This report explains the designing process

of a Ratchet tool using CAD & Metrology

Coursework 2
Computer Aided Design
M10MAE

Nipun Kothare
7652305

0
 Contents
1. Introduction ............................................................................................................................................................... 1
1.1. Mechanism ........................................................................................................................................................ 1
1.1.1. Ratchet Gear Mechanism.......................................................................................................................... 1
1.1.2. Switch Mechanism .................................................................................................................................... 1
1.1.3. Nut Lock Mechanism................................................................................................................................. 1
1.2. Subassembly ..................................................................................................................................................... 2
1.2.1. Head ........................................................................................................... Error! Bookmark not defined.
1.2.2. Switch ........................................................................................................................................................ 2
2. Design ........................................................................................................................................................................ 3
2.1. Metrology.......................................................................................................................................................... 3
2.2. Part List ............................................................................................................................................................. 4
2.3. Parameterized Model ....................................................................................................................................... 4
2.3.1. Parameter 1: Length of Ratchet ................................................................................................................ 5
2.3.2. Parameter 2: Dimension of Square Driver ................................................................................................ 5
2.3.3. Parameter 3: Dimension of Hexagonal Socket ......................................................................................... 5
3. QFD Analysis .............................................................................................................................................................. 6
3.1. Customer Requirements ................................................................................................................................... 6
3.2. Technical Requirements.................................................................................................................................... 6
3.3. Inter-Relationships ............................................................................................................................................ 6
3.4. Roof ................................................................................................................................................................... 6
3.5. Planning Matrix ................................................................................................................................................. 6
The Planning Matrix is used to evaluate overall weighting of each customer requirements amongst other
parameters .................................................................................................................................................................... 6
3.6. Targets............................................................................................................................................................... 6
3.7. QFD Matrix ........................................................................................................................................................ 7
4. DFA Analysis............................................................................................................................................................... 8
4.1. Functional Analysis............................................................................................................................................ 8
4.2. Handling Analysis .............................................................................................................................................. 8
4.3. Assembly Flowchart .......................................................................................................................................... 8
4.4. Fitting Analysis .................................................................................................................................................. 8
4.5. Secondary Operation ........................................................................................................................................ 8
4.6. Ratchet DFA Report........................................................................................................................................... 9
Conclusion ....................................................................................................................................................................... 10
Appendix A Functional & Handing Analysis ....................................................................................................................... i
Appendix B Fitting Analysis & Secondary Operations....................................................................................................... ii
Main Assembly - Ratchet .............................................................................................................................................. iii
Appendix C Technical Drawings: ...................................................................................................................................... iii
Part_01_Ratchet_body................................................................................................................................................. iv
Part_02_Cover_Plate..................................................................................................................................................... v
Part_03_Hexagonal_Bolts ............................................................................................................................................ vi
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 Part_04_Conical_Spring_Free ..................................................................................................................................... vii
Part_05_Pawl_Right ................................................................................................................................................... viii
Part_06_Switch_Block .................................................................................................................................................. ix
Part_07_Switch_Lever................................................................................................................................................... x
Part_08_Gear ............................................................................................................................................................... xi
Part_09_Release.......................................................................................................................................................... xii
Part_10_Release_Washer ...........................................................................................................................................xiii
Part_11_Plunger ..........................................................................................................................................................xiv
Part_12_Square Driver ................................................................................................................................................ xv
Part_13_Retention_Ball ..............................................................................................................................................xvi
Part_14_Cylindrical_Spring ........................................................................................................................................ xvii
Part_15_Hexagonal_Socket ...................................................................................................................................... xviii
Sub_Assembly_1_Head ............................................................................................................................................... xix
Sub_Assembly_2_Switch ..............................................................................................................................................xx
References ...................................................................................................................................................................... xxi

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1. Introduction
Ratchets are used for rotation of gears in one direction while restricting the other. It is used as a tool
for socket wrenches where it is used in tandem with a calibrated nut to open bolts of specific profiles.
In this report, we will try to design a ratchet that is compatible with the Hex Nut design. We will first
understand the mechanisms involved. We will then develop a design of all the components required to
develop the product. We will then assemble these components into a final CAD Product using Catia.
We will then develop a 2D draft of the assembly and its sub-components. Finally, we will carry out a
DFA & QFD analysis of the assembly.

