Ideas for Classroom Projects

Ideas for Classroom Projects
Leaving Certificate
Technology
Classroom Project Ideas
Contents
Desk Fan
Desk Fan PPT ...................................................................................................... 1
Vacuum Forming PPT ......................................................................................... 4
Design for Manufacture ....................................................................................... 6
Motorcycle Project
Motorcycle Project PPT....................................................................................... 15
Manufacturing Instructions.................................................................................. 17
Dragster Project
Dragster project PPT............................................................................................ 26
Manufacturing Instructions.................................................................................. 29
Mobile Phone Holder
Mobile Phone Holder PPT ................................................................................... 37
Inspire and Create PPT ........................................................................................ 41
Manufacturing Instructions.................................................................................. 45
Presentation Notes ............................................................................................... 49
Burglar Alarm
Burglar Alarm PPT .............................................................................................. 58
Alarm Circuit ....................................................................................................... 60
Manufacturing Instructions.................................................................................. 61
JC Technology
Computer Desk Lamp .......................................................................................... 63
Remote Control Hovercraft.................................................................................. 67
Note: CAD drawings for Desk Fan, Motorcycle Project and Burglar Alarm are available on RD6
Technology Resource CD.
Project Ideas
Design
Design and
and Manufacturing
Manufacturing
Manufacturing & Vacuum Forming
Design for Manufacturing
Design Brief:
Design and Manufacture a Working Model Electric Fan
Project Option 1
Project Option 2
Projects
Projects 1
1&
&2
2 -- Desk
Desk Fan
Fan
These are Integrated projects covering a range of processes and manufacturing skills including
Design, Mechanisms, Electronics control, CNC machining, Vacuum Forming etc.
Manufacturing & Vacuum Forming
Manufacturing & Vacuum Forming
Mould Manufacture – 1 Design Variations
Design for Manufacturing. - Project Option 1
Given an MDF block 125 x 75 x 20 mm design a basic shape to encapsulate the
components, support the mechanisms and house the electronic controls.
The design must be manufactured using the
materials supplied and incorporate the following:
•
Have a vacuum formed base that will support the fan and
house the Electronic circuit, Switch & 3 Volt battery
•
Have a 8Ø brass support bracket that will locate the motor,
and the support base in appropriate position.
•
The fan must have a variable Electronic Speed control circuit.
•
All electrical connections must be soldered.
•
Each student should endeavor to individualize her/his design.
The rational behind this Project is that it will allow the teacher to
Manage the Design & Manufacturing Process within the constraints of
the Classroom/Workshop environment. E.g., Materials, Cost, Machines
& Equipment, Time, Reduced Waste & Health & Safety.
Manufacturing & Vacuum Forming
Manufacturing & Vacuum Forming
Mould Manufacture - 2
Wood Plane used to get Draft
Without proper draft the mould cannot be
removed from the vacuum formed case without
damaging it.
Tilting the table on a Scroll saw or Band
saw will give the necessary angle but will
require finishing by a sanding block.
Examples of six Pattern Designs from the MDF blank
Mould Manufacture - 3
A most important requirement in mould design is DRAFT which must be al least 3 to 5 º.
Table set to 5º on Belt Sander
Refinement to the mould may be by achieved using readily available components
in the workshop e.g. coins, washers, rivets, expanded polystyrene shapes, badges
etc.
Internal holes or cavities in a mould must
have 2Ø mm drilled holes through to the base
of the mould so as all air can be removed by
the vacuum pump.
Wood chisel used to get Draft
•
The base of the mould may be drilled and
treaded M6 to allow a handle to be attached to
assist in pull the mould from the formed
shape.
•
A mould may be dusted with talcum powder to
assist in releasing them from the formed
shape.
VACUUM FORMING MACHINE
Turn on the Vacuum Forming at least 30min before use.
Set outside Temperature Zones set to full power
Set centre Temperature Zones set to 75% power.
Do not over heat the Polyester sheet asit will sag.
