System Integration
Have you answered these questions?
Implemented methods of packaging? ✅
Designed your final project to look like a finished product? ✅
Documented system integration of your final project? ✅
Linked to your system integration documentation from your final project page? ✅
Individual Assignment:
Design and document the system integration for your final project
This week, I faced some challenges while integrating my project, as the system and mechanism were meant to be placed inside the whale I’m designing. It took me longer than expected because I had to carefully consider which mechanism to use and determine the necessary components to ensure the system fits and works properly inside the object, according to my concept, and so that it looks like a finished piece. Below, I will show the process I’ve been working on.
This week is entirely focused on the final project. Below is the link to go directly to the final project.
1. System Design and Planning
1.1. Designing the concept for the final object.
In week 2, I worked on the modeling by exploring Blender software. Having the initial idea, I started from the concept of designing a whale that moves harmoniously and lights up, all triggered by the sound of a baby crying. With those ideas clearly defined, I began thinking about the mechanism and the components I would use.
The whale will have a structural, mechanical, and electronic system. The ESP32-C3 microcontroller will be responsible for activating both the whale's movement and its lighting system upon detecting the baby's cry. The mechanism will allow the whale to move up and down smoothly, while integrated lights will enhance the visual effect of the design.
1.2. Structural system
For this, I tried using Blender to do part of the modeling, but it became too complicated, so I decided to use Rhinoceros instead.
Did I face any challenges?
Yes, I did. I had to carefully think about how to create the curves, since the shape of the whale is entirely curved, and my goal was to make it as accurate as possible.
Modeling was difficult because I first had to figure out how to build the shapes before actually starting.
In the end, I was able to do it, and I really liked the result. The final shape of the whale met my expectations.
The structure consists of four main components that will be manufactured using 3D printing. Each part has been designed to fit together precisely and will be assembled using a mechanical connection system, allowing the entire body of the whale to form a cohesive and stable structure.
1.3. Mechanical system
It took me quite some time to figure out the shape of some small, bone-like parts that could connect with one another. I asked for support from a fellow Fab Academy student, Armando, who is a mechanical engineer.
With his experience, he suggested adding an eccentric point. I didn’t know what that was at first, but he explained that it’s an additional point in the mechanical part of the piece that enables indirect movement or connection.
That point ended up being essential to connect the entire internal spine of the whale. In the end, the simple solution I had in mind evolved into something much more functional and interesting.
To do this, I created a 2D model to better understand how it would work. In the model, you can see a shaft along with the eccentric point that simulates the movement.
I had some difficulties when it came to figuring out how to integrate the electronic system into the whale design.
In addition to the challenges of modeling, one of the most complex parts was planning how to embed the electronic components inside the whale, especially since I also had to consider the movement mechanism.
In the end, I designed a few simple parts. One of them acts like a column with an off-center (eccentric) point. This eccentric point connects to the tail section of the whale.
In the video, you can see how those axes would work. In the end, a very simple solution allowed me to minimize the use of servomotors: instead of the two I initially planned to use, I ended up using only one thanks to a simpler and more efficient system.
1.4. Electronic system
For the electronic system, I completed the design in week 06, and in week 08 I fabricated the circuit board that will be used in this project. The whale is split in half and divided into 8 sections. The electronic system will be integrated into the fin area, where the components will be attached using silicone. The wires will be neatly tied and also secured with adhesive to ensure a clean and organized layout. This section will remain visible from the outside, showcasing a tidy and well-structured appearance.
Another important aspect, aside from the mechanism, was selecting the right electronic components to ensure the crib mobile works optimally based on my concept.
The components I'm using are:
A NeoPixel, which will display randomly changing colors.
1 SG90 servo motor, which will operate within a rotation angle of 5 to 8 degrees.
KY-038 sound sensor, which will be triggered by the baby’s cry.
Xiao ESP32-C3 microcontroller.
This is the sketch showing how the components will be arranged inside the whale. They are all connected to a direct power source through a 2-meter USB cable.
Here you can visualize the 3D object, which shows how it will look in the end. The other object represents half of the design, created in this way to make assembly easier. This structure also simplifies the installation of the electronic components.
The device's structure is divided into two symmetrical halves. In the central section, which is the widest, the integration system is located. On the right side, the printed circuit board (PCB) is positioned, while on the left side are the servomotor and sensor. In the central area, the Neopixel strip is placed, connected to the mechanism for visual effects.
2. Manufacturing of parts
2.1. CNC laser – manufacturing of the mechanical part of the whale’s internal structure.
I created a preliminary design to evaluate how the internal structure would function and to ensure that the parts fit together correctly. This process was carried out using CNC laser cutting.
The material I chose was acrylic with a sandblasted finish.
2.2. Printing 3D
I designed the parts in Rhinoceros. Then, I exported them in STL format to open them in Ultimaker Cura and define the desired print finish. After that, I generated the G-code file. As soon as I saved it, the software gave me an estimated print time of 15 hours.
