Unit 8: Automata Design Challenge

From PLTW IED website for teachers:

This problem is designed to promote critical thinking and problem-solving skills, and therefore, is ill structured with minimal guidance as to a solution path. Students are required to determine an appropriate course of action and create a unique design solution. It is expected that they will struggle somewhat with the lack of specific instructions provided for the problem and will typically ask for more specific direction. Rather than describe an acceptable solution path, you(the teacher) should act as a facilitator—emphasize organized thought and help students transfer what they have learned to new situations.

Students explain their thought processes and reasoning at every step of their solution process. This type of formative assessment is particularly important when you assess student achievement of objectives that are difficult to assess from the work that students submit.

Avoid providing guidance and suggestions for next steps until students have exhausted all of their own ideas. Promote the benefits of “failure” and the opportunities it provides to improve the solution.

Accepting feedback and making appropriate revisions is also an important aspect of critical thinking and problem solving. Be sure to emphasize the importance of reflection, revision, and optimization as part of the design process, not simply an assessment of work after the fact.

LEARNING OBJECTIVES

Engineering Mindset

• Demonstrate independent thinking and self-direction in pursuit of accomplishing a goal.
• Synthesize an open-ended, loosely defined, problem into a meaningful, well-defined problem.
• Demonstrate flexibility and adaptability to change.
• Persevere to solve a problem or achieve a goal.

From PLTW IED website for students:

INTRODUCTION

Automata (aw-ʹtom-uh-tuh) is derived from a Greek word that means self-acting. With an automaton, an input such as a falling mass, a motor, or your hand movement is used to move parts that ultimately result in the motion of a figure. In this problem, you will design, build and test a mechanical system to automate the motion of objects. The automaton will be designed as a toy for a child between the ages of 9 and 12 years old.

Procedure

1. Locate your box created in Project 3.9 Manufacturing a Box.
2. Read the Automata Design Brief and Problem 8.2 Automata Design Challenge Checklists and Rubric.
3. Under the direction of your teacher, add constraints and product safety requirements.
4. Use the design process to generate solutions to the problem and document the process in your PLTW Engineering Notebook.
5. Use the Problem 8.2 Automata Design Challenge Checklists and Rubric to self-assess your solution process and result. Improve your documentation, as needed. Submit your scored checklists and rubric with notes to indicate the revisions you made as a result of the self-assessment.
6. Submit a project portfolio to include the following:
   • Title page
   • Design Brief
   • Image of the final working prototype
   • Design process documentation to include a summary of your work during each step of the design process.
   • Working drawings that include:
     • A fully dimensioned part drawing for each individual part to include appropriate tolerances.
     • An assembly drawing of the automata toy to guide the construction. Update the drawing to represent the final product.
7. Present your automata.

Automata Design Process:

Applying the Engineering Design process, toward this goal, began with introduction in Unit 3 in October and completion with Unit 8 in June:

Step 1: Identify the problem and create the Design Brief:

Client Company: Automata Toys

Target Consumer : Child between the ages of 5 and 12 years old.

Problem Statement : A manufacturer opened a competition to design and build an original hand-operated toy for its U.S.-based market for girls and boys age 5 to 12 years.

Design Statement : Design a toy that includes a mechanical system that will produce realistic motion of a figure(s) or object(s) resulting from the rotation of an axle. The motion results in the interaction or coordinated movement of at least two separate displayed objects, using at least two cams.