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Project Ideas
Manufacturing & Vacuum Forming
Manufacturing & Vacuum Forming
Finishing a Vacuum Formed Object
Desk Fan 2
Finished base made from 2 mm Polystyrenes is
trimmed to shape using:
• A band-saw.
•Tin snips.
• GERBIL cutter.
•(A Gerbil is a multi-purpose Vacuum
Forming cutting & Finishing Machine).
Vacuum Formed Base
Supplied Parts
Speed control circuit & Motor
Parts and Dimensioned drawings for Desk Fan 2
•A Tungsten Carbide cutting tool is used for creating
a 10 mm flange around the edge of vacuum forms. This
add considerable strength to the Form.
•A belt sander, a file or a sanding block may also be
used to finish Forms.
The finished fan base is then drilled to
accommodate Switches, Variable resistor, LED and
pulley mechanism support etc.
Base Dimensions
Manufacturing & Vacuum Forming
Brass washer
Fan Stand & Alternative Design
Manufacturing & Vacuum Forming
Making the Brass support Bar
Assembled Project 2
Completed Variable speed Model Fan
A PCB mounted electronic circuit using a
TIP 121 chip is used to provide a range of
speeds.
Note that motor holder has been spray
painted.
Model Fan has been drawn up and fully
rendered in Solid Works.
Facing in the Lathe
Centre Drilling in the Lathe
Accurate Tapping in the Lathe
Advanced design options may include:
•Allow the fan direction to be adjustable.
•A mechanism that will make the fan oscillate
Manufacturing & Vacuum Forming
Manufacturing & Vacuum Forming
Completed Project 1.
Manufacture of the bracket Project 1
Assembled fixed speed Model Fan assembled using parts provided.
•Bracket is marked out, shaped, drilled, then polished before bending.
•The Bracket must be accurately bent using a Bending Machine or
Folding Bars
Dimensions for Vacuum Form for Base.
Model Fan has been drawn up and
fully rendered in Solid Works.
A larger diameter Propeller and Solar Motor will change this
project to a Generator. Add two LED to indicate current Output
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Project Ideas
Manufacturing & Vacuum Forming
Manufacturing & Vacuum Forming
Bracket Design - Project 2
Advanced option 3 for this Project.
•
Design and make a brass fan rotor.
•
The cone may be made on the made on a CNC lathe.
•
The fan is soldered to a brass cone.
•
Brass Cone is Screwed & Tapped M5.
Given a Brass strip 30 x 165 x 1 mm design alternative of
support brackets that will;
1.
Support the drive shaft.
2.
Hold the motor in position.
3.
Provide for the bracket to be attached to the base.
•Gear or chain drive may be used.
•A mechanism designed to allow the fan to oscillate.
•Reversible DPDT Centre “Off” Switch is fitted.
•Red/Green LED fitted to indicate Forward/Reverse.
Brass Cone soldered
to Rotor
•The speed control may be recycled for use in any motorized project
Manufacturing & Vacuum Forming
Summary
Most or all of the following headings with associated
theory may be integrated into the overall design project.
1.
Design theory and practice
2.
Appropriate material selection
3.
Marking out and fitting skills
4.
Assembly and joining processes
5.
Electronic circuit design theory and practice
6.
PCB Wizard & Solid Works
7.
Mould making theory and practice
8.
Finishes, polishing, spray painting of surface.
9.
Project Management
10. Workshop Safety considerations
Remember “Design is not always about Inspiration and Genius”
It is mostly about “Perspiration and Hard Work”
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Project Ideas
Design
Design and
and Manufacturing
Manufacturing
Manufacturing – Vacuum Forming
Process
A sheet of thermoplastic material is
clamped around its edges and heated
until flexible. A heat-proof mould of the
required shape is raised into the
softened plastic. The air between the
sheet and the mould is evacuated by a
vacuum pump. Atmospheric pressure
then forces the plastic sheet tightly
over the mould.
Vacuum
Vacuum Forming
Forming
Manufacturing – Vacuum Forming
THE STAGES INVOLVED IN VACUUM FORMING
1. First, a former is made from a
material such as a soft wood. The
edges or sides are shaped at an
angle/draft of 3º so that when the
plastic is formed over it, the former can
be removed easily.