1.1. Mechanism
1.1.1.Ratchet Gear Mechanism
The rotation of the ratchet in only one direction is achieved using
a gear - pawl mechanism. The teeth of the pal are designed
asymmetrically relative to the gear. This means the pawl behaves
differently when the gear rotates clockwise or anti-clockwise.
Let’s say that the mechanism locks on rotation in the clockwise
direction whereas it is free to move in the anticlockwise direction.
This means that the ratchet can be engaged for torque transfer
when the rotation with reference to the nut is in clockwise Figure 1 Gear Pawl Mechanism
direction. When the ratchet is returned to its original position
using an anti-clockwise rotation, no torque is transferred and the ratchet is free to move; allowing for
continuous torque application in a single direction.

1.1.2.Switch Mechanism
The ratchet should be flexible in its operational direction to allow
for torque application in the direction compatible with the user`s
requirements. This is applicable especially in cases where loosening
& tightening of the same nut is required. This can be introduced by
introducing 2 pawls that engage with the same gear in opposite
directions. A switch mechanism can ensure that the transfer
between engagement of the 2 pawls. Each pawl corresponds to Figure 2 Switch Mechanism consisting of
rotation in one direction for the gear. Gear (Red), Pawl (Blue), Switch Block
(Green) & Conical Springs (Brown)

1.1.3.Nut Lock Mechanism

To allow for flexibility usage of different socket sizes, a mechanism
needs to be introduced to hold & remove sockets according to the
user`s convenience. This can allow the user to freely change
between different sizes according to his/her convenience. A square
driver is used to achieve this purpose which constitutes of a square
profile of calibrated dimensions. The square driver is coaxially
engaged with the gear. The hexagonal socket also has a square
profile on its top other end which sits congruently with the driver.
The square driver consists of a plunger shaft placed inside its hollow
space. The plunger is directly linked to a release which sits on top of
the gear with the support of a vertical spring. A triangle-shaped slit
is placed in the plunger where the retention ball sits inside a
horizontal slot in the square driver. The spherical ball usually pokes Figure 3 Nut Locking Mechanism -
out of the slot due to pressure experienced from the plunger. Consists of Retention Ball (Yellow),
Square Driver (Red) & Hexagonal Socket
(Blue)

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When the release is pressed by the user, it pushes the plunger downwards, allowing the ball to move
in due to increase in the size of slot access to it. The socket can now be placed inside the driver as the
ball no more behaves as an obstruction to its entry. Once the socket is placed, the user can let go of
the release. The spring connected to washer of the release, brings the system back to its original
position, pushing the plunger upwards & the retention ball inwards. The outer surface of the retention
ball sits congruently with a slot placed inside the hexagonal socket, completing the locking process. The
same process can also be used to remove the socket.

1.2. Subassembly
To simplify the designing process, we can further breakdown the assembly into smaller sub-assembly
carrying out individual functions. In the ratchet 2 major sub-assembly based on functionality are –

1.2.1.Head – This consists of gear & all components co-axially including the socket, the locking
mechanism for the square driver, the retention ball & the washers.
1.2.2.Switch – This consists of components directly involved in the engagement of the gear & pawl and
of direction of rotation of the gear i.e. the pawls, conical springs, switch lever & switch block.

