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.