Gasket Project
Goal: Develop foundational manufacturing skills by measuring mechanical components, creating dimensioned sketches for CAD modeling, and using GibbsCAM software to produce parts on a CNC mill.
1. Introduction
The Gasket Project introduced me to the fundamentals of precision manufacturing and dimensional measurement. My task was to create a 1/16-inch-thick PVC gasket that would precisely align with a custom aluminum block, meeting a tight tolerance of ±0.005 inches. This project emphasized the importance of accurate design, manufacturing, and fit in producing functional mechanical components. ​By combining CAD modeling in SolidWorks, CNC machining, and careful measurement techniques, I successfully designed and fabricated a gasket that fit perfectly on the first attempt. This project provided an invaluable introduction to the practical application of manufacturing tools and processes in engineering design.
4. Assembly
The assembly phase tested the accuracy of the gasket by aligning it with the aluminum block. Steps: Alignment Verification: I placed the gasket on the aluminum block and verified that the locating pins, pockets, and threaded holes aligned perfectly. Dimensional Fit: The gasket’s ability to fit snugly without any overhang or misalignment demonstrated the success of my design and manufacturing processes.
2. Design Process
The design phase involved translating the given dimensions of the aluminum block into a detailed gasket model. Steps: 1.Dimensional Measurement: I used calipers and micrometers to measure the critical features of the aluminum block, ensuring that the gasket’s pockets, threaded holes, and locating pin cutouts would align perfectly. 2.CAD Modeling: Using SolidWorks, I developed a fully dimensioned model of the gasket. This step was critical in visualizing how the gasket would interact with the aluminum block and ensuring that tight tolerances were met. 3.Error Prevention: I incorporated tight tolerances and accounted for potential sources of error, such as tool misalignment, during the modeling process.
5. Challenges & Iterations
Although my gasket fit perfectly on the first attempt, the process highlighted potential areas for refinement: Toolpath Optimization: While machining, I observed minor tool marks on the PVC material, which could be reduced in future iterations by fine-tuning the G-code or using different cutting speeds. Deburring Process: Ensuring clean edges required additional time during post-processing. Exploring ways to reduce burr formation during machining could streamline this step.
3. Manufacturing Process
After finalizing the SolidWorks model, I moved to the manufacturing phase, using a combination of CNC machining and manual techniques. Key Steps: CNC Machining: I machined the gasket from 1/16-inch PVC stock using a CNC milling machine. The G-code for the operation was generated using GibbsCAM. Precautions were taken to minimize tool deflection and ensure a consistent cut. Post-Processing: Minor adjustments, such as deburring and smoothing edges, were made to ensure a clean fit between the gasket and the block. Precision Check: After machining, I carefully measured the gasket and compared it against the aluminum block using the same tools employed in the design phase.
6. Performance
The gasket successfully met the tight tolerance requirements and aligned perfectly with the aluminum block. This outcome demonstrated the effectiveness of my design and manufacturing process and underscored the importance of precision in engineering.
7. Lessons & Skills Learned
8. Final Thoughts
9. Media & Supporting Materials
Importance of Planning: Careful planning during the design phase prevented errors and reduced the need for rework during manufacturing. Value of Precision: Achieving tight tolerances required a deliberate focus on every detail, from initial measurements to post-processing. Hands-On Manufacturing: Gaining experience with industrial tools like CNC mills provided insights into how theoretical knowledge translates into practical applications. Technical Skills: Dimensional Measurement: Mastered the use of calipers and micrometers to measure critical dimensions with high precision. CAD Modeling in SolidWorks: Improved proficiency in creating accurate and dimensioned technical models. CNC Machining: Gained hands-on experience with GibbsCAM and CNC milling workflows, including toolpath generation and G-code interpretation. Quality Control: Developed techniques for inspecting and verifying parts to meet tight tolerances. Soft Skills: Time Management: Effectively managed the limited project timeline by prioritizing tasks and ensuring seamless transitions between design, manufacturing, and assembly phases. Error Anticipation: Proactively accounted for potential manufacturing errors, reducing the risk of misalignment or incorrect fits. Attention to Detail: Cultivated a meticulous approach to measurement, modeling, and post-processing to achieve high precision.
