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MAE 151 Music Box Design Binder

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2. 4 Interlacing Multiple Music 5 LION KING Thank You Thank you for choosing The Rise of Simba Themed Music Box To get the most from this box please read all instructions thoroughly and keep them where they will be read by all that use the product Enjoy the product 127 LION KING Getting to Know the Music Box Take a few moments to familiarize yourself with the music box and its controls You may find it helpful to bookmark this section and refer to it as you read through the rest of this manual THE MUSIC BOX COMPONENTS VN 1 Speaker 9 Hlectronics container 2 Volume control knob 10 Powet switch 3 Guide tube 11 Mute switch 4 Activation hole 12 Powet connector 5 Alignment pin 13 USB connector 6 Alignment stud 14 Activation ball 7 Ballcatch mechanism 8 Ball sensing mechanism mu 128 Page LION KING FIRST STEPS INSTALLING THE BATTERY 1 Remove the electronics container is attached to the music box via Velcro 2 Remove the electronics container top cover It is attached to the electronics container via Velcro 2 Insert 2 9 volt batteries into each of the battery slots shown in the figure on the right Attach the electronic connectors to the battery and then reverse disassembly to install It at LION KING 129 Page TURNING ON THE MUSIC BOX
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6. OIN 49 278 104720 Jepios 007 007 L 9 429 729 160 160 Jeyijdurv S91U01 9919 S Jeyiduuv 00712 0012 v preoq lqileduuoO 0 A S6 0 S6 0 45 SNN 45 wyo 20151594 vv wyo 022 1016 15 8001 L wyo 20151594 8001 4 wyo 0 10131594 61 6 71 L wyo Jejeuionuelog ANOLY 6v 5 Anoze Joyoedeo ero 5 ANOOL Jowoedeo 4127 Ero L 3110 0 2 00 5 Jexyeeds souonosa 120 120 pnis 5 02 7 pnis 862 967 sduis Z L LYS ZO YZ pueJq 911901 xod3 168 269 72072 pueJq eop 0 0 400 r 86 7 001 poom peeu 2 9 82 0 700 01 28 2 001 poom peasy pad 2 2 1 9 i I I 7 0 700 68 ZZ v LOOPS I DOIN suid pein 4 1919 814 99 0 ut 0 0 02
7. 0 2 1 150 092 092 4 LL O LL O L 8 pooM 9L 0 910 L 48 21 2 002 001 8 2 1 2 L pooM Japulg ISNIN TST IYN xog ISnIN LGL 3VIN SONI 8 86 8 5 968 5 19 jured Ued 6 6690 L yas 9 seuunDy Bury 00 00 L sunoy p luud 00 2 002 5 L sunoy p luud qn 194 797 L 1095 2 86 9 969 xoed z YSO 720 WWE 0870 720 5 Japulg 81 ISNIN TST IYN MAE 151 Music Box Design Binder SECTION 5 MANUAL t utu 124 Page LION KING MAE 151 Music Box Design Binder Group MAE 151 MUSIC BOX The Rise of Simba gt 125 Page LION KING Table of Contents Thank YOU MERC Getting to Know the Music 2 Music BOX Components 2 3 3 Installing Battery 3 Turning on the Music 4 Using the Music Box 4 Adjusting the Volume
8. L1nv430 S3HONI NI SNOISN3MIO 031312395 SSMYSHLO SS31Nn T d vLISZ ZO salva A33 100 O3 L c NOILdl4OS3G Japulg ISNIN TST IYN E 3SV3 13M SNI333NISN3S bd ONIA 0 e L c v S 9 4 8 lo awos 2508 SAY UR EGER UM V ods Ius ON 325 gt 3105 SL ON VIG SN3ds3N G3N VLNOO NOLLVIWIOAN aivo Sr 10 S3903 dHVHSDVJHH AuvL3hidONd eisno ou3 ISNA Cw v 3VW TWNOILOWeS Uu S3ONvN3101 S3HONI NI SNOISN3WIQ 3WW 021312395 SSMYSHLO SSIINN 100 3SV313M SNIN33NION3 bd vAONddV L c 5 9 4 8 Japulg ISNIN TST IYN MAE 151 Music Box Design Binder SECTION 5 FINAL BOM tt 121 Page LION KING ey 08 0 720 5 0079 005 YOUMS 0071 001 Spo 1olsis 1o1oud 9 955
9. 65 SECTION 3 SPEAKER BOX ARDUINO BOX FABRICATION 68 SECTION 4 WIRINGIDIAGRANIE eae 72 SECTION 5 PROGRAMMING u u 77 7 j LION KING MAE 151 Music Box Design Binder Phase 3 Testing Redesign testing 22 100200 00 sa as esse asas 83 SECTION 1 PROTOTYPE 6 50 Eo eere Ecc e ERE Ee Er Er a E 84 2 2 256 sa 86 SECTION 3 FINAL PRODUCT PROTOTYPE u 91 SECTION A EINAEPROTOTYPE EIT 94 Final EE 96 SECTION 1 FINAL BIG STACK PICTURES SECTION 2 FINAL WIRING DIAGRAM SECTION 3 FINAL 5 52 SECTION S HR NE E EN 132 SECTION STATUS 55 Pate
10. Theoretical Mass 0 83 kg True Mass 0 80 kg of wooden post 6 Maximum Stress 5 61 MPa Total Cost 2 66 Numbers of Parts to be cut 8 sides 5 wooden posts Joint Method Wood Glue ur LION KING MAE 151 Music Box Design Binder Structure Mathematical Model e This mathematical model was developed to understand and quickly calculate numbers of posts or plates required for given load This was utilize to come up with viable solutions and design concepts for the music box o Calculation of the stress gt calculate the applied stress of one post the following equations were used Total Loading Fapplied Applied Applied of Posts or Plates Across Sectional o Calculation of the allowable and applied bucking force gt Tocalculate the buckling force of one post the following buckling equation was used E TEI _ Buckling buckling 2 buckling KL Across Sectional Where Force in E modulus of elasticity 9x109 Pa area moment of inertia L unsupported length of column 0 1 m K column effective length factor 1 for this application In order to find the moment of inertia of for the post we must use the equation Where r the radius of the post o Failure Criteria 1 Principle Stress and Yield Stress Comparison lt 2 Bucking Force and Applied Force Fapplied lt Fpuckling 3 Factor of
11. LION KING MAE 151 Music Box Design Binder SECTION 2 BALL RAMP DETECTION CATCH RELEASE FABRICATION Spas LION KING MAE 151 Music Box Design Binder Initial Fabrication of Prototype Ball Detection Catch and Release e Ball Path 1 Polycarbonate tube cut down to the needed length 8cm 2 Tube dimensioned and holes and slots dimensioned from the bottom edge 3 Holes and slots machined into the tube 4 Later testing revealed the servo occasionally did not catch the ball so a rod was added against which the ball would hit to slow it down EEG uL c A e Ball Detection 1 Photoresistor and LEDs purchased 2 Different LEDs tested for brightness red chosen as best detected 3 Leads soldered to both components 4 Wooden mounting structures for the LED and photoresistor manufactured and mounted on the Music Box structure 5 Created electronic circuit to utilize the LED and photoresistor and Arduino coded E _ LION KING MAE 151 Music Box Design Binder e Ball Catch and Release 1 Added an extension to the lever arm attached to servo 2 Wooden mounting structures for servo manufactured and mounted on Music Box structure 3 Servo connected with electronics to the Arduino and code developed for the servo to function 4 The LED mount servo mount and photo sensor mount are made into block shapes because we wanted to use simple but solid shapes to hold our internal p
12. 8 tt t 48 Page LION KING MAE 151 Music Box Design Binder SECTION 5 THEME SPEAKER ELECTRONIC ENCLOSURE SOUND PRODUCTION DESIGN CONCEPT WW LION KING MAE 151 Music Box Design Binder Theme Design Concept The theme was obtained from the survey This was done so we can sell out box to most of the customers The Theme was chosen to be Lion King We will have figurines and we will paint top blue and bottom green Speaker Design Concept The given speaker was used The design for the structure was as a rock to match our theme design The speaker mount was designed for the speaker to lie slanted in the music box We decided not to make the speaker mount horizontal because we wanted to give the speaker mount enough room to allow it to be removed easily from the music box if needed The speaker mount will be attached with Velcro so any internal malfunctions or issues can easily be solved by removing the speaker mount LION KING MAE 151 Music Box Design Binder Arduino Enclosure Design Concept The enclosure was design with the usability in mind The design allows to program the box easily with the port availability on its front end We decided to have the opening on the top so the battery can be replaced In addition this panel will have the battery holder and the switches so the energy can be saved when the box is not used We also decided to make th
13. 5 2 MAIN LOOP ee void 4 Read photoresistor value int resistorvalue analogRead photopin String lightsensor Light sensor serialPrint lightsensor resistorvalue Check if it is below threshold ball is passing if resistorvalue brightness String light Light String lessthanthreshold Threshold serialPrint light resistorvalue lessthanthreshold brightness executeSequence else Make sure the servo is not blocking the ball path myservo write releaseangle LION KING MAE 151 Music Box Design Binder serialPrint serialPrint This method is called when the ball is detected Any Rind of Light show should be added here but pay attention to the delays and make sure you re keeping the overall delay durations constant CurrentLy set up so green LEDs Light up as Long as ball is in box red LEDs are on as Long as servo arm is blocking path and yellow LEDs are on as Long as music is playing void executeSequence serialPrint Executing Main Sequence SR setLEDs HIGH LOW LOW LOW LOW LOW LOW Activate servo to block ball myservo write catchangle serialPrint Servo arm deployed delay musicstart sensetime compensates
14. 1 AT Crength Dryauel Radius r 2 V Dpistance travel Velocity Required Torque vs Servo Arm Length time 0 45 0 40 2 d MEM 0 35 acceleration t2 9 0 02 0 30 2 0 25 4 Frorce Mmass a i e 0 20 e 0 04 u 0 15 5 Trorque F 0 10 Available 0 05 6 Puehcanical Required Power 0 00 0 1 2 3 4 5 6 Servo Arm cm 7 lcurrent Vvoitage Pmechanical 8 E Vprovided To design different radius of the arm and the target time were varied and results were tabulated as shown below Radius of Degree Travel n Required Required Required 4 x Velocity Acceleration Torque Available the distance Distance Electrical Current Amps Current mA i Force N arm cm travel m m s m s 2 Power at5V at5V Required N m Torque N m 1973 92 7895 68 17765 29 31582 73 49348 02 246 74 986 96 2220 66 3947 84 6168 50 73 11 292 43 657 97 1169 73 1827 70 8 0 016 0 393 19 63 0 39 0 00 0 16 0 15 0 15 0 03 30 84 0 031 0 785 39 27 0 79 0 02 0 16 0 62 0 62 0 12 123 37 1 18 0 04 0 16 1 39 1 39 0 28 277 58 0 063 1 571 78 54 1 57 0 06 0 16 2 47 2 47 0 49 493 48 0 079 1 963 98 17 1 96 0 10 0 16 3 86 3 86 0 77 771 06 o o S 853883 o
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16. pi 2 EI L 2 A higher value of E Young s Modulus the higher the max load before buckling occurs is obtained Birch had the higher value of E than poplar the two commercial sold dowel pins that were wood based for low density BOM Item Description Size Oty Unit Price Total price Birch Wood Dowel Home Depot 0 5 in Diameter x 36 in 1 11 1 11 Plywood Plate 12x12x11 32 in 1 2 Dowel Pin 1 4 in 0 25 0 25 Total Cost 3 36 25 Page LION KING MAE 151 Music Box Design Binder Eric s Structure Design Detailed Structure Design 2 Images Stress Test Torque Test pipet S Ee Box Design Concept Box Design Concept Lot ES von Mises N mm 2 MPa Sue aio 15 Deformation scale 0 9064 wy LION KING 16 URES mm 3 059 001 2 8040 001 254904001 2 294e4001 2 039 4001 1 764e3001 1 52904001 127404001 1 020 001 7 647 000 5 090e4000 2 549e4000 U 000e 4000 Design 42 Specifications Details Weight 2 4 kg Strength MAE 151 Music Box Design Binder Maximum Stress MPa 1 6 Maximum Displacement mm 3 Maximum Displacement mm Due to Torque 2 5 gt Ease of Manufacturing Manufacturing the box would only require cutting out the two base plates and slots to insert the pillars to connect the two plates together Addition holes need to be cut for