2. The finished former is placed in a
vacuum forming machine.
3. A sheet of plastic e.g. polystyrene is
clamped in position above the mould
Manufacturing – Vacuum Forming
COMPLETED MOULD
7. The 'vacuum' is turned on and this
pumps out all the air beneath the plastic
sheet. Atmospheric pressure above the
plastic sheet forces it down on the mould.
The shape of the mould can now be clearly
seen through the plastic sheet. When the
plastic has cooled the vacuum pump is
switched off.
8. The plastic sheet is removed from the
vacuum former. The sheet has the
shape of the former pressed into its
surface.
9. The excess plastic is trimmed so that
only the plastic bowl remains An
enlarged view of the final dish is seen
opposite.
Materials
High Impact Polystyrene sheets from
1mm to 3mm in range of colours are
available Including clear sheet used for
bubble packaging in presentation boxes.
Manufacturing – Vacuum Forming
MOULDING PROCESS
4. The heating elements are then turned
on and the plastic slowly becomes soft
and pliable as it heats up. The plastic
can be seen to ‘sag’ and as the surface
expands
5. After a few minutes the plastic is
ready for ‘forming’ as it becomes very
flexible or rubbery.
6. The heater is turned off and the
mould is moved upwards by lifting the
lever until it locks in position.
Manufacturing – Vacuum Forming
Mould Manufacture
To achieve the desired shape moulds may be made
by gluing layers of material together and then
shaping using a variety of hand and machine tools
such as CNC Routers, Laser Cutting, Scroll Saws,
Spindle molding table and Belt sanders .
Materials used in mould construction may be
MDF, Balsa wood, Modelling clay. MDF is
usually used in school and cast aluminum or
epoxy resin in industry. Mould strength and
rigidity may increased by designing in
recesses, grooves or steps.
Example of trays or bubble or blister
packaging produced by vacuum forming
Web site link to commercial blister vacuum forming & packaging
http://www.uni-plastic.com/Thermoforming%20&%20Vacuun%20Forming.htm
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Project Ideas
Manufacturing – Vacuum Forming
Manufacturing – Vacuum Forming
MAKING A MOULD
Commercial examples of Vacuum Forming
By using light plywood, aluminum or Perspex
sheet as a base layer on your mould, it may
be attached using two sided tape so that it
may be easily removed and used as the base
for your completed project. See example of
car mould opposite.
When designing a mould it is most important
to considering the removal of the vacuum
formed shell. No overhanging lips or negative
angles. A draft angles of 3° to 5° must be
provided on all surfaces of the mould. The
formed plastic and the mold is very difficult
to seperate and may split or crack. A wooden
mould may be dusted with Talcuum powder
to aid removal.
Manufacturing – Vacuum Forming
Manufacturing – Vacuum Forming
Mould Manufacture
Tips & Tricks
1. MDF & 3mm plywood sheet are cheap and suitable materials used
for manufacturing Moulds.
2. Complex shapes can be built up in layers.
STEPS in the DEVELOPMENT of the PATTERN
1. MDF block basic shaped to encapsulate the
components and support the mechanism.
3. Two sided tape, coins, dowels, metal crests, car badges,
superglue, wood fillers, matches may be used to enhance or
personalize a mould.
2. MDF block design refined to hold 9V battery
and provide ergonomically designed profiles for
Switches, LED & Variable resistors
4. Hole saws, counter sinking bits, counter boring bits, sanding
blocks.
5. Existing shapes may be filled with patching plaster to make a
mould.
6. Internal holes cavities in a mould must have 2 Ø mm holes drilled
through to the base of the mould to all the cavity to emptied by the
vacuum pump.
7. Large or complicated shape may be dusted with talcum powder to
assist in releasing them from the mould.
3. Finished 2 mm Polystyrenes mould ready for
motor drilling and fitting of electronic components
and pulley mechanism support.
