Embedded Files
A breakdown of our final product design
Table of Contents:
Final Demonstration Video
Final Demonstration Video
The video shows Amaris operating the final product, pushing the project's shopping cart pass to the other side.
Final Design Solution
Final Design Solution
More information regarding key components.
Arm
Arm
The final design decision for the arm structure was a ball-socket end-fitting gas strut [top image]. This type of gas strut allows for rotation along the X and Y-axis, causing one end of a gas strut to break when testing using the McMaster mount. To address this issue, the team machined a custom mount out of steel [bottom image] to restrain the X-axis rotation and prevent the ends from breaking under the door's weight. After rounds of testing with different gas strut strengths, a gas strut with a compression force of 90 lbs gave the desired results, despite the calculated numerical compression force of 73.6 lbs.
Pivot
Pivot
The design for the pivot component underwent several changes, concluding with the decision to use a piano hinge. Before the final design decision of a piano hinge, the team was initially set on using a self-locking hinge [top image]. Its intended use for the project was to lock the door at a 90-degree angle, assisting the gas struts if their compression force was not enough to sustain the door. However, testing proved the locking mechanism could not hold the door's weight. This resulted in the team turning to a piano hinge design [bottom image], which can support the door's weight but relies solely on the force of the gas struts to maintain the door at a 90-degree angle.
Door
Door
The final design decision for the door is a 1/8-inch aluminum 6061 sheet metal cut to a width of 30 inches and a length of 48 inches [top image], with an aluminum frame. The initial door design did not include an aluminum frame around its inner perimeter, which resulted in severe deflection once the components were assembled. To address this issue, the team installed an aluminum frame made of aluminum L brackets cut at a 45-degree angle [bottom image]. This frame prevented any noticeable deflection by increasing the thickness of the door and improving its rigidity.
Final Performance Results
Final Performance Results
How did the final design perform?
Once the door, wooden frame, and piano hinge were installed, the team tested three different gas struts with compression forces of 50 lbs, 60 lbs, and 90 lbs. The images on the left demonstrate that the gas struts with compression forces of 50 lbs [top left] and 60 lbs [bottom left] were not enough to sustain the door open at 90 degrees. The 50 lb gas strut would slowly close the door, while the 60 lb gas strut held the door at an angle less than 90 degrees. The 90 lb gas strut proved to work the best, providing enough force to hold the door at a 90-degree angle while still allowing the door to be shut.
Final CAD Photos
Final CAD Photos
A small collection of our final CAD for the full assembly
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