2.

875
Mechanical Assembly
and Its Role in Product Design

Pencil Sharpener Presentation#1

November 14, 2001
Hernan Joglar
John Sharkey 1
 Presentation Contents
Product Description
Company Background
CAD Exploded view
Parts and Material List
Photo of Product Disassembly
Product Structural Decomposition
Major Sub-Assemblies
Critical Mates and Clearances
Gearbox Key Characteristics and Datum Flow Chain
Assembly liaison diagram
Assembly Time Analysis
Example Assembly Process
Fixtures and Special Tooling
Potential Problems and Risks
Suggested Assembly Improvements
Backups
DFA Gross Motions - Product Structural Decomposition
DFA Fine Motions - Part Liaisons and Mates
Related Product Line
2
 Boston Stapler Product Description
Battery Operated Pencil Sharpener: Model #16750 (black)
Referred to as a razor spiral cutter model
Operation activated by axial force of pencil insertion
Safety lockout feature prevents operation without receptacle
Features 1 year warranty
No replaceable parts, Hunt simply replaces defective units
Product Assembly Specifications:
29 identified parts, comprising 7 sub-assemblies
35 assembly features and liaisons
Physical dimensions: 4.75 x 3.00 x 2.25 at 6.1 ounce weight
Popular with graphic artists and designers
provides clean, sharp pencil points for a wide range of pencil types,
including composite pencils
Approximately 250,000 units sold last year
Distributed through all major office supply retail stores
Staples, Office Depot, Wal-Mart, Target, etc
Typically sells for around $5.00 3
 Hunt Manufacturing Corporation
Founded in 1899 by George Bartol
Went public in 1982 after a series of expansions and acquisitions.
Corporate headquarters in Statesville, NC
Donald L. Thompson became president and CEO in 1996
Product design center located in Statesville, NC
Outsources most manufacturing within the United States
Boston Series of pencil sharpeners manufactured in China
1300 employees nationwide
Sales revenue of $286M in 2000, 1.6% increase over 1999
Main product lines is graphics equipment and office supplies
A global leader in the pencil-sharpener market
Boston family of pencil sharpeners and
staplers accounts for 40% of company sales
Other significant products lines include:
Exacto razor blades
Conte crayons and pastels
Bienfang paper, painter markers,
foam boards and laminates
Seal imaging equipment 4
 CAD Exploded View

5
[ Model developed using Autodesk Inventer Version 3.0 ]
 Parts and Material List
P/N Part Name Qty Material Description
1 Base Screws 2 Self-threading steel screw
2 Pencil guide 1 Injection molded plastic
3 Battery compartment screw 1 Self-threading steel screw
4 Shavings receptacle 1 Injection molded plastic
5 Sharpener base 1 Injection molded plastic
6 Rubber foot (Underneath of base) 1 black rubber
7 Sharpener case 1 Injection molded plastic
8 Contacts on battery compartment cover 2 stainless steel contacts with plastic rivets
9 Battery compartment cover 1 Injection molded plastic
10 Rubber foot (Underneath of battery comp. cover) 1 black rubber
11 Battery Compartment housing 1 Injection molded plastic
12 Contacts and rivets on battery compartment 3 stainless steel contacts and brass rivets
13 Battery installation paper guide 1 white paper with black graphic print
14 Blue wire 1 22 gage aluminum braid wire
15 Gearbox housing 1 Injection molded plastic
16 Output Gear 1 Injection molded plastic
17 Intermediate Gear 1 Injection molded plastic
18 Driven Gear 1 Injection molded plastic
19 Gearbox cover screw 1 Self-threading steel screw
20 Electric motor 1 Brush commutated DC permament magnet motor
21 Safety lever 1 Injection molded plastic
22 Lubrication 1 red petroleum jelly on gears and motor
23 Contacts and rivets on gear housing cover 3 stainless steel contacts and brass rivets
24 Red wire 1 22 gage aluminum braid wire
25 Black wire 1 22 gage aluminum braid wire
26 Gearbox cover 1 Injection molded plastic
27 Blade screw and nut 1 Machine screw and hex nut
28 Blade 1 Stainless steel razor blade
29 Blade holder 1 Injection molded plastic 6
 Photo of Product Disassembly
14 9
24 15 25 5 8 4

