Final Project Journal

Project Ideation

Project Construction

Tool Chain 

Design/Preparation Process

Designing the 3D parts

Downloading the components from GrabCad

RFID module & card: https://grabcad.com/library/modulo-sensor-rfid-rc522-rf-ic-1

Speaker: https://grabcad.com/library/speaker-audiopro-90x50-mm-1

potentiometer:  https://grabcad.com/library/potentiometer-b10k-1

knob: https://grabcad.com/library/rotary-encoder-or-potentiometer-knob-1/details?folder_id=9662310

mini mp3 https://grabcad.com/library/mini-mp3-for-arduino-1

Arduino UNO: https://grabcad.com/library/arduino-127 

Virtual Assembly of all parts on Fusion360 & creating the suitable projects & slots

Preparing the 2.5 parts on LaserWork V6

• .dxf file of each side was exported from fusion 360 & imported to LaserWork

• The cut area (black) was defined with a cut speed of 40 & power of 55

• The (red) part was to be scanned with a speed of 300 & power of 13

• The (yellow) part was to be speed cut with a speed of 300 & power of 10

• I downloaded this design from .3axis website & added it to the front side

• Finally, the file was saved in .rld format

Preparing the 3D parts with Cura software

The .stl files of all brackets & the cards holder were downloaded from Fusion360 & imported to Ultimaker Cura software, then choosing the printer ( PRUSA i3 MK2 )  & the material ( PLA)

I prepare 2 files as there was no available time slot to print them all together

• Profile: 0.3 mm extra fast (to save time)

• Infill: 20% 

• Support: no supportThe best orientation is chosen to lay flat on the base side

• Brim: None

• Brackets file: number of layers: 51, weight: 14 g, time: 69 min

• Cards Holder file: number of layers: 237, weight: 34 g, time: 141 min

• .gcode files were saved 

Tool Chain 

Cutting the 2.5D parts

• Firstly, the machine was turned on & the .rld or .ai file was imported

• The cut & speed cut parameters were checked, then the file was downloaded to the machine

•  plywood sheet was inserted into the machine, the focus was checked using the focus block and the origin's position was adjusted by pressing the "origin" button

• The proper file was selected, and the "TrachFrame" was run to check the used area, then we pressed "run". It spent 69 seconds.

for more details, click here!

Project Electronics & Power Management 

Project Programming

• This part reads the number on RFID card & play the sound clip that has the same number on the SD card 

Reference to DFPlayer_Mini (mini-mp3 module): https://docs.rs-online.com/58c2/A700000006944490.pdf

RFID: https://github.com/miguelbalboa/rfid

Project Integration & Testing 

Wiring the whole circuit

I connected the 5v pin & one  of the GND pins of Arduino to the breadboard 

Note: I used this website to create the welcome audio message  & the audio of the numbers

Sharing & Collaboration 

I would like to thank the sweetest Areej, she helped me a lot in exporting .dxf files from fusion sketches and she suggested me to convert the online design on the front side from .cdr to .dxf format, so that I can use it in LaserWork software

And of course, our amazing instructors Esraa, Nada and Abdelrahman helped me a lot (Thank you 🙏)

Overcoming Challenges 

4- The most challenging thing is that during the assembly, I accidentally reversed the polarity of the electrical power connector (-ve pin to the Arduino VIN) which caused the 5-volt regulator of the Arduino board to burn (this is what I discovered later, as the VIN pin is directly connected to the voltage regulator & it does not have reverse polarity protection, for more details kindly check these links: https://docs.arduino.cc/learn/electronics/power-pins, https://forum.arduino.cc/t/i-reversed-gnd-and-vin/234305/2)

As a result, the device was working properly through the USB connector, but it didn't work using the 9-volt adapter as an external power source (the Arduino board itself was working, but there was a noise sound from the speaker and the mp3 module did not work, as it did not light up)

I tried to use the 5-volt adaptor instead, but it did not turn on the circuit. After many trials to fix the problem, I found a solution on the Internet to solder a new 5-volt regulator in place of the faulty regulator (for more details check these links: https://www.instructables.com/Fix-an-Arduino-That-Only-Works-Via-USB-blown-Regul/, https://hassanulmakers.wordpress.com/2015/02/14/tutorial-replacing-the-voltage-regulator-on-the-arduino/ )

Since I do not have a solder or soldering skills, I came up with an idea to use the 5v regulator (that we have in the kit) exactly as we used it at the end of week 8 session, I followed the same wiring diagram:

+ve pin of the power connector: to the regulator input pin

a jumper from the regulator input pin: to Arduino VIN

a jumper from the regulator GND pin: to the common ground drain on the breadboard

a jumper from the regulator output pin: to the positive drain of the breadboard

Finally, it worked successfully with the 9v adaptor Alhmadullah

Future Work

• Creating a simple GUI to write a number on the new RFID cards instead of using the serial monitor

• Adding more features, like activating the shuffle button to play a random sound clip except for the welcome audio clip

• Adding side B option to play cards on both sides

• Printing 3D or 2.5 characters or models & attaching RFID stickers on them, so they will talk after placing them on the play area

• Adding LED to indicate that the device is on or off, and if side A or side B is activated

• To be portable, by powering it with a battery instead of the adaptor

• Adding extra part to hold the mp3 module

Click here to find all files