I printed the section that contains the housing for the electronic system, which will be integrated into the object.
I made a small 3D-printed sample to ensure that the mechanical parts fit properly and without any issues.
Did I encounter any issues while working on this project?
Yes, I faced some challenges. Initially, I considered using the molding and casting technique, but when I started working with 3D printing, I realized I needed to print 8 parts, and the estimated print time was 15 hours—not including potential errors. I was only able to print one part, and it alone took 15 hours.
Because of this, I decided to have the pieces printed externally in white at Garage Lab, where they were able to print all 8 parts in just 3 hours and 14 minutes.
Due to time constraints, I decided to move forward with 3D printing technology and ruled out the molding and casting option.
3. Assembly
I placed the components on the PCB and then installed it inside the whale.
I placed the components correctly, having previously planned the placement of each one. The PCB was positioned on the right side, while the servo motor was located on the left side.
All the electronic components are placed inside the whale, ensuring that the wiring remains hidden. I was a bit worried about this aspect of the project, but my instructor Roberto told me that the wiring should be inside, as the idea is for it to remain out of sight. And indeed, everything is properly organized inside, so it is not visible on the outside.
4. Arduino IDE
#include <ESP32Servo.h>
#include <Adafruit_NeoPixel.h>
#define SERVO_PIN 2 // GPIO2 (D3)
#define LED_PIN 5 // GPIO3 (D1)
#define IR_SENSOR_PIN 21 // GPIO4 (D4)
#define NUM_LEDS 30
Servo myServo;
Adafruit_NeoPixel pixels(NUM_LEDS, LED_PIN, NEO_GRB + NEO_KHZ800);
void setup() {
Serial.begin(115200);
pinMode(IR_SENSOR_PIN, INPUT); // Digital IR sensor
// Initialize the servo
myServo.attach(SERVO_PIN);
myServo.write(0);
// Initialize NeoPixel
pixels.begin();
pixels.clear();
pixels.show();
Serial.println("System ready with infrared sensor.");
}
void loop() {
int irDetected = digitalRead(IR_SENSOR_PIN);
if (irDetected == LOW) { // Change to HIGH if your sensor works the opposite way
// Object detected
myServo.write(10);
// Change the NeoPixel colors randomly
for (int i = 0; i < NUM_LEDS; i++) {
int r = random(0, 256);
int g = random(0, 256);
int b = random(0, 256);
pixels.setPixelColor(i, pixels.Color(r, g, b));
}
pixels.show();
} else {
// No object detected
myServo.write(0);
pixels.clear();
pixels.show();
}
delay(100);
}
To control the electronic part of the project, I used Arduino IDE to generate the necessary code. Through this development environment, I programmed the logic required to control the electronic components, ensuring their proper operation within the system.
I generated code in ChatGPT to run tests, as the sound sensor is the one missing to complete the electronic part. For now, I am using the components I have: the XIAO ESP32-C3 board, an infrared sensor, a NeoPixel, and a servo motor.
Based on that information, I received functional code from ChatGPT, which I then adapted and uploaded to the board using the Arduino IDE. This allowed me to successfully control the electronic components of the project.
5. Results
I placed the components correctly, having previously planned the placement of each one. The PCB was positioned on the right side, while the servo motor was located on the left side.
I started running the programming tests. In the program, I used a provisional infrared sensor while I wait to get a sound sensor. However, I conducted the tests to ensure that the functionality was as I had envisioned.
It was indeed turning out exactly as I had imagined in my head.
Reflections
Initially, my intention was to use molding and casting for the whale's construction. However, when I attempted to use the 3D printer to make the molds, I realized the printing process would be too slow and would significantly delay the project. At that point, I decided to look for an external 3D printing service at another lab. This decision turned out to be the best one, as it saved me time and provided a finer finish. Printing the pieces in 3D became the most efficient and effective option.
Integrating the mechanical parts inside the whale was one of the biggest challenges of the project. I spent a lot of time figuring out how to fit each mechanical component inside the structure and how to arrange the electronic systems in a way that would keep them hidden from view. It was a process where, between dreams and the reality of design, I managed to find optimal solutions to the fitting and functionality problems.
Design is not just about the overall shape; it’s about the details that make the difference. In this case, the precise placement of the components, both mechanical and electronic, was essential for achieving a clean and functional integration. Every design decision, no matter how small, had a huge impact on the system's efficiency and the final result. The planning and attention to detail at each phase of design and integration were key to the project’s success.
This project taught me that system integration is not just about assembling parts, but understanding how they interact with each other within the context of a larger design. The choice of materials, the manufacturing process, programming, and component distribution were critical decisions that defined the success of the functional whale. Although there were moments of uncertainty, each challenge provided an opportunity to learn and improve my skills in design, integration, and problem-solving.
Access to files
NeoPixel-Servo.ino
whale.rar