12

11

23

2
7

21 11
20

17 18 19 1 3 26 27 28 29
16

7
 Product Structural Decomposition
Complete Assembly

Pencil guide Base screws Bat. Comp. Shavings Battery Sharpener Base
Motor Gearbox
screws receptacle Compartment case

Sharpener
Bat. Comp.
Gearbox base
Black wire housing
cover screw
Gearbox Electric Rubber
Bat. Comp.
housing motor foot
contacts

Output gear Safety lever Battery

Bat. install. Comp. cover
Intermediate guide
Lubrication
gear
Contacts battery
Driven gear Comp. cover
Gearbox cover
Battery
Cutter Comp. cover
Unit Gearbox cover
contacts Rubber
foot
Blade nut Red wire
and bolt
Blue wire General Assembly
Blade

Gearbox cover Sub- Assembly

Blade holder

Part

8
 Major Sub-Assemblies
Safety lever pin
Motor rim Gearbox Cover Input contact
Edge
Output gear
Driven
gear

Intermediate
Motor contact

Output contact
Intermediate gear
Gearbox housing

Motor Gearbox Sub-Assembly Gearbox cover Sub-Assembly

Mating
Blade Blade holder features

Bolt

Electric in-out
Nut contacts Electric contact
Red and black
electric wires rivets
Cutter Unit Sub-Assembly Battery Compartment Sub-Assembly 9
 Critical Mate and Clearance Ratio #1
Slots

Shaver Receptacle to Shaver Case

clower
1.990 2.019 0.014
2.019
cupper
1.713 1.792 0.044
1.792

Rims

10
 Critical Mate and Clearance Ratio #2
Base to Sharpener Case Edge Interface

c rim slot
2.114 2.097 0.007 Holes
2.097

c peg hole #1
0233 0.200 0.142 Slot along
0.233 edge

Slot

c peg hole # 2
0229 0.200 0.127
Rim along
edge
0.229 Rim

Pegs

Note: Clearance ratio requires Sliding

surfaces
Gearbox and battery compartment
sub-assemblies to be inserted.
11
 Critical Mate and Clearance Ratio #3

Rim and
snap fit

c rim slot
1.567 1.692 0.0798
1.597

Slots

Rims

Slot

12
 Gearbox DFC and Key Characteristics
3 5 6
2 4 1Gear housing cover
1
2Driven gear block
3Intermediate gear block
4Output gear block
5Top lateral stopping peg
6Top central stopping peg
7Motor Location pegs
8Gear housing
9Motor gear
1Driven gear input pinion
Z 13
1Driven gear output pinion
17
1Driven gear stand
10 18
14
9

11
X 1 Driven gear pin
1 Intermediate gear input pinion
1Intermediate gear output pinion
12 15 16
19
1Intermediate gear stand and hole
7 20 21 1Intermediate gear pin
22
1Output gear
24 23 1Output gear stand
2Bottom lateral stopping peg
2Bottom central stopping peg
2Top part of motor compartment in gear housing
2Hole in gear housing for motor location
2Motor

13
 z axis pre-load Output Shaft
Output Gear
Motor Upper Surface
Gearbox Flex Center
Output Gear
Base
Bored
Contact Bored
Stanchion
Hole
Integrated
Stanchion
Bored
Outer Pitch Circle
Datum Flow Chain
Stanchion KC #3
Squared
Step Inner Pitch Circle for Motor/Gearbox
Outside
Perimeter
Bored
Stanchion
Center
Hole Intermediate Gear
Sub-Assembly
Thin
Stanchion
Outer Pitch Circle
5 dof
KC #2
Inner Pitch Circle