2
2. Design
2.1. Metrology
Parameters Parts Involved Metrology CAD Comments
A calibrated scale can be used for measuring
Length of lengths of a larger scale which require lower
Ratchet Body, resolution of 1 mm.
Length
Plunger, Release Length can be placed as a dimensional
& Socket constraint for distance between 2 nodes or
the length of a line segment.
Holes, Gear,
Diameters of circular profiles can be
Washer, Square
measured using a Vernier caliper. It provides
Diameter Driver, Retention
a resolution of 0.02 mm
Ball, Hexagonal
Dimensional constraint of diameter can be
Socket, Plunger,
assigned in 2D sketching of CATIA software
Release, Bolts
Holes (except for
Diameters of circular profiles can be
blind holes) e.g.
measured using a Vernier caliper. It provides
Socket Depth,
Depth a resolution of 0.02 mm
Holes placed
Holes can be developed in the cad software
inside the
with the use of pocket & hole tool.
ratchet body
A screw gauge can be used to measure
Dimensions of
parameters that are too small to measure
Smaller pawl, springs,
with the naked eye. Resolution - 0.01 mm
Dimensions switch lever &
Due to its high resolution, CAD software can
block
easily design smaller sketches & profiles.
All parts present
in the outer body
Fillets can be measured using radius gauges
e.g., Ratchet
Fillets/Chamfers Fillets /Chamfer tools available in Part
Body, Release,
design can be used to specify for the edges.
Square Driver,
Plunger, Nut etc.
Figure 4 Metrology & CAD Processes involved in Part Design

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2.2. Part List

Part Sub-
No. Assembly Part Name
1 Body Ratchet Body
2 Body Cover Plate
3 Body Hexagonal Bolts
4 Switch Conical Spring
5 Switch Pawl
6 Switch Switch Block
7 Switch Switch Lever
8 Head Gear
9 Head Release
10 Head Release Washer
11 Head Plunger
12 Head Square Driver
13 Head Retention Ball
Cylindrical
14 Head Spring
Hexagonal
15 Socket Socket
Figure 5 Components of Ratchet Assembly

Each component is first assigned a part name & part no. After development of the part design, the parts
are imported to the assembly design feature of CATIA. The components are positioned in the assembly
design by providing suitable constraints with reference to each other. First the sub-assemblies are
developed separately. Each of the sub-assemblies is then constrained with each other & the ratchet
body to finally form the main assembly. The two primary tools used for assembly design are mate &
coincidence tools. Each component is re manipulated post assembly to ensure that the components
are not under-constrained. The assembly is finally linked to the parameters of the individual part files
to develop a parameterized model. Suitable drafting is carried out for individual components, sub-
assemblies, & assemblies that can be used to in the future to reconstruct these parts/products by
designers.

2.3. Parameterized Model

Parameters can be defined in CATIA to control specific geometrical characteristics of a product design.
These should be evaluated considering the possibility of modifications in the product design. It should
also consider the changes experienced in the market demands of the product. We will first select 3
parameters that are relevant to the product design.

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2.3.1.Parameter 1: Length of Ratchet

As ratchet are primarily used to tighten or loosen nuts & bolts, a key characteristic of the ratchet is the
torque generated by it. The torque generated is given by the equation

𝑇𝑜𝑟𝑞𝑢𝑒 = 𝐹𝑜𝑟𝑐𝑒 ∗ 𝑅𝑎𝑑𝑖𝑢𝑠

Figure 6 Length Parameter of Ratchet

Since this ratchet utilizes manual forces, we can assume only a slight variation in the forces that can be
experienced by the ratchet. This may not be sufficient for the high range of torques that may be
required in day to day life. Hence ratchets of various length are manufactured to vary the radius of
force application. Although an increase in length will always increase the torque experienced by the
nut, it also increases the mass of the ratchet significantly since the handle is a solid cylinder to minimize
bending. Hence control of the length of the ratchet is an important parameter. This parameter can be
modified for the assembly by adjusting the parameter section ‘Length of Ratchet’ in the component
‘Part_01_Ratchet_Body.CATPART’.

2.3.2.Parameter 2: Dimension of Square Driver

As has been discussed earlier, the socket engages with the ratchet with the use of a square driver. This
driver is usually developed in specific dimensions for both the ratchet & the socket. It is hence necessary
to parametrize the size of the square driver to allow for manufacture of ratchets compatible to different
sockets.