The Gasket Project provided me with a foundational understanding of precision manufacturing and quality control. By successfully creating a functional gasket on the first attempt, I demonstrated the importance of careful planning, accurate design, and attention to detail. The skills I gained from this project, including SolidWorks modeling, CNC machining, and dimensional measurement, will be invaluable in future engineering challenges.
CAD Model: A downloadable SolidWorks file of the gasket design. Photos: A side-by-side comparison of the gasket and aluminum block. Close-up views of key features, such as locating pin cutouts and threaded holes. G-Code Documentation: The G-code used for CNC machining is available for review upon request.
Dimensional drawing using SolidWorks
Finished gasket placed on top of the provided custom aluminum block
Side-by-side comparison view
of the aluminum block (left) and fabricated gasket (right)
CNC mill machine used to fabricate the finished product
Degrees of Freedom:
Cartesian Motion System
Goal: Design and test a functional prototype by integrating mechanical and electrical components, while embodying ideal joint types and optimizing mechanical component shapes for functionality, accuracy, and manufacturability.
1. Introduction
Our team designed and built a succulent watering machine, an automated system capable of delivering precise amounts of water to succulents by moving along x and y coordinates. The project combined mechanical design, electrical integration, and software programming to achieve an efficient and functional system. The machine, powered by four motors, controls water injection at small intervals through a motor-driven effector that pushes the syringe. Utilizing 8020 aluminum extrusions, linear guides, pulleys, and custom 3D-printed and laser-cut components, we successfully created a modular and portable device. The motion system was powered by an Arduino, programmed to execute precise movements and coordinate water delivery.
4. Assembly
The assembly process was guided by our CAD model, ensuring the physical prototype closely matched the simulated design. Key steps included: •Linear Actuator Assembly: Aligning the belt sliders, pulleys, and guides to achieve smooth and precise motion. •Effector Integration: Securing the effector mechanism and connecting it to the syringe for precise water injection. •Cable Management: Organizing wires to prevent interference while maintaining flexibility for motion.
2. Design Process
The development of the succulent watering machine involved multiple iterative steps, from concept generation to final implementation. The process began with brainstorming and sketching potential solutions, focusing on modularity and manufacturability. Initial CAD Modeling & Motion Simulation: We used SolidWorks to model individual components and simulate the system’s motion. This step ensured the inter-compatibility of parts and highlighted any potential design challenges. We created modular linear actuators for motion along the x and y axes, while the effector mechanism added an extra degree of precision for water delivery. Iterative Development of the Belt Slider: One of the most critical components was the belt slider, which allowed the belts to maintain proper tension while enabling smooth motion. However, the initial tolerance values were too tight, which caused misalignment and disrupted functionality. We addressed this issue by iteratively sanding down the sliders and modifying their design in subsequent versions to ensure proper belt tension and fit.
5. Challenges & Iterations
The testing phase revealed areas for improvement and gave us opportunities to refine our design. Initial Challenges: •Belt Slider Tolerance Issues: The original design of the belt sliders was too tight, leading to improper fit and misaligned pulley belts. We sanded down the components and adjusted tolerances in subsequent designs, which resolved the issue. •Effector Calibration: The effector required recalibration to ensure consistent and accurate operation, particularly in controlling syringe movement. Final Iterations: These challenges were addressed through multiple refinements, allowing the system to achieve reliable and precise operation. Each iteration brought us closer to a functional and efficient prototype. Programming and Motion Control The control system for the succulent watering machine was powered by an Arduino, programmed using Repetier Host. The motion commands were written in G-code, allowing us to: •Define precise x-y coordinates for each watering position. •Control the duration and intervals of water injection through the effector mechanism. After the initial code was written, we refined it to improve accuracy, particularly for returning the effector to its starting position without disrupting the belt alignment.