Constraints

1. The design of the system must include a wood box 4.5” x 4.25” x 4”
2. The Project mechanical system must be human powered, turned by handle.
3. The system must produce repetitive motion of figures or objects related to a theme
4. The assembled hand-operated toy must fit 6 in. x 8 in. x 12 in. when in a static state.
5. The axle must pass through the wood box. Turning the axle must convert the rotational motion of the axle to linear motion of objects outside of the wood box.
6. In addition to an axle, the mechanical system must include at least one cam.
7. The system must include components from at least 3 different materials, including the wood used to construct the box. We will design and 3D Print the crank handle in the 3D printer. We will laser cut the parts from 1/8" plywood. You can add another material or paint the parts to create variation. (Connectors & adhesives are not included)
8. The automata objects should display realistic motion of the real objects they represent. And the designer must create a motion graph to represent the desired motion(s) of the displayed objects.
9. A 3D solid model of each cam must incorporate parameter variables.
10. The toy must meet quality and reliability specifications:
    1. When a force of 4.8 Newtons is exerted horizontally on any component and in any direction at a height of 5 cm above the surface, the system must remain solidly founded (no part of the design lifts off of the surface).
    2. The system must operate as designed for at least one minute at a sustained speed of one revolution per second without damage to any component of the design.
    3. There must be no visible “slip” or “disconnect” between components in all cycles.
11. The design must allow for the reduction of friction during operation:
    1. Between the fingers and the handle
    2. Between the axle and its support
    3. Between the follower rod and the components that guide the rod
12. The product is safe within the criteria established.

Brainstorming sketches of your Automata

Applying the skills from Units 1: Generate solutions through research and brainstorming

Research automata, watch videos on automata

Create thumbnail sketches of possible ideas

Construct the box

Unit 3: Measurements, Quality Controls in Manufacturing

Draw orthographic and isometric drawings of the construction of your box

Create a Flow Chart showing the steps you and your teammates would follow to efficiently produce the boxes

Work as a team to put together your boxes in an assembly line fashion

Perform quality control measurements and see which team was most efficient time-wise and withquality of construction

Design a CAM

Unit 4: Design a Cam and Create a polar graph in Excel

Create various cam shapes and sizes and measure their displacements in graphs created in Excel

Test the Cams in teams, documenting measured movements in computer-aided Inventor assemblies and operations

Develop Automata design

Step 3 of Engineering Design Process:

Applying skills from Unit 2: Develop your best solution with orthographic drawing in Engineering notebook, to scale at actual size

Develop a scaled drawing of your automata profile view, designing the parts and proportions and placement on the box in multiview

Modeling the parts in Inventor

Step 4 of Engineering Design Process: Create a prototype

We modeled the 3D parts, cam, followers, axle, and box parts in Inventor, where we were assembling when the Coronavirus hit and we left to finish the project on paper at home.

Finalize Manual Drawings for Automata parts

Step 4 completed in pencil, in Engineering notebook - due Wednesday, March 11th

Please submit, in Google Classroom, your photos of your drawings you sketched on graph paper provided in class (1/4" quadrants) OR in your engineering notebook (also 1/4" quadrants) and PLEASE use resources to help you draw these items. they can be simplified like any other toy, in a stylized way, but resources will help you make them more professional.

Be sure you know exactly what you are doing in this drawing, before you can proceed to model the parts on the computer.

These are Actual Size, dimensioned, drawings of your design on Graph Paper(or in your engineering notebook).

You should include all the parts and how they are assembled together, so you can determine them at actual size.

That way you know they are proportioned with each other when you make separate parts in Inventor

Please use the DocScan app on your iPad or iPhone. It will straighten the paper and add contrast so its easy to understand your drawings.

This photo/scan will be a part of your portfolio.

These will be graded with a rubric for:

1)clarification (simplified and easy to follow) of your automata design, Drawing describes all the parts (moving and non moving) that will be assembled on top of the automata box. Points will be deducted for any vagueness or uncertainty that will slow down your modeling.

2)Proportion at Actual size, with dimensions

3)Resourcefulness: Elements are well-proportioned and show resourcefulness in referencing or observing resources

4)Creativity: The concept shows creative problem-solving, creating a toy that will be appealing and entertaining to children or adults

Visual Analysis of your Automata

Assignment 6.2 Visual Analysis of your own Automata - due March 20th

Instructions: Apply the Elements and Principles of Design to your automata, while you proceed with developing your design:

Procedure:

1. In your engineering notebook, go to the page where you have a sketch of your design at actual size.

2. On the same page as your sketch(or on a new page, if you prefer), add notes or add colors to your sketch, describing how you will apply the Principles of Design to your automata to make it more appealing.