The square driver used in our design is of dimension 6.35 mm (0.75 inch). We should keep in mind that
this dimension is specifically assigned for the socket. The ratchet will require an appropriate clearance
over this value to ensure an interference fit. The dimension for the ratchet has been kept at 6.37 mm
with an interference of 0.01 mm on both sides of the driver. The driver size parameter can be modified
for the assembly by adjusting the parameter section ‘Square Driver size’ in the component
‘Part_12_Square_Driver.CATPART’.

2.3.3.Parameter 3: Dimension of Hexagonal Socket

As mentioned earlier, ratchets are designed for computability to multiple sockets of
different sizes. Usually ratchets are sold along with compatible sockets of different
sizes. This size can range from 0.1 mm to 20 mm. Hence, we will parameterize this
dimension.

The socket size taken for this design in 12 mm. The socket size can be measured by
finding the distance between the hexagonal edges as shown in the image on the
right. The socket size parameter can be modified for the assembly by adjusting the
parameter section ‘Socket Size’ in the component
‘Part_15_Hexagonal_Socket.CATPART’.

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3. QFD Analysis
Quality Functional Deployment is a tool used to combine customer
requirements & technical data to develop objective of designing a
product. The image below shows the constituent sections of a QFD
Matrix.

3.1. Customer Requirements

This section provides a list for the key requirements of the voice of a
customer. Some key concerns for the customer are listed below. A
weighted value of 1-5 is assigned to each of the customer
requirements based on importance that the customer places to the
criteria.

3.2. Technical Requirements Figure 7 Components of a QFD

In this section, key product characteristics are identified from an Matrix
engineering point of view. The direction in which each engineering
characteristic improves the product is also identified if applicable.

3.3. Inter-Relationships
This is a two – dimensional matrix that identifies the strength of relationship of each engineering
characteristic to each customer requirement. Each relationship level is assigned a weight.

3.4. Roof
The roof is a triangular section at the top of the QFD matrix that identifies the inter-relationships
between the engineering characteristics.

3.5. Planning Matrix

The Planning Matrix is used to evaluate overall weighting of each customer requirements amongst
other parameters

Parameter Calculation/Evaluation Process

Performance Score Score achieved based on a questionnaire to customers on performance of
product in each criterion
Planned Desired Performance of Product in the criteria (out of 5)
Satisfaction Rating
Improvement Improvement Factor
Factor = ( Importance Weighting – Planned Satisfaction Rating ) ∗ 0.2 + 1
Sales Point This criterion is used to include any features that can be used directly for
promotion of the product.
Overall Weighting Overall Weighting
= Weight of Criteria ∗ (Improvement Factor + Sales Point)
Figure 8 Calculation of Parameters for Planning Matrix

3.6. Targets

Finally, Technical Priorities are evaluated based on a weighted sum of overall weighting & relationship
value for each engineering characteristics. Engineering targets are set for each characteristic based
on its priority value.

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3.7. QFD Matrix Relationship Symbol Rating
˄
Strong Positive Relationship ˄˄ 9
^
˄ Medium Relationship ˄ 3
˄˄ Weak Relationship ˅ 1
˅ No Relationship ˂˃ 0
˅ ˅
˅ ˄
˅ ˄˄ ˅ ˅
^ ^
˄ ˄ ˅ ˅

Direction of Improvement ↑ ↓ ↓ ↑ ↑ ↓ - - ↑ ↓ ↑ ↑
Engineering Characteristics Performance Range Technical Details Planning Matrix

