18.2 - Design Process

Iteration Documentation:

Documented below are some of our previous iterations/design ideas.

The use of a Geneva Drive allows our slider to be split into distinct steps as the motor runs continuously. In our original concept drawing, the crank of the slider-crank system would be attached to the output of the Geneva Drive, and thus would only have an equal number of steps as there were slots in the Geneva Drive output. As a simple 4-slot Geneva Drive would only create 4 steps of motion in the slider, our initial design concept was to use two 4-slot Geneva Drives in series in order to increase the number of steps in our slider motion from 4 to 16. However, after thinking about how to implement this, we realized this would only translate the motion of the 4-step rotation across the Geneva Drives, rather than creating 16 individual steps as we desired. To navigate this problem, we pivoted to using gears to accomplish this instead. By fixing a 12-tooth pinion to the output of the Geneva Drive, and fixing our crank to a separate 48-tooth gear, we could create a 1:4 gear ratio that transformed the 4-step slider path to 16 steps. An image of the first-cut iteration of the Geneva Drive design is shown below in Figure 4.

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While the fundamental designs of our components were not modified during the manufacturing process, most of the iteration of our design went into adjustments of component alignment. When testing the fit of the Geneva Drive components and gears without securing them into a base plate, we initially believed the fit of the components was correct. After creating a testing board to secure the rotary bearings, we determined that the peg of the continuously-rotating Geneva Drive was not correctly aligned with the 4 slots of the Geneva Drive, preventing smooth motion. Because of this, we were required to recut the circular piece of the Geneva Drive after a better measurement of the alignment after the components were anchored, moving the peg hole towards the outer diameter of the circle by 3 mm.

In addition to the peg misalignment in the Geneva Drive, we encountered errors with the size of our shaft holes in the initial cuts of multiple components. The hole diameters were 0.02 mm too wide for our shafts and caused a lot of slippage between the gears and links, but this was easily remedied with recuts and superglue. Additionally, on the final design, we will switch from smooth shafts to a keyed shaft for all shaft/gear interfaces to limit the relative motion between the gears and the shafts. This will allow us to easily swap between gears should they wear faster than expected or need regular maintenance. The testing anchor plate can be seen below in Figure 5.

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The next component we iterated through was various link lengths to ensure the slider crank would operate as we expected. We utilized MotionGen to quickly test various link lengths that satisfy the Grashof Condition and still allow the necessary total length traveled. We arrived at the link lengths shown in our Grashof Calculations as seen in Figure 6.

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Figure 6. MotionGen animation of Slider Crank with Finalized Lengths

Our finalized prototype gear train is shown below in Figure 7.

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For our final version of the project, our team made the decision to change plans and replace the strain gauge with a limit switch for two reasons:

• Noise: A (cheap) strain gauge will experience a very large amount of noise in its reading. In order to account for this, we would need to filter the signal, which would add a lot of complexity, or apply a very tight cutoff value on the reading. However, if this cutoff value is too tight, we could potentially trigger a false positive due to even the slightest environmental changes (for example, people talking nearby or someone bumping our table would both cause additional vibration and lead to abnormal strain readings). Any false positive would then result in the wrong height being recorded, therefore contaminating our final result. A limit switch can avoid this issue since it is less sensitive to vibration.

• Fragility: Cheap strain gauges are very fragile and will break easily. This could lead to issues with lead times and potentially stall our progress. Additionally, even if it doesn’t break completely, repeated impacts can still lead to shifts in performance and may lead to the strain gauge reading a different range of strain values, which would require us to constantly re-calibrate our values and would not produce a consistent result. Limit gauges are typically much more sturdy and reliable.

Bill of Materials: