Day 3
Modelling and Mounting Simulation
Embedded Files
Ideation
Ideation
Tell us about your assignment's idea for this week. Why do you care about this idea? What inspired you? (Please include images or links to sources of inspiration)
Tell us about your assignment's idea for this week. Why do you care about this idea? What inspired you? (Please include images or links to sources of inspiration)
In day 3, our task is to start modelling our Final Project and build a 3D CAD model of the smart lamp.
Our main reference will be the Cardboard model in addition to some curvy features and more accurate components mountings.
We call this phase realization phase, as we will see the full model size & how to fix components, how to join parts together, and simulate legs & neck rotation.
Here's a list of what we plan for:
Try to make core body not too box-y shape
Being able to rotate front & back legs and folding them together without intersection
Using T-joints in all possible joints, and adding minimum 3d printed brackets only if essentially needed (20grams of PLA is our limit)
Finding cool diffusion solutions
Tool Chain
Tool Chain
Which software/machines/materials did you use in the assignment? Why?
Which software/machines/materials did you use in the assignment? Why?
Software
Software
using Fusion 360 for design.Â
Laser Work software to laser cutting
Ultimaker Cura software for 3d printing
Tools
Tools
This is Morn MT3050D CO2 Laser Cutter.Â
This is PRUSA i3 MK2 3D Printer.Â
materials
materials
PLA material.
3mm MDF.
Design/Preparation Process
Design/Preparation Process
Explain the design and/or preparation process of your assignment. How did you use the tool or software to design and/or prepare your assignment before fabrication/implementation?
Explain the design and/or preparation process of your assignment. How did you use the tool or software to design and/or prepare your assignment before fabrication/implementation?
In this section, Project design will be explained.
In this section, Project design will be explained.
Bob mainly consists of the following:
Bob mainly consists of the following:
Main body
Main body
Control Box
Head
Head
Bulb housing
RoTating Legs
RoTating Legs
Position Adjustment
Ears
Ears
Dachshund or Dalmatian ears
neck
neck
Static link between Head & Body
Let's start with the Main Body
Let's start with the Main Body
uploading components
uploading components
First and foremost, we started the design process by uploading all components STEP files on Fusion 360 as shown
Our plan is to tailor the size of Bob's main body (Control Box) on the main essential components needed to be used.
For organizing the design, we created component for electronic components bodies, and for each subassembly.
Base
Base
Sides
Sides
Head
Head
Final Outcome
Final Outcome
Development/Implementation Process
Development/Implementation Process
Explain the development/implementation process of your assignment. How did you use the machine/tool to manufacture or implement the design of your assignment?
Explain the development/implementation process of your assignment. How did you use the machine/tool to manufacture or implement the design of your assignment?
exporting dxf & STL
exporting dxf & STL
Using dxf for laser add-on, we exported the faces to dxf for lasercutting
We exported stl files for brackets using Save as Mesh
Adding potentiometer guage, and dog's spots
Browsing to get a picture of black and white dog's spots
Convert png to dxf Convertio
Using Solid Edge software to merge the spots into sides and legs parts
Doing the same with the gauge icon and adding AUTO in the middle.
Lasercutting
Lasercutting
Select all > delete overlap
Cut || speed: 35, Power: 50
Speed Cut || speed: 300, Power: 20
Sheet size: 30x50cm Plywood 3mm
Track frame to insure you are cutting in correct area
Start cutting (run)
Lasercutting_Trim.mp4
3D printing
3D printing
Infill: 20%
Layer height: 0.2mm
Material: 19g PLA
3d printing.mp4Assembly guide
Assembly guide
head assembly
head assembly
Full Stand
Sit
Sleep
Fold
Transparent Paper
Rectangular Pattern
Circular Pattern
Ribs Pattern :D
Overcoming Challenges
Overcoming Challenges
What kinds of challenges or problems did you face while doing the assignment, tutorials, or exercises? How did you solve them? Did you ask for help from an instructor or peer? Please provide a link to the tutorial or article that you used to solve your problem (if any)
What kinds of challenges or problems did you face while doing the assignment, tutorials, or exercises? How did you solve them? Did you ask for help from an instructor or peer? Please provide a link to the tutorial or article that you used to solve your problem (if any)
head brackets in frustum shape
head brackets in frustum shape
It took us a lot of failed trials until we reached the best practice for head & brackets drawing.
Drawing the base with brackets offset inside with the needed thickness, and then extruding each component alone.
Making sure the corner bolt holes are having enough spacing between each other so that the bolts won't intersect.
neck and head base
neck and head base
We didn't have a solid idea of how to connect the head base with the neck and keep the rotation feature without intersecting the body. The neck had to be extended enough out of the front and head base should have side extensions to create a rotating bracket.
Our peer Esraa gave us the hint about this idea while we were all brainstorming.
rotating legs
rotating legs
Normal thinking was adding bolt and nut to make the legs rotate freely, but we faced these 2 challenges:
Hex nuts are disconnected and gets loose after several rotations, so we went to Lock Nuts option as they don't get loose with rotation.
Front and back are fixed with sides with Interlocking slots, and they are extended from side with 3mm distance, so the legs rotation is blocked by this extension, so we added 3mm thickness wooden spaces to overcome this extension.
circuit troubleshooting
circuit troubleshooting
Big thanks to our best friend AVO Meter ^^
We faced 1 bulb failure, it was not working.
We found also one jumper not functioning.
Minimum size & limited resources
Minimum size & limited resources
We were keen on keeping the dog small in size and not look too bulky, if we added the breadboard, the body would have been much bigger, we first thought of trying to not use a breadboard, but no we had to use it for common nodes, so after browsing in available electronics shops we found that mini mini breadboard.
Limited grams of 3d printing was also a challenge, so we made as minimum brackets as possible to be able to print the head base rotating bracket
Assignment Design Files
Assignment Design Files
Backstage
Backstage
Go to Light source, white background, using one angle shots
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