17. e Notes Assigned to Group Lion King is Ds Gs Es 3 Determining the MIDI Notes Numbers 59 B3 em 7 60 C4 261 63 3 822 62 61 293 67 277 18 3405 3 608 64 63 F4 32963 311 13 3034 3 214 55 4 349 23 2 863 67 66 G4 39200 369 99 2551 2 703 69 58 A4 440 00 415 30 2 273 2 408 71 70 B4 49388 466 16 2025 2 145 72 C5 523 25 1910 74 73 D5 58733 554 37 1703 1804 76 75 5 65926 622 25 1517 1 607 77 F5 698 46 1 432 79 78 G5 78399 73999 1276 1351 81 80 5 88000 830 61 1136 1204 83 82 B5 98777 932 33 1012 1073 5 n 955 MIDI Note Numbers Assigned to Group Lion King is 74 0 5 sec 79 0 5 sec 76 1 sec ur LION KING MAE 151 Music Box Design Binder SECTION 7 TIMING CONCEPT FUNT LION KING MAE 151 Music Box Design Binder Analytical Model for Timing The timing is represented by two 2 second windows staggered by 0 5 seconds o One window is from the time when the ball enters the box and leaves the box 2 second o Second Window is from the time music begins and stops 2 Second Assuming u 0 Basic Kinematic Equation u ut 1 Using 1 time it takes from to Box 2 Ahy_ MEET i 2 n i t4 5553 Should be minimal t4 04 lt 0 5 6 _1 t3 U2 The time to start playing the music t Time of Delay in Programming U3 t
18. the ball slot and the alignment holes Visual Criteria Simplistic box that allows decorations on the outside of the box and figurine placement outside the box Not very clustered and each teammate can decorate a side of the box with their chosen design gt Interior Space Other than the three pillars around the center there is plenty of space to wire the speakers and electronics inside the box Reliability If we can measure correctly the points to spread the three pillars evenly there will be a good distribution of stress and force Key factor would be the placement of the pillars other things will be more or less trivial Cost Total cost of music box structure 5 35 Material Properties Top Bottom Plywood Plate Poplar Wood Pillars Elastic Module Elastic Module 2000000000 2000000000 N m N m Poisons ratio Poisons ratio N A 0 394 0 394 N A Density Density 5 690 5 400 kg kg m BOM Item Description Size Oty Unit Price Total price Poplar Pillar 2 Diameter 1 4 74 Foot 4 74 Plywood Plates 30 cm 2 0 0 Flathead Nails 2 6 3 07 30 nails 0 61 27 Page LION KING MAE 151 Music Box Design Binder Thomas Van s Structure Design Detailed Structure Design 3 Model Vertical Load 800 N Test EE Torque Load 15 N m Test von Mises Mmm 2 1345 1233 1121 10
19. 0 5 n 1 0 s g tL ur LION KING MAE 151 Music Box Design Binder SECTION 8 COMPLETE CONCEPT DESIGN BOM INS E LION KING YNIA 09 e t Pra n guesyiexoedg 6 1 2 1 5 1 5 S Z Lese JO 295 991 ui p lu s id sSurweJp euu 99 p lu s id si u8is p 1 2 JO USno4 5191 e 815 1492005 Jo WO9 8 Japulg 3ISnIN TST AV MAE 151 Music Box Design Binder PHASE 2 PROTOTYPE DEVELOPMENT 61 LION KING MAE 151 Music Box Design Binder SECTION 1 STRUCTURE FABRICATION LION KING MAE 151 Music Box Design Binder Fabrication of Prototype Structure e Following steps were taken to fabricate the structure prototype 1 Dimensioned the two top and bottom plywood plates from the center alignment hole a In addition dimensioning from the center point also allows the structure to be more reliable since the outer dimensions are less important and are trivial compared to the two alignment pins and pipe hole 2 Clamp and drill both plywood plates together to ensure they match together 3 Cutthe sides of square plate to obtain the o
20. 3 being sometime it may fail early or late o Power Consumption if possible 3 3 V and 0 2 amps for the hall effect sensor BOM Item Descripion Size Qty Unit Price Total price Two Acrylic Plate 1 515 515 Link 1 59 Glue 1 S2 52 Pin 1 6 50 6 50 Spring 1 5 25 5 25 Total Cost 520 Total Cost 20 40 Page tmu LION KING MAE 151 Music Box Design Binder Thomas Van s Ball Sense Design Design 2 Specifications Details o Detection Method Install Hall Effect sensor at the entrance o Catch Method Lever and spring o Release Method Lever and spring o Ease of Manufacturing Basic drilling o Visual Criteria Ease Access Simple and works well o Reliability Accuracy No power consumed when off and acts as electronic fail safe Easily adjustable for optimized and reliable stoppage o Power Consumption if possible 0 75A 0 6V No power consumed when off and acts as electronic fail safe This is 4 5W If 15 operated for 2 seconds for every cycle it would use 9 W s per cyclle which is equal to 0 002500002 W h 3 3 V and 0 2 amps for the Hall Effect sensor Roughly speaking a 9V battery is a 500 mA hour battery ad can put out 500 mA for 1 hour so 9 volts x 5 amps 4 5 watts for 1 hour Probably less in real life That s 4 5 watts for 3600 seconds We use in 2 second intervals That s 1800 cycles According to this website a 9 volt battery will stor
21. 43 G2 97999 92 499 1020 1081 s 2 11000 10383 9091 9631 47 49 B2 12347 116 54 8099 8 581 48 C3 130 81 7 645 50 49 D3 14683 13859 681 7216 52 31 16481 15556 5068 6428 53 F3 174 61 5727 55 1 G3 19600 18500 5102 5405 57 26 A3 22000 207 65 4545 4816 59 28 B3 24594 233 08 4050 4290 60 C4 261 63 3 822 62 51 D4 29367 277 18 3405 3 608 63 E4 32963 311 13 3034 3214 65 F4 349 23 2 863 65 G4 39200 369 99 2551 2 703 gs 50 A4 440 00 41530 2273 2408 B4 49388 466 16 2025 2 145 72 C45 523 25 1910 74 1 D5 58733 55437 1703 1804 5 5 55926 62225 1517 1607 77 5 698 46 1432 79 78 G5 78399 73999 1276 1351 81 80 5 88000 830 61 1146 1204 83 82 B5 98777 932 33 102 1073 84 C6 1045 5 0 9556 86 52 D6 11747 11087 08513 0 9020 97 13185 1244 5 07584 0 8034 89 F6 1396 9 0 7159 91 20 G6 15680 1480 0 06378 0 6757 93 22 17600 16612 05682 0 6020 95 24 BE 19755 18647 05052 0 5363 96 2093 0 0 4778 21 D 23493 22175 04257 0 4510 100 29 26370 24890 03792 0 4018 101 F7 2793 0 0 3580 103 12 c 31350 29600 03189 0 3378 105 104 7 35200 33224 02841 0 3010 107 106 B7 39511 37293 02531 02681 108 4186 0 0 2389 tuu LION KING MAE 151 Music Box Design Binder Development of Notes Assigned to Group 1 Obtained Assigned notes for grand piano 19 31 2 Related these notes and obtained its letter names
22. Bursa 2414 4012145407 ysiuly stu uoduuo2 pajre4 jo uoneJ8aju 4131545 51494094109 JO Suse 8 Suusauigu3 ugisag 29140 uonenjeng usiseq 1 u is q YT ST T pam 39890 uBisag jenu 0 PT ST T jeoneweujew 1 suonnjos 31915509 jo Bulwoysulesg PI OT T 71 9 1 uoN SpaaN paloig v1 9 T gz 458 9102 105 ptoz TV6VE PIM uo pes tT EZ qad pueg palosg Japulg 2ISnIW TST IYN NID ab i d 4319M X X X X jo 5101 pue1sudM X X X X X X X 3293 1487 saxog SNN X X 1 U1O 5 X punos 4545 pue JO X X X Sury spe no 8 598 ISPS 40 Va usis
23. Projected Action item Completed Status Assigned Person Date Review Midterm 2 19 2014 Complete Team Determine Improve ments 2 19 2014 Complete Team Begin Redesign 2 19 2014 Complete Team Next Week 2 21 2 28 Action item Due date Status Assigned Person Finish Music Box Structure 2 24 2014 N C Eric Finish Speaker Structure 2 25 2014 N C Eric amp Henry amp Fady Improve Sound 2 26 2014 N C Fady amp Kushal Paint Box 2 27 2014 N C Thomas Assemble Music Box 2 28 2014 N C Team Note None at this moment Concerns None at this moment 139 Page LION KING Status Report Week 8 2 21 2 28 tiu LION KING Group Information Kushal Shah Thomas Van Henry Diep Fady Barsoum Eric Kuo This Week 2 21 2 28 Projected Action item Completed Status Assigned Person Date Finish Box Structure 2 24 2014 Complete Eric Finish Speaker Structure 2 25 2014 Complete Eric amp Henry amp Fady Improve Electronics Sound 2 26 2014 Complete Fady amp Kushal Paint Box 2 27 2014 Complete Thomas Put Everything Together 2 28 2014 P Team Next Week 2 28 3 7 Action item Due date Status Assigned Person Assembly Together Full Structure 3 2 2014 Eric amp Kushal Test Electronics 3 7 2014 N C Team Fix Any 5 during Testing 3 7 2014 N C Team Note None atthis moment Concerns None atthis momen
24. 1 Press the bottom switch to power the speaker system Turning the switch on will make it sit lower than if it was in the off position The switch will not illuminate 2 Press the top switch to power the rest of the electronics When the switch is pressed and turned on the top switch will illuminate If both switches are depressed with the top switch being illuminated the entire box is on and ready to be used USING THE MUSIC BOX 1 Place activation ball in the activation hole To play music from the music box place the ball in the hole as depicted in the drawing Music should begin playing and LEDs will flash 2 The ball will fall out of the bottom of the music box AL The ball that was inserted in the step above will be released from the hole shown in the drawing ADJUSTING THE VOLUME 1 Locate the volume control knob on the side of the speaker box Turn it to adjust the volume Turning the volume control knob counterclockwise will increase the volume Turning the knob clockwise will decrease the volume Turn off the bottom switch on the electronics box to mute sound completely INTERLACING MULTIPLE MUSIC BOXES By having multiple music boxes it is possible to mate them all together in order to play an symphony of music The activation ball tur LION KING will fall through multiple boxes which will play multiple segments of a song Follow the instructions below for more details 1 Line up the align
25. 133 SECTION2 TEAMMEMBER CONTRIBUTIONS nea eode ineo oct eed se Ec de E vee sage Dre ER vba wed 143 tru LION KING MAE 151 Music Box Design Binder PHASE 1 CONCEPT DEVELOPMENT 3 Page ur LION KING MAE 151 Music Box Design Binder SECTION 1 PROBLEM FORMULATION tetur THEE LION KING MAE 151 Music Box Design Binder Process of Problem Formulation In order to define the project definition first the problem was formulated The primary problem that was formulated for the project was to design a music box that incorporated ball drop according to customer needs As a result the customer need survey was developed and shared throughout the social media to obtain variety of samples of the market Then this survey was analyzed and project goal statement and objectives were developed around customer needs Customer Need Survey This survey was published on the social media websites as twitter and Facebook Music Box Customer Survey Required How far should the sound of the music box be able to travel 10 feet 5 feet 20 feet 1 feet Out of these themes which should the music box be Adventure Time Pokemon Lion King Avatar The Last Airbender How much would you pay for this music box 10 20 20 50 30 40 Over 40 What type of material would you like the box to be Wood Steel Aluminum What is your top priority you would want to se
