Final Project Journal

Project Ideation

1- Tell us about the idea of your project. Why do you care about this? What were you inspired by? Include images and videos of similar projects

the project is centerd around the song (طير بينا يا قلبي ) by mohamed fawzi

includes a music box that plays the song and an automata representing a horse carriage that moves in harmony with the songthe box has two modes , the first mode is when the song is played with the moving horse carriage it has an ultrasonic sensor, the horse's speed changes according to the distance the user stands from the box

Project Construction

2- Explain the CAD process of your project. How did you use the software to design your project? (List the softwares/tools/materials...etc that you used)

for the design i only used fusion 360

i started by uploading an image of the horse with its parts separated in order to trace the lines and sculpt the body

traced the outlines of the torso,legs and tail

sculpted the torso by using the sculpt tool

sculpted the neck using the sculpt tool

extruded the front legs and added a fillet to the edges
sculpted the tail and positioned the neck to subtract the intersecting mass with the torso

started to sculpt the head by using the sculpt tool

sculpted the ear separately from the head

joined the ear and the head together then joined the head withe the neck

created extensions to the head and tail parts and added pegs to them to rotate around
then created cavities so the head and tail can move freely inside the torso

subtracted the legs from the torso

aligned the legs respectively and made room for the legs to move freely in the torso

created spur gears using spur gear plugin in fusion 360 to design the movement

i followed this tutorial :

https://www.youtube.com/watch?v=B8A_11o7QZ0

then created holes in the torso to attached the legs
made the holes in the torso threaded so a screw can work in it

i made the threading 3.5mm
after printing it works fine with the 3mm screw

threading the hole in upper front leg

legs with holes aligned with the threaded holes int he torso

made the hole in the main gear that drives the three others in the shape of the end in the dc motor

created arms to attache the lines that move the legs to the gears
made the peg of arm1 0.2 mm smaller than the center hole of the gear and hollowed it
then made the other arm smaller than the hollowed part in arm1 by 0.2mm to snap fit in arm1

example of the arms and gear assembled

i added a support part to the torso with to holes
on for the thread holes to mount the screws
and the other hole is for the line that will move the head and tail
then i made holes in the head and tail part to attach the line that will move them

once finished with the horse, i started with the carriage by uploading the sketch

traced the lines of the sketch to create the side parts and the wheels

extruded the sides and the wheels and added middle parts to join them
then made holes to attach the supports of the wheels

sketched where i want to add the supports for the wheels and support for the carriage itself

final render of the carriage after assembly

after finishing the horse & carriage , i started another project to design the enclosure for the box
i started by adding models of the electrical components that i downloaded from Grabcad

then added the horse and carriage to the project and aligned the components respectively i added to motors , one for moving the gears , and the other motor with the wheel to move carriage wheels with an elastic band

created a housing for the gears and the motor to station them

and created supports for the upper motor to suspend it under the carriage

made holes in the top part for the lines of the legs to pass through and another 2 holes under the threaded holes of the horse support to mount the horse securely on the box

sketched the other sides of the box and made holes and slots for the components to be mounted on

final assembly

final render of the box

duplicated the parts of the lamps and subtracted the tabs from the top side and added holes for the screws and lamp power lines

final assembly

final render

enclosure v39.avi

3- Explain the fabrication process of your project. How did you use the machine to fabricate your project? (List the softwares/tools/materials...etc that you used)

i used cura for 3d printing the horse & gears and laser works for laser cutting the box parts

i first started with laser cutting the box and the carriage

i arranged the cart on rd works
had 2 cut lines, the black one was for cutting with speed 10 and power 60
the red line was for simple lines withe speed 10 and power 10

then arranged the box parts on rd box , set the black cut line with 10 speed and 60 power and set the scan for the image icons with 350 speed and 20 power

carriage parts after cutting

box parts after cutting

after that i added the 3d files on cura to prepare them for printing

print details are found attached to the horse parts file

head 3d print.mp4

printing head and tail

torso 3d print.mp4

printing torso

legs 3d print.mp4

printing legs

head and tail

horse parts

gears and arms

Project Electronics & Power Management

4- Describe your electronic circuit. What are the input and action components? What is the function of each? How do the components integrate together to form your smart system? (List the softwares/tools/components...etc that you used)

my circuit components consists of :

arduino board : the brain for the circuit
Dfp mp3 player: to play the song from the memory card
speaker : to play sound
2 dc geared motors : to create the movement for the horse and the carriage
l298n motor driver : to drive the motors on different speeds
ultrasonic sensor : to sense distance between the box and other objects
2 push buttons : first button for the wind input and the second one for the play input
toggle witch : to switch between 2 modes
dc power connector

the components to their respective pins are

wind button : A1

play button : A0

carriage motor driver : 9

horse motor driver : 10

mp3 player busy pin : 6

automatic made switch : A3

sensing mode switch : A4

ultrasonic sensor trig: 3

ultrasonic sensor echo: 2

the arduino board and the motor driver take voltage directly form the dc power c

to integrate the nice to have feature in the circuit i added 2 white led lamps in parallel and a 220 ohm resistor to the +ve end and attached it to pin 11 on arduino