Surface Tolerance for Ratchet Body

Material Strength for Components

Diameter of Retention Ball

Thickness of Head Section

Customer Importance

Square Driver Profile Size

No. of Fillets / Chamfers

Diameter of Main Rod

Improvement Factor

Percentage of Total
Overall Weighting
Weight of Ratchet

Length of Ratchet

Planned Rating
No. of Springs
No. of Rivets

Our Product
No. of Bolts

Sales Point
Customer Requirement
Torque Generated 5 ˄ ˂˃ ˂˃ ˄ ˂˃ ˂˃ ˄ ˄ ˄ ˄ ˄˄ ˄ 5 5 1.0 1.3 6.5 13.80
No. of Compatible sockets 5 ˂˃ ˄ ˂˃ ˂˃ ˂˃ ˂˃ ˄˄ ˄ ˂˃ ˂˃ ˂˃ ˂˃ 2 4 1.4 1.2 8 16.99
Reversibility of Ratchet rotation 2 ˂˃ ˂˃ ˄ ˂˃ ˂˃ ˄ ˂˃ ˄ ˂˃ ˄ ˂˃ ˅ 1 2 1.2 1.1 2.6 5.52
Reachability of Tool 3 ˂˃ ˂˃ ˂˃ ˂˃ ˂˃ ˂˃ ˄ ˄ ˅ ˄ ˄˄ ˅ 3 4 1.2 1 3.6 7.64
Grip 2 ˂˃ ˄ ˂˃ ˄ ˄ ˂˃ ˄ ˄ ˄ ˄ ˅ ˂˃ 3 3 1.0 1 2 4.25
Cost 3 ˂˃ ˅ ˄ ˄ ˅ ˄ ˅ ˂˃ ˄ ˂˃ ˅ ˅ 2 4 1.4 1.4 5.4 11.46
Portability 2 ˂˃ ˂˃ ˂˃ ˂˃ ˂˃ ˂˃ ˄ ˂˃ ˄ ˄ ˅ ˄ 1 3 1.4 1.2 3.2 6.79
Safety 2 ˄ ˄ ˂˃ ˂˃ ˄˄ ˂˃ ˄ ˄ ˂˃ ˄ ˄ ˂˃ 5 5 1.0 1 2 4.25
Failure - Proofing 3 ˄˄ ˄ ˅ ˄ ˂˃ ˅ ˂˃ ˂˃ ˄ ˂˃ ˄ ˅ 4 4 1.0 1.2 3.6 7.64
Handling 3 ˂˃ ˂˃ ˄ ˄ ˂˃ ˂˃ ˅ ˂˃ ˅ ˄˄ ˄ ˄ 4 4 1.0 1 3 6.37
Replaceability of Parts 2 ˄ ˄ ˅ ˄˄ ˅ ˅ ˅ ˄ ˅ ˂˃ ˅ ˄ 5 5 1.0 1.2 2.4 5.10
Aesthetics 3 ˂˃ ˄ ˅ ˄ ˄˄ ˄ ˂˃ ˂˃ ˅ ˂˃ ˅ ˅ 3 4 1.2 1.4 4.8 10.19
Technical Priorities 65.1 73.8 44 97.5 75 44 135 81 76 87 135 65
Percentage of Total 6.66 7.55 4.5 9.97 7.7 5 14 8.3 7.8 8.9 14 6.7
940 0.05 6.35 10 190.1 11.28
Technical Benchmarking Mpa mm 1 2 10 3 3 mm mm mm 207 g mm mm
1100 0.02 4-8 12 300 12
DESIGN TARGETS MPa mm 0 3 12 3 4 mm mm mm 180 g mm mm
Figure 9 QFD Matrix

7
 4. DFA Analysis
DFA (Design for Assembly) is a concept used to analyse the complexities involved in assembling a
product. A DFA analysis can help understand the implication of improving assembly methods on
manufacturing performance & quality. Each component of the product is analysed individually and
summed together to find the overall performance of the product. This consists of primarily 4 steps –

4.1. Functional Analysis – Categorisation of Parts into Essential ‘A’ parts & Non- Essential ‘B’ parts
based on a criteria chart (refer Appendix A).
𝑇𝑜𝑡𝑎𝑙 𝑁𝑜. 𝑜𝑓 𝐴 𝑃𝑎𝑟𝑡𝑠 9
𝐷𝑒𝑠𝑖𝑔𝑛 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = = = 60%
𝑇𝑜𝑡𝑎𝑙 𝑁𝑜. 𝑜𝑓 𝑃𝑎𝑟𝑡𝑠 15
A Design Efficiency of 60% defines a good Functional Performance.