3. Manufacturing Process
The manufacturing phase involved using a combination of 3D printing, laser cutting, and manual machining to fabricate custom parts. Key Components: •3D Printing: Lightweight parts such as motor mounts and effector components were printed for precise fit and flexibility. •Laser Cutting: The acrylic pieces, including supports for the effector mechanism, were laser-cut for durability and accuracy. •Manual Drilling and Tapping: The aluminum extrusions were drilled and tapped to provide mounting points for the linear actuators and support brackets. This combination of manufacturing techniques ensured the machine met our design and functional requirements while staying lightweight and portable.
6. Performance
The final performance of the Cartesian Motion System showcased its ability to execute precise 2.5-degree-of-freedom motion, smoothly navigating the workspace while maintaining accuracy and reliability. The system successfully completed its assigned task of moving along the x and y axes with controlled positioning, demonstrating the integration of mechanical design, motor control, and effective teamwork.
7. Lessons & Skills Learned
Skills Gained Technical Skills: •CAD Design and Iteration: Improved ability to model and refine components in SolidWorks for better inter-compatibility. •Arduino Programming: Enhanced understanding of motion control and integration with mechanical systems. •Prototyping Techniques: Gained hands-on experience with 3D printing, laser cutting, and manual machining. Soft Skills: •Collaboration: Coordinated with teammates to manage tasks, brainstorm solutions, and meet deadlines. •Iterative Problem Solving: Addressed challenges such as belt tension issues and effector calibration through testing and redesign. •Project Management: Learned to prioritize tasks effectively and allocate resources efficiently.
8. Final Thoughts
The succulent watering machine project exemplified the engineering design process, from conceptualization and prototyping to refinement and implementation. By integrating multiple disciplines—mechanical design, electronics, and programming—we created a system that not only met the project requirements but also demonstrated innovation and functionality. The lessons learned from this project, particularly in iterative design and troubleshooting, will be invaluable in future engineering endeavors.
9. Media & Supporting Materials
•Video Demonstration: Showcasing the system in action. •CAD Models and Photos: Detailed images of the modular actuators, belt slider, and effector mechanism. •G-code Documentation: Available for download upon request.
SolidWorks assembly file (minus the timing pulley belts)
Final product on the day of classroom presentations
Machine in motion
Video taken by Dr. Enrique S. Gutierrez Wing
MATLAB Code
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Motor Speed Control
Goal: Apply motor speed control concepts to simulate and design a platform capable of transporting a dynamically unstable load.
1. Introduction
The goal of the Motor Speed Control project was to design, simulate, and build a system capable of transporting a dynamically unstable load—a 1-foot-long vertical prismatic bar—across a variable distance of 5 to 10 feet and back, without toppling. The project required us to integrate mechanical, electrical, and programming skills to create a stable, efficient, and fast-moving system. The challenge of maintaining stability while optimizing speed underscored the importance of control systems in engineering design. Our team utilized SolidWorks Motion Simulation to design and test the dynamic behavior of the system before physical prototyping. The system was powered by a 12V gear motor, controlled via an Arduino UNO, with a PID control strategy implemented to regulate the motor speed dynamically.
2. Design Process
The project began with conceptualizing a platform capable of transporting the prismatic bar efficiently and safely. Using SolidWorks, we modeled multiple design iterations to test the system's stability under various loads and speeds. Key Features: 1.Dynamic Stability: The design focused on maintaining the prismatic bar's stability by ensuring smooth acceleration, deceleration, and consistent speed during motion. 2.Platform and Motor Integration: The platform was constructed using foam board and custom wheels, chosen for their lightweight and customizable properties. A 12V gear motor was selected for its balance of speed and torque, critical for handling the variable travel distance. 3.PID Control Implementation: The Arduino-controlled PID algorithm adjusted motor speed dynamically to maintain stability under varying conditions, such as load shifts and abrupt starts or stops.
