This project is one of the most challenging that I've ever had to complete. I've never been pushed this hard to consistently produce prototypes and final designs within a strict time constraint. In addition to working to get each component graded on time, I had to work to stay on schedule so that my partner and I didn't lose time on other components. Another thing that made this project difficult is the fact that we had to work on complex components in small windows of time. Getting the prototype was fairly simple, but it took an intensive amount of effort to ensure that the final versions of each component maintained good craftsmanship and high functionality.
This project has taught me the importance of being a creative problem solver. There were a plethora of design challenges and malfunctions that hindered progress in the moment, but those issues served as stepping stones to my learning process. I am now better equipped with the skills to troubleshoot. Furthermore, working with my partner, Kenadie, was extremely important. We developed good communication and time management skills when working together. This project proved the importance of dividing and conquering when working in a team.
I am most proud of my dedication to ensuring that the aesthetic of our pinball machine lined up with our functionality. This was not an easy feat, as many creative choices required work time on top of the time allotted for the completion of components themselves. The work put into the design of our pinball machine truly showed in the end, which I appreciate.
For this class, all of our sub projects' design process are outlined in the below Engineering Design Notebook.
We completed the final pinball launcher. All of the individual launcher pieces were ready separately, and today was spent assembling them. Our plan for the final launcher was to include an alignment block attached to the pinball shell at the bottom corner, two large springs to push the pinball with spring force, and a smaller spring on the outside of the pinball machine shell (with the knob) to prevent hitting.
On Inkscape, we digitally fabricated a star pattern to later print out using the Glowforge in different sizes. The different stars were then stacked and glued with wood glue to create the knob shape. The aligment block and hitter piece were both also digitally fabricated. We followed a similar design on creating squares and gluing them together.
Assembling the launcher and attaching it to the pinball machine shell required measurements on the inside and the outside of the shell to ensure the hole we made was drilled at the correct angle with the alignment block. The hole was drilled with a bit the same diameter as the axel used for the launcher, 0.25in. We drilled a small hole in the star knob to glue the axel in. Once glued, the small spring was added on the axel and we slid it through the hole drilled through the shell and alignment block. The last step was to attach our digitally fabricated hitter.
Our class to a trip to the Pinball Museum. We got to play with and study the pinball machines to better understand our project and designs. Below are the three pinball machines that my partner and I liked the most.
We appreciated the simplistic design that this machine had. Much of our designed game space mirrors this machine's. We believe we can recreate many of the components here.
The figure 8 like pathway that this pinball machine has inspired us to incorporate "hiking trails" in our design. This is a reach component we now have in mind for out pinball machine.
This design aligned most with our desired theme and also uses components we think we can recreate.
We were able to see how the components functioned on the inside. One of the first things we looked at was the start button. The button's placement varies, but what it does is the same. In this video, you can see that once the button is pressed, a switch closes which turns on the other components in the pinball machine. You can partially see this in the scoreboard video below. The mechanics behind the start button ultimately rely on an open and closed switch that delivers an electric current to power the pinball machine.
The scoreboard my partner and I will create will use one screen and track the ball count and player's score. The scoreboard shown here uses multiple screens however it functions similarly. The video shows the scoreboard displaying the final score after the end of a game and resetting once the start button is pressed to begin a new game. We understand that the scoreboard is programmed with if/else statements that know when to increase the score number and decrease the ball count.
The triangular bumper is used in all of the pinball machines that we looked at. When the ball hits a sensor on a specific side of the bumper, it closes a switch causing a component called a linear actuator to hit the ball across the playing field. Oftentimes, a triangular bumper is positioned diagonally from the flippers (as seen in the video), likely as an easy point grab as the flippers typically hit the ball in that direction during gameplay.
There were multiple target types in the pinball machines. The star targets are a type that you can only hit once in game play. When the ball hits these, the target goes down and doesn't come back up.
The red targets are the kind that you can continuously hit. When you hit one of these, the an open circuit closes and the scoreboard knows to increase the score.
We noticed that some pinball machines had a component to prevent the ball from passing a certain point when launched into gameplay. We sketched out how this component works. There is a piece that is attached by an axle-like component. It can flip up one way, but not the other because of the piece of it that hits the top. There were mechanized versions of this same component, but we liked this design because we think we can most easily recreate it.