4.2. Handling Analysis – Involves a survey of questions required for handling the part. This is used
to find out the Handling Index of the Part (refer Appendix A).
𝐻𝑎𝑛𝑑𝑙𝑖𝑛𝑔 𝐼𝑛𝑑𝑒𝑥 (𝑃𝑟𝑜𝑑𝑢𝑐𝑡) = ∑ 𝐻𝑎𝑛𝑑𝑙𝑖𝑛𝑔 𝐼𝑛𝑑𝑒𝑥 (𝑃𝑎𝑟𝑡𝑠) = 20.50
𝐻𝑎𝑛𝑑𝑙𝑖𝑛𝑔 𝐼𝑛𝑑𝑒𝑥 20.50
𝐻𝑎𝑛𝑑𝑙𝑖𝑛𝑔 𝑅𝑎𝑡𝑖𝑜 = ′ ′
= = 2.28
𝑇𝑜𝑡𝑎𝑙 𝑁𝑜. 𝑜𝑓 𝐴 𝑃𝑎𝑟𝑡𝑠 9
A Handling Ratio of 2.28 defines a good Handling Performance.

4.3. Assembly Flowchart – This involves identification of the best possible process available for
assembly flow of the product. The flowchart is initiated with the development of the Head
sub-assembly. This is later added to the Ratchet Body where the main assembly is carried out
(Flowchart on next page).

4.4. Fitting Analysis – A survey of questions pertaining to fitment of a part/sub-assembly inside

the already assembled components to find out the Fitting Index of the Part.
𝐹𝑖𝑡𝑡𝑖𝑛𝑔 𝐼𝑛𝑑𝑒𝑥 (𝑃𝑟𝑜𝑑𝑢𝑐𝑡) = ∑ 𝐹𝑖𝑡𝑡𝑖𝑛𝑔 𝐼𝑛𝑑𝑒𝑥 (𝑃𝑎𝑟𝑡𝑠) = 25.30
𝐹𝑖𝑡𝑡𝑖𝑛𝑔 𝐼𝑛𝑑𝑒𝑥 25.30
𝐹𝑖𝑡𝑡𝑖𝑛𝑔 𝑅𝑎𝑡𝑖𝑜 = = = 2.81
𝑇𝑜𝑡𝑎𝑙 𝑁𝑜. 𝑜𝑓 ′ 𝐴′ 𝑃𝑎𝑟𝑡𝑠 9
A Fitting Ratio of 2.81 defines a satisfactory Fitting Performance.

4.5. Secondary Operation – Analysis of any additional operations involved in the assembly
process. It is possible to further improve the fitting index by modifying the assembly process
provided. A mechanical deformation is experienced by the square driver, gear & release
washer during the assembly process to thermally join the rubber material based bodies. By
introducing pre-manufactured Gears which are pre-joined with a washer & square driver, the
secondary operations carried out during assembly can be eliminated.

8
 4.6. Ratchet DFA Report

Assembly – Reversible Ratchet with Drive 6.35 mm Key

Version - 1 Work Holder
Date – 16/08/2017 Insertion
Secondary Operation
No Part Name Qty FA A's B's Handling Assembly Flow
. Index
1 Release 1 A 1 0 1.2
1