z , x , y Center
Hole Driven Gear
Inside Hole &
Perimeter Low 5 dof
Stand KC #1
x , y , z Squared Axle & Outer Pitch Circle
Notch Med Stand 5 dof
Pinion
Axle & & Rotor 5 dof
Threaded Tall Stand Top
Stanchion Centering Centering Base
Hole x,y Boss Centering Motor Case & Rotor
Peg on w/pinion gear
Thru Hole Boss
Stanchion Cylindrical Base
x , y , z , z Top
5 dof With Surface
Dimples W/Holes
Edge
Guides
Safety Lever
Motor/Gearbox Housing
6 dof
Box Base
Guides Center
Hole
Note: 5 dof = { X , Y , Z, X , Y } Assembly Fixture 14
Simplified Gearbox DFC: Driven to Intermediate Gear
Co-planarity KC Top surface
Bottom surface driven gear
input pinion input pinion
Intermediate Pitch circle Driven gear
gear driven gear
Pitch circle input pinion output
Top surface
pinion
Tangency KC Gear hole
Gear hole Bottom
Top surface surface
Bottom
surface

X ,Y Z , y , x X ,Y
Driven gear
Z , y , x Intermediate Driven gear pin
gear pin stand

Driven Intermediate
gear gear stand Gear
Top Stopping pegs
block Z , y , x Housing
Intermediate and contact end Bottom stopping pegs
gear block and contact surface Rim
Edges X , Y , z
Pitch circle of Bottom Stopping
driven gear pegs
Gear Housing cover

Gear pins
Rim

Gear stands
Pitch circle of
Gears top surfaces 15
intermediate gear
 Pencil Sharpener Liaison Diagram and Fasteners Classification

p14 c26 p12 c24

p11 c6
p13 c25

c38 p6 C37
c15 c22

p4 c1 p7 c3 p5 c23 p10
p20
c5
c2 p9
c18 c13 c31 p8
c4
p2
c20 p27
c17 c14 p29
c21
c12 p28
c10 c7 p21

c16 p24
c34
c19
p26 c32 p23

c8 c35 p25
p15
c11
p18 c9
c33

c29 Liaisons Using

c27 Permanent Liaisons Threaded Features
p17 c30
Rivets Screws

Adhesive Nut & Bolt

c28 p16

C36 Soldering Other mates

16
 Assembly Time Analysis
Throughput requirement based on production volume
250,000 units/year @ 250 workdays/year = 1000 units/day
1000 units/day @ 8 hours/day = 125 units/hour = 2.08 mins/unit
Assembly time per Boothroyd Handling and Insertion Times
Handling Time per unit = 106.98 (sec/unit)
207.18
Location Time per unit = 47.50 (sec/unit) (sec)
Reversible Fastening Time per unit = 54.20 (sec/unit)
Irreversible Fastening Time per unit = 121.00 (sec/unit)
Total predicted assembly time = 329.68 (sec/unit)
Note: does not include inspection and test time

Measured Handling, Location and Reversible Fastening Times

Test#1 309 sec - Test#4 169 sec
Test#2 222 sec - Test#5 153 sec
Test#3 198 sec
Assembly Efficiency
Three un-necessary parts: Sharpener case, paper guide, and pencil guide
Assembly efficiency
19 parts * 3 sec/ part
57 sec
17.3%
(total assembly time) 329.68 sec 17
 Example Assembly Process

SA 7 SA 7
Cutter Unit Cutter Unit
Assy Inspect
18.25 sec 5 sec
SA5
SA6 SA 6 SA5a SA5a SA5a
Gearbox Cover Gearbox Cover Gearbox Gearbox Gearbox
Assy Inspect
48.06 sec
Assy Solder Test
5 sec Motor/Gearbox Assy
87.30 + 30 sec
SA5 SA 5
Battery Comp. Battery Comp. SA1 SA1
Assy Inspect Final Final
Assy Inspect
19.62 sec 5 sec
101.83 sec 20 sec
SA3 SA 3 SA2
Battery Cover Battery Cover Base Package
Assy Inspect Assy & Ship
19.62 sec 5 sec 33.5 sec 30 sec

