Element E: Design concept generation, analysis, and selection (M4, M5)
After generating a list of functions and creating a function decomposition placeholder, I sketched three possible designs with actual components utilizing functions from the list of possibilities. Additionally, my peers and I exchanged valuable feedback during this process.
Device 2.3.1: Pin released hammer
Device 2.3.1 begins with a falling arm, which strikes a pin that is suspending a hammer in the air. When struck, the pin is dislodged, allowing the hammer to fall freely, which is my output function.
This design offers a high degree of reliability, but overall I believe that it fails to meet many stakeholder needs. For one matter, it lacks complexity that would satisfy the need to be interesting. Additionally, it lacks a mechatronic component. For these reasons it is not a good candidate to continue exploring.
Device 2.3.2: Articulated stairs to hammer
Device 2.3.2 begins with a falling arm striking a steel ball, which then rolls onto a half articulated staircase. This staircase carries it up, giving it potential energy, before dropping it. It lands on a lever, which lifts a ring with a string attached, releasing a hammer.
This device is the one that I felt was most promising, but additional analysis combined with peer feedback revealed many serious flaws. The most concerning of which is the initial input being ill suited actually push the steel ball any significant distance. Even if the ball were perfectly positioned, most energy would likely be spent on the arm rebounding off the ball. Additionally, having the staircase constantly articulated will make it difficult for the ball to roll onto it, as the staircase could be mid rotation cycle. This means that unless timing is perfect the ball will be pushed away by the staircase. However, with revision this design could satisfy most or all stakeholder needs, and for this reason this option is the one that I will continue to iterate upon and pursue.
Device 2.3.3: Magnet car to hammer
Device 2.3.3 opens with a falling arm Depressing a lever, which in turn knocks over an electromagnet. This powered magnet then repels a magnet mounted on a wooden car, pushing them over the edge of a ramp. The cart then accelerates down the ramp, until a razor blade mounted on the front cuts a rope, releasing the hammer to swing.
This device seems like it meets several of my stakeholder needs, but it has several weaknesses. The main weakness is that it utilizes several consumable components, increasing cost, maintenance, and reducing reliability. These components are the string and razor. The razor will dull over time, and the string must be replaced after each cut. Additionally, the cart's mass must be small enough to be pushed by the magnet, but heavy enough to cut the rope. This higher cost and lack of reliability mean that significant revision would be necessary.