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12. Design and Build a Machine

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The goal for these 2 weeks was to work as a group to design and build a functioning machine.
We as a group decided to make an onigiri shaping machine.

Assignment objectives for 9th Apr - 22 Apr:

1. Mechanical Design: Design a machine that includes mechanism + actuation + automation + application. Build the mechanical parts and operate it manually.
2. Machine Design: Actuate and automate my machine.

In this documentation, I will document my own contribution, which was to make the Iris mechanism for shaping the onigiri from 3 sides. The overall machine building process is documented on the group documentation page.
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Halfway through, due to disagreements about realistic scope of machine and how to allocate tasks, we were asked by management to work in separate locations. Although I was not convinced or confident to finish my assigned task on time and successfully, I did not have another choice (other than to do my groupwork individually), so this is a documentation of my best endeavor.

Although I did not manage to complete the machine in the end, the experience gave me a lot of first-hand understanding about mechanism design, and I’m happy with the progress I made in just over a week. My main regret is not having had the chance to explore the Machine Design aspect of the assignment.

Concept:

While we were exploring the best approach for shaping the rice ball, the Iris mechanism was suggested to us by Nagano san and Rico. It’s a mechanism used in camera lenses and some valves, for controllling the exact amount of light or various substances flowing through a hole.
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We thought this might potentially be an efficient approach to making a expandable triangle-shaped mold. After an initial test with a cardboard prototype, we decided to proceed with this mechanism.

The beauty of this mechanism is the intricacy with which it can control the exact hole size with just one motor. However, as I found out later when testing with rice, it might not have been the most efficient approach for shaping something substancial such as rice. In addition, my team members were not available to help fix the remaining problems, and I did not think I could finalise the mechanism by myself in the remaining 2 days, so we decided to drop this mechanism and adopt a much simpler approach in the end.

Mechanism Design:

1.Cardboard Prototype

Apr 12th (Sat)
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After the instructors showed us this mechanism, I tried making a life-sized prototype for testing it on real rice.
Although this mechanism is supposedly easy according to my instructors, I found it personally very challenging to get my head around the actual designing of it!

2. Testing the prototype

Apr 13th (Sun)
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Next morning, we tried the cardboard prototype on real-rice.
It seemed to shape the rice quite well, so we all agreed to proceed with this approach.

At the end of the day, we discussed the task allocation, and I was tasked with building the whole Iris mechanism. I had tried to delegate some tasks to other members, since I was not confident to finish everything by myself, however this was dismissed as it was apparently the easiest part:(
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3. CAD design

Apr 14th (Mon) - 16th (Wed):
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I found this tutorial helpful in completing the CAD model.
Need to document the CAD modelling process here

In this step, I especially struggled with figuring out the correct measurements (lengths and angles) to fit the design inside our frame. In addition, halfway through, the other 2 members found an alternative frame, and I had to adjust the sizes again.

Nagano san actually shared a much simpler design after I had nearly completed mine, and I contemplated using it, but since I had a working model already, and ours needed to be scaled up and designed for laser cutters, I decided to stick to mine.

Designing the Main Iris Part

As I had forgotten all my high school trigonometry I used this site

Designing Gears

Tsuchiya san shared this tutorial page Yamamoto san recommended using TinkerCAD but their feature only supported up to 200 blades (I needed 256)

4. Test-Fabricate

Apr 17th (Thu)
I laser-cut a 1/36th scale model to test that my design works.
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Here I made a mistake of printing it too small (although it was a conscious decision in order to save materials), as the gear teeth were too small for it to be tested properly.

Based on this test model, I refined my design further, such as making the center circle more light-weight, making the slot thicker in width for smoother movement, etc.

5. Fabricate

Apr 18th (Fri)
Next day, I laser cut everything at life-size, and assembled it to test that it works ok. I also tested that the gears work well together. I found that gears work better when 3D printed than when Laser-cut, due to the resilience of material. I also completed the remaining design, such as figuring out all the layers in order to calculate the length of the 3D printed rod. alt text

6. Assemble and Test

Apr 19th (Sat)
Finally, I 3D printed the triangular molds and the rod, and assembled all the parts, including attaching tiny wheels to help with the gear movement.
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I had to make some extra parts to adjust the heights, but in the end, I managed to get it working quite smoothly.
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7. Actuate

Apr 20th (Sun)
Based on yesterday’s test, I added some extra parts for supporting the vertical structure and for fixing the motors in place. In the afternoon, Tsuchiya-san helped me connect the gears to the motor and we actuated the mechanism with a stepper motor. alt text

I also tried to shape real rice, first without the motor (moving the gears manually), but I found it surprisingly difficult to mold the rice (it took a lot of force to close the iris). By this time I was becoming sceptical of the machine completing successfully on time.
Finally, we motorised the rice shaping, and as I feared, our motor was not strong enough to shape the onigiri.
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There were also a number of other problems with the design, and since I only had the rest of the day to fix it, I decided I probably would not complete it. So we as a group decided to drop this mechanism and complete a much simpler machine.

Bill of Materials (BOM):

Reflections:

This week I learnt to…
- Work and communicate effectively as a team
- Communication needs to be improved - Design, plan and build a machine
- Designing of the machine: - Analyse and solve technical problems
- - Recognise opportunities for improvements in the design
- I was disappointed that I didn’t manage to learn about the Machine design aspects, such as motor-control, motion control

Assignment Checklist:

  • [] Documented the machine building process to the group page
  • [] Documented my individual contribution to this project on my own website
  • [] Linked to the group page from my individual page as well as from group page to my individual pages
  • [] Shown how my team planned, allocated tasks and executed the project (Group page)
  • [] Described problems and how the team solved them (Group page)
  • [] Listed possible improvements for this project (Group page)
  • [] Included my design files (Group page)
  • [] I need to present my machine globally and/or include a 1 min video (1920x1080 HTML5 MP4) + slide (1920x1080 PNG) (Group page)