Note: Test, inspection and packaging times are SWAGS 18

 Fixtures and Special Tooling
Fixtures
Riveting fixture. or special tooling, for battery compartment
Riveting fixture, or special tooling, for gearbox cover
Bending fixture for gearbox cover electrical contacts
Bending fixture for battery cover electrical contacts
Bending fixture for battery compartment electrical contacts (nice to have)
Soldering station and fixture for electric motor (black and blue leads)
Soldering station and fixture for battery compartment (black and red leads)

Standard Tools and Special Tooling

Heat stake tooling for battery compartment electrical contacts
Magnetic Phillips head screwdriver (4 length) for battery compartment screw
Small wrench, or pliers, for blade screw and nut
Wire strippers (22 gage)
Wire tinning and pre-form bending
Soldering station for gearbox cover
Electrical test station for operation of motor/gearbox sub-assembly
Lubrication dispenser gun

19
 Potential Problems and Risk Areas

Description Probability Impact

Personnel injury from razor blade Med High

Reversed motor polarity wiring (black on +) High High

Reversed battery compartment wiring (red on right) High High

Solder joint or wire breakage during gearbox insertion Low High

Solder joint or wire breakage during motor insertion Low High

Motor pinion clearance thru gearbox hole High Med

Loss of motor location during final assembly High Med

Improper location of battery compartment on gearbox Med Med

Part damage from shaver receptacle insertion (snap fit) Med Med

20
 Suggested Design Improvements
Description Impact
Reversed motor polarity wiring (black on +)
- Use wire connector instead of solder joint Med
Reversed battery compartment wiring (red on right)
- Imprint wiring polarity on battery compartment injection mold High
Solder joint or wire breakage during gearbox insertion
- Use wire connector instead of solder joint Med
Solder joint or wire breakage during motor insertion
- Use wire connector instead of solder joint Med
Motor pinion clearance thru gearbox hole
- Reduce and control gearbox manufacturing variance Med
Loss of motor location during final assembly
- Include snap/fit feature between battery compartment and gearbox High
Improper location of battery compartment on gearbox
- Use wire connectors instead of solder joint Med
Part damage during shaver receptacle insertion (snap fit)
- Training, coupled with control of manufacturing variations Low 21
 Backups
Part Handling: Gross Motion ( 2 slides)
Part Insertion: Fine Motions ( 2 slides)
Part Liaisons and Mates
Related Product Lines
Product Structural Decomposition

22
 Part Handling: Gross Motion
Size Thick G.M. Alpha Beta Handling
Order P/N Description Qty (mm) (mm) Code (deg) (deg) (deg) (sec)
1 29 Position blade holder 1 35 6 10 180 180 360 1.50
2 28 Locate blade 1 21 0.5 13 180 180 360 2.06
3 27 Locate and fasten blade screw and nut (tools: screwdriver & pliers) 1 9 1.5 03 180 0 180 1.69
4 SA7 Inspect & Release Cutter Sub-Assembly 1 35 6 5.25
5 26 Position Gearbox cover 1 65 1.9 10 180 180 360 1.50
6 23 Locate & rivet cover contacts 3 18 0.2 13 180 360 540 2.06
7 24 Solder red wire to cover 1 130 1 03 0 1.69
8 25 Solder blue wire to cover 1 111 1 03 0 1.69
9 SA6 Inspect & Release Gearbox Cover Sub-Assembly 1 65 1.9 10
10 15 Position gearbox housing (inverted) 1 58 50 10 180 180 360 1.50
11 22 Apply lubrication to axle stands 3 00 0 1.13
12 16 Locate output gear 1 25 2 03 180 0 180 1.69
13 17 Locate intermediate gear 1 21 5.8 00 180 0 180 1.13
14 18 Locate driven gear 1 21 5.8 00 180 0 180 1.13
15 22 Apply lubrication to gear surfaces and axles 3 00 0 0 0 1.13
16 SA6 Position gearbox cover sub-assembly 1 65 1.9 00 180 0 180 1.13
17 21 Locate safety lever on gearbox cover (retain with one hand) 1 11 6.1 85 180 270 450 5.00
18 SA6 Locate gearbox cover sub-assembly & safety lever (2 hand ops) 1 65 1.9 85 180 0 180 5.00
19 19 Locate and fasten gearbox cover screw (self-threading) 1 15 3 00 180 0 180 1.13
20 sa5 Invert & position partially complete gearbox sub-assembly 1 65 50 00 180 0 180 1.13
21 20 Position electric motor near gearbox 1 43 23.6 10 180 360 540 1.50
22 14 Solder blue wire to motor (2 hand ops) 1 111 1 03 0 1.69
23 25 Solder black wire to motor (2 hand ops) 1 86 1 03 0 1.69
24 20 Locate electric motor in gearbox 1 43 23.6 85 180 45 225 5.00
25 SA7 Locate cutter unit sub-assembly 1 35 6 80 180 90 270 4.10
26 SA5 Inspect, Test & Release Motor/Gearbox Sub-Assembly 1 65 50