26. 3 3101 S3HONI SNOISN3MWIG 021312395 SS31Nn AIO 83gANfnN Ia Vd ON Wall 9 a bd NID 1 L v S 9 4 8 1 ROOM rm ESI XX 3 Sv Lua NI NOLO DOO Nd PIST 00C dS8IN rizzo scd 963 45 VIVOJN o FN 5 XLO S3903 dMVHSDV3H8 Joxeads oisn 207 to wedsxouos JASNY T so v S Oluo uO 5 S39NvM3101 wal 021312395 SS31Nn 100 3sSv313 bd WAOYddY NOILdl4OS3 L c r S 9 4 8 Japulg 3ISnIN TST IYN 711 CONDI awos vara 9 15 00048 1 vi sz zo uous Ene Sr X10 53903 div HS Jayeads JSN XXX S 9 4 8 SI lt 40 NOISSIINH 3d LNOHLIN S Li Vd NI suu Kuedupooy 3O ALu3dONd 3105 SI ONMAYYQ
27. 9poJA Ye YNIA NOT T 7 ss 10 arva os Noudmossc 5 8 lt T 4 81 aun3onaas 92712145 s daiq AuusH Ady pue Wea ay q s1doouoo 8 5 e 530 2 09 8 5 Japulg ISNIN TST AV Design 41 Specifications Details Mass The box contains 0 7902 kg Strength MAE 151 Music Box Design Binder Maximum Stress MPa 2 372 Maximum Displacement mm 0 152 Maximum Displacement mm Due to Buckling Study 10 5 gt Ease of Manufacturing Very easy to manufacture Cut respective lengths from stock dowel purchased from Home Depot Lowes Ace or from woodshop Visual Criteria Clean spacious Reliability The factor of safety under tensile loading of top plate is 5 8 13 8 is UTS amp 2 372 is max tensile stress Material Properties Top Bottom Plate Wooden Dowel Birch 1st choice d ii ket 63222 02 ym iir 168253 Poisons ratio N A 0 22 ic 0 3 Density kg cm 3 0 000544 Density kg cm 3 0 00061 dr d 10 to 24 Compression Strength Mpa 100 Why chosen material for posts BIGGER YOUNG S Modulus allows a higher tolerable critical load for buckling The buckling equation
28. Kushal Need Matrix 3 days Wed 1 8 14 Fri 1 10 14 Eric Kushal Structure Design 9 13 days Fri 1 10 14 Mon 1 20 14 Team Team Brainstorming of the Solutions 3 days Fri 1 10 14 Mon 1 13 14 Team Team Brainstorm Summary 1 day Mon 1 13 14 Mon 1 13 14 Fady Kushal Rough Sketch of the Concepts 3 days Mon 1 13 14 Wed 1 15 14 Team Team Structure Math Model 3 days Mon 1 13 14 Wed 1 15 14 Kushal Kushal Viable Concept Selection 1 day Wed 1 15 14 Wed 1 15 14 Team Team Analysis of Viable Concepts 3 days Wed 1 15 14 Fri 1 17 14 Team Team Downselction 1 day Fri 1 17 14 Fri 1 17 14 Team Team Cad Design 3 days Fri 1 17 14 Mon 1 20 14 Henry Kushal Engineering Drawings 3 days Fri 1 17 14 Mon 1 20 14 Henry Kushal Detect Catch Release Design 9 days Mon 1 20 14 Thu 1 30 14 Rough Sketch of the Concepts 3 days Mon 1 20 14 Wed 1 22 14 Team Team Ball Kinematics Math Model 1 day Wed 1 22 14 Wed 1 22 14 Kushal Kushal Viable Concept Selection 1 day Wed 1 22 14 Wed 1 22 14 Team Team Analysis of Viable Concepts 3 days Wed 1 22 14 Fri 1 24 14 Team Team Downselction 1 day Fri 1 24 14 Fri 1 24 14 Team Team Cad Design 2 days Fri 1 24 14 Mon 1 27 14 Henry Kushal Engineering Drawings 3 days Mon 1 27 14 Wed 1 29 14 Henry Kushal 16 Page MAE 151 Music Box Design Binder Internal Theme Speaker Design 7 days Fri 1 31 14 Mon 2 10 14 Rough Sketch of the Concepts 3 days Fri 1 31 14 Tue 2 4 14 Team Team Power Math Model 2 days Fri 1 31 14
29. Kushal Shah Thomas Van Outline Idea Gathering 1 17 2014 75 96 Team Gantt Chart 1 17 2014 Complete Henry Diep Next Week 1 18 1 24 Action item Due date Status Assigned Person Finish the Outline 1 20 2014 N C Team Virtual Work Two Sketch Designs 1 22 2014 N C Each Member Selecting 5 Designs 1 22 2014 N C Team Meeting Giving Criteria to Designs and Down selecting Matrix 1 24 2014 N C Team Meeting Note None this moment Concerns None at this moment teur LION KING 134 Page Status Report Week 3 1 18 1 24 gt LION KING Group Information Kushal Shah Thomas Van Henry Diep Fady Barsoum Eric Kuo First Two Weeks 1 18 1 24 Projected Action item Completed Status Assigned Person Date Finish the Outline 1 17 2014 Complete Team Two Sketch Designs 1 20 2014 Complete Team Selecting 5 Designs 1 22 2014 Complete Team Giving Criteria to Designs and Down Selecting Matrix 1 22 2014 Complete Team CAD Design of 5 Selected Designs 1 24 2014 IP Each Member Next Week 1 24 1 31 Action item Due date Status Assigned Person Select 1 Design to Fabricate 1 29 2014 N C Team Meeting Begin Looking for Stores Vendorsfor Fabrication 1 29 2014 N C Each Member Order Addition Parts Supplies 1 31 2014 N C Team Meeting Assign Tasks for Fabric ation Electronics 1 31 2014 N C Team Meeting Note None at this moment Concerns None a
30. for ball in box lost time Some MIDI setup stuff talkMIDI xB 0 0x79 Default bank GM1 talkMIDI 0xCO instrument 0 Set instrument number is 1 data byte command Music should start now Play first note lasts 5 seconds noteOn 0 note 0 127 velocity 127 high setLEDs HIGH HIGH LOW LOW LOW HIGH HIGH serialPrint Note 1 delay noteidelay 5 noteOff 0 note 127 delay 5 Play second note lasts 5 seconds noteOn 0 note 1 127 velocity 127 fairly high setLEDs HIGH LOW HIGH LOW HIGH LOW HIGH serialPrint Note 2 delay note2delay 5 noteOff 0 note 1 127 delay 5 Play third note lasts 1 second noteOn 0 note 2 127 velocity 110 fairly high 80 Page tur LION KING MAE 151 Music Box Design Binder SetAllLEDs HIGH serialPrint Note 3 delay releasetime balldroptime Activate servo to release ball myservo write releaseangle serialPrint Servo arm retracted delay balldroptime serialPrint Ball out of box setLEDs LOW HIGH HIGH HIGH HIGH HIGH HIGH turns off green LEDs delay note3delay hold note for the rest of the time noteOff 0 note 2 127 serialPrint Music stopped playing SetAllLEDs LOW A convenient method to bulk change LED values HIGHs LOWs Order of parameters are greens yellows reds void setLEDs boolean 201 boolean 202 boolean 203 boole
31. length 0 5 in Diameter 1 0 66 0 66 Ply wood Plates 12 in 12in 11 32 2 1 00 2 00 Total Cost 2 66 33 Page tur LION KING MAE 151 Music Box Design Binder Downselction In order to justify why we chose a certain structure over the other four we created a comparison chart and Pugh chart listing the structure strength weight manufacturing efficiency space cost amplifying advantage shown below Comparison Chart For Down selection of the Structure Improtance 1 e 2 3 2 p Henry Kushal Thomas Eric Fady 1 SIEHE Maximum 2 372 2 25 1 345 1 6 2 46 Stess 2 Weight 0 79 0 82 1 04 2 4 0 81 3 Cost 2 70 2 66 3 5 35 3 33 4 Space 1 5 5 is the 5 4 3 2 3 best Manufacturing Wood Wood Wood Glues Nails Nails 5 Wood Wood Attachements Glue Glue Screws Glue Glue 3 Manufacturing Cutting 3 Big dowels 5 Parts 4 dowels 5 dowels 4 Squares Posts 5 5 6 Amplifying Advantage 1 1 2 4 3 1 5 Importance SSS _ Strength Maximum stess 1 1 1 1 E Manufacturing 34 teur LION KING MAE 151 Music Box Design Binder Structure Design Justification Through this Pugh chart we decided to go with Design 5 because his structure had a well distributed stress buckling and displacement loading results from FEA studies In addition there was minimal torque for each of the dowel pins Kushal s structure had a
32. 09 0896 0784 0672 0560 0448 0336 0224 0112 0000 Yield strength 6200 00 von Mises N mm 2 0879 0806 0732 0659 0586 0513 0439 0366 0293 0220 0146 0073 0000 Yield strength 6 200 000 mtr LION KING MAE 151 Music Box Design Binder Design 43 Specifications Details Weight 1 04 kg Strength Maximum Stress MPa 1 345 Maximum Displacement mm 0 1273 Maximum Displacement mm Due to Torque 0 05154 gt Ease of Manufacturing 4 rectangular wooden posts secured via wood screws Visual Criteria Symmetric and Clean gt Interior Space A lot of space Can be varied by reducing post size Reliability Sturdy 5 on 1 5 scale Material Properties Top Bottom Plywood Plate Poplar Wood Pillars i Elastic Module BASG MOUNE 2000000000 2000000000 Wm N m Poisons ratio Poisons ratio N A 0 394 0 394 N A Density Density 690 400 kg kg m BOM Plywood 0 5 in thickness cut to size 1 00 1 00 Plywood Plates 12 in 12in 11 32 1 00 2 00 Total Cost 3 00 Cost Total cost of music box structure 3 00 Mate LION KING MAE 151 Music Box Design Binder Fady Barsoum s Structure Design Detailed Structure Design 4 Images Model structure Shady DestiNeight Static URES mm Plot type Static stress Streest M
33. 9 e Compressive Strength 15 MPa e Factor of Safety 2 67 e Buckling Load Factor 10 Structure Design BOM Item Description Size Oty Unit Price Total price Wood Posts 50cm or 20 in length 0 5 in Diameter 1 0 66 0 66 Ply wood Plates 12 in 12in 11 32 2 1 00 2 00 Total Cost 2 66 36 Page mtu rw LION KING MAE 151 Music Box Design Binder SECTION 4 BALL RAMP DETECTION CATCH RELEASE DESIGN CONCEPT LION KING MAE 151 Music Box Design Binder Music Box Detection Catch and Release Concept Development Summary Goal to develop the concept design for components needed to detect catch and release the ball o Detection Catch and Release Design Concept Process Necessary specifications determined and discussed Solutions brainstormed by group Complete solution proposals sketches developed by each group member Separate components of each complete solution analyzed and compared Performed down selection for each component and design was finalized o Primary Components that were obtained for the final Design are o Ball Ramp Straight Down Polycarbonate Tube o Detection Method Photoresist or and LED light o Catch Release Method Servo o Joint Method Wood Glue Screws LION KING MAE 151 Music Box Design Binder Ball Drop Kinematics Mathematical Model e In order to come up with logical design concepts mathematical mo
34. A S SSTINN 3WW 100 3SV3 13M SNIN33NION3 bd WAOYddY NOILdl42S3G L c r S 9 4 8 Japulg ISNIN TST IYN DNI eit 801 L S 9 4 8 lal JOOMAM Leu MM SOEN 037 _ MOM TVUN3QI4NOO Au v13nidONd 00 2 eg Holvoxosoisnw 2 5 Er S9 OIUOJ _ S n y Pl S3HONI NI 34 Y SNOISN3WIQ Wal 021312395 3SMM3HLO SS31Nn GCE 1 052 00 00071 005 2 2 em RON 005 q 100 Id NOlLdl2S3G OCNMM L z 5 9 4 8 Japulg ISNIN TST IYN DNIA NOI ina 3ed 60T L v 5 9 2 8 1 GOOM c junoWjosues 09 200 o 9 ISAN d ene 500 XXXX O10 XXX v s OluOJUO AVIV PUE I S309NV33101 11nv33g
35. Components 6 25 days 2 14 14 2 21 14 Team Team Reconstruction Finish Construction 5 days Mon 2 24 14 Fri 2 28 14 Team Team Final Testing 6 days Fri 2 28 14 Fri 3 7 14 Team Team for Final Report Binder Fri3 7 14 Fri3 14 14 Team Team Final Presentation Project End 0 days Wed 3 19 14 Wed 3 19 14 Team Team 17 Page LION KING MAE 151 Music Box Design Binder Brainstorming Concepts Generation e Before moving to design concept development brainstorming session was performed and following notes were taken Themes e Lion King Henry Toy figurines of characters Servo to move figurines recreating first scene O Pride Rock Yellow LEDs to simulate sunset e Avatar the Last Air bender Eric O LEDs of 4 different elemental symbols O Lights fade in and out e Pok mon Kushal Poke balls Theme LED strips shooting out from sides to simulate Poke balls opening e Adventure Time Thomas Drawing painting with LEDs O ATLogo lit up with LEDs e Doctor Who Blue police call box TARDIS with blue LED on top Motor that spins the blue box O Outer space background Structure e Top and bottom plates dimensions given e Wooden dowels around the sides See SolidWorks models for different structural layouts Ball Detection Methods Actuated switch Henry e Magnetometer Eric Kushal e Push Switch Kushal e LED and Photo resistor Thomas Fady 7