2 Release Washer 1 A 1 0 1
1

3 Gear 1 A 1 0 1 1.7
1.7 4

4 Cylindrical Spring 1 A 1 0 1.6

1.6
5 Plunger 1 B 0 1 1.2
1

6 Square Driver 1 B 0 1 1.3

1.7 4
7 Retention Ball 1 A 1 0 1.5
1.6
8 Ratchet Body 1 A 1 0 1.1
1

9 Switch Lever 1 B 0 1 1.5

1

10 Switch Block 1 B 0 1 1.5

4.7

11 Head Sub-assembly 1 NA NA NA NA
1
12 Pawl 2 A 2 0 1.1
1.7
13 Conical Spring 2 A 2 0 1.7
2.3

14 Cover Plate 1 B 0 1 1.9

4

Total No. Of Parts 15 Total Handling Index 20.50

Total No. Of A Parts 9 Handling Ratio 2.28
Total No. Of B Parts 6 Total Fitting Index 25.30
Design Efficiency (%) 60.00 Fitting Ratio 2.81

9
Conclusion
1. The mechanisms & the sub-assemblies involved in the product have been recognised.
2. The product measurements have been carried out using sufficient measurement tools.
3. There is a developed model of the Ratchet on CATIA along with design of each component.
4. The model has been parameterised for 3 key functions of the product.
5. 2D Draft have been generated for the component, sub-assembly & main assembly with
appropriate dimensions & tolerancing.
6. The QFD analysis concludes with the targets set for engineering characteristics. It also
provides for a developed weighting criterion for each customer requirement.
7. The DFA analysis of the product shows a good performance for Functional Analysis & Handling
Analysis & a satisfactory performance for Fitting Analysis. It also presents a flowchart for the
asmebly process to be carried out. An alternate flowchart has been processed

10
Appendix A Functional & Handing Analysis

Part No. Sub-Assy. Part Name Functional Analysis Handling Analysis

End to End Rotational
Criteria Chart Part Type Size & Weight Handling Difficulties HI
Orientation Orientation

Gripping Problem
Strip Roll/Pallet

Not Easy to See

Not Easy to See

Handling Index
Severely Nest
Untouchable
Convenient

None Reqd

None Reqd
Easy to See

Easy to See
Very Small

Very Large

Adherent

Abrasive
Flexible
Fragile

Tangle
Value

Value

Value

Value
Large
N=No, Y= Yes A/B
1 Body Ratchet Body - A Y 1 0 Y 0.1 Y 0 1.1
2 Body Cover Plate NYNN B Y 1 Y 0.2 Y 0.5 Y 0.2 1.9
3 Body Hexagonal Bolts NNN B Y 1 Y Y 0.5 Y 0.1 Y 0 1.6
4 Switch Conical Spring YYY A Y 1 Y 0.6 Y 0.1 Y 0 1.7
5 Switch Pawl YYY A Y 1 0 Y 0.1 0 1.1
6 Switch Switch Block YNNN B Y 1 0 Y 0.1 Y 0.4 1.5
7 Switch Switch Lever NNN B Y 1 0 Y 0.1 Y 0.4 1.5
8 Head Gear YYY A Y 1 0 0 0 1
9 Head Release YYY A Y 1 Y 0.2 0 0 1.2
10 Head Release Washer NYYY A Y 1 0 0 0 1
11 Head Plunger NNN B Y 1 Y 0.2 0 0 1.2
12 Head Square Driver NNN B Y 1 0 Y 0.1 Y 0.2 1.3
13 Head Retention Ball YYY A Y 1.5 0 0 0 1.5
14 Head Cylindrical Spring YYY A Y 1 Y 0.6 0 0 1.6
15 Socket Hexagonal Socket NNYYY A Y 1 0 Y 0.1 Y 0.2 1.3

i
Appendix B Fitting Analysis & Secondary Operations

Part No. Sub-Assy. Part Name Fitting Analysis Secondary Operation

Process Process Proc Setting/Test Proc
Part Placing/Fastening Other FI Non - Mechanical Fastening
Direction Quantity ess ing/Measuri ess

