User:John McNamara/Projects/project2

Project Preference

 * 1) 1 Beat Bearing
 * 2) 2 Automatic Shaker Table
 * 3) 3 Makerbot Pla

Problem Statement
For the second project for ENES 100 I will be implementing the Beat Bearing project. In this project I will be will be building the previous groups design.

Project Plan
In the next four weeks my group should successfully make the board and get it working with the arduino. We should be able to build a board so that when a bearing is put on top of a washer it will signal a speaker to sound.

Week 1 Narrative
My first week tasks for the beat bearing project was to read the previous groups CDIO report. After reading this report the project was still very confusing. When our group met on Thursday we were all confused so you suggested that we message someone that had worked on the project before, we did. During that class that day we were able to find the old groups box and go through it. We found a couple parts but not many so this next week our group will have to talk to you about ordering parts. Jake was able to meet up with one of the people that had previously worked on the project to ask questions about the project. After he met and talked with them he called me and clarified some things up for me. Turns out that many of the pieces in the the bod were prototypes. Knowing this clarified many things up for me.



This is one of the previous groups prototypes which I think our group should take and make work. The previous group said it did not work due to the bolts. I think that we can solve this by counter sink screwing the washers and using countersink bolts. Also I think that instead of there being Plexiglas under where the hole is from the washer it should be drilled out. The previous group also had many extra Plexiglas strips but they were very rough so in order for them to be used I will sand them down or re cut them so they are the same width and length.

Week 2 Narrative
My tasks for this week was to use acrylic adhesive to bind the Plexiglas runners to the Plexiglas board and to cut the washers in half. This week I almost completed the board. Me and Jake came in and were able to glue the runners and the board together and get most of the washers cut.





Before gluing we decided to test fit the board to make sure all the pieces fit on properly. When we did this we ran into a problem, the final one was too wide. We then figured out that the two thinner strips were for the first and last runners. After test fitting the pieces we decided to practice using the adhesive so we took the scraps and practiced gluing them together.







Applying the glue to the Plexiglas is harder then it looks. Even after numerous practicing attempts we could not successfully combine two pieces so that there were no bubbles. We also did not have the proper applicator so we had to improvise, we used a syringe. We used the blue clamps to keep pressure on the board to ensure a secure tight fit. To see me gluing the board watch this video. <br \>

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The next thing I did was cut the washers. To ensure that we were in the center of the washer while cutting we made a template to mark the washers. After we marked all the washers up we started cutting them. We used a Dremel with a #420 cutting disk. Even though these disks were heavy duty they still wore fast. We used 3 disks cutting about 16 washers. We also could only cut 16 washers because we ran out of washers. Video of cutting the washers.Since we ran out on, Saturday I ran to the store and picked up more. This week I met with Professor Forester and he explained to me that we needed to either find or make code so that the arduino will play 40 drum rudiments and so that when we push one of the buttons of turn one of the knobs on the midi board so does the sound. Next week I will finish building the board and my group should have the arduio playing the 40 rudiments.

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Week 3 Narrative
My tasks for the week were to create a new washer template in Google SketchUp and to wire the negative side washers to the board. The washer template from the previous group was too big for the washers so I used their existing file but made the holes smaller. The first time I changed the hole size the holes were a good size but when we tested to make sure it would work we found that the gap between the two was too big. Luckily we decided to just print a portion of the template so we didn't waist that much time. To fix the holes being too far apart I made the the holes three quarter of the distance they previously were. When we printed this one out it worked, but we ran out of time and because it was just a portion of the template size we were unable to print the full template out Friday. I decided to take the file home and make a full template to send to Jake to print because he was going in on Saturday. I finished it at my house and then sent him the sketch up file as well as the makerbot file. When he went in and tried to print he could see in the maker ware that the holes were not extruded through the template. Luckily I was home so i fixed it and re sent the files. On Saturday Jake came to my house and we wired the board up in my garage. We used the drill bits the previous group used but we found them to be just a tad too small so we used a little bigger one. Using the template we printed i drilled hole on the inside of the holes for the wired to pass through. To wire the board up he cut and stripped the wires while i twisted them together once we had enough wire we fed it through the holes in the board. From there I wrapped the wire around the washer halves and put a small dot of superglue on wire and washer to hold them together. We then checked to make sure that there was current running through each row of washers, which there was. We did not glue to washer to the board in case something went wrong and we had to pull the wires out.

<Gallery> File:Image (14).jpeg|Here is a view to see that the diameter of the circle is a perfect fit. The gap between the outside of the washer and the template is not a proper fit. File:Image (16).jpeg|This is the second sample template that was a perfect fit for the washers. File:Image (13).jpeg|This is how the template turned out when i drew it in sketch-up i tried to extrude the first one all the way through but it would not let me but luckily we were able to use the test template. File:Washer Template.png|This is the template in Google sketch-up File:Washers wired.JPG|This is what the template looks like with the negatives being wired.

</Gallery> This is a video of the holes being drilled

http://www.youtube.com/watch?v=cTbcQ7UVPfg

This is a video of Jake and I testing the current through the board

http://www.youtube.com/watch?v=e9xbzYueD0U

Week 4 Narrative
My tasks for week four was to check for continuity in the negative half of the board. This week we also had to re attach a few washers that fell off. The washers fell off because the wires holding them on were too short. They became too short because when we striped the wires when pulling up a few wires broke off. To fix this problem we took the wire that was already fed through the board and added wire to it by simply twisting the two pieces together. We would have just replaced the wires but because where the wire fell off was in the middle of the board we had to improvise. We also cut the rest of the washers I marked them while Jake cut them. My other task for this week was to work on the CDIO report. Me and Jake decided to work on it together. At first we tried incorporating drop down boxes in our report but we shortly realized that it was more complicated then it looked so we decided that it wasn't worth putting in. I will be primarly filling out the Hardware Manufacturing Process of the CDIO report. I will use information i have gathered over the weeks of the project cycle as well as information from the previous groups work. I will be talking about the cutting of the washers, the acrylic welding, and the wiring of the board.

<Gallery> File:Image (18).jpeg|This is a photo of the stripped wire that will be put on the wire that is too small. </Gallery>

Below are some videos of the four rows being tested for continuity.

http://www.youtube.com/watch?v=iTvwIAPeA9s

http://www.youtube.com/watch?v=m85GAHDxjlQ

http://www.youtube.com/watch?v=BnRGDPMG7_0

http://www.youtube.com/watch?v=vCtI4hbFYxA