The launcher has a universal function across all pinball machines to push the pinball into play. The launcher is constructed with a spring and metal axle. A part of that axle sticks out of the machine to be pulled by the player. When the axle is pulled back, the spring coils back creating potential energy. Once, released the axle quickly pushed back into place and launches the pinball into play. The way that the launchers were made is similar to how Kenadie and I crafted out launcher.
The purpose of the ball return is to return the once in play pinball back to the starting position after game play. Unlike the ball returns we have constructed, the ones that we studied were mechanized. On the right, you can see that once the ball drops past the flippers, gravity pulls it and it lands in the space below. While it is not visible, there is a component that pushes the ball back in position to be launched again. This component is likely a servo activated by a sensor.
There are a plethora of lighting plans that we saw in the different pinball machines. Some lights were on parts of the game that interacted with the ball, and others were integrated to the paths of the ball. Regardless of the placement, the lights, whether they were bulbs or neopixels, turned on based on the coded if/else statements. They all reacted to switches and sensors triggered during game play. Lighting sequences varied based on if a certain component was hit by the pinball or a certain number of points were scored.
The flippers are a crucial part of the pinball machine as they are the only thing the user touches in play other than the launcher. The flippers hit the pinball from different angles so that the ball can stay in play and hit the different components in the game. The flippers move at a fixed angle when the designated button is hit. Once that button is hit a circuit closes and the flipper moves. Once that circuit opens again the flipper goes back into its rest position. The movement of the flippers is done with servos.
This was a unique layout that we saw on one of the pinball machines incorporating a 3D cityscape. We took inspiration from this design and are planning to create a similar affect using plateaus and mountains. The way that this is done on the right is with laser cut plastic. We plan on using wood for our design.
These are our final flippers. They needed to rotate upwards at an angle that would cause the pinball to hit the top of the pinball machine when the corresponding button was pressed. The flippers were constructed using laser-cut wood, solenoids, and precut drive shafts.
In our design, the flipper seen on top of the machine is connected to a drive shaft that goes through the board. On the underside of the board, the drive shaft goes through a flipper-shaped lever that is hit by the solenoid. This design helped when prototyping because Kenadie and I were able to gage the rotation of the flipper when the board was flipped over because the pieces were parallel. Additionally, the flipper is reset to its starting position by a pull spring. The spring is screwed to the side of the lever on the back side of the pinball machine.
These are our final targets. Working on this component was unique as we had to individually design and prototype and later come together to combine the functioning parts when installing them into our board. The function of the target is to add to the overall score when the ball hits it. We had the choice of top mounted and bottom mounted targets. We chose bottom mounted. The constraints detail that the body of the targets had to be assembled using finger joints. So, we worked within Onshape to create our design.
The targets work by holding a switch component. A paddle that is placed in the shell and pokes through the board triggers the switch when hit by the ball. The paddle stays in place using a singular screw as it prevents it from moving forward. After multiple iterations of prototypes, I was able to combine my final prototype findings with Kenadie's and install the final target.
Kenadie and I decided on a cactus to match our Western theme to meet the design requirement. Our final targets are functional, however, they aren't reliable, so we plan on revisiting this component soon.
Our final big components in this project were the bumpers. The bumpers served to be to most challenging for us to complete as we had many complications throughout. The purpose of the bumpers is to interact with the ball by slamming on them. This is done when the ball comes between the bumper topper and the board. The space that the bumper takes up has a ring of copper tape around it. The cone shape the squeezes the ball out when slammed is also covered in copper tape. Similar to the ball guide component, two wires are connected to the sections of tape. When the ball touches both surfaces of tape, it closes the circuit. The bumper uses a solenoid to function.
Kenadie and I began by designing the mount for the bumpers and toppers that matched our theme on Onshape. We also designed multiple disc shapes. The arguably most important disc is the one that connects the solenoid to the bumper above the board. This was done by creating a concentric hole in the middle that wraps around a piece of the solenoid. There are screw holes for screws (that are secured with nuts) that attach to the cone above the board. When the solenoid activates, the topper and cone move downward toward the board.
When prototyping and finalizing the design, we ran into a plethora of issues with wiring, copper tape placement, coding, and more. Through continuous troubleshooting, Kenadie and I were able to complete our bumpers.