving this important milestone. Lack of clamps for regrouping of electrical cables was however another issue which was tackled by reusing the clumsy remainders that was available. This process of assembling back the restoring springs was also challenging since they were supposed to test positive with respect to their functions. Some of the component’s functions were also forgotten in the process of this important exercise due to traceability problems. Figure 10 below shows the assembly process in progress while 11 shows a component whose function would not be properly traced. Figure 10: Assembly process in progress. Figure 11: Component whose function could not be traceable. The final assembly shown below was arrived at by covering the inner assembly which had been made ready for the exercise. It is also important to note that the exterior functions such as the press handle and the regulation knobs. Figure 12 below shows the complete assembly of the bread toaster at its original and best working conditions. Figure 12: Reassembled toaster ready for use. Part 3: Materials Used in Production of the Toaster As noted within the dismantling and reassembly sections above various materials were used during the manufacture of this bread toaster for a variety of reasons. For example, Nichrome heating component was utilised due to its ability to withstand high temperatures thereby making it durable. Thermoset plastic was used for the base due to its resistibility against heat – it is also had to deform. The manufacturability of the materials consisted in this toaster was among other reasons why the materials were used. The functionality of such materials as copper cables was also handy since there is no other affordable material that surpasses copper in terms of conductivity. Considering affordability on some of the materials gives alibis that next time the manufacturer wants to produce a premium quality gadget they should go cheaper alternatives that are upcoming such as alloys made of steel. Conclusion The process of reverse engineering taught many lessons to me and other counterparts that undertook this experiment. The dismantling exercise at particular was noted to be huge challenge due to the inability to tell how the inside assembly was done by the manufacturer. It is therefore recommended that prior to undertaking the initial dismantling exercise caution be taken not to damage the parts – application of gradual force is suggested. Regarding the materials, it was a big lesson since it was noted that different materials were used for different purposes thus coming up with a completely functional item. Reference List Advameg, Inc. (2014). Toaster. Retrieved September 1, 2014, from http://www.madehow.com/Volume-7/Toaster.html Schroede, M., Zarske, M. S., & Yowell, J. (2009). Hands-on Activity: Engineering in Reverse! 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