3. Below your sketch or on the next page of your engineering notebook, create an "Elements and Principles of Design" table with at least four columns and four rows, similar to the table you filled out in the last assignment, 6.1.

Objective: Describe how you will use the Principles of Design to make your automata visually pleasing.

Be sure to use at least one Principle of Design with each of four different elements

Be sure to use at least four different Principles of Design between your four elements.

Assessment:

Rubric is attached showing the four criteria from which the page from your engineering notebook will be graded for 20 points, with 5 points for each criteria:.

1. Fill out the Visual Design Principles and Elements Matrix worksheet with photo

2. Identification: Elements of Design (at least four different Elements of Design)

3. Analysis: Principles of Design (at least four different Principles of Design)

4. Drawing: visual communication of the automata (profile view) is enhanced with color(colored pencils or shading to indicate different colors) and notes

Functional Analysis of your Automata

Due April 6, worth 50 points.

Please complete and submit your Functional Analysis of your Automata in Google Classroom.

You will describe, visualize, analyze, and troubleshoot the function of your automata.

This is a 3-day classroom assignment to be started today, Part 1 on Monday March 30th, Part 2 continued during class on Wednesday,, April 1st, and Part 3 completed on Monday, April 6th , due on Tuesday, April 7th at 4pm.

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Class Schedule:

Monday, March 30th, I will have a Zoom Meeting at 11am to explain the assignment and answer any questions. The meeting is scheduled during Period 4 (Green day) but Period 8 students are welcome to join, if they are available at that time.

Tuesday, March 31st, I will have another Zoom Meeting at 11am for Period 8 to explain the assignment. Any student from period 4 is welcome, if you missed the first zoom meeting on Monday.

Wednesday, April 1, you will all work independently to complete most of the assignment, working on your drawings in your engineering notebook.

Friday I will be available to have another Zoom meeting at 11am to answer any more questions or problems you encounter. Email me to request a Zoom meeting.

The assignment is due Monday at 4pm for Period 4(Green Day), Tuesday at 4pm for Period 8(White Day)..

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I have provided your own copy of a Google document in Google Classroom, on which you can paste your photos of your drawings from your engineering notebook and type your answers.

You can also create a pdf from the document and fill it out in notability, if you wish.

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Procedure:

Monday, March 30 for Period 4 (Tuesday, March 31 for Period 8):

Part 1 (30 points). Sketch three orthographic projections in your PLTW Engineering Notebook and label the individual components.

Objective: Visually communicating your device in three orthographic views. Make your lines deliberate(not hairy or uncertain) so it is understood.

Grading is 10 points for each view, drawn to scale (actual size in engineering notebook), showing parts, connections, with notes explaining movements or the amount of movement distance with arrows, annotations, etc...

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Wednesday, April 1 for Period 4 (Thu, April 2 for Period 8):

Part 2 (10 points to complete Function Inputs-Outputs chart):

Finish filling out the Function Inputs-Outputs chart for your Automata.

Identify the system inputs, intended product function, and outputs in the table provided. Use simple machines’ terminology to explain the object’s sequential operation

Be specific. Put yourself in a place of observing every move, every click or sound, every sensation of pulling, pushing, leverage with your hands, stability, etc....

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Monday, April 6 for Period 4 (Tuesday, April 7 for Period 8)

Part 3: Questions (10 points for 5 questions):

1 How much will your follower rise, or be displaced, depending on the radial dimension of the Cam, as the CAM rotates?

2 How will you stabilize your motions and insure the follower is constrained to move only up and down in one vertical axis?

3 How will you design your follower, so it will not slip, and it will connect and consistently push your parts with control?

4 What are possible problems that could occur with your device?

5 How will you try to prevent these problems in operation?