Useless Box Challenge

SOLIDWORKS Tutorials

Advanced Design-Hinge

Objectives

Using a layout sketch
Suppressing features to create part configurations
Creating a new part in the context of the assembly
Detecting collisions in assemblies
This tutorial assumes that you know how to perform basic assembly operations, such as moving and rotating components, and adding mates.

Extrude-Thin and Sweep

Drill Holes

Mirror

Layout for Cuts

2 Cuts

This cuts out 2 sections of the top for the first half of the hinge

3 Cuts

This cuts out 3 sections of the top for the second half of the hinge

First Half

Second Half

Pin-locks the halves together

Final Hinge

SOLIDWORKS MOTION TUTORIAL

Objectives

Run a SOLIDWORKS Motion study for a model that includes a spring and a motor.
Plot the results.
Duplicate the motion study with modified simulation parameters.
Use the results to redesign the model.

Plot 1 - 1200 Tab

Magnitude of the Contact Force Between the Rocker and the Camshaft (Newtons) vs. Time (sec)

Plot 2 - 2000 Tab

Magnitude of the Contact Force Between the Rocker and the Camshaft (Newtons) vs. Time (sec)

The Part

The Useless Box

The Components

Battery Holder

(Made by partner)

Motor

Forward/Reverse Switch

Button

Engineering Notebook Drawings of Components

Forward/Reverse Switch and Limit Switch

Motor

Box Outer Shell/Arm Device/Motor Axle

Servo Mount/Theme Design

SOLIDWORKS Modeling

Redesign (outer shell)

The redesign of the lower lid was necessary because the original was completely messed up and the hinge on the original print broke. The upper lid also did not have a hole for the switch.

Redesign (inner components)

After reprinting the upper and lower lid I attempted to print this plate to mount the inner components on, however that section of the print failed.

Test Prints and Printing Videos

Arm Device Test Print

First two attempts did not fit on the motor. The third attempt did not fit in the box with the new lid.

Outer Shell Print

The lower lid broke on the build plate after print was complete. The upper lid was designed wrong. The pin that was designed as a hinge failed as well. The main outer shell stayed in tact.

Outer Shell of Box

Box and Lid

Together

PrusaSlicer Images

Original Outer Shell Print

This is the print where multiple parts failed

Printed in orange Elegoo Rapid PETG

This is the print where my servo wall failed

Printed in black Generic PLA

Soldering

Soldering Schematic

My Soldering

Soldering Close-Ups

Servo and Arm

This version of the arm did not fit into the box. I had to redesign the arm without the alien head.

Servo Testing

The circuit works! The limit switch pauses the motor's turning, the forward/reverse switch changes the direction

The Final Product

The Final Design (Outer Shell)

Due to time constraints and limited print space, I decided not to reprint the outer shell despite having a broken hinge. Instead I drilled holes into the sides where the hinge feature would sit and into the lower lid. Zip-tying the features together created a hinge that the arm can easily push up.

The Final Design (Inner Components)

To attain precise measurements (and potentially use heat set nuts), I printed a wall to mount the servo and drilled holes in it exactly where they needed to be instead of risking the need to make multiple prints.

(Insert gif of working servo mounted to wall)

The Final Design (Working Product)

(Insert gif of working box)

Drawing Package

Page updated

Google Sites

Report abuse