23
 Part Handling: Gross Motion (cont)
Size Thick G.M. Alpha Beta Handling
Order P/N Description Qty (mm) (mm) Code (deg) (deg) (deg) (sec)
27 11 Position battery compartment housing (inverted) 1 70 32 10 180 180 360 1.50
28 12 Locate & rivet battery compartment contacts 2 22 0.2 13 180 180 360 2.06
29 SA4 Inspect & Release Battery Compartment Sub-Assembly 70 32
30 9 Position battery compartment cover 1 43 2.5 10 180 180 360 1.50
31 8 Locate and rivet (plastic heat stake) battery cover contacts 2 20 0.2 13 180 180 360 2.06
32 SA3 Inspect & Release Battery Compartment Cover Sub-Assembly 43 2.5
33 5 Position sharpener base 1 75 7 10 180 180 360 1.50
34 SA3 Locate battery compartment cover sub-assembly 1 43 2.5 10 180 180 360 1.50
35 11 Locate rubber feet on base and battery compartment cover 2 25 1.6 10 180 180 360 1.50
36 SA2 Inspect & Release Base Sub-Assembly 1 75 7
37 SA5 Position motor/gearbox sub-assembly 1 65 50 00 0 180 180 1.13
38 SA4 Locate battery compartment sub-assembly on motor/gearbox 1 70 26 80 180 180 360 4.10
39 25 Solder black wire to battery compartment 1 86 1 03 0 1.69
40 24 Solder red wire to battery compartment 1 130 1 03 0 1.69
41 7 Position sharpener case 1 82 36 10 180 180 360 1.50
42 SA4/ Locate battery compartment & motor/gearbox in sharpener case 2 96 32 80 180 10 190 4.10
43 3 Locate and fasten battery compartment screw 1 8 3 01 180 0 180 1.43
44 SA2 Locate base sub-assembly in sharpener case 1 75 7 10 180 180 360 1.50
45 3 Locate and fasten battery compartment screws 2 9 3 01 180 0 180 1.43
46 1 Locate and fasten sharpener case screws 2 14 3 01 180 0 180 1.43
47 13 Install battery installation paper guide 1 50 1 13 180 180 360 2.06
48 sa1 Invert and reposition partially complete sharpener assembly 1 96 50 00 180 0 180 1.13
49 2 Locate pencil guide (tricky alignment) 1 32 11.7 05 180 0 180 1.84
50 4 Locate shavings receptacle (snap fit) 1 73 36 05 180 15 195 1.84
51 SA1 Inspect, Test & Release Pencil Sharpener Assembly 1 115 50