36. G3NVINOO NOUL VINOJN TIVILN3OIJNOO Al Y L3RIdOMHd v gt 5 S3ONYN3101 NEUE 1 tt gt 9 C q vLISTIZO 31va A33 100 3SV313M SNIN33NION3 bd O3 NOILdl4OS3 L c r Japulg 3ISnIN TST IYN L c v S SI 10 NOISSINB 3d d 01 00c dS8lN V 176720 Iousny SV uo Lu 325 2105 3HLSI ONM MG SHL N G3NVINOO do EY SP XLO 529003 dHVHSDIV3N8 Jexeads oisn 200 te xogos 2 l 500 XXXX v So DiuoJu 16 3VW FU 3WWN Wal 021312395 SS31Nn J 100 3SV3 13M SNIN33NION3 bd WAOYddY NOILdl4OS3 L c r S Japulg ISNIN TST AV 9 v S 9 awos uim Mani cou hatin stu XX 3 Sv Lua NI NOLO DOO Nd Id 9eH 007dSHIN 12 20 uous ios piii oo d 453 SIHL Q3N VLNOO
37. INGS tL 103 Page LION KING DNIA NOI L r S 9 4 8 Lo 5 SV NI NOLO OON 001 8 1 Y Dus IOUS ds acs oun avo St XLO S3903 dYVHSYVIY9 ANV13midONd K quiessy eunjonags oisn 00 t9 Iquessy einjonas xog ONIN 2 5 RS so V paes XXX s OIUO1I LGL IYW B vona anw 02140395 SS31Nn 19 gt S einso ou3 5140455213 JepjoH 1 5 o g g Ie vd ON Wall 9 a 100 3sSv313 SNISH33NION3 bd WAOYddY L c r S 9 4 8 Japulg ISNIN TST AV SOT L 5 lad OMS Id 00 8 X sind dol yc Tl v13d RODA AYNLONYLSENS 2 0 Ww JISNIY v LGL IVW JO esty 3WW u6noiJu 8 1 eq 210 u 6u Ionb pup 9JD JO 8 si pub D Onulsuo2o 1
38. LION KING MAE 151 Music Box Design Binder Ball Catch Release Methods e plate rotated into place by servo to partly block path Henry e Plate opens or closes by servo to completely block path Eric Electromagnet to keep the ball from moving Eric Servo arm to block path Kushal e Spring and solenoid Kushal Thomas e Plate opens or closes by solenoid to completely block path Ball Movement e Straight pipe down Henry Eric Thomas e Angled pipe down Eric e Vertical pipes at entrance and exit with angled pipes in between Kushal e Metal track along which ball rolls Fady LION KING MAE 151 Music Box Design Binder SECTION 3 STRUCTURE DESIGN CONCEPT INS LION KING MAE 151 Music Box Design Binder Music Box Structure Design Process Summary e Goal To create concept design of the structure part of the music box e In order to achieve this goal following procedure was followed o Structure Design Concept Process Structure Customer Needs and Specification discussed and analyzed Brainstormed few possible solutions Mathematical model developed Sketches of possible solutions generated and selected five design concepts 5design concepts analyzed for their performance and the cost Performed down selection and finalized the design Engineering drawings produced e Primary Design Parameters that were obtained for the final Design are
39. MAE 151 MUSIC BOX DESIGN BINDER LION KING CHRONICLES Group 31 Henry Thomas Kushal Eric Fady Presented by Lion King Group Group 31 COMPANY DESIGN WORKS 5200 ENGINEERING HALL IRVINE CA 92697 2700 MAE 151 Music Box Design Binder TABLE OF CONTENT 1 Concept Development cede dete 3 SECTION 4 PROBLEM FORMULATION 4 Process of Problem Form l ER AK EXER YEAR RARE CER IA TRA KEY VERUS VEA ER TEN VR EX ERA 5 Customer Need SUFVeyV Fea ra tuos Erie ga 5 Customer Need Survey Results Customer Need SUMMON ves 098896088666 gx RR ARRA SNR 7 SECTION 2 PROJECT DEFINATION Goal Statement Code of Ethics Preliminary Project Gantt Chart Music Box Needs Metrics Matrix Specification Sleet certe et tar ta dye eden ape rede Projected Timeline and Task Assignments for the Project Brainstorming Concepts Generation nasse enses SECTION STRUCTOREDESIGNICONCEPT Music Box Detection Catch and Release Concept Development Summary Ball Drop Kinematics Mathe
40. Mon 2 3 14 Kushal Kushal Viable Concept Selection 3 days Mon 2 3 14 Wed 2 5 14 Team Team Analysis of Viable Concepts 3 days Tue 2 4 14 Thu 2 6 14 Team Team Downselction 1 day Thu 2 6 14 Thu 2 6 14 Team Team Cad Design 2 days Fri 1 31 14 Mon 2 3 14 Henry Kushal Engineering Drawings 2 days Fri 2 7 14 Mon 2 10 14 Henry Kushal Full Integration of the Design 5 days Mon 2 3 14 Fri 2 7 14 Henry Kushal Cad Design 5 days Mon 2 3 14 Fri 2 7 14 Henry Kushal Engineering Drawings 5 days Mon 2 3 14 Fri 2 7 14 Henry Kushal Main Structure Fabrication 1 day Fri 1 31 14 Fri 1 31 14 Eric Henry Music Electronic Fabrication 5 days Mon 2 3 14 Fri 2 7 14 Fady Kushal Thomas Music Programming 1 day Fri 1 31 14 Fri 1 31 14 Kushal Thomas Fady Detect Catch Release Electronics 1 day Wed 2 5 14 Wed 2 5 14 Thomas Kushal Fady Detect Catch Release Programming 1 day Wed 2 5 14 Wed 2 5 14 Thomas Kushal Fady Internal Theme Electronics 3 days Fri 2 7 14 Tue 2 11 14 Fady Kushal Thomas Internal Theme Programming 2 days Fri 2 7 14 Mon 2 10 14 Fady Kushal Thomas Internal Theme Fabrication 1 day Tue 2 11 14 Tue 2 11 14 Henry Eric Internal Theme Painting 1 day Wed 2 12 14 Wed 2 12 14 Henry Eric System Integration 4 days Mon 2 10 14 Thu 2 13 14 Henry Eric Midterm Review 0 days Thu 2 13 14 Thu 2 13 14 Team Team Phase 3 Steps toward final Design 26 days Thu 2 13 14 Wed 3 19 14 Team Team paled
41. Mute Cuica EXCA 3IS ks 47 Low Mid Tom 63 Open Hi Conga 79 Open Cuica EXC 4 32 Square Click 48 High Mid Tom 64 Low Conga 80 Mute Triangle EXC S Metronome Click 49 Crash Cymbal 1 65 High Timbale _____ 81 Open Triangle EXCI 34 Metronome Bell S HighTom 66 Low Timbale shake 35 Acoustic Bass Drum 51 Ride Cymbal 67 High Agogo SJinglebel 36 Bass 52 Chinese Cymbal 68 Low Agogo 37SideS ck 55 Ride Bel 69Cabaa S Castanes 38 Acoustic Snare 54 Tambourine 70 Maracas 86 Mute Surdo EXC6 _ 39 Hand Clap 55 Splash Cymbal 71 Short Whistle EXC 2 87 Open Surdo EXC 40 Electric Snare 56 Cowbell 72 Long Whistle Exca _ Low Floor Tom 57 Crash Cymbal 3 73 Short Guiro 42 Closed Hi hat EXC T S amp Vibrasiap 74 Long J AM PORE LION KING MAE 151 Music Box Design Binder 2 Note Chart for MIDI Obtained from Google MIDI Note Fr number name ms 21 AD 27 500 36 36 23 22 BO 30868 29 135 3240 3432 24 Cl 32 703 30 58 26 23 Dl 36708 34 648 2724 2886 28 27 El 41203 38 891 2427 2571 29 Fl 43 654 2291 31 30 Gl 48999 46249 2041 2162 33 32 Al 55000 51913 1818 1926 35 34 Bl 61735 58 270 1620 17 16 36 C2 65 406 15 29 38 2 D2 73416 69296 1562 1429 40 gt E2 82407 77382 1213 1286 41 F2 87 307 1145
42. Safety Material Strength oy Factor of Safety FS ae 1 e Using this equations diameter of the posts and the number of the posts were varied and the results were obtained and were tabulated as shown below LION KING u uA pulu day ue ay os SIU 5592049 8 5 1da2uoo ay pie p31e 12 sem ajqe 941 sw ne edi 55946 2104 ed ss ns xm ed 1504 Bulpong Buyong ______ 3 uluoss ns 3ND3 3 Japulg ISNIN TST AV 1504 au 0 504 1504 Jad 94 91141510 60 355 c 01 3091 07 3097 101 erau 1504 1504 241 JO Jo uisus 010798 DNIA en32nJ1s y JO 10 8 e SuneaJ5 MIN MIN MIN 150d ay JO Jayaweig ane ors xw o 60 3008 92 so t 08 6043008 8106 wo 0 m 6093008 6915 or 0 6043008 08 6043008 6006 zo 08 u ul u 504 jo 150 150924 onsej3 JequnN 801 JO ygua 1 0 5 pue 5
43. a music box through the use of an online survey Throughout the course of a few weeks approximately 50 people took the survey From the survey it was concluded that 4496 of the people would like the speaker to be able to be heard 10 feet away 49 would like the music box to have a Lion King theme 4196 would buy the completed box for 30 40 dollars 5996 of the people would like the music box to be made of wood and 6496 would choose reliability as the number one priority of the music box After analyzing and tabulating data it was concluded that the following will be customer needs for our music box Lion King Theme Wood Material Sound loud enough to be heard 10 feet away Crisp and clear sound Cater to Teens and Preteens Lovers of The Lion King movie Ages 8 21 Majority Survey Takers were in this age range Sturdy Able to handle large loading Multiple music box compatibility tru LION KING MAE 151 Music Box Design Binder SECTION 2 PROJECT DEFINATION Du LION KING MAE 151 Music Box Design Binder Goal Statement The goal of this project is to create design and fabricate a music box that incorporates the theme of customer s choice with the wondrous music created by Composer Dunn Rankin The music box will be designed and constructed from scratch and will be tested for performance before its final design and then final product will be fabricated and presented In addition the musi
44. achment of the pipe onto the box It also helps with the leveling of the pipe to make sure it sits upright between the top and bottom plates of the music box We also raised the position of the slot making it higher so that the height thickness between the slot and the bottom of the tube wasn t too small As seen in Pipe Prototype 2 a low height thickness resulted in fracture This final rendition of the pipe proved successful as the pipe is upright in the box In addition we tested the slowing down mechanisms and the orifices do make sure the ball slows down near the sensors for detection as well as slowing down the ball before it hits the servo arm wy LION KING MAE 151 Music Box Design Binder Speaker Iteration 41 Speaker iteration 1 was very barebones in the aspect that its main purpose was to angle the speaker for acoustics Features e Two plywood side pieces e One piece of fiberboard to mount the speaker onto the side pieces e Pieces were attached via wood screws Speaker Iteration 2 Speaker iteration 2 was the final version of this part Our main intention for this version was to compact the amplifier circuit into the box for simplicity looks This made us have to make our speaker box assembly wider to incorporate the circuit We made it wider by making a top piece and cleaner by creating a back piece with two output holes for wires Features e Extruded cut on one of the speaker side pieces for mountin
45. an y 1 boolean 02 boolean r01 boolean r02 digitalWrite g1 201 digitalWrite g2 202 digitalWrite g3 203 digitalWrite y1 y01 digitalWrite y2 digitalWrite r1 r01 digitalWrite r2 A convenient method to change ALL LED values to either HIGH or LOW void setAllLEDs boolean setLEDs a a a a a a a Prints to serial monitor onLy if debug is true CURRENTLY NOT FUNCTIONING void serialPrint String message if debug Serial println message void initializeLEDoutputs pinMode led OUTPUT pinMode g1 OUTPUT pinMode g2 OUTPUT pinMode g3 OUTPUT pinMode r1 OUTPUT pinMode r2 OUTPUT ur BI Page LION KING MAE 151 Music Box Design Binder pinMode y1 OUTPUT pinMode y2 OUTPUT void setupMIDI Setup soft serial for MIDI control mySerial begin 31250 Reset the VS1053 pinMode resetMIDI OUTPUT digitalWrite resetMIDI LOW delay 100 digitalWrite resetMIDI HIGH delay 100 talkMIDI xB 0x07 120 xB is channel message set channel volume to near max 127 These Likely will not or SHOULD NOT be changed Send MIDI note on message Like pressing a piano key channel ranges from 0 15 void noteOn byte channel byte i byte attack velocity talkMIDI 0x90 channel i attack velocity Send a MIDI note off message Like releasing a piano key void noteOff byte channel byte i byte release vel
