This is a GCSE DT Systems and Control practise project I have created. This is a task my teacher has set our whole class and in which we have freedom to create things to meet the requirements.

Sorry for the lack of uploads im afraid exams take priority.

I will try to post whenever I can.

Step 1: Contents

Mind map
Sensors
Output devices
Examples of automata
First Ideas
Circuit development
Examples of CAMS
Movements
Manufacturing plan guide
Circuit design
Diary slide
Method of Manufacture
Development of case
Manufacturing process
Manufacturing process (cont.)
Video
Testing
Evaluation
Specifications

Step 2: Mind Map

Here is a simple mind map I have made to explore target markets.

Step 3: Exploring Sensors

This is an exploration of common sensors that I could have chosen for my design.

Step 4: Output Devices

The picture shows exploration of suitable outputs that are readily available that I could have used for my project.

Step 5: Examples of Existing Automata

This is my research of existing automata and machines which I could possibly convert into automata.

Step 6: First Ideas

These are my initial drawings about possible design paths I could explore. (mind my awful drawing)

Step 7: Circuit Development

This is a development of my circuit which is based on a 555 timer monostable circuit.

My first circuit was a 555 timer monostable circuit and was vey messy and didn’t include
the correct output components. My improvement has the correct outputs and the
correct timing for my idea, it is also a lot tidier and easier to model around.
My new circuit also has added parts which are essential to the circuit.

Calculation of timings

T=1.1CR

02.60 = 1.1 x 100 μF
x ??

02.60 ⁄(1.1x100x10-6) =25k resistor

Step 8: Examples of CAMS

This was my research about different types of cams and how offsets can effect them.

I will use a snail shaped CAM because it will raise and
drop the finger plates once per cycle, this drop will also cause a tapping sound on what ever
surface the project is held on. This will make timing the fingers to get the
pattern required easier.

Step 9: Movements

This is a table of movements and different ways of converting between these types of motion.

Step 10: Manufacturing Plan Guide

This is a time estimate for each part of the project in a workshop. This also shows the equipment, quality control checks, material and risk assessment needed for every stage.

Step 11: Circuit Design

This shows the Mask, Real world view and parts list as well as the circuit diagram.

It also has a step by step guide of what to do after the board has been etched.

After your circuit has been developed drill all the
holes with a 1mm drill bit then using a 1.5mm drill bit drill out the
transistor, terminal block and strain holes. After drill out the 3 strain holes
with a 3.5 mm drill bit. Then scrub down with wet and dry paper

Step 12: Diary Slide

This shows documentation of me making the circuit.

Step 13: Method of Manufacture

This gives instructions on how to put each mechanical part together.

All parts are plastic.

The motor and battery box will be attached
with screws. The button will be attached with the provided nut. The led will be
attached with a holder and the pcb will
be held with pcb sticky pads.

I have also included the appropriate laser cutting files.

Step 14: Development of Case

This shows my initial prototyping ideas and what developed from that.

Step 15: Manufacturing Process

This shows me constructing the case.

Step 16: Manufacturing Process (cont.)

Continuation from last step.

Step 17: Testing

This shows my testing to see if the product actually does its job.

Step 18: Evaluation

Overall I came across some problems when making my final design. One of which was the
fact that when you use acrylic rod the thickness changes slightly therefore I
was forced to file my cams hole size a little bit bigger. Another was that the
cams kept moving out of place however this was fixed with some minor
adjustments of the positioning.

I believe there could be some improvements on my design such as using another
material to use for the fingers. E.g. A moulded clay finger I believe this
could have been achieved if I was given more time and had some previous
experience with moulding clay.

Another improvement could have been not to use clear acrylic due to the fact that when
solvent cement is applied it leaves a joint which you can see into.