24
 Part Insertion: Fine Motion
Size Thick F.M. Handling Insertion Total
Order P/N Description Qty (mm) (mm) Code (sec) (sec) Time
1 29 Position blade holder 1 35 6 00 1.50 0.00 1.50
2 28 Locate blade 1 21 0.5 40 2.06 4.50 6.56
3 27 Locate and fasten blade screw and nut (tools: screwdriver & pliers) 1 9 1.5 48 1.69 8.50 10.19
4 SA7 Inspect & Release Cutter Sub-Assembly 1 35 6 5.25 18.25
5 26 Position Gearbox cover 1 65 1.9 00 1.50 0.00 1.50
6 23 Locate & rivet cover contacts 3 18 0.2 35 2.06 7.00 27.18
7 24 Solder red wire to cover 1 130 1 95 1.69 8.00 9.69
8 25 Solder blue wire to cover 1 111 1 95 1.69 8.00 9.69
9 SA6 Inspect & Release Gearbox Cover Sub-Assembly 1 65 1.9 48.06
10 15 Position gearbox housing (inverted) 1 58 50 00 1.50 0.00 1.50
11 22 Apply lubrication to axle stands 3 99 1.13 1.20 6.99
12 16 Locate output gear 1 25 2 00 1.69 1.50 3.19
13 17 Locate intermediate gear 1 21 5.8 00 1.13 1.50 2.63
14 18 Locate driven gear 1 21 5.8 00 1.13 1.50 2.63
15 22 Apply lubrication to gear surfaces and axles 3 99 1.13 1.20 6.99
16 SA6 Position gearbox cover sub-assembly 1 65 1.9 00 1.13 0.00 1.13
17 21 Locate safety lever on gearbox cover (retain with one hand) 1 11 6.1 00 5.00 1.50 6.50
18 SA6 Locate gearbox cover sub-assembly & safety lever (2 hand ops) 1 65 1.9 06 5.00 5.50 10.50
19 19 Locate and fasten gearbox cover screw (self-threading) 1 15 3 38 1.13 6.00 7.13
20 sa5 Invert & position partially complete gearbox sub-assembly 1 65 50 00 1.13 0.00 1.13
21 20 Position electric motor near gearbox 1 43 23.6 00 1.50 0.00 1.50
22 14 Solder blue wire to motor (2 hand ops) 1 111 1 95 1.69 8.00 9.69
23 25 Solder black wire to motor (2 hand ops) 1 86 1 95 1.69 8.00 9.69
24 20 Locate electric motor in gearbox 1 43 23.6 11 5.00 5.00 10.00
25 SA7 Locate cutter unit sub-assembly 1 35 6 30 4.10 2.00 6.10
26 SA5 Inspect, Test & Release Motor/Gearbox Sub-Assembly 1 65 50 87.30

25
 Part Insertion: Fine Motion (cont)
Size Thick F.M. Handling Insertion Total
Order P/N Description Qty (mm) (mm) Code (sec) (sec) Time
27 11 Position battery compartment housing (inverted) 1 70 32 00 1.50 0.00 1.50
28 12 Locate & rivet battery compartment contacts 2 22 0.2 35 2.06 7.00 18.12
29 SA4 Inspect & Release Battery Compartment Sub-Assembly 70 32 19.62
30 9 Position battery compartment cover 1 43 2.5 00 1.50 0.00 1.50
31 8 Locate and rivet (plastic heat stake) battery cover contacts 2 20 0.2 35 2.06 7.00 18.12
32 SA3 Inspect & Release Battery Compartment Cover Sub-Assembly 43 2.5 19.62
33 5 Position sharpener base 1 75 7 00 1.50 0.00 1.50
34 SA3 Locate battery compartment cover sub-assembly 1 43 2.5 30 1.50 2.00 3.50
35 11 Locate rubber feet on base and battery compartment cover 2 25 1.6 97 1.50 12.00 27.00
36 SA2 Inspect & Release Base Sub-Assembly 1 75 7 32.00
37 SA5 Position motor/gearbox sub-assembly 1 65 50 00 1.13 0.00 1.13
38 SA4 Locate battery compartment sub-assembly on motor/gearbox 1 70 26 02 4.10 2.50 6.60
39 25 Solder black wire to battery compartment 1 86 1 95 1.69 8.00 9.69
40 24 Solder red wire to battery compartment 1 130 1 95 1.69 8.00 9.69
41 7 Position sharpener case 1 82 36 00 1.50 0.00 1.50
42 SA4/ Locate battery compartment & motor/gearbox in sharpener case 2 96 32 08 4.10 6.50 21.20
43 3 Locate and fasten battery compartment screw 1 8 3 48 1.43 8.50 9.93
44 SA2 Locate base sub-assembly in sharpener case 1 75 7 00 1.50 1.50 3.00
45 3 Locate and fasten battery compartment screws 2 9 3 38 1.43 6.00 14.86
46 1 Locate and fasten sharpener case screws 2 14 3 38 1.43 6.00 14.86
47 13 Install battery installation paper guide 1 50 1 00 2.06 1.50 3.56
48 sa1 Invert and reposition partially complete sharpener assembly 1 96 50 00 1.13 0.00 1.13
49 2 Locate pencil guide (tricky alignment) 1 32 11.7 30 1.84 2.00 3.84
50 4 Locate shavings receptacle (snap fit) 1 73 36 30 1.84 2.00 3.84
51 SA1 Inspect, Test & Release Pencil Sharpener Assembly 1 115 50 104.83
Assembly Total (sec) = 329.68
(min) = 5.49