5- What is your power source? How did you select the suitable power source for your project? (List the softwares/tools/components...etc that you used)

i chose to use a 9v dc wall adapter as it has enough voltage to power the motors and the arduino board

Project Programming

6- Describe the code of your project. How did you program each function of the project?

i started by the first mode in the project

my main objective was to make 2 inputs :

the wind button : turns the horse and the wheels for three steps with accompanying sound
the play button : cannot work unless the wind button was pushed at least once ,after that it can play the song and move the horse and wheels

for the mp3 player code i followed this tutorial :
https://www.youtube.com/watch?v=azcRVLsgWF0&t=304s

mode 1 code :

for the second mode i wanted the horse to move on different speeds according to the distance between the box and any other object:

if between 10 and 20 cm : run on high speed
if between 20 and 30 cm : run on medium speed
if between 30 and 40 cm : run on low speed

mode 2 code :

for the complete mode i wanted to be able to switch between made1 and mode 2

complete mode combined of mode 1 and mode 2:

for the nice to have feature i wanted to add lights that brighten up when the song starts and dim when it ends

complete coding with nice to have feature:

Project Integration & Testing

7- Demonstrate with text and visuals how did you integrate the project’s modules together? What are the testing results? (Include a Demo video separately, showing a proof of functionality)

i started by assembling the horse movement with wire lines attached the head and tail respectively and connected to one wire that moves both up and down

head & tail assembly.mp4

movement example

horse assembly.mp4

horse assembly

head movment.mp4

horse movement

cart assembly.mp4

carriage assembly

spur gears.mp4

gears assembly

component assembly.mp4

gears mounting

movment assembly.mp4

components and horse legs lines mounting

20220324_224624.mp4

test before mounting front side

20220325_024950.mp4

final result

Sharing & Collaboration

8- Did you ask for feedback? What are the ideas that others have contributed or suggested? What was someone else’s idea that you built upon? How did you help your peers? How did your peers help you?

shreif and israa helped me a lot with the mp3 coding as i struggled with the songs and inputs for them to play

rawan helped me with the ultrasonic sensor coding as we shared the same concept for the sensors in our projects

and for the song, mr. tarek refaat was kind enough to give me the midi file for the song so i can edit and adjust for the project

on my end, i brought my mini grinder to help with sanding our projects and fix defects, turned out to be a huge help and saved as time.

and as we had to stay late, i helped operating the machines while the lap specialist was off duty.

Overcoming Challenges

9- When you got stuck, what/who did you turn to? At what point did you have to pause to research or learn more before moving on? What are some mistakes, pitfalls, or challenges that others can avoid if they were doing this project?

i struggled A LOT with the ODC 3d printer as it kept failing and ruin the first layers , i wasted too much time trying to calibrate it or to use it in any way but failed.

i had to go to maadi fab lab , but the time slots wasn't enough for all the parts to print ,as i had 2 hours in the slot and my files needed more than 4 hours, so i had to out source and contact other labs in order to save time.

for the laser cutter the ventilation system wasn't working properly by the time i got to use it, the smoke was to thick it triggered the fire alarm system and the security personal had to advice us not to use it until the ventilation is fixed , as it could trigger the alarm for the entire tower, so i took the wood planks i needed and went to another office to use their machine .

i struggled again with the complete code as it kept mixing between the two modes , thanks to omar okasha ,who came to my aid and helped me with the code , the solving to my problem was to simply treat the toggle switch as a push button in the coding.

Future Work

10- If you had more time, what is one thing you would change/ Do next in your project?

i wanted to add the nice to have feature which is the glowing street lamps

i sketched the outline of the street lamp using a reference image , then added t- slots and tabs for mounting

street lamp sketch

20220412_234031_1.mp4

the experience i gained with using fusion 360 and the other soft wares will help me design more intricate automatas based on our culture, and by programing the Arduino i can design simple gadgets and toys for other future projects

Final Project Design Files

horse and gear parts with print details STL

horse &carriage.f3d

arduino programing

carriage.rld

enclouser.rld

enclouser.f3z

Page updated

Report abuse