Spring 2018 Week 11: Presentation 2 and a Switch

April 11, 2018

This week, our team presented our second presentation of the semester. In this presentation, I reiterated the design requirements and specifications. Bryan went over the manufacturing progress and contingencies and dependencies. Lastly, Kevin went over the BOM and Gantt Chart for our team.

                     

On Friday of this week, our team put some extra time in the SDCC. I was able to drill and countersink the holes for 6 more straights. After Kevin prints out more brackets, our team will have successfully completed 13 of the 15 straights needed for the project.

While I was completing this, Bryan worked on welding the mounting components of our supports. However, Bryan ran into a slight setback because it seems that the shielding gas tank is empty; we have to purchase another tank to continue the project.

Lastly, after seeing the Bogie team's bogie fit in the curve section, Kevin worked on completing the switch section, shown Figure 1. Now that we have verified that the bogie will fit in the modular sections without binding, we can start completing all the components for the track.

Figure 1: Completed Switch Section

Spring 2018, Week 10: Making Straights

April 4, 2018

This week is the first week back from our Spring Break. Our team continues to manufacture parts for the small scale track. This week, I managed to assemble 5 straight sections. While I was doing this, Kevin continued working on the curve and switch sections. 

As of this week, we managed to create 2 curves and half a switch (Figure 1). We are currently waiting on the Small Scale Bogie team's design to determine if the bogie will fit in the curve section. When we can verify this, we will proceed with completing the switch section. 

Figure 1: Incomplete switch section

In addition to manufacturing parts for the track, our team is also preparing for the second presentation of the semester. 

Week 9: Attempting Curves and Assembling Straight Sections

March 21, 2018

This week, our team attempted to create curve sections with the bender Kevin manufactured. As shown Figure 1, it seems that we have created a curve that will keep the bogie from binding. Using calipers, we our gap stays within the tolerance of 2.5 + 0.5 inches. All we need to do now is wait for the bogie team's design, so we can test the rails.

Figure 1: Curve section Prototype

As well as creating a curve, our team completed 2 straight sections (Figure 2), and mounted the sections onto the supports, shown in Figure 3. In Figure 3, a view of the completed supports is also featured.

Figure 2: Straight Section Prototype

Figure 3: Straight Sections Mounted on Supports 

Going into Spring Break, we are making good progress into completing the entire track section by Maker Faire. To be honest, this break is much needed. The team has spent a lot of extra time in the shop to stay on track. Hopefully this break will rejuvenate the team, and we will be ready to hit the ground running in a couple weeks.

Spring 2018: Week 8 - Support Status and Creating a New Bender

March 14, 2018

During this week, the team was at the shop three times. Throughout the week, Bryan finished welding bolts onto the leveling system (Figure 1), and he also completed welding all the top sections of the support section. With all support leveling systems completed, Kevin and I proceeded to cement these systems, shown in Figure 2. In addition to completing the supports, Kevin also worked on creating a bender that would reduce the amount of twist on the aluminum bar stock. By the end of the week, Kevin managed to manufacture the bender in Figure 3. After some testing with spare aluminum bars, we found that the bars did not twist a significant amount.

Figure 1: Welded nuts on Support Leveling System

Figure 2: Angelo and Kevin cementing leveling systems

Figure 3: Kevin's metal bender

Overall, this week was very productive. We managed to complete 90% of all the supports, and might of found a solution to the twisting problems we were experiencing with our other benders. With a little over two months before Maker Faire, our team is on track to finish on time. Next time, we hope to start creating bends, and completing some straight sections as well.

Spring 2018: Week 7: Cementing Support Sections and Attempting a Curve

March 7, 2018

During this week, our team continued working on the support sections. Bryan is now comfortable with the welder, so he managed to complete all the bottom sections of the supports. In the meantime, Kevin and I used this opportunity to cement three bottom sections, shown in Figure 1.

        

Figure 1: Cement Process of  Bottom Support Section

In addition to the support sections, our team also attempted to create a curved section with the benders in the shop. Much to our dismay, the bends that we were getting were not concentric. Furthermore, the aluminum curves were also twisting, so the rails were not parallel. Therefore, we all agreed to explore other bending methods in the coming weeks. 

Spring 2018: Week 6- Manufacturing Progress

February 28, 2018

This week, our team continued to practice our welding on spare metal in the shop. We all tried welding the steel flat bar to the square tubing, but we all came into problems of overheating the thinner square tube, causing the walls to melt. After some time, Bryan had the most success controlling the heat, so we decided to designate him as the team welder.

While Bryan worked on the welding all of the configuration in Figure 1, Kevin and I prepared more square tubing for the top section of the support, seen in Figure 2. Kevin was also able to print the third rail support component of the switch section, seen in Figure 3, at home.

During this week, as well as previous weeks, our team has come in on our off days to work on the project. With so many parts to manufacture for this project, coming in once a week will not suffice.

Figure 1: Leveling System of the Support Structure

Figure 2: Top Portion of Support Section

Figure 3: 3-D printed Third Rail Support

Spring 2018 Week 5- Presentation 1

February 21, 2018

This week, our team presented the progress of our progress and goals for the semester. I presented the current status of the designs for our project, as well as our manufacturing progress. From last semester, the only major change we made with the Small Scale Bogie Team was to decrease the inner track width from 2 inches to 1.5 inches. This change would decrease the clearance gap at the switch section, eliminating any concerns that the bogie will fall through. As far as manufacturing, we are still in the process of welding and assembling all portions of the support section.

Overall the presentation went well, but our instructors suggested that we improve on Assertion Evidence for future presentations. Our presentation can be found below. 

Spring 2018: Week 4- Prepping Parts for Welding

February 14, 2018

This week, the team continued to prep the steel bar stocks and square tubing for welding (Figure 1  and 2), shown in Figure 3. Dan from the Full Scale bogie team was able to demonstrate TIG welding for the team, and allowed each of us to practice under his supervision. However, due to our inexperience in TIG welding, we were unable to properly join weld the parts in Figure 4. Personally, I had a little trouble keeping my hand steady as I formed a straight puddle line. Although I feel like we're behind schedule, I still feel confident that my team will finish on time. 

Figure 1: Angelo and Bryan Grinding the Steel Flat Bars

Figure 2: Kevin drilling a bore into one end of the steel flat bar

Figure 3: Steel Flat Bar Prep for Welding

Figure 4: Leveling Configuration of Support Section