Spring 2018, Week 15: Completing the Final Presentation

May 9, 2018

On Wednesday, we came into the SSDC to adjust any sections that would cause the bogie to bind. We re-bent a curve section, as well as shaved the brackets, which seemed to alleviate any binding concerns. With our small scale track complete, all that was left for the rest of the semester is to finish the final report and presentation for our senior project. On Thursday, our team met up in the Student Union to complete the presentation. After our presentation on Friday, our team will come into the SDCC to break down the track for Maker Faire.

Spring 2018, Week 14: Completing the Track

May 2, 2018

Throughout the week, our team managed to complete all the sections of the track. Early in the week, I managed to assemble the rest of the straight sections because the brackets were all finally printed. In addition to completing the straights, I also bent the curves for the last curved section, all while Kevin completed the last switch section. On Wednesday, Bryan and I finished assembling a complete track, as seen in Figure 1. With the small scale track finally completed, our team can start focusing on the final presentation of the semester, as well as the final report. This as been a long, exhausting process, but it feels great finally seeing our track completed. All that is left is to ensure that the bogies have no problems binding around the track.

Figure 1: Completed Small Scale Track

Spring 2018, Week 13

April 25, 2018

This week, the team continued to manufacture the track. With the mounting sleeves deburred, our team can finally start assembling portions of the track. As can be seen in Figure 1, our team managed to mount a straight and switch section on the track. Our team is still waiting on brackets to be printed, so we have to wait till next week to complete our track. As of now, we still have to finish about 6 straights, one curve, and one switch.

Figure 1: Mounted Switch and Straight.

Spring 2018, Week 12: Correcting Mounting sleeves and Waiting on Brackets

April 18, 2018

This week, our team continued to work our way towards manufacturing the track. We ran into some issues with the mounting sleeves that Bryan was welding because the metal burrs were preventing the sleeves from sliding onto the L-shape square tubing. Thus, Bryan utilized the class period to shave them down.

Meanwhile, my workload slowed down this week because our team ran out of brackets to assemble the straights. With the mounting brackets and the 3-D printed brackets incomplete, our manufacturing has stalled slightly. However, I am still confident that my team will complete this in the coming weeks.

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

Spring 2018, Week 3: Preparing Support Section Parts

       This week, the materials required for the support section of the track, seen in Figures 1 & 2, arrived at the shop. As such, our team spent much of our time prepping the steel square tubes and bar stocks for welding. 

Figure 1: Support Section of the Track

Figure 2: Bottom Configuration of the Support Section

        

            In addition to prepping the materials, the team asked Dan from the Full Scale Bogie team to demonstrate how to use the gas welder in the shop. By next week, we hope to be able to learn how to effectively weld, so that all the support sections can be completed. After all the welding is completed, we can proceed with pouring the cement.

Spring 2018: Week 2- Lightning Talks

      For week 2 of the semester, all the sub-groups participated in Lightning Talks to discuss the current progress of the teams, as well as the goals for the upcoming semester. The slides for the Lightning Talk can be found below.  For the track and manufacturing team, our goal is to construct a switch section prototype as soon as possible.

      The only factor that can slow down our progress as of now is waiting for the aluminum order to come in from Midwest Steel and Aluminum. The parts for the support structure should be coming in the upcoming days.

      Lastly, the team has decided to abandon the metal bender in the shop. We came to this decision because we felt that metal bender could not produce the bends necessary for this project to be successful. Instead, we have opted to use the Manual Roll Bender RM-3, which actually came in the mail today.

      With Maker Faire less than 16 weeks away, time is becoming more and more valuable for our team. Nonetheless, I feel positive about the progress for our team to complete a successful small scale track.

Spring 2018: Week 1: Finalizing BOM

In this week's meeting, the small scale sub-teams worked together to lower the total cost of its Bill of Materials. The small scale track and manufacturing team re-checked the inventory to find usable parts, but no significant stock could be found.

Overall, the team was able to lower cost by about $1500+. The next step for my team is to begin ordering the necessary parts for rapid typing the switch section of our design. In the meantime, we will be using plywood available in the warehouse to construct this switch section.