8. The base of the mould may be drilled and treaded M6 to allow a
handle to be attached to pull the mould from the formed shape.
Manufacturing – Vacuum Forming
Manufacturing – Vacuum Forming
FOUR COMPLETED MOULDS
Examples of six Pattern Designs made from the MDF blank
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Remember “Design is not always about inspiration and genius” is more about “Perspiration and hard work”
The rational behind this project is to present a plan that may assist the teacher in managing the
manufacturing and design process in a Technology Room. The constraints placed on the teacher
will be material available and cost, the machines and tools available and time allocated to
manufacturing the project.
All students should experience a successful outcome to their project and the better student has scope to develop
further enhancements to their design.
All electrical connections should be soldered. Each student should individualise his/her design.
The student may be given the following materials.
1. Diameter 8mm x 100mm brass rod or Brass Strip 164 x 30 x 1mm.
2. MDF board 140 x 70 x 24mm.
3. Electronic / mechanical components for their design.
A vacuum formed secure base that will support the fan and house:
• A switch & 3 volt battery
• Associated speed control and a power on/off LED indicator.
• Have a means of supporting the motor or a brass support bracket that will position the motor, drive
pulleys and drive shaft in appropriate positions securely to accommodate a speed reduction.
Design and Manufacture a Working model Electric Fan.
Your design must be manufactured using the materials supplied and incorporate the following:
Design for Manufacture
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Project Ideas
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N.B. The speed control circuit / drive may be recycled for use in any motorised project.
• Red/Green LED fitted to indicate forward / reverse operation.
• Reversible DPDT ‘Centre Off’ switch is fitted.
• A mechanism designed to allow the fan to oscillate.
• Gear or chain drive may be used.
• The fan is soldered to the brass cone.
• The Brass Cone is Screwed & Tapped M5.
• The brass cone may be made on the made on a CNC lathe.
• Design and make a brass fan rotor to replace the “bought in option”.
Further advanced Design Options for this Project
• The student must measuring the motor to establish distances and drill hole diameters before marking out the bracket.
• The bracket shape and method of attaching it to the base also gives the student the opportunity to personalize their design
- see sketch page for possible solutions.
• The bracket should be de-burred and polished before bending.
• To further develop the project for the better student the rotor may also be designed and made from brass.
From the Brass strip the student must design a support bracket to hold the motor and drive mechanism in the appropriate
positions;
The student should be required to make a “mock-up” model of their design as a homework exercise to test proportion &
function. Light cardboard sheet and tube, masking tape, thumb-tacks, cocktail sticks and Blue-tack may be used.
This provides the opportunity for the student to refine or modified their design before moving on to expensive materials and
wasting valuable time on a shape that may not have a successful outcome.
Each piece of material used in a design should serve at least two functions to reduce the number of parts required.
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Project Ideas
Quantity
1
1
1
1 (optional)
1 (optional)
1
1 of each
1
2
4
2
2
1
1
1
1
1
1
1
1
1
1
Description
MDF board 140 x 70 x 24mm
Polystyrene sheet x 2mm V/Forming
Brass Strip 164 x 30 x 1mm
Brass bar Dia. 8mm x 100mm
Motor mount 20mm clip to suit 1.5 – 4.5V motor
Steel bar 50 x 2Ømm chromed.
Pulley black Polystyrenes 12Ø & 25Ø
Polythene Fan 60 Ø mm
Steel self tapping screws No 4 x 6.5
4 Flat steel washers to suit M3.
S/Steel Pan Head M3 x 8.
S/Steel nuts M3.
Miniature Switch SPDT
Miniature high torque Motor 3Volt
Red & Green LED per packet of 100
Led bezel to suit 5Ø Led
150 or 220 Ω fixed resistor
Knob to match resistor spindle 6 Ø mm
22KΩ variable resistor.