46. ape Hollow Cylindrical Dowel Pin Holes x5 Pin Material Hardwood Dowel Dowel Pin Shape Round Alignment Pin Holes x2 Overall Weight 0 8kg Steel Ball Low Carbon Steel Ball Diameter 0 75 Speaker Brand Workman Model SA400 Dimensions 4 x4 Impedance 80 Power 0 5 Watt Max Frequency 250 5000 Hz Weight 5oz Servo Overall Height Width Length 23mm x 11mm x 29mm Voltage 3V to 6V DC Weight 0 005kg Weight with Arm 0 015kg Speed 0 12sec 60 at 4 8V Torque 1 6 kg cm 0 157 N m Working Temp 30C to 60C Photoresistor Sensor Length 4 46mm 0 18in Width 5mm 0 20in Height 2 09mm 0 08in Weight 0 25g 0 010z Resistance Light 5 10 ur LION KING 14 MAE 151 Music Box Design Binder Resistance Dark Up to 200kQ Voltage 2 5V or higher Arduino Operating Voltage 5V or 3 3V choice by slide switch Clock Speed 16MHz SRAM 2KB Flash Memory 32KB Analog Input Pins 8 Digital I O Pins 14 DC Jack Input Voltage 7V to 12V 20V miniUSB Input Voltage 5V 5 5V Maximum Attiny 2313 20 PU 8bit Operating Voltages 2 7V to 5 5V Power Consumption 32kHz 1 8V SRAM 128B PWN Channels 4 Programmable 1 0 Lines 18 Fully Static Operation Yes Endurance 1000 Write Erase Cy
47. aq 19207 5 Jo eg 9525 pog Suipeo1 ay 3 edid UISIUeu29 A Apuns Md 5 ASNN usisaq ugnoJu 295 p do A p sem 52 8 speau 015 2 eui BulzAjeue ayy SIIB Sp N 215 Japulg 8 5 ISNIN TST AV Specification Sheet MAE 151 Music Box Design Binder MARGINAL IDEAL NEED METRIC UNITS VALUE VALUE Loudness soupa od Ft 10 25 large distance Loud Clear Sound MAUNG Ig d ae Loudness Loud Pitch and no static noise Loading Able to withstand Durability addition boxes 5 D 30 Cost 40 50 30 40 manufacture Weight How heavy box is kg 2 Less than 2 LED Photo Light up when ball of Run 50 60 60 80 Sensor in box Able to withstand 50 continuous ball Reliable drops of Run 50 60 60 80 And hold the load Catch amp Time between ball 15 15 Release drops How it looks Subjective Clean ang Appeal Appealing 13 Page 4 1 LION KING MAE 151 Music Box Design Binder Technical Specification Sheet Music Box Body Overall Height Width Length 3 94 x 11 81 x 11 81 Body Material Plywood Body Shape Octagon Pipe Hole Diameter Inner and Outer 1 11 8 Pipe Material Impact Resistant Polycarbonate Pipe Sh
48. c box will be designed and programmed in such way that this music box can be integrated into the music box to play a full song with other boxes In conclusion this box will satisfy two major requirements reliability and needs of the customer Target audience for this music box are young children in their teens and preteens The needs of these customers will be determined from method of online survey Using this survey results customer needs and specifications will be developed Our team thinks that a loud and crisp sound produced and lights lit from the music box will entertain children and teens ages 8 to 21 years In addition the background of the music box adds a nice theme to any location the customer decides to put the music box The team also understands that teens and preteens can have reckless tendencies and therefore has also designed the music box to be durable and not collapse or distort under various loadings Objectives 1 Produce design concepts and solutions with the specifications and customer needs Down select the design solutions Fabricate a prototype of the selected design Produce electronics and program the controls of the box Test and Redesign ww B mw m Final Test and Final Presentation LION KING MAE 151 Music Box Design Binder Code of Ethics e After developing goal statement code of ethics presented below was developed 1 Professional Obligations Group Lion King shall comply w
49. cles Low Power Idle Standby Mode Power Down Yes Internal Calibrated Oscillator Yes Speed Grades 0 10MHz 2 7 5 5V 0 20MHz 4 5 5 5V Music Instrument Shield Codec VS1053 MP3 and MIDI Wiring MIDI Mode Analog Positive Supply 0 3V to 3 6V Digital Positive Supply 0 3V to 1 85V Positive Supply 0 3V to 3 6V Current at Any Non Power Pin 50 Operating Temperature to 85C Storage Temperature 65C to 150C Microphone Input Impedance 45 Microphone Input Amplifier Gain 26dB Line Input Impedance 80kQ Frequency Response 0 1dB 0 1dB ttl ur LION KING 15 Page MAE 151 Music Box Design Binder Projected Timeline and Task Assignments for the Project LION KING Task Name Duration Start Finish Primary Lead Secondary Lead toes l eese Team Organization 1 day Mon 1 6 14 Mon 1 6 14 Kushal Kushal Project Shared Document Drive 1 day Mon 1 6 14 Mon 1 6 14 Kushal Kushal Gantt Chart 1 day Mon 1 6 14 Mon 1 6 14 Kushal Henry Project Website 1 day Mon 1 6 14 Mon 1 6 14 Kushal Kushal Project Definition 14 days Mon 1 6 14 Sat 1 11 14 Customer Needs 3 days Mon 1 6 14 Wed 1 8 14 Thomas Kushal Project Goal Statement 3 days Mon 1 6 14 Wed 1 8 14 Thomas Kushal Product Specifications 3 days Wed 1 8 14 Fri 1 10 14 Eric
50. criteria is the straight down polycarbonate tube with dowel pins as it is the most reliable one of the easiest to manufacture and costs the least while providing easy access to and view of the ball 45 Page 7 LION KING MAE 151 Music Box Design Binder Detection Method Selection 1 3 10K Importance Concept Hall Effect Sensor Snap Switch Optical Fair chance of 1 Reliability Good ball getting Good stuck 2 Ease of One component One component Two components 4 Manufacturing 3 wires two wires wires 3 Cost 0 95 4 42 1 40 DATUM 1 2 Importance 5 Optical Snap Switch Hall Effect 1 Reliability 0 1 0 2 Ease of Manufacturing 0 1 1 3 Cost 0 1 1 gt 0 1 2 Therefore for the detection method we determined the solution that best fits our criteria is the Hall Effect sensor as it is the simplest to incorporate into our designs and we believe works as reliably as the Optical sensor at a lower cost However if we encounter any difficulties with it as none of our group members have any prior experience working with a Hall Effect sensor our next best option is the Optical sensor photoresistor which has more components and costs more but is more reliable than the Snap Switch We later determined through research that the Hall Effect sensor is not as reliable at detecting a metal ball as we had initially thought it would be This n
51. ctagon shape 4 Cut down dowel pins to correct lengths and chamfer both sides for easy fitting into top and bottom plywood plates 5 Glue and assemble plates as one whole piece to ensure proper connections between top and bottom plywood plates aa LION KING MAE 151 Music Box Design Binder Finished Structure Design Isometric View 6 The top plate of the box is painted like the sky to fit our theme of the Lion King while the bottom plate is painted like the grass and the dowels represent the trees Colored Structure Post Structure Analysis The top and bottom structure is octagon shaped and is composed of plywood The 5 hardwood dowel pins are glued onto the base only so that the top can be removed to allow accessibility of the inside area where the electronics are to be placed The overall dimensions of the music box structure are 10cm tall 30cm long and 30cm wide The pipe whole diameter is 1inch and the alignment pins are both 0 25inches in diameter The weight of the box is 0 85kg and should be able to hold a maximum stress load of 2 25MPa with a 0 079mm displacement The amount of torsion stress load it can have is 5 61MPa with a 0 260mm displacement The music box has been tested to be able to align properly with other music boxes properly without issues There weren t any complications with the manufacturing of the music box structure as the music box is designed to be simplistic but reliable and efficient
52. del of ball kinematics was devolved and it is presented below y To find the velocity of the ball at given height 02 v2 2a hy ho a To find the time that ball takes to achieve its instantaneous velocity Vf Vo t at Height Velocity Time at Height Velocity Time at Delta at the at the the at the at the the trigger trigger Trigger shutter Shutter Shutter h cm m s t s h cm V m s t s Ah No Box Failure 3 0 77 0 0782 7 1 17 0 1195 4 0000 1 box above failure 13 1 60 0 1629 17 1 83 0 1863 4 0000 2 box above failure 23 2 12 0 2167 27 2 30 0 2347 4 0000 e It can be seen from the table above that the ball travels with high velocity and the time period for catching the ball is very short This short catching time should be considered in designing the ball drop mu au 39 Page LION KING MAE 151 Music Box Design Binder Detailed Design Concepts e Few design concepts were generated by the team and they are presented below Kushal Shah s Ball Sense Design Detailed Ball Sense Catch Design 1 Images Design 41 Specifications Details o Detection Method Install Hall Effect sensor at the entrance o Catch Method Lever and spring o Release Method Lever and spring o Ease of Manufacturing Difficult but 3D printing may be easier o Visual Criteria Ease Access Clean and adventurous but hard to get inside if it failed o Reliability Accuracy
53. e 580 mA hours This means 58 amps at 9 volts for 1 hour which is 5 22 watt hours or 18 8 KJ BOM Item Descripion Medium Solenoid 14 95 14 95 15 95 Total Cost 15 95 Mate LION KING Fady Barsoum s Ball Sense Design Detailed Ball Sense Catch Design 3 Images Attachment points of the photoresistor and LED Removable Access Door attach with velcro MAE 151 Music Box Design Binder Viewports Slot for servo plate that blocks ball s path Design 43 Specifications Details o Detection Method Photo resistor and LED o Catch Method Servo moves a plate into a slot in the pipe blocking the path of the ball o Release Method Servo removes plate from underneath the ball o Ease of Manufacturing A bit of machining on a PVC pipe is all needed o Visual Criteria Ease Access Removable half of pipe to allow for access o Reliability Accuracy 4 being sometime it may fail early or late o Power Consumption if possible 3 3 V and 0 2 amps for the Hall Effect sensor servo activated twice BOM nee Q Unit Total D tem Descripion Size Bree Brice PVC Pipe ID 1 OD 1 3 8 1 51 67 51 67 Sensor Optical Detector Phototransistor s1 43 LED 1 0 27 0 27 Micro Servo 1 5 36 5 36 Velcro 1 0 62 0 62 Total Cost 9 05 Total Cost 9 05 42 Page tur LION KING Henry Diep s Ball Sense Design Detailed Ball Sense Ca