Soldering/Weldin
Adhesive/Electric
Restricted Access
Requires Holding

Not Straight Line

Not From Above
Plastic Bending

Re-Orientation
Simultaneous
Self Securing

Staright Line

Fitting Index
Self Locates

Mechanical
Resistance

Additional
Alignment

Screwing
Diffculty
Multiple

Difficult
Liquid
Screw

Single
Value

Value

Value

Value

Value

Value

Value

Value
Rivet

Easy
Column1 Column2 Column3

al
9 Head Release Y 1 0 0 0 0 1
10 Head Release Washer Y 1 0 0 0 0 1
8 Head Gear Y 1 0 0 0Y 0.7 1.7 Y 4
14 Head Cylindrical Spring Y 1 0 0 0 Y 0.6 1.6
11 Head Plunger Y 1 0 0 0 0 1
12 Head Square Driver Y 1 0 0 0Y 0.7 1.7 Y 4
13 Head Retention Ball Y 1 0 0 0 Y 0.6 1.6
1 Body Ratchet Body Y 1 0 0 0 0 1
7 Switch Switch Lever Y 1 0 0 0 0 1
6 Switch Switch Block Y 4 0 Y 0.7 0 0 4.7
NA Head Head Sub-Assy. Y 1 0 0 0 0 1
5 Switch Pawl Y 1 0 0 0Y 0.7 1.7
4 Switch Conical Spring Y 1 0 Y 0.7 0 Y 0.6 2.3
2 Body Cover Plate Y 4 0 0 0 0 4

ii
Appendix C Technical Drawings:
Main Assembly - Ratchet

iii
Part_01_Ratchet_body

iv
Part_02_Cover_Plate

v
Part_03_Hexagonal_Bolts

vi
Part_04_Conical_Spring_Free

vii
Part_05_Pawl_Right

viii
Part_06_Switch_Block

ix
Part_07_Switch_Lever

x
Part_08_Gear

xi
Part_09_Release

xii
Part_10_Release_Washer

xiii
Part_11_Plunger

xiv
Part_12_Square Driver

xv
Part_13_Retention_Ball

xvi
Part_14_Cylindrical_Spring

xvii
Part_15_Hexagonal_Socket

xviii
Sub_Assembly_1_Head

xix
Sub_Assembly_2_Switch

xx
References

➢ Assembly Report - Plug International (2013) available from

<https://cumoodle.coventry.ac.uk/pluginfile.php/1747804/mod_label/intro/Plug%20DFA.jpg> [19 August
2017]

➢ BS 8888:2017 - Technical Product Documentation and Specification (2017) BSI Standards Limited 2017.
available from
<https://bsol.bsigroup.com/Download/SubscriptionPdfDocument?materialNumber=000000000030334593&d
ocumentNumber=BS%208888%3A2017> [16 August 2017]

➢ Clarke PRO359 - 20 Piece 1/4" Drive Socket Set (2017) available from
<https://www.machinemart.co.uk/p/clarke-pro359-20-piece-14-drive-socket-set/> [10 August 2017]

➢ Crow, K. (2017) Customer-Focused Development with QFD [online] available from <http://www.npd-
solutions.com/qfd.html> [17 August 2017]

➢ Design for Assembly Manual (2017) available from

<https://cumoodle.coventry.ac.uk/pluginfile.php/1747799/mod_resource/content/0/Design%20For%20Asse
mbly%20Manual.pdf> [19 August 2017]

➢ Science Channel (2010) How Its Made 05 - Ratchets [online] available from
<https://www.youtube.com/watch?v=N_GUDMVWVss&t=220s> [16 August 2017]

➢ Stevens, K. (2017) Introduction to Metrology [online lecture] module M10MAE, Coventry: Coventry University
available from < https://cumoodle.coventry.ac.uk/mod/resource/view.php?id=1356810> [15 August 2017]

➢ Torque Wrench Digital 1/2"Sq Drive (2017) available from <http://www.demon-tweeks.co.uk/tools-

workshop/ratchets-sets/sealey-angle-torque-wrench-digital-1-2sq-drive-20-200nm-stw306> [12 August 2017]

➢ Lowe, A. (2010) QFD Tutorial [online] available from <http://www.webducate.net/qfd/qfd.html> [20 August
2017]

xxi