Week 5/16-5/20 Final words

The prototype was finally completed. There were a few modifications that were made, differing from the final design of the CAD model. The third structure on the bottom was scrapped as it had a geometric flaw. This week consisted of fabricating the bogie. Fortunately, there were uni-struts that was available to us. Drilling through uni-struts was probably the most difficult task as they are very thick and strong. If the bogie could have been this simple in the first place, it would have more room for optimization. Uni-struts were not the ideal material in this application but it was the most available. Sheet metal is a very useful material as you can shape it to be anything and this project demonstrates that. Fabricating the bogie was probably the most interesting and exciting part of this project. I'm still proud of my work as the structure that holds everything together was improvised. The design process was fueled from needing to build a functional bogie on time for Maker Faire. The belt was the main issue but if there was more time, a more suitable belt could have been found.

Week 5/9

I was able to finish welding the guide arm and the motor mount. This was difficult as it was my first time welding. Getting the feel of melting metal is a new feeling. Its nothing like soldering.

This week I also made last minute modifications. The plan was to use uni-struts to connect the top box structures. Initially, there were no spring nuts and L brackets available. I had resorted to drilling holes and using long bolts and nuts to connect everything. This unfortunately wasted a lot of time as drilling consumed to much time. Drilling through uni-struts was difficult as they are thick. I eventually ended up with getting spring nuts and it made the assembly MUCH easier.

Week 5/2

Learned some welding today. The sheet metal parts that were laser cut from a local metal vendor came in. There were parts that i missed in the DXF file therefore i had to create another one and include it. Some of the parts that came in were not correct either so i had to saw off a piece for it to fit.

Week 4/25

Still waited for the sheet metal parts to come in. Dan said the vendors made an error and ended up shipping it with another client. I helped out the full scale control team with soldering and showed them stripping wire techniques that I've learned in my previous job.

Week 4/18

Not much progress as parts have yet to arrive. The full scale control has reached out to me to help figure out the pin connections on the motor driver. The manufacturer failed to deliver the pin connector adapter. I've reviewed the schematics and pin layout and see that its possible to solder wires.

Week 4/11

I have been updating the drawing for the sheet metal cut out every week as there have been a lot of revisions. Now, one of the largest parts, the downtube, was removed. This is due to recent calculations and simulations of legos by the other team memeber, Dan, showing that the current design has a flaw with its pivot mechanism.

The left side of this drawing was initially full.