54. e Arduino and the shield Holder The holes will drilled to run the wires around in the box gt 51 Page LION KING MAE 151 Music Box Design Binder Sound Production Design Concept Concept 1 From Arduino e Not actual instrument sound Concept 2 From Arduino MIDI Shield e Allows to play many different music Concept 3 Arduino play a prerecorded sound file stored on an MP3 type player e Takes up lot of memory Down Selection 1 2 3 Importance Concept Arduino Wave M Arduino 1 Sound Quality 1 5 3 5 4 2 Cost 20 540 625 3 Ease of Programming Memory Usage and 3 5 4 Debugging 1 5 4 Power Consumption 1 5 4 3 4 2 7 DATUM 1 2 Importance Prerecorded Sound Arduino MIDI Via Arduino Shield 1 Sound Quality 1 5 1 1 2 Cost 0 1 3 Ease of Programming Memory Usage and Debugging 1 5 4 Power Consumption 1 5 0 1 gt 0 0 e From this chart we decided to produce the sound from the MIDI shield because it will produce clear sound and it will allow the user to construct desired music for later time Py ILS LION KING MAE 151 Music Box Design Binder SECTION 6 MUSIC ASSIGNMENT DESIGN FOR PROGRAMMING IE LION KING MAE 151 Music Box Design Binder Developing Music Notes The Music Instrument Shield was used in the music b
55. e for the music box Reliability Looks Lightweight Durability Submit Never submit passwords through Google Forms Powered by This content is neither created nor endorsed by Google Google Drive Report Abuse Terms of Service Additional Terms aa iu LION KING MAE 151 Music Box Design Binder Customer Need Survey Results How far should the sound of the music box be able to travel 10 26 44 20 feet 18 5 feet 5 896 4 1 feet 10 20feet 18 31 5 feet 1ifeet 10 17 10 feet 26 Out of these themes which should the music box be Adventure Time 12 16 27 Avatar The L 7 Lion King 29 49 Avatar The Last Airbender 7 1296 Adventure Tim 7 How much would you pay for this music box 40 50 13 10 20 7 12 20 30 11 19 30 40 24 41 40 50 13 22 10 20 7 SOver 50 4 7 Lion King 29 Pokemon 16 Over 50 4 30 40 24 20 30 11 What type of material would you like the box to be Wood 35 59 7 Aluminum 12 Steel 12 20 Aluminum 12 20 Steel 12 Wood 35 What is your top priority you would want to see for the music box Reliability 38 6496 Looks 10 17 Durability 5 Lightweight 6 10 Durability 5 8 Looks 10 Reliability 38 tetur E LION KING MAE 151 Music Box Design Binder Customer Need Summary Team was able to narrow down what customers wanted in
56. ecessitated we switch to the Optical Sensor instead as it was the next best option for our criteria LION KING MAE 151 Music Box Design Binder Catch and Release Mechanism Selection 1 2 3 Importance Concept Solenoid Spring and Lever Servo and Plank 1 Reliability Good Inaccurate timing Good Ease of 2 Easy Difficult Easy S Cost 15 27 5 5 36 4 Power Usage Bad None Ok 2 Importance 3 Solenoid 1 Reliability 0 2 Ease of Manufacturing 0 3 Cost 1 4 Power Consumption 1 x 2 Both the Servo and Plank mechanism and the spring and Lever mechanism scored the highest on our chart However the Servo and Plank scored higher than the spring and Lever in the two most important criteria Reliability and Ease of Manufacturing Therefore the Servo and Plank was chosen as the solution that best fits our criteria With the concepts decided on we next designed the electronics that will make each of the needed electronic components function properly Servo Speed Mathematical Model tout 47 Page LION KING MAE 151 Music Box Design Binder To calculate required speed and the required electrical power and current were calculated using the equations below and values of time period to catch the ball from previous section The graph shows the torque required for different target times and different servo arm lengths
57. ed and welcome Listen to what other group members have to say to ensure best results for music box d Addition meetings may be schedule if necessary to promote project Try and find suitable times for all group members if all need to attend IV Time Management a Group Lion King shall assign tasks equally to each of the group members Group Lion King shall complete assigned tasks by the due date If they are unable to complete the assigned task by the due date they shall state when they may complete the assigned task Group members will help each other complete assignments to meet deadlines and move the project ahead Don t take on the responsibility of too many tasks if one is unable to complete all of them by the due date ate LION KING YT 61 pow YT LT E UOW ant ud 1 01 2 vr Te T vt og nut 1 61 uow UOW vi sc c vI OT c tt e c vi t c ves u3 5 5 9 5 9 5 sep c shepz 5 shepz shepZ 5 9 s ep c YNIA 291014 eut sapuig 10
58. g the potentiometer for volume control e Expanded area to include amplifier circuit e Top and back panels to cover internals WINS LION KING MAE 151 Music Box Design Binder SECTION 3 FINAL PRODUCT FABRICATION MAE 151 Music Box Design Binder For our final iteration of the prototype we wanted the whole music box to look like a finished product that we could sell in a department store We painted the box in its entirety and added props such as Lion King themed toys and shrubbery In addition we wanted to pack all our internals as clean as possible For this reason we created a 3 D electronics box that houses the batteries Arduino MIDI shield as well as our main circuit board Features of the 3 D printed electronics box e Two cages for the two batteries e Output hole for Arduino cable e Output hole for headphone jack e Holders for the Arduino board e Two holes for the LED switches Our main goal was to package everything without any exposure to our internals As you can see from the pictures all our parts are closed Main features of the final iteration e Foam plate with Lion King background photo e Added 7 LED s for display o two red the foam background photo o two yellow on the foam background photo o 3 green on the bottom plate that is covered by shrubbery e Painted the entire box according to theme e Included the lion king figurines amp shrubbery props e Used
59. h holes 5 Paint the speaker box when finished Arduino box 1 The main portion of the Arduino box is plastic After being drawn on SolidWorks it is sent to the 3D printer for rapid manufacturing dn LION KING MAE 151 Music Box Design Binder 2 After verifying that the box is to spec we install the Arduino and two 9V batteries 3 The top cover of the music box is made out of wood We draw the dimensions on the wood and cut it Top cover is then painted and attached to the Arduino via Velco strips ur a LION KING MAE 151 Music Box Design Binder SECTION 4 WIRING DIAGRAM PUN MAE 151 Music Box Design Binder The following are the electronic schematics and diagrams developed to make the electronic components in the Detection Catch and Release aspect of the Music Box function properly Arduino shown but actual connection is done through a solder or bread board Detection LED 5V Red 635nm Photoresistor aa LION KING MAE 151 Music Box Design Binder 5V 1 2 1 cam e ume gt gt gt gt gt o gt 2 2 gt UJ e eL 2 m m rm un NI 20 IVNV Ball Catch and Release w LION KING MAE 151 Music Box Design Binder Servo Arduino Uno D7 Rev3 D8 D9 PWM D10 PWM SS D11 PWM MOSI D12 MISO D13 SCK c e lt _ TX RX The fo
60. ieces together Both of the blocks for each of the mounts are the same size to give a uniform symmetrical look to our music box In addition the blocks are large enough that they won t crack or break from screwing but small enough to not clutter up the internal music box space e Electronics 1 Following the schematics in the design section we wired the components and tested them 2 Adjusted resistor values based on sensitivity requirements through trial and error NL 67 LION KING MAE 151 Music Box Design Binder SECTION 3 SPEAKER BOX ARDUINO BOX FABRICATION INS LION KING MAE 151 Music Box Design Binder Initial Fabrication and Prototype of Speaker Box and Arduino Box e Speaker Box 1 Speaker box end plates are to be created from 3 8 wood Speaker holder and box cover is to be constructed from 1 8 fiberboard Everything will be assembled with screws 2 First we draw appropriate cut marks and drill marks on the material as noted on the engineering drawings Side pieces are taped together and cut at the same time to ensure symmetry Holes to line up with top were sketched with both plates still together to ensure they were drilled at the same area 3 Cut wood and fiberboard on band saw and drill marked holes LE LION KING MAE 151 Music Box Design Binder 4 Assemble with screws and mount electronic components such as speaker and potentiometer Guide wires throug
61. ision Polycarbonate being a sensitive plastic had to be treated with caution A 1 8 mill bit was used to avoid fractures or melting of the polycarbonate The RPM used ranged around 1600 a moderate rate to be using the mill at The slot was made by taking 0 025 cuts The holes were drilled with very cautious and very slow feed rates The reason this pipe did not make it to our final prototype is that we found it to be too obtrusive and hard to manufacture the stopping mechanisms for this case To create the blocker we had to carefully drill a hole and find a pin with the right size Even still the whole design looked bare We also found that the holes for the LED s and photoresistor did not work well The holes were too small for reliable interactions P tn LION KING MAE 151 Music Box Design Binder Pipe Prototype 42 3 D printed pipe This pipe was our second iteration of the catch and release pipe This time we went with a 3 D printed pipe made from ABS plastic We went with 3 D printing because of its ease of manufacturing This way we could create any shape or layout we wanted without having to spend hours on the mill This pipe features two side slots for the passage of light between the LED s and the photoresistor With the magic of 3 D printing we did not have to create holes and insert right fitting pins in them to create our blockers anymore Instead we 3 D printed slot extrusions inside the tube This gave an overal
62. ith the customer needs with the highest standards of honor and integrity a Customer needs shall not be altered or distorted if data results are unfavorable All actions of the Group Lion King shall be recorded and documented weekly in the form of status reports c Group Lion King shall use equipment best fit for the music box as long as it does not conflict with the customer needs or interests Safety Group Lion King shall hold paramount the safety health and welfare of those involved in the project a Group Lion King shall abide by lab rules of the room when working in the lab failure to do so will result in leave of lab station b Safety goggles and closed toe shoes shall always be worn as well as sleeves rolled up Failure to comply will result in leave of lab member s action s is overruled under circumstances that endanger life or project different method shall be used to complete the action d Group Lion King shall always use the safest method to manufacture and build the music box Etiquette Group Lion King shall treat each other with mutual respect and work together to complete the music box a Ifan issue arises the matter will be dispute an orderly fashion amongst group members Attend weekly meetings with group and the teaching assistant If a group member cannot make it it is their job to be up to date with project information c Constructive criticism and honest feedback is recommend