Battery Holder 2 x AA = 3Volts
Battery Clip PP3
Length Pulley drive belt
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Bending Machine, Drill with Stand, Vacuum Forming Machine, Height Gauge
Drill bits 2, 2.5, 3.5 & 4 Ø, Fine water paper, Hand Clamp,
Phillips screwdriver, Pliers, Metal polish & cloth,
Soldering Iron, Solder, Red & Black link wire, Wire Stripers, Super Glue, Stanley knife.
Additional Tools & Equipment Required
Item
1
2
3a
3b
3c
4
5
6
7
8
9
10
11
12
13
14
15
16
16
16
17
18
Materials may be purchased from;
Miko Metals; 021-4966907
Central Technology Ltd; 01-8223355
Rapid Electronics Ltd; 0044 -1206 751166
4 Moulds per sheet.
Miko Metals
Miko Metals
37-0360
37-0350 per pk of 50
37-0375 & 37-0380 Pk of 10
06- 0690 or 06-0692 per unit
33-3150
33-1760
33-4115
33-4305
75-0211
37-0144
55-1776 & 55-1772
55-0260
62-0350 & 62-0354 per 100
32-1200
65-0502
18-0125
18-0092
52- 5082
Rapid Electronics Ref Code
Desk top Fan Project - Material List
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Project Ideas
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Suitable materials for use in vacuum forming are conventionally thermoplastics, the most common and
easiest being High Impact Polystyrene Sheeting (HIPS). This is molded around a wood, structural foam
or cast/machined aluminum mold and can form to almost any shape. Vacuum forming is also appropriate
for transparent materials such as acrylic which are widely used in applications for aerospace such as
PCW (passenger cabin windows) canopies for military fixed wing aircraft and "bubbles" for rotary wing
aircraft.
Relatively deep parts can be formed if the form-able sheet is mechanically or pneumatically stretched
prior to bringing it in contact with the mold surface and before vacuum is applied.
Vacuum forming is usually – but not always – restricted to forming plastic parts that are rather shallow in
depth. A thin sheet is formed into rigid cavities for unit doses of pharmaceuticals and for loose objects
that are carded or presented as point-of-purchase items. Thick sheet is formed into permanent objects
such as turnpike signs and protective covers.
Normally, draft angles must be present in the design on the mold (a recommended minimum of 3°),
otherwise release of the formed plastic and the mold is very difficult.
The vacuum forming process can be used to make product packaging, speaker casings and even car
dashboards.
A sheet of thermoplastic material is clamped around its edges and heated until flexible. A heat-proof mould of the required shape is
raised into the softened plastic. The air between the sheet and the mould is evacuated by a vacuum pump. Atmospheric pressure then
forces the plastic sheet tightly over the mould. A permanently 3-D shape is formed.
Process
Vacuum Forming
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Project Ideas
Steps in the Vacuum Forming Process
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1. MDF & 3mm plywood sheet are cheap and suitable materials used for manufacturing Moulds.
2. Complex shapes can be built up in layers.
3. Two sided tape, coins, dowels, metal crests, car badges, superglue, wood fillers, matches may be used to enhance
or personalize a mould.
4. Hole saws, counter sinking bits, counter boring bits, sanding blocks.
5. Existing shapes may be filled with patching plaster to make a mould.
6. Internal holes cavities in a mould must have 2 Ø mm holes drilled through to the base of the mould to all the
cavity to emptied by the vacuum pump.
7. Large or complicated shape may be dusted with talcum powder to assist in releasing them from the mould.
8. The base of the mould may be drilled and treaded M6 to allow a handle to be attached to pull the mould from the
formed shape.
9. Do not over heated the plastic sheet as it will sags and this increases the like-hood of webs between moulds.
10.Well designed pattern with smooth finish are easily removed from the finished vacuum form.
Vacuum Forming Tips & Tricks
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Examples of Student Projects - Vacuum Forms used to house Electronic Projects.
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Project Ideas
Motorcycle Project
Motorcycle Project
Design and make a project of simple construction,suitable for a
Leaving Certificate Technology class.
The Main body or frame:
Body profile made from sheet Aluminium 1mm,
Blank size shown in the diagram.
Three part design:
1. Main body
Finished outline is Symmetrical.
