The Challenges of Automated Mat Hoisting

We are excited to announce the successful completion of our automated mat hoisting project! After overcoming numerous challenges and dedicating significant effort, we have achieved our goal of creating a fully functional system. We would like to provide you with a summary of the tasks completed during the project and the challenges we encountered along the way:

Tasks completed for the project:

1. App Development:

   - Successfully coded an application that controlled a DC Gear motor through the press of a button. (up and down button)

   - Developed the app to establish a wireless connection via Wi-Fi to our Makerboard, enabling remote control of the motor.

2. Prototype Construction:

   - Constructed a prototype of the automated mat hoisting system using cardboard and various materials at our disposal.

   - The prototype served as a practical testing platform for the lifting system and pulley designs.

3. 3D Design and Printing:

   - Utilized Solidworks, a 3D software, to design pulleys and a cylinder that represented the rolled mats.

   - Ensured precise fitment of the screws within the designed components.

   - Utilized a 3D printer to manufacture the designed pulleys and cylinder, allowing for functional testing and further refinement.

4. Integration and Wiring:

   - Soldered two wires onto the DC motor and DC Gear motor later to establish a secure connection with the Makerboard.

   - Ensured proper integration of the motor within the automated mat hoisting system.

5. Structural Assembly:

   - Constructed a sturdy wooden structure capable of accommodating the pulleys.

   - Drilled the pulleys into the wooden structure to ensure stability during operation.

   - Drilled the H-bridge and Makerboard to the back of the wooden structure to make it look nicer.

   - Hot glued a wooden structure so the board can stay vertical without falling.

   - Hot glued the DC gear motor to the side

6. Completed the Final Project as intended and originally planned!

Overcoming challenges working as a group

During the final week of this project, our group encountered difficulties with respect to communication, individual responsibilities and division among group members.  Ultimately, our team was able to work through these difficulties.  Despite prior disputes, our team was able to unite in order to collaboratively and cohesively present our project to the class as a team. This greatly benefited the quality of our final presentation.  Furthermore, our team feels that our disputes are resolved and that each team member was effectively able to contribute value to the project. 

Challenges faced and overcome:

1. Motor Selection:

   - Originally planned to use a servo motor but discovered that its limited rotation of 180 degrees would not suffice.

   - Conducted  extensive research to identify and familiarize ourselves with alternative motor options suitable for our project    

      requirements.

2. Safe Motor Connection:

   - Selected a DC motor as a suitable alternative to the servo motor.

   - Encountered challenges with safely connecting the DC motor to the Makerboard without risking damage to the Arduino.

   - Initially attempted a circuit consisting of a PN2222 Transistor, a 1N4001 diode, and a 270 Ω resistor but found it ineffective.

   - Implemented an H bridge to address the voltage spike issue, ensuring proper motor control.

3. Code Optimization:

   - Developed code to control the motor's rotation based on user input.

   - Encountered an issue where the motor would consistently run at maximum speed after compiling code changes.

   - Addressed this challenge by enhancing the app to include a feature that allowed users to select the desired motor speed and delay.

Challenges that were difficult to overcome but that we have proudly overcome:

1. Tangling of the Hoisting String:

   -  Encountered initial difficulties with tangling of the hoisting string, despite attempting various wire types, filaments, and shoelaces,  

      the string used for hoisting the mats continued to tangle.

   - Incorporated a pulley on the motor shaft, allowing the string to roll smoothly without tangling.

   - Added a knot on the string to further prevent tangling and ensure consistent performance.

   - Changed the string to a Kevlar string which seemed to work better and the tangling wasn't as bad as before.

2. Pulley Roughness:

   - Discovered that the pulleys exhibited roughness, impeding the smooth movement of the string.

   - Efforts to rectify the issue were removing the 3D printed pulleys and try to use screws instead.

   - The screws also exhibited a kind of friction on the string so we added rubber pulleys to cover the screws.

3. Tension, Weight Management and Torque (The Switch to a Gear Motor):

   - Encountered difficulty in achieving the appropriate tension in the string used for hoisting the mats.

   - Required more torque from the dc motor.

   - Attempted to cut the rod in half to take some weight off.

  - Switched to a gear motor that provided the necessary torque to lift the mats effectively.

  - Fine-tuned the tension in the string used for hoisting the mats, striking the balance between stability and smooth movement.

  - Developed code to control the motor's speed and delay, allowing users to set their preferred operating parameters.