Tuesday, December 19, 2017

Weeks 15 & 16 Presentation 3

Our final presentation was very successful. Most of the feedback regarding out current design state and progress has been positive. The most important outcome of this set of presentations was the thought of designing the rails to be narrower. Narrowing the rails would reduce 3D printing time and material usage for both our team as well as the bogie team. Another benefit of this option is that the gap at the switch sections that must be crossed by the bogie will also be reduced. We have agreed with the bogie team to investigate this further. Our goal is to build another prototype to test during the winter intersession.

Happy Holidays!

Week 11-14: Rapid Prototyping

Rapid prototyping has been very successful. For our rapid prototypes two sets of linear rails were produced. This allowed us to test the mating between our modular sections. A total of 6 hangar brackets were produced utilizing a 3D printer.

The aluminum rails were produced in house at Spartan Superway. All that was needed was to cut the aluminum stock to size, mark the hole locations and drill the holes. The drilled holes were then counter-sunk so that the mounting screw sat flush in the track.

The hanger brackets were a bit more of a tedious endeavor. One of the goals was to reduce the amount of time necessary to print the brackets. Using typical print settings, each bracket was estimated to need about 6 hours to complete. With a total of 60 brackets to produce this would take approximately 360 hours. To reduce print time we decided to increase the nozzle diameter in our 3D printed. Initially a 0.4 mm nozzle was installed in the printer. This is common since it provides a good balance between speed and print quality. First we tested a 1.0 mm nozzle. After a few test prints we established that the produced bracket print quality was unsuitable for the project. This large of a nozzle diameter produces inconsistencies in the printed dimension. A 0.8 mm print nozzle was then tested. This nozzle worked quite well. All of the printed parts were dimensional accurate and the surface quality of the print was more than acceptable. Most importantly, print time was cut in half to only 3 hours per bracket.

The only thing left to do was to assemble the linear rail sections and test them with the bogie. This ended up working quite well as shown in the video below. Unfortunately, we were not able to prototype a turn or switch section as of yet. Since we will be focusing on a double rail both of the rails must be concentric. We fear that the bending machine available at Superway will provide inconsistent bends. Our suspicions were confirmed after we tried to bend a test strip. We will be looking into utilizing a ring roller for these sections.

Friday, October 27, 2017

Week 9 & 10: Presentation 2

This week we showcased our design iterations and some of our calculations for our project. The biggest take-away from this presentation leads us right back to the drawing board. Our support structure doesn't allow for angular adjustments. This can be very problematic when we showcase our project on uneven terrain. Thankfully, we can still continue with rapid prototyping our linear, curved and switch segments while working on redesigning our support structure. Back to the drawing board...

Presentation 2:

Week 6-8 Design Iterations and Beginning Rapid Prototyping

These weeks have been very time consuming. We have spent a lot of time focusing on the design aspects for our track. We have performed some rudimentary stress calculations for our hangar brackets to make sure that they are structurally sound. After multiple iterations of our switch design we are coming much closer to a finalized design. The support structure for our project is reaching near completion as well. Even with all of the CAD work we have been working on we have began rapid prototyping and experimenting with 3D printing our hangar brackets.

Monday, October 2, 2017

Week 4 & 5: Presentations

In week 4 and 5, the class showcased their plans for the semester in the first big presentation. The presentation contains details regarding the concept behind Spartan Superway, design specifications on the project, and our Gantt chart for project scheduling.

Our "1/12th Scale Track and Manufacturing Team" presentation is published below:

Wednesday, September 27, 2017

Week 3: Communication and Presentation Preparation

This Spartan Superway class session has been one of the most productive thus far. As a group we now have a much better understanding of the Futran system. We do not yet have any design specifications from Futran but we now have a much better understanding of the system as a whole. The entire twelfth scale team has established a method of communication. Our team is going to have to be in constant communication with the bogie team to design a track that is manufacturable and that works well with the bogie. We are also going to have to spend some time talking to controls and identify a means for positioning. We spent some time talking to the bogie team today about the switching mechanism for our bogie and we all have reached an understanding of how the entire system will come together. By the end of the class session, we have a few specifications in mind. We are going to need to communicate more with the bogie team before the presentation day so that we are all on the same page regarding design and specifications. By the next class session we will need to have our presentation ready and at the minimum, some hand sketches of our track system.

Wednesday, September 6, 2017

Week 2: Lightning Talk

This week, all of the teams presented their project descriptions, specifications, and goals through the lightning talk presentations. After the presentation, Professor Furman provided us with input regarding the assembly of the track for presentation opportunities such as Maker Faire. Thus, we implemented this goal on our project specifications. Everyone in the team stayed afterwards to speak on possible improvements for this year's iteration of the 12th-scale track and the following tasks that need to be finished for the upcoming week.

Next Week's Objectives / To-do List:

  • Start designing for the Futran Railway System
  • Finish research on the Futran Railway System
  • Contact previous year's manufacturing/track team for help and advice
  • Evaluate weak points of existing track
  • Explore possible replacements for supports

Project Specifications (Initial)

         1. Create a new 12th scale model track using the Futran rail system
              a) Collaborate with other 12th scale teams

         2. Improve manufacturability of  track components 

         3. Speed up the assembly and disassembly process for presentations such as Maker Faire
              a) Ideally, we would like a track that could be set up in such a way that once the track is held level the ground posts could be adjusted so that the track remains in place.

Lightning Presentation: How, What, and Why

Wednesday, August 30, 2017

Week 1: Schedules and Contact Information

This week we discussed project specifications in preparation for our first lightning talk on September 6, 2017.

To help with future coordinating for out group we have attached all of our schedules below.

Bryan Oyan's Schedule:

Angelo Banzon's Schedule:

Kevin Brasil's Schedule:
Along with work on Sunday, Monday and Fridays from 6AM-1PM.

Contact Information:
Bryan:    bryanoyan2013@gmail.com
Angelo:  angelo.j.banzon@gmail.com
Kevin:    kevinabrasil@gmail.com