63. l cleaner look to the pipe The main downside to 3 D printing is the weakness of the ABS material As seen in the photo on the side the main slot we created for the servo arm made the material from the bottom of the slot to the bottom of the tube very slim This slim material made the strength at that location very low This led to the shearing of that portion of the tube as seen from the picture above Also the pipe had no mechanism to slow down the ball near the sensors this led to unreliable sensor readings Lessons we learned e The height thickness of 3 D printed parts needed to be increased o This version s thickness was too small leading to the fracture e Stopping mechanisms near the LED photoresistor need to be added mu au 88 Page LION KING MAE 151 Music Box Design Binder Pipe Prototype 3 3 D printed with orifices The third and last iteration of the design was a 3 D printed one as well This time around we created orifices near the sensors for reliable readings and at the middle of the tube for slowing down purposes Like the 3 D pipe before it we went to Rapidtech to print the tube In addition to the new orifices other new features were a lip that protruded into the bottom hole of the bottom plate and a foot that revolved 180 degrees around the bottom of the pipe The protruding bottom lip of the tube allows the pipe to make sure it is indeed straight and leveled The foot allows for more surface area for the att
64. llowing electronic diagrams and schematics are for all of the preceding components and how they might be connected using a breadboard INS Spas LION KING MAE 151 Music Box Design Binder All Electronics 3300 D3 PWM 04 05 PWM Arduino Red 635nm Vy ao D9 PWM D10 PWM SS D11 PWM MOSI D12 MISO D13 SCK 76 tmu LION KING MAE 151 Music Box Design Binder SECTION 5 PROGRAMMING PUN LION KING MAE 151 Music Box Design Binder TODO Adjust deLays ZZ Fix serial output include lt SoftwareSerial h gt include lt Servo h gt Serial int baudrate 57600 Servo Servo myservo byte servopin 12 int catchangle 90 Servo catch angle blocking ball int releaseangle 130 Servo release angle allowing ball Debug flag SERIAL OUTPUT CURRENTLY NOT FUNCTIONING boolean debug false true output messages to serial monitor MIDI Shield Variables SoftwareSerial mySerial 2 3 RX TX byte 0 The MIDI note value to be played byte resetMIDI 4 Tied to VS1053 Reset Line pin byte ledPin 11 MIDI traffic inidicator pin int instrument 1 1 Piano Music Notes to be played int note 74 79 76 Group 31 key numbers Sensing int photopin A0 Photoresistor pin int brightness 840 LED Trigger Brightness a higher number is more sensitive but p
65. lywood Plate Poplar Wood Pillars i Elastic Module BARNE MOAS 2000000000 2000000000 Wm N m Poisons ratio Poisons ratio N A 0 394 0 394 N A Density Density 690 400 kg kg m BOM 5033 Plywood Plates 12 in 12in 11 32 1 00 3 00 Total Cost 3 33 Cost Total cost of music box structure 3 33 Mate LION KING MAE 151 Music Box Design Binder Kushal Shah s Structure Design Detailed Structure Design 5 Images Model Vertical Load 800 N Test Torsional Load 800 N Test von Mises Nimm 2 MPa LION KING Design 5 Specifications Details gt Mass The box contains 0 83 kg MAE 151 Music Box Design Binder Strength Maximum Stress MPa 5 61 Maximum Displacement mm 0 079 Maximum Displacement mm Due to Torsional Study 260 gt Ease of Manufacturing Five Posts cuts and Wood Glue Simple Visual Criteria Clean spacious Reliability Very Reliable Minimal Stresses Material Properties Top Bottom Plate Wooden Post Elastic Module MPa 6200 Elastic Module MPa 8000 Compressive Strength MPa 10 24 Compressive Strength MPa 24 Poisons ratio N A 0 22 Poisons ratio N A 0 35 Density kg m 3 500 Density kg m 3 560 BOM Item Description Size Qty Unit Price Total price Wood Posts 50cm or 20 in
66. matical Model ac e Ee vo SR ER AR Detailed Design Concepts s isi soa 40 TE 44 Servo Speed Mathematical essen einn 47 SECTION 5 THEME SPEAKER ELECTRONIC ENCLOSURE SOUND PRODUCTION DESIGN CONCEPT 49 Arduino Enclosure Design Concept ua 51 Production Design VR A FER RR 52 Down Selection SECTION 6 MUSIC ASSIGNMENT DESIGN FOR PROGRAMMING Developing Music NOTES aquy 54 Development of Notes Assigned to GrOUp eese aE sss asa ases sa dada 56 SECTION 7 TIMING 57 Analytical Model for TIMING Fe or Even west re o er V EEREN RERE 58 SECTION 8 COMPLETE CONCEPT DESIGN BOM ENS RAE YR ER WERE E ER ERR ERR EE RENE 59 Rough BOM Concept Design xuma i tar 60 Phase 2 Prototype Development 61 SECTION 1 STRUCTURE FABRICATION 62 SECTION 2 BALL RAMP DETECTION CATCH RELEASE
67. maximum tensile stress of 2 25 MPa with max 0 079mm displacement a maximum torsion of 5 61 MPa with 0 260mm max displacement and a tensile and torsion buckling max displacement of 10 8mm and 33 65mm respectively The total cost of his structure is 2 66 which is the cheapest out of the five structures to build Also it is easy to manufacture as it only uses glue to adhere the posts to the plates The material used for the structure is made of plywood and hardwood dowel pins that were supplied by the instructor and was bought in bulk which reduced its price In terms of interior space there is plenty of space in the inside of the structure for the electronics and speaker to be placed inside After finalization of the structural design of our music box the CAD model was then printed out and the music box structural design was sent to the manufacturing stage tL ur LION KING MAE 151 Music Box Design Binder won Mises Ninm 2 MPa 58 515 488 42 374 28 23 187 14 05 0468 3226908 mE After choosing the design following results were obtained from the FEA for final concept design e The mass of the box 0 83 kg Structure Design FEA Results von Mises inar MPa 225 206 187 158 15 130 112 257 0746 0562 0374 0187 905e 007 FEA Result Summary e Maximum Stress due to torsion MPa 5 61 e Maximum Stress due to compressive stress MPa 2 25 Maximum Displacement mm 0 07
68. ment stud and alignment screw of top plate of one box with the corresponding holes on the bottom plate of the other box There are matching holes on the bottom plate that match the stud and screw on the top plate Be sure to line them up for the next step 2 Physically join the two boxes together by inserting the alignment stud and alignment screw into its corresponding holes on the other box Mate the top and bottom plates together The stud and screw should go through the holes and stick out partially top plate of the lower boxes and the bottom plate of the top box should sit flat against each other Proper alignment will allow the activation ball to fall through the activation slot on both boxes 3 Lock the assembly together Lock the two music boxes together using the supplied nut This will ensure the boxes stay together and not fall apart under load tout 131 Page LION KING APPENDIX gt tat 132 Page KING SECTION 1 STATUS REPORTS gt ur 133 Page LION KING Status Report Week 2 1 6 1 17 t Kushal Shah Thomas Van M THE LION KING Group Information Henry Diep Fady Barsoum Eric Kuo First Two Weeks 1 6 1 17 Projected Action item Completed Status Assigned Person Date Team Building Introduction 1 10 2014 Complete Team Development of Website Documentation Method 1 10 2014 Complete
69. ng a sudden decrease in photosensivity value The servo arm which is activated by this sudden decrease is now in the process of catching the ball This first catch and release prototype was successful in catching the ball It worked for the no box fail and 1 box fail For two box fail case it worked 7 out of 10 times Things We Learned e Need to slow down the ball near our sensors for better detection Tube needed to have cleaner look no drill tip sticking out e The distance between the sensors and the servo arm needs to be MAXIMIZED e The L servo mount is too small o The nail started to crack the wood piece because tin LION KING MAE 151 Music Box Design Binder SECTION 2 REDESIGN Amt LION KING MAE 151 Music Box Design Binder Pipe Prototype 1 High Impact Polycarbonate Our first design iteration for the catch and release pipe was our High Impact Polycarbonate version We decided to use polycarbonate in particular because of its transparency Reason being that we defined one of our customer goods as being able for the user to see the ball through the pipe Three key features of this first iteration are the two side holes for the LED and photoresistor sensors the cut slot for the servo arm and the blocker in the middle to slow down the ball This 1 outer diameter 1 1 8 High Impact Polycarbonate tube was ordered from McMaster Carr The holes and slot were all made using a milling machine for prec
70. nth Strings __ 83 Calliope Lead Lead 3 115 Pitched Percussion 20 Church Organ 52 Synth 84 Chiff Lead Lead 4 116 Woodblock 21 Reed Organ 53 Choir Aahs_ 85 Charang Lead Lead 5 117 Taiko Drum 22 Accordion 54 Voice Oohs 86 Voice Lead Lead 6 118 Melodic Tom 23 Harmonica 55 Synth Voie 87 Fifths Lead Lead 7 119 Synth Dum 24 Tango Accordion 56 Orchestra Hit 88 Bass Lead Lead 8 120 Reverse Cymbal 25 Acoustic Guitar nylon 57 Trumpet 89 New Age Pad 1 121 Guitar Fret Noise 26 Acoustic Guitar steel 58 Trombone 90 Warm Pad Pad 2 122 Breath Noise 27 Electric Guitar Gazz 59 Tuba 91 Polysynth 3 123 Seashore 28 Electric Guitar clean 60 Muted Trumpet 92 Choir Pad 4 124 29 Electric Guitar muted 61 French Hom 93 Bowed Pad S 125 Telephone Ring 36 Overdriven Guitar ___ 62 Brass Section 94 Metallic Pad 6 126 Helicopter 31 Distortion Guitar 63 Synth Brassi 95 Halo ad 127Appluse 32 Guitar Harmonics ___ 64 Synth 96 Sweep Pad 8 128 Gunshot 2 High Floor Tom 59 Ride Cymbal 2 75 44 Pedal Hi ha EXC T 60 High Bongo 76 Hi Wood Block 29 Scratch Push EXC 7 45 Low Tom 61 Low Bongo 77 Low Wood Block 30 Scratch Pull EXC 7 46 Open Hi hat EXC T 62 Mute Hi Conga 78
71. nto their component parts and for each component we compared the solutions using an individual Pugh comparison chart LION KING MAE 151 Ball Path Selection Music Box Design Binder Concept Chances of getting stuck Manufacturing Accessibility View of the ball Ball Arresting Cost 1 Straight Down PVC None Cutting to length creating viewports creating entryway Easy Tiny Viewports None 1 67 2 Straight Down Polycarbonate None Cutting to length creating entryway Easy Full None 3 52 3 Dowel Pins Polycarbonate Low Cutting to length a few drilled holes creating entryway Easy Full A bit of hindrance 3 66 4 Tube Path Polycarbonate Depends on angles but relatively high Cutting to length and assembly Medium Full Very Slowed 44 5 Springs Path Depends on angles but relatively high Cut paths out of wood add springs and clear wall Difficult Can be full Very Slowed 1 s DATUM 1 2 3 4 pu Dowel Pins Tube Path Springs PVC Polycarbonate Polycarbonate Path Chances of 1 1 1 getting stuck 9 2 Manufacturing 1 1 1 1 B Accessibility 0 0 1 1 4 View of the 1 0 0 1 ball 5 Ball Arrest 0 1 1 1 6 Cost 1 1 1 1 1 2 We determined the Ball Path solution that best fits our