Fall 2017, Weeks 11-12: Presentations, Final Designs, and Semester Wrap-Up

In these final two weeks of the semester, each project group presented their 3rd and final presentation of the semester. After watching the presentations, it is clear that everyone is a little behind schedule, but I remain optimistic that everyone will be able to finish in the spring.

In terms of project progress, our team has not met our semester goal of rapid prototyping a switch section. Our team had difficulty creating concentric curves with the bending machine in the shop, so we are still trying to determine how to make a prototype. If bending metal is no longer an option, our team is considering the option of using wood. Although this section will not as durable as a metal section, we will be able to test if our design will help the bogie pass the clearance gap.

The final design for the attachment to the switch section can be viewed below. 

 

This design was chosen because it provides a smooth transition onto the third rail of the system. The third rail can be inserted into the sleeve located on the lower section of the attachment. The results of FEA through SolidWorks shows that the attachment will not fail under the load of multiple bogies pushing against the third rail.

To wrap up the semester, our team is currently completing the final report for the semester. We have also finished the Bill of Materials for our design. Looking to next semester, it is clear that we have a lot of work ahead of us.

Fall 2017, Weeks 10-12: Rapid Prototyping and Obstacles

These past few weeks, our team has continued to rapid prototype straight sections for the track. By the end of week 11, our team was able to construct a second straight section. However, with the cost of a single support, our team cannot yet mount the straight sections. Nonetheless, we can begin testing the robustness of our track with the bogie team. 

To minimize the BOM as much as possible, our team is leaning towards reducing the cross section of the aluminum rails to 1'' by 0.25''; previously, it was 1.5'' by 0.25''. We are able to do this because the bogie team's design does not need extra room at the bottom of the track. The reduction of the track's cross section also improves our specification of concentric curves, because it becomes easier to bend, and there are viable bending machines that we can use. 

To be honest, I was hoping to have made a curved section by this point of the project, but the obstacles we are facing in terms of bending machines is to be expected. We are hopeful that this problem will be resolved in the next few weeks.

Fall 2017, Weeks 8 and 9: Presentation 2 and Support Structure

In week 8 of the Spartan Superway project, our team presented our second presentation for the semester. After presenting our material, our peers pointed out that our designed support structure required an additional leveling system for un-leveled ground. My team considered ideas such as drilling holes through the support base to insert 4 adjustable bolts. This would allow us to angle the support as needed.

In week 9, my team continued to rapid prototype various components of the track. We also tested the bending machine in the workshop, and realized that the accuracy of the machine is not suitable for the tolerances of our project. With this complication, my team has to reconsider alternative methods to bend the aluminum. We also had to reconsider the size of aluminum that we would be using for the project. 

Fall 2017, Week 7: Final Design Decisions

As we near the start of the rapid prototyping stage, our team must still finalize a few designs. First of all, to clear the gap of the switch, my team and I designed the switch assembly in the figure below.

To overcome the clearance gap of the switch, we decided to introduce a third rail. This third rail consists of three portions: the straight rail which inserts into the switch bracket attachment (in blue), the curved rail, and a wedge, used to support the curved rail. The assembly also needed a middle bracket to support all the weight present around the wedge area; thus, the middle half bracket was created. This geometry was chosen because our team wanted to avoid mounting anything onto the curved area.

The entire 3D model for this track is near completion, but our team is still considering options for how to mount the support beams and brackets. Our hope is to complete this by next week, so that a test model can finally be fabricated. 

Fall 2017, Weeks 5 and 6: Further Design Work

After completing Presentation 1 of the semester last week, the 1/12 scale team continued further design work for the new track. To tackle the problem of the switch rail, I first calculated the minimum curve radius of the turn. With an assumed front axle rotation of 20 degrees, I found that about an 11 inch curve will allow the bogie to run smoothly. Below is one design option for the switch.

To guide the switch, we are currently revising the idea I had a couple weeks ago. The gap that the bogie must clear is longer than I anticipated, so I decided to go with another design.

By next week, my team and I hope to have a complete Bill of Materials, as well as a concrete solution to supporting the track.