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Antoine Guivarch guivarch@mit.edu

Taesik Lee tslee@mit.edu

Carissa Tudryn tudi@mit.edu



2.875

Mechanical Assembly and its Role in Product Development

Dr. Daniel Whitney

Project Assignment #1
Quartz Analog Alarm Clock

Description of the product





Table of contents




Assembly drawing p.3

Exploded view p.4

Bill of Materials p.5


Description of each part p.6

List of mates p.8


Drawings & pictures of parts and p.10

subassemblies

We purchased a battery-operated quartz analog alarm-clock for $13 at the Coop. It is manufactured by Westclox in China (that is what the back casing says). The instruction manual mentions the following address in the United States, as well as a fax number in the same state:

General Time Service Center

120 Newton Bridge Road

Athens, Georgia, USA 30607-1163.
We disassembled the clock into several different parts listed below in the order of disassembly. We had to break two wires connecting a coil to a printed circuit board (PCB1), but nothing else was broken, so that we were able to reassemble the clock entirely. The smaller parts (gears) were marked with a pen so as to remember where they go and which side up.
3 casing screws

Battery cover (dark gray plastic)

Back casing (dark gray plastic)

Top alarm button (shiny gray plastic)

On/off alarm button (gray plastic)

Setting knob (black plastic)

Clock cover (transparent plastic – clipped)

2 thinner screws attaching the spring slide to the gear box subsystem

Spring slide (black), linked by a wire

2 shorter screws attaching the bell subsystem

Bell subsystem (metal, black plastic, motor), linked by two wires

Second hand (shiny gray)

Minute hand (black with fluorescent sticker)

Hour hand (black with fluorescent sticker)

Alarm hand (gray)

Gear box subsystem (see below)

1 gray flex cable linking the gear box subsystem to a small circuit board

Small circuit board (PCB 2) (just for connecting wires – soldering)

Gear box subsystem


Gear box cover (clipped, with sliding switch on top)

1 gear T with metal axis and three slots (T for top, inscription on top)

1 gear (white) FL (far left if coil to the right, inscription on top)

1 gray gear L (left if coil to the right, inscription on top)

1 tiny gear B (bottom, under the coil) (+ black ring inside)

1 gray front casing

1 coil stand (black with metal contact, lifted and pulled out)

1 Coil on metal frame (two wires out of the coil to the circuit board, pushed out of its stand)

1 White peg (to be in connection with the setting knob)

1 gear “movie real” IT (inside top) on

1 gear off axis I2T (inside 2nd top)

1 transparent peg on

1 black stand

1 circuit board (PCB1 for Printed Circuit Board 1) (1 resistor, 1 transistor, 2 capacitors, 1 metal thing, must be the quartz)

1 white roller I3T on top

1 gear I4T with little peg

1 gear I5T popped out of the gear box base

1 gear box base

Bell sub-system


Double-ring bell ringer

Motor plus capacitor

Bell on black plastic stand
Exploded View on next page

BILL OF MATERIALS

5 subsystems, 32 parts

Front Casing Subsystem FC

10 parts
Front casing FC1

Clock paper FC2

Battery + contact FC3

Battery – contact FC4

LED FC5

Transparent clock cover FC6

Alarm hand FC7

Hour hand FC8

Minute hand FC9

Second hand FC10

SPRING SLIDE SS

7 parts
Base SS1

Slide SS2

Spring SS3

Electric contact holder SS4

Electric contact bumper SS5

Metal contacts SS6 (comes with SS5)

& SS7
BELL SUBSYSTEM BSS

6 parts
Support BSS1

Motor BSS2

Ring holder BSS3

Rings (2x, no difference) BSS4

Bell BSS5

Capacitor BSS6

GEAR BOX GB

4 parts
Gear box GB1

Gear box switch GB2

Printed Circuit Board GB3

Flex cable GB4

BACK CASING SUBSYSTEM BC

5 parts
Back casing BC1

Battery cover BC2

Alarm button BC3

On / off switch BC4

Knob setter BC5

Not counted: wires

screws

DESCRIPTION OF EACH PART
























































PART #

NAME

FUNCTION / COMMENTS

MATERIAL

COLOR




FC (Front Casing)

 

 

 




FC1

Front cover

 

Injection molded thermoplastic*:
Acrylic Resin
Hard, not brittle, smooth glass-like surface

Light grey




FC2

Clock paper

 

 

 




FC3

Battery + contact

 

Aluminum

 




FC4

Battery – contact

 

Aluminum

 




FC5

LED

 

Acrylic Resin casing with diode inside

 




FC6

Transparent clock cover

 

Acrylic Resin

Transparent




SS (Spring Slide)

 

 

 




SS1

Base

The only reason for this part to exist is that the gear box was outsourced, otherwise the slide would go directly on GB1

Acrylic Resin

Black




SS2

Slide

 

Acrylic Resin

Black




SS3

Spring

 

Steel

 




SS4

Electric contact holder

 

Acrylic Resin

Black




SS5

Electric contact bumper

 

Acrylic Resin

Black




SS6

Metal contact

Comes with SS5

Copper

 




SS7

Metal contact

 

Copper

 




BSS (Bell Subsystem)

 

 

 




BSS1

Support

 

Acrylic Resin

Black




BSS2

Motor

Probably outsourced

 

 




BSS3

Ring holder

 

Acrylic Resin

Black




BSS4

Rings

The two rings have no difference: same part number but quantity 2

Aluminum

 




BSS5

Bell

 

Steel

 




BSS6

Capacitor

 

 

 






























































































PART #

NAME

FUNCTION / COMMENTS

MATERIAL

COLOR




GB (Gear Box)

 

 

 

 




GB1

Gear box

Contains extra room for internal battery, has instructions carved on the plastic: probably outsourced and used in another product, that is why we chose not to include it in our analysis

Acrylic Resin

Black




GB2

Gear box switch

A slot stops the sliding movement
One spring cantilever makes sure the switch is not in an intermediate position

Acrylic Resin

Black




GB3

Printed Circuit Board

Simple connecting role (no electric components, just wires soldered)

Copper, Silicium

Green




GB4

Flex cable

 

Copper

Grey




GB5

Alarm hand

 

Acrylic Resin

Grey




GB6

Hour hand

 

Acrylic Resin with fluorescent material

Black + fl. green




GB7

Minute hand

 

Acrylic Resin with fluorescent material

Black + fl. green




GB8

Second hand

 

Acrylic Resin

Silver




BC (Back Casing)

 

 

 

 




BC1

Back casing

 

Acrylic Resin

Dark grey




BC2

Battery cover

 

Acrylic Resin

Dark grey




BC3

Alarm button

 

Acrylic Resin

Silver




BC4

On / off switch

Made to match the size of GB2 black knob (probably not designed by the same company)

Acrylic Resin

Light grey




BC5

Knob setter

Sets both alarm and time depending on the depth of insertion of the knob

Acrylic Resin

Black



















* Thermoplastics are materials that flow when introduced to high heat. They are moldable under this high heat and pressure. This process molds plastic resins. Injection molding machines are used to form almost all the parts of this alarm clock. The plastic resin is added to the machine along with any dyes or colors. Once the resin moves to the barrel, it is heated to a their specific melting temperature. Once the resin is “melt”, it is added to the mold. The plastic in the mold cools and becomes a solid part.
















( Taken from http://bakelite_world_2001.tripod.com/itsbakeliteyouknow/id8.html and http://www.cheresources.com/injectionzz.shtml )
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