User:Jzest/ENES-100/Project 3/CDIO

Design
Current design to be translated from sketchup to 3dtin is shown here Preliminary drawing for gear box using 3dtin.com shown here was printed at 50.8mm

Problems and Solutions for printing
Solution: Raised printing temperature from 230°C to 235°C Solution: Added supports in Makerware so the Makerbot will be able to print the box properly Solution: Still able to use it as a prototype to check size Solution: Rescaled dimensions to 35mmx35mmx17.5mm Solution: Added another row of blocks to the wall in 3dtin and printed at 35mmx35mmx17.5mm Examples of three stages of gear box prototypes are pictured to the right along with the first functional box in position.
 * Problem: Holes at the edge of the floor after about 1-2 minutes of printing;
 * Problem: Preemptively stopped printing because the design is hollow;
 * Problem: Spool got jammed up and caused the box to be printed with a seam between the roof and walls;
 * Problem: Box is too big to fit between pins on underside of motor;
 * Problem: The opening for the gear to slide into was 2mm too short due to a bump on the end of the gear.

Design Changes
There have been two major design changes:
 * 1) The door will be opened by a turning arm in direct contact with the door knob. The new exposed axle design is shown to the right New direction for opening door.jpg
 * 2) The motor will sit tight to the floor. Here is a link to the .stl files for both gear boxes, one with and one without the floor. The pin creating separation between the motor and board was removed with a hacksaw. Pin that was removed.jpg

Broken Motor
Problem: Central core came out of the motor from in the middle of the coil because the tabs holding it into the motor did not have screws in them. Solution: Bend tabs back into place with needle-nose pliers and replace the four missing screws. Removed fan in process.

Design Overhaul 2
Scrapped gear box idea to lower the power gear to underneath of the board.