72. ocity talkMIDI 0x80 channel i release velocity PLays MIDI note Doesn t check to see that is greater than 127 that data values are Less than 127 void talkMIDI byte cmd byte data1 byte data2 digitalWrite ledPin HIGH mySerial write cmd mySerial write data1 Some commands only have one data byte All cmds less than have 2 data bytes sort of http 253 ccarh org handout midiprotocol if cmd xF lt OxBO mySerial write data2 82 Page tur LION KING MAE 151 Music Box Design Binder PHASE 3 TESTING REDESIGN TESTING 83 Page ur LION KING MAE 151 Music Box Design Binder SECTION 1 PROTOTYPE TESTING WINS iu LION KING MAE 151 Music Box Design Binder Here we see a picture of our midterm structure test when the T A s put an 80kg load on top of our fabricated music box As we can see from the picture our 5 post structure was strong enough to handle all 80 kg s of force downward The picture on the left shows the midterm testing of our catch and release mechanisms As seen in the photo the ball is in the middle of the drop test It is about to impact our blocker the drill bit in the middle which will decrease the speed of the ball The red LED is constantly on providing a constant photosensitivity value for the photoresistor This picture shows that the ball is pass the photoresistor amp LED sensing portion creati
73. odel name structuret Deformation sesir 1 Study name DistWeight Static Plot type Static displacement Displacement won Meses scale 4 632 002 24595430 6 299e 002 2254420 5569 002 20495201 5 039 002 1445504 44092 002 14347319 3 779 002 12297731 3148 002 2519002 8188497 1 890 002 6148879 1 260e 002 4093262 4 2049844 6299 03 is 27 1 000 030 Model name structure von Mises Nim 2 URES mm Study name Torsion Static Model structure Plot type Static nodal stress Stresst Deformation scale 1 5 Study Torsion Static 6 537e 002 Plot type Static displacement Deformation scale 1 5992 002 18748370 1 5225791 5 448 002 4 303 002 43703213 4358 002 12180635 3813e 002 1 0658058 3 269 002 9135479 2 724e 002 7612904 2479 002 6090323 1 634e 002 4567745 1 090 002 3045167 gee 1 009 030 10 30 LION KING MAE 151 Music Box Design Binder Design 4 Specifications Details Weight 0 81 kg Strength Maximum Stress MPa 2 46 Maximum Displacement mm 0 076 Maximum Displacement mm Due to Torque 0 065 gt Ease of Manufacturing Three posts and 3 wood panels Visual Criteria Crowded like a theater gt Interior Space Less than most access limited to one side Reliability Sturdy 5 on 1 5 scale Material Properties Top Bottom P
74. otentially more prone to false detection LED Pins byte led 2 random byte 1 5 greens byte 22 6 byte 23 7 byte y1 9 yellows byte y2 10 byte r128 reds byte r2 13 Delays These for timing all in milliseconds They should be adjusted based on high speed footage int sensetime 26 ball enters box ball sensed int musicstart 500 activating servo playing music int noteldelay 500 play note 1 play note 2 78 Page PEST LION KING MAE 151 Music Box Design Binder int note2delay 500 play note 2 play note int releasetime 500 play note 3 release ball int note3delay 500 release ball stop note int balldroptime 100 release ball ball exits box MET UM EE INITIALIZATION E ere E d Initialization takes while so don t drop ball until 1 25 after turning the arduino on void setup Setup serial communication Serial begin baudrate serialPrint Initializing Setup servo myservo attach servopin myservo write releaseangle make sure it s in the open position Setup LEDs initializeLEDoutputs Setup MIDI Shield setupMIDI serialPrint Initialization complete serialPrint mes serialPrint yes
75. ox Following sheet specifications were obtained for music design From these sheets desired music can be produced 1 MIDI Chart for Instruments Obtained from Music Instrument Shield Website T Acoustic Grand Piano 33 Acoustic Bass 65 Soprano Sax 2 Bright Acoustic Piano 34 Electric Bass finger 66 AMoSax 3 Electric Grand Piano 35 Electric Bass pick 67 Tenor Sx Z Honky tonk Piano 36 Fretless Bass 68 Baritone Sx 5 Electric Piano 1 37 Slap Bass 1 69 Oboe 101 Brightness FX 5 6 Electric Piano 2 38 Slap Bass 2 70 English Horn 102 Goblins FX 6 7 Harpsichord _ 39SymhBass 7 Bassoon 40SymhBas2 _____ ___________ 104Sc R FX 9 Cesa T0 Giockenspie ____ 106Bano Ti Music Box ______ 4360 7SRecorder 107Shamien 12 Vibraphone 44 Contrabass 76 Pan Fue P13 Marimba 45 Tremolo Strings 77 Blown Bottle 109 Kalimba 114 Xylophone 46Pizzicato Strings 78 Shakuhachi 110 Bag Pipe 15 Tubular Bells 47 Orchestral Harp 79 Whistle 16 Dulcimer 00 _________ 112 Shanra Drawbar Organ 49 String Ensembles 1 81 Square Lead Lead T 113 Tinkle Bell Percussive Organ 50 String Ensembles 2 82 Saw Lead Lead 114 Agogo 19 Rock Organ 51 Sy
76. pipe prototype 3 e Cubic servo mounts less prone to wood chipping cracking by the driving screw e Used speaker iteration 2 92 Page tur LION KING MAE 151 Music Box Design Binder SERVIN 93 LION KING MAE 151 Music Box Design Binder SECTION 4 FINAL PROTOTYPE FIT TESTING WINS us LION KING MAE 151 Music Box Design Binder Pictured above are illustrations of our music box in the final fit test during the Senior Winter Design Review As you can see above our music box fit and performed just fine INS LION KING MAE 151 Music Box Design Binder FINAL PRODUCT w LION KING MAE 151 Music Box Design Binder SECTION 1 FINAL BIG STACK PICTURES PERI LION KING MAE 151 Music Box Design Binder The Final Stack LION KING MAE 151 Music Box Design Binder The Sub Stacks 7 LION KING MAE 151 Music Box Design Binder SECTION 2 FINAL WIRING DIAGRAM gt 100 Page LION KING MAE 151 Music Box Design Binder 101 LION KING MAE 151 Music Box Design Binder Electronic Schematic VCC2 Bottom Switch 100 Ball Detection Photoresistor 7257 adio Top Switch Volume Dial 10 9 z m 2254 102 tmu LION KING MAE 151 Music Box Design Binder SECTION 3 FINAL DRAW
77. t 77 LION KING Status Report Week 9 2 28 3 7 mti ur LION KING Group Information Kushal Shah Thomas Van Henry Diep Fady Barsoum Eric Kuo This Week 2 28 3 7 Projected Action item Completed Status Assigned Person Date Assemble Box with Intema ls 3 7 2014 Complete Team Test Intemals integrated with Box 3 7 2014 Complete Kushal amp Fady Solder remaining wiring 3 7 2014 Complete Fady amp Kushal Touch ups on Box paint and design 3 7 2014 Complete Thomas amp Henry Next Week 3 7 3 14 Action item Due date Status Assigned Person Assemble Final Documentation 3 14 2014 N C Team Final Revision of Box 3 14 2014 N C Team Begin Final Powerpoint Presentation 3 14 2014 N C Team Note None at thismoment Concerns None at thismoment AR ta LION KING Status Report Week 10 3 7 3 14 LION KING Group Information Kushal Shah Thomas Van Henry Diep Fady Barsoum Eric Kuo This Week 3 7 3 14 Projected Action item Completed Status Assigned Person Date Assemble Final Documentation 3 17 2014 Team Finish Missing Documentation 3 17 2014 Team Begin Powerpoint 3 17 2014 LP Team Final Check of box 3 17 2014 Note None atthis moment Concerns None atthis moment 142 Page tur LION KING
78. t this moment 135 Page teur LION KING Status Report Week 4 1 24 1 31 t Sep M THE LION KING Group Information Kushal Shah Thomas Van Henry Diep Fady Barsoum Eric Kuo This Week 1 24 1 31 Projected Action item Completed Status Assigned Person Date Select 1 Body Design to Fabricate 1 27 2014 Complete Kushal Thomas Henry Fady Ball Sensorand Catch Design 1 29 2014 Complete Team Obtain Wood from Steve 1 29 2014 Complete Eric Obtain Electronics from Raymond 1 29 2014 Complete Team Fabrication of Body N A Eric amp Henry Electronics N A Kushal Thomas Next Week 1 31 2 7 Action item Due date Status Assigned Person Finish Fabrication 1 29 2014 N C Eric amp Henry Finish Electronics with Calculations 1 29 2014 N C Kushal Thomas Fady Begin Assembly with Electronics 2 7 2014 N C Team Test Box 2 7 2014 N C Team Note None at this moment Concerns None this moment nutu bus LION KING Status Report Week 5 1 31 2 7 M LION KING Group Information Kushal Shah Thomas Van Henry Diep Fady Barsoum Eric Kuo This Week 1 31 2 7 Projected Action item Completed Status Assigned Person Date Finished Body Fabrication 1 31 2014 Complete Eric amp Henry Finished Electronics 2 5 2014 Complete Fad
79. tch Design 4 Images Design 4 Specifications Details MAE 151 Music Box Design Binder o Detection Method Hall effect sensor one piece easier lighter less hassle o Catch Method Servo moves a plate into a slot in the pipe blocking the path of the ball Obstructing dowel pins o Release Method Servo removes plate from underneath the ball o Ease of Manufacturing Just need to drill corresponding holes into polycarbonate Could use machine shop mill to mill polycarbonate o Visual Criteria Ease Access Make it look wacky with punctured pins going through the pipe o Reliability Accuracy Good strong pins to withstand the impact of the ball assuming the above box fails o Power Consumption if possible 3 3 V and 0 2 amps for the Hall Effect sensor servo activated twice Power required to power hall servo arm BOM m Unit Total Item Descripion Size Oty Brice price ID 1 1 8 OD 1 Z Polycarbonate pipe ji a a 1 3 98 ft 3 98 Maple dowel rods dia less dense than oak 36 length ibi Multi fit foam sleeve Dia 6 1 4 78 4 78 Total Cost 9 66 Total Cost 9 66 43 Page ur LION KING MAE 151 Music Box Design Binder Downselction e The preceding design concepts are complete solutions consisting of 1 The path of the ball 2 Detection method 3 Catch and release mechanism We broke down these detailed complete design solutions down i
80. y Kushal Thomas Obtain Speaker 2 7 2014 Complete Team Start Documentations 2 10 2014 P Team Work on Amplifier sound 2 10 2014 EP Kushal amp Fady Next Week 2 7 2 14 Action item Due date Status Assigned Person Complete Structure 2 11 2014 N C Eric Thomas Henry Get Amplifier Working 2 10 2014 Kushal Thomas Fady Assembly Documentation 2 10 2014 N C Team Test Box 2 10 2014 N C Team Note None this moment Concerns None at this moment 137 Page tur LION KING Status Report Week 6 2 7 2 14 mtm ui THE LION KING Group Information Kushal Shah Thomas Van Henry Diep Fady Barsoum Eric Kuo This Week 2 7 2 14 Projected Action item Completed Status Assigned Person Date Complete Structure 2 11 2014 Complete Eric Thomas Henry Get Amplifier Working 2 10 2014 Complete Fady Kushal Thomas Assemble Documentation 2 10 2014 Complete Team Test Box 2 10 2014 Next Week 2 14 2 21 Action item Due date Status Assigned Person Review Midterm Results 2 19 2014 N C Team Determine improvements 2 21 2014 N C Team Begin redesign 2 21 2014 N C Team Note None this moment Concerns None at this moment 138 Page LION KING Status Report Week 7 2 14 2 21 gt LION KING Group Information Kushal Shah Thomas Van Henry Diep Fady Barsoum Eric Kuo This Week 2 14 2 21

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