Final Project Journal

Illusion Kit

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

Creating an educational kits that simplifying the scientific idea which will help the kids to get the knowledge, have fun and power their mindset.

I do care about this idea because I love science and I wanna give the kids the chance to see the Magic power of science

I was inspired by receiving a gift that a Ferris wheel (laser cut).

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)

Design:

first I sketched the design on a paper to estimate the dimensions
choosing the design of the characters that is attached to the disc from thingiverse

start to design on fusion 360:

Start with the sides then the base then the top, then I start to design the coupler -that is attached to the motor - jointed to the disc.

I started to design with 2D on fusion360 the front side 200x 100mm and adding t-slot and X-slot
I made copy from the front making new component "paste new"
designing the side part 200x100mm and adding X-slot, T slot to fix the parts together
To create a T-slot:
1. Draw a rectangle representing the slot. (5 X 2.4)
2. Draw a smaller rectangle at middle of the first rectangle to create the T-shape.(8X3)
3. using constrain tool to put the slot in its preferable position
4. Extrude the sketch to create the slot.
I made copy from the side by making new component "paste new"
I sketched the bottom and the top parts to fit with the previous parts.
I added the ports positions of the electronics components.
I made all the sketches fully defined.
extrude all the parts to give them thickness 3mm
Extruding:
1. Once the sketch is ready, select "Finish Sketch."
2. Click on the "Create" dropdown menu and select "Extrude." or from the tool bar select "Extrude".
3. Select the parts that want to extrude by clicking on them.
4. Enter the extrusion distance in the dialog box or use the drag handles to adjust the extrusion depth.(3mm)
5. Click "OK" to apply the extrusion.
assembling all the parts to fit together and preview them
Select the sketch you want to export as a DXF.
Press the right-click button and choose (save as DXF).(Chose the part that I wanna save, click create, save as dxf, then choose the file where I wanna save it, and repeat that step with each part to save the whole model)
After exporting my parts to dxf files, I moved to laserwork to prepare my files for printing.
I adjust the speed and power of the machine to be ready for cutting.

Sketching T-slot

Sketching the sides

to save file as f3d:

click file then export it will show a window to select the f3d format and the location in your pc of laptop

note: make sure to break any linked components before this step

as shown in the following pic. you also can find it in the following link

the box

Joining 2 sides together

the disc

using extrude option to all the openings for the ports of the electronic parts

Designing the coupler

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)

After designing the parts on fusion 360and saving files with .stl for 3D printing and .dxf for laser cut.

for 3D printing:(coupler)

open Ultimaker Cura software to prepare the model and adjusting the parameters as following:

Scale: 100%

Resolution: 0.2 mm

Strength : 20 % Infill

Time: 13min.

Weight: 1.43 g.

Machine:

download file on SD card then placed it in the 3D printer, chose the file, started printing.

For laser cut:

using laserwork software, I imported the dxf file to prepare it for laser cutting.

All the parts were for cut (black color, speed:30- power:50).

saving the file in .rld and open it on the PC connected to the machine, making sure that all parameters were right then download to the machine.

Machine:

checking the nozzle, origin, and framing to check fitting the part with wood sheet, then start.

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)

The action components: Motor-LED
Input : slide switch - LDR sensor

slide switch will open the circuit and the LDR will sense the light to work and if there is no light the motor will turned off.

output: motor
tools: dc gearmotor-motor driver-Arduino Uno-breadboard-LDR sensor-jumper wire-slide switch-resistor
Software:

Tinkercad- Arduino IDE

Simulating the electric circuit using tinkercad

Wiring all the components together:

wiring the motor driver :

two sides (blue and green wires for the motors)
the red and orange wires for the power source

(red wire--positive/ orange -- ground)

wiring the motor driver :

two sides (blue and green wires for the motors)
the red and orange wires for the power source

(red wire--positive/ orange -- ground)

connecting the LDR sensor with Arduino

we have 4 terminals on LDR(Analog - digital-ground-VCC)

the ground with the common ground on the breadboard- digital with pin11 on Arduino-VCC with the common positive on breadboard

connecting the Arduino with breadboard

(red wire connecting between pin (5V) and common positive on breadboard)

(purple wire connecting between ground on Arduino and common ground on bread board )

connecting slide switch to the breadboard and Arduino

(the grey wire to common ground on breadboard-orange wire to pin 6 on Arduino-brown wire to common positive)

connecting Screw terminal block to the breadboard to power the circuit

(red wire common positive-black wire common negative)

by plug in the 9V adaptor the circuit will get the needed power

all components together

video_20240316_094542_edit.mp4

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)

voltage source: 9V adaptor

I searched for the Data sheet of the dc motor to identify the amount of voltage needed to power the circuit and I found that we can power it with adaptor

Project Programming

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

started to simulate the circuit using tinkercad.
building the electronic components together.
coding the circuit using "Arduino software C"

define the pins first which one is input and which is output.
adding the condition "if-else" to control the LRD sensor :
If
else--if the slide switch is high then pin in1-in2 and pin for LED all are going to e high
else all pins are going to e low

testing the circuit first before being added the cardboard.
adding the circuit to the cardboard enclosure.
connecting the machine with the power source.

video_20240316_094542_edit.mp4

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)

Integrating all the components(Electronics and the Fabricated parts) together with nails and nuts:

1- Attaching the coupler with the disc

3- Attaching all the characters to the disc

5-Attaching the motor to the upper surface of the box

2-Attaching the parts of each character together

4-testing that the motor and the coupler are jointed together

6- Attaching all the electric parts to the base of the box and also the sides.

7-Finall attaching all the components together

video_20240315_172535_edit.mp4

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?

Yes, when I was designing the coupler the instructor Suggested to add an open from the side of the coupler so we can attach the motor to the coupler, I added to my design and It was helpful

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?

While designing the base of the box the parts that will be attached to the 4 sides were as shown in the pic. below( I didn’t leave a space between the openings and the boundaries)