26
 Part Handling: Gross Motion (cont)

Size Thick G.M. Alpha Beta + Handling

Order P/N Description Qty (mm) (mm) Code (deg) (deg) (deg) (sec)
27 9 Position battery compartment cover 1 43 2.5 10 180 180 360 1.50
28 8 Locate and rivet (plastic heat stake) battery cover contacts 2 20 0.2 13 180 180 360 2.06
29 SA3 Inspect & Release Battery Compartment Cover Sub-Assembly 43 2.5
30 11 Position battery compartment housing (inverted) 1 70 32 10 180 180 360 1.50
31 19 Contacts and rivets
32 12 Locate & rivet battery compartment contacts 2 22 0.2 13 180 180 360 2.06
33 SA4 Inspect & Release Battery Compartment Sub-Assembly 70 32
34 5 Position sharpener base 1 75 7 00 180 90 270 1.13
35 SA3 Locate battery compartment cover sub-assembly 1 43 2.5 10 180 180 360 1.50
36 11 Locate rubber feet on base and battery compartment cover 2 25 1.6 10 180 180 360 1.50
37 SA2 Inspect & Release Base Sub-Assembly
38 SA5 Position motor/gearbox sub-assembly 1 65 50 00 0 180 180 1.13
39 SA4 Locate battery compartment sub-assembly on motor/gearbox 1 70 26 80 180 180 360 4.10
40 25 Solder black wire to battery compartment 1 86 1 03 0 1.69
41 24 Solder red wire to battery compartment 1 130 1 03 0 1.69
42 7 Position sharpener case 1 82 36 10 180 180 360 1.50
SA4
43 SA5 Locate battery compartment & motor/gearbox in sharpener case 2 96 32 80 180 10 190 4.10
44 3 Locate and fasten battery compartment screw 1 8 3 01 180 0 180 1.43
45 SA2 Locate base sub-assembly in sharpener case 1 75 7 10 180 180 360 1.50
46 3 Locate and fasten battery compartment screws 2 9 3 01 180 0 180 1.43
47 1 Locate and fasten sharpener case screws 2 14 3 01 180 0 180 1.43
48 13 Install battery installation paper guide 1 50 1 13 180 180 360 2.06
49 sa1 Invert and reposition partially complete sharpener assembly 1 96 50 00 180 0 180 1.13
50 2 Locate pencil guide (tricky alignment) 1 32 11.7 05 180 0 180 1.84
51 4 Locate shavings receptacle (snap fit) 1 73 36 05 180 15 195 1.84
52 SA1 Inspect, Test & Release Pencil Sharpener Assembly 1 115 50