3. Manufacturing Process
The system required a combination of precision and flexibility in its components, achieved through 3D printing, laser cutting, and manual assembly. Key Manufacturing Steps: •Platform Construction: The platform base was laser-cut from foam board to ensure consistent dimensions and lightweight construction. While we initially considered using O-rings to enhance wheel traction, we opted to 3D print rubber wheels for better performance and durability. The wheels were reprinted to a smaller size after initial tests revealed that smaller wheels would maximize performance, enabling us to approach the theoretical maximum velocity of 0.8175 m/s², determined through handwritten calculations involving a free-body diagram and motion analysis in SolidWorks. Unfortunately, delays caused by reprinting meant we could not obtain all four wheels in time, and we adapted by laser-cutting the wheels, ensuring we met project deadlines while maintaining functionality. •Motor and Electronics Integration: The motor housing and mounts were 3D-printed for precise alignment and secure attachment. Electronics, including the Arduino and power amplifier, were mounted to ensure proper heat dissipation and accessibility for adjustments.
4. Assembly
SolidWorks Motion Study: We began with a multibody simulation in SolidWorks to evaluate the system's dynamic behavior. The simulation allowed us to: •Test stability thresholds for different acceleration rates. •Optimize platform dimensions to reduce tipping moments. •Achieve an initial record time for transporting the bar over a 5-foot distance. Initial Prototype Testing: Once the prototype was assembled, we conducted physical tests to evaluate real-world performance. Key observations included: •The motor response time was slower than expected, causing jerky acceleration. •Oscillations in the bar's stability indicated the need for fine-tuning the PID control parameters.
7. Lessons & Skills Learned
The challenges with wheel reprinting, motor response, and platform stability highlighted the importance of careful planning and iterative refinement in achieving a high-performing system. The ability to adapt to real-world constraints ensured the project's success. Skills Gained: Technical Skills: •PID Control Implementation: Developed expertise in designing and tuning feedback loops for motor speed regulation. •Motion Simulation: Gained hands-on experience with SolidWorks Motion Study to analyze dynamic behavior. •Arduino Programming: Improved proficiency in coding control algorithms and integrating hardware components. Soft Skills: •Team Collaboration: Effectively coordinated with teammates to split tasks, test components, and troubleshoot issues. •Iterative Problem Solving: Adapted to challenges by iteratively refining designs and control parameters. •Time Management: Balanced simulation, manufacturing, and testing phases within strict deadlines.
5. Challenges & Iterations
PID Parameter Tuning: •We iteratively adjusted the proportional, integral, and derivative gains to improve system response and reduce oscillations. •The refined PID settings ensured smooth acceleration and deceleration, critical for maintaining bar stability. Motor and Platform Adjustments: •We identified inconsistencies in wheel alignment, leading to uneven motion. Re-aligning the wheels resolved the issue. •Additional weights were strategically added to the platform to lower its center of gravity, enhancing overall stability.
8. Final Thoughts
This project underscored the value of integrating mechanical, electrical, and programming skills to solve real-world engineering challenges. From motion simulation and calculations to physical prototyping and refinement, the Motor Speed Control project provided invaluable insights into dynamic system control and optimization. The lessons learned—particularly in iterative design, troubleshooting, and adapting to constraints—will serve as a strong foundation for tackling future engineering problems with confidence and precision.
6. Performance
After refining the design and controls, the system successfully transported the prismatic bar across the specified distance in record time without toppling. The final iteration demonstrated: •Smooth acceleration and deceleration with minimal oscillations. •Consistent performance across variable distances, meeting the project requirements.
9. Media & Supporting Materials
•Video Demonstration: Showcasing the final system in action. •SolidWorks Motion Study Analysis Video: A detailed visualization of the system's dynamic behavior; exported Excel data of acceleration at various time values can be provided upon request. •PID Control Code: The documented Arduino code for motor speed regulation can be provided upon request.
First prototype with the smaller, 3D-printed rubber wheels
After settling on the perfect wheel size, we landed on this final prototype
Motion Analysis results in SolidWorks confirmed that the maximum theoretical acceleration is 0.8175 m/s²
Successful test run traveling 5 feet