Design Evolution

Initial Design Idea Sketch (Jacob)

This was the very first sketch of the concept, back when we were still deciding what sort of solution we wanted to approach

Initial Design Idea Sketch (Daniel)

Our first sketch had the servo mount as part of the main housing.

Second Design Idea Sketch (Daniel)

After some though, we decided it was better to have the servo apart from the main housing. So we added an arm extension that would place the servo away from the hat, and thus would put the servo in a more optimal position for moving the sunglasses properly.

First Circuit Design

First design iteration which just made the servo move when the light got to a certain brightness

Second Circuit Design (Micah)

Second circuit iteration which added one button to switch between modes of down, up, and mode that uses brightness of light.

Second Circuit Design (Eliezer)

The second circuit added a button that moved the servo depending on the photoresistor value threshold. The circuit was built by Eliezer and contained different Arduino code from Micah's. The video displays the circuit in function.

IMG_2142.MOV

Final Circuit Design

Final circuit iteration which added two more buttons. Modes stayed the same but, the two added buttons allowed the threshold for the photoresistor to be raised or lowered.

First Servo Attachment

First time the servo was attached to the sunglasses. This was an experiment to see what connection methods could work.

Test Prints

While designing the CAD parts, I (Jacob) made many, many test prints to see how well my designs would fit the parts they were designed for. I wanted them to be fairly secure but not need any additional attachment aside from a friction fit, so repeated test prints was critical to the success of these parts.

Component Housing

We initially planned that all the 3D printed components would be attached to one giant contiguous 3D printed base plate that would attach to the hat, to make the device stronger and easier to assemble. However, we realized that such a large 3D printed piece would take an incredibly long time to print (not to mention the filament used), and if there was an issue with its design , it provided almost no flexibility to move things around. Therefore, we replaced the base with a piece of cardboard, and added tabs to put bolts through on the electronics holder components. While this was less strong and unprofessional looking, it provided much more flexibility with regard to placement of components and placement of attachment holes. We didn't finish the design of the housing before deciding to replace it with cardboard, which is why the image to the left appears unfinished.

Servo Housing

We realized that some sort of housing was needed for the servo otherwise it would just spin so we put the servo in a a housing to position it in the best place, and hold it steady when rotating.

Initial Servo Arm Design

The initial arm was designed with built in pegs to firmly connect to the servo holder

Final Servo Arm Design

Apparently makerbot had issues figuring out how to deal with the pegs that needed to be printed sideways with support structure, so the servo connecting arm was redesigned to replace the pegs with holes that bolts could be inserted into. During this redesign, the width of the arm was reduced to improve printing time.

Pegs

The servo and photoresistor arms were originally designed to attach to the cardboard base via a peg that would be bolted on at two connection points (see left hand rendering). Additionally, when the servo arm was redesigned, the right hand peg was designed to link the servo arm and servo holder with no need for bolts. I (Jacob) designed both pegs with fairly tight tolerances as I wanted some friction in their fits, and when printing them at home, they successfully fit the holes as I wanted them to. However, for whatever reason, neither of them fit when they were printed on campus, and they were all replaced with standard metal bolts.

Prototype Hat Layout

First hat layout with second iteration circuit.

Last Hat Layout

Last hat design iteration included the three button layout to add more customization for the wearer.

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