27
 Part Liaisons and Mates in Pencil Sharpener
Mate No Mated parts Liaison/Mate Description
1 Sharpener case/shavings receptacle Snap fit of rim and slot.
2 Battery compartment cover/sharpener base Rim and slot in one end of the cover and rim and slot with snap fit in the other
end
3 Sharpener base/sharpener case Slot and rim along the contact edge and two peg and hole fits. The pegs
accommodate internal screws that keep the parts fastened.
4 Gear and motor housing/ battery housing Rim and slot plus sliding surface
5 Gearbox housing/ sharpener case Sliding surface
6 Battery compartment housing/ sharpener case Peg and hole, rim and slot, and sliding surfaces
7 Electric motor/gearbox housing Two pegs and two holes
8 Gearbox housing/gearbox cover Two pegs and two holes
9 Driven gear/gearbox housing Peg and hole and sliding surface
10 Driven gear/electric motor Sliding surface on gear teeth
11 Cutter unit/output gear Square shaped peg and hole (pressed fit)
12 Blade holder/blade Alignment provided by two prongs and attachment is accomplished by nut
and bolt
13 Pencil guide/sharpener case Rim and slot
14 Pencil guide/cutter unit Circular rim and hole
15 Electric motor/battery compartment Circular rim and slot ???
16 Safety lever/gearbox cover Peg and hole
17 Shavings Receptacle/Safety lever Sliding surfaces
18 Shavings receptacle/pencil guide Sliding surfaces
19 Safety lever/gearbox housing Peg and hole
20 Blade holder/blade nut and bolt peg and hole
21 Blade/blade nut and bolt Peg and hole
Blade external surface with bolt head bottom surface
22 sharpener base/rubber foot Permanent liaison thruogh adhesive
23 Battery compartment cover/rubber foot Permanent liaison thruogh adhesive
24 Battery compartment housing/battery comp Permanent liason through rivets
contacts
25 Battery compartment housing/battery paper guide Sliding surface

28
 Part Liaisons and Mates in Pencil Sharpener (cont.)

Mate No Mated parts Liaison/Mate Description

26 Battery comp. contacts/black wire Permanent liaison through soldering
27 Driven gear/intermediate gear Sliding surface on gear teeth
28 Intermediate gear/output gear Sliding surface on gear teeth
29 Intermediate gear/gearbox housing Peg and hole and sliding surface
30 Output gear/gearbox housing Peg and hole and sliding surface
31 Battery compartment cover/contacts and rivets on Permanent liason through rivets
battery compartment cover
32 Gearbox cover/contacts and rivets on gearbox Permanent liason through rivets
cover
33 Contacts and rivets on gearbox cover/output gear sliding surface

34 Contacts and rivets on gearbox cover/red wire Permanent liaison through soldering
35 Contacts and rivets on gearbox cover/blue wire Permanent liaison through soldering
36 Electric Motor/black wire Permanent liaison through soldering
37 Battery compartment housing/blue wire Permanent liaison through soldering
36 Electric Motor/red wire Permanent liaison through soldering

29
 Related Product Line
Boston Electric Auto-Reset Pencil Sharpener
Item # 10111416 , Style # 019221 $12.99 each
New exclusive design offers modern styling with proven
Boston quality, Auto-Reset thermal overload, solid steel
cutter and nonskid rubber feet.
Boston Electric Standup Pencil Sharpener
Item # 10114645 , Style # 001730 $19.99 each
Features X-ACTO precision cutters for longer life.
Unique stand up design stands out on your desk. 2 year
warranty.
Boston Powerhouse Electric Sharpener
Item # 20052504 , Style # 001799 $21.99 each
This new powerful, heavy-duty commercial grade
sharpener uses X-Acto precision steel cutters and a Pencil-
Saver feature to sharpen to a perfect point. Features auto-
reset and built-in pencil holder.
Boston Battery Pencil Sharpener
Item # 10100669 , Style # 016750 $5.99 each
Sleek, compact design with powerful razor blade
sharpening mechanism. Safety features-Auto on-off
switch; sharpener doesn't operate if receptacle isn't
secured. Runs on 4 AA batteries (not included).
30
 Product Structural Decomposition

sa1

sa5 p7 p1 p2 sa4 p3 p4 sa2

p12 p13 p11

p5 p6 sa3

sa6 p14 p15 p16 p17 p18 p19 p20 p21 p22 sa7
p8 p9 p10

p23 p24 p25 p26 p27 p28 p29

31