Nov 22nd weekly update

This past week we focused on the manufacturing of three parts for our most
critical module for the Mile Stone 7 assignment that was due this past
Friday. The three parts that we manufactured were the pulleys for our
conveyor belt, the side bars/braces for the conveyor belt, and the axle for
the conveyor belt.

To manufacture the pulleys, multiple processes were used. Last week we
decided that we wanted to manufacture our own pulleys rather than spending
$60 on pulleys we had found on the McMaster-Carr website. To accomplish
this we used the water jet to cut two circles of 1/16" aluminum and then
used sand paper to sand down the sides of the polypropylene wheels that
were provided in the kit. Then using a drill, a center punch, a center
drill, a step drill and a size I drill bit, we were able to make the holes
for the axle in the 1/16" aluminum circles. These parts put together on the
axle make a pulley that can be used in our most critical module design.

To manufacture the side bars/braces, we used the 1/4" aluminum plate that
was provided in the kit. We used the ban saw to cut this plate into four
equal width braces. These will be welded together to make two 2ft long
braces to support the conveyor belt.

The last part to manufacture was the axle. For this part we used the 3/8"
aluminum rod that was provided in the kit. The aluminum rod was lathed down
to the appropriate diameter and length.

Another part that we made last week for our most critical module was the
scoops that will attach to the conveyor belt and pick up the ping pong
balls. To manufacture the scoops we cut on the water jet 6 strips of
aluminum (1/16" thick). These 6 strips were bent slowly, using the metal
bender in the machine shop, into a curved shape. Unfortunately, due to the
nature of the metal bender, each scoop could not be made into a perfectly
curved shape, nor could each scoop be made the same. This irregularity will
simply allow for some scoops to work better than others, and if we have
time during the testing period, if we find one particular scoop is working
much better than the others, we can alter them the best we can.

One of our other accomplishments this past week was ordering the belt for
the conveyor. We ordered 5 feet of belt, knowing that we will only need
about 4 feet, and we will have to cut the belt to size and then fasten the
ends together, most likely using the Kevlar string that is provided in the
kit.

Since we have to demonstrate our working most critical module this
Wednesday, there is much we still have to finish. We have to cut the holes
for the axles in the side braces of the conveyor belt, attach the motor
mount to the side of one of the support braces, connect the two ends of the
belt, put the belt on the pulleys, and then attach the scoops to the belt.

The last thing we should also begin working on this week is our 1 minute
film that has to be shown during the competition. We plan on bringing a
video camera to the shop so we can get some video of us working on
constructing the most critical module.