2. Front forks
Profile marked out, holes drilled and
then cut from given blank according
to accompanying dimensioned
drawing
3. Handlebars
Additional components required:
• 3 Wheels
•
1 Gears Wheel
Finished part.
• 1 Motor
•
1 Worm gear
• 2 Battery Holders
The finished profile is then bent
to shape as shown.
•
1 Seat & Petrol Tank
• 1 Switch
•
4 AA Batteries
Motorcycle Project
Motorcycle Project
Handlebars
Front forks:
Mark out and drill the blank.
Cut out the profile and finally
bend as required.
Mark out the desired profile according
to the given dimensions. Then drill the
three Ø 4mm holes and cut out the
profile.
Now bend both sides at right
angles to produce the final design
as shown.
Completed Handlebars shown
opposite.
Motorcycle Project
Motorcycle Project
Handlebars
Main parts assembled:
Finishing Methods
As with all projects there are a number of possible finishes.
Assembled view of the three main parts of
the Motorcycle
Polishing:
Front forks
Mechanical:
Polishing Mops & soaps
Mottling
Finished Motorcycle:
The additional components are
then added to give the final
assembled Motorcycle project
shown.
Fine grade emery cloth
Graded Steel Wool
Main body
Chemical Polishes:
Brasso, Silvo, Peek.
Plastic Coating:
Dip coating
Painting:
Metal Spraying:
Standard colours & specialist paints
Cold spray able Metal coatings.
www.artcam.com
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Project Ideas
Motorcycle Project
Motorcycle Project
Project Enhancements:
Metal Dyes:
These are special chemical that react with the metal to produce a
range of finishes.
Antiquing solutions
Cupric Nitrate
Introduce Timing circuits:
Travel set distance forward / reverse
Flashing LED’s:
Astable circuit
Sound Chip:
Motor Cycle Sound when switched on.
Black
Cobalt Nitrate
Copper Sulphate
Silver Nitrate
Sample of special Chemical finishes:
Rusty Brown
Tilt Switches:
Turn off the Drive should the Motor Cycle fall over.
Finally design and make a suitable Seat and Fuel Tank for the project.
Flemish Violet
Tri Colour
www.ssschemical.com/
Motorcycle Project
Some typical Technology room sheet metalworking tools:
Tin Snips
Hand Nibbler
Sheetmetal Clamp
Conical drill
Folding Bars
Simple vice jaw folders
Rollers
Folders
Bench vice folders
Combined bench mounted, hand
operated rollers, folders and
shears.
Shears
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Project Ideas
Motor Cycle Project
Design and make a project of simple construction, suitable for a Leaving
Certificate Technology class.
Introduction:
This project was designed in 1mm sheet Aluminium. It could just as well be made from Mild
Steel, Brass, Copper or Acrylic. It consists of three main parts:
Main body.
Front Forks.
Handle Bars.
It uses a unique double back wheel design for stability and a switch that keeps the assembly
together without the need for screws.
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Project Ideas
All dimensions on the project are interdependent; if the thickness of the Aluminium is altered
then the switch would have to be altered as the neck of the switch will be too short to
assemble the three main parts. Likewise if the size of the gear wheel or the worm gear are
altered then the position of the axle hole would also have to be altered to correspond.
All the other components used are attached with double sided adhesive pads. The motor and
holder fit neatly to the underside of the main body and the two battery holders attach to the
sides to replicate the exhausts for design purposes.
The Main Body:
When you get the blank piece of Aluminium the first thing you need to do is check for a
straight true edge. The edge of the Rule or the back of the Try Square may be used for this
purpose. Having satisfied yourself that you have one true edge, you now take the Try Square
and proceed to mark out, cut and file a further edge at right angles to the first edge. This gives
two good edges from which to mark out the Body profile according to the given dimensions.
A scriber would be normally be used to mark out but if you don’t want to mark the surface a
standard pencil will do. Having marked out the profile from the given dimensions, the next
step is to centre punch the position of the three 4mm holes for drilling.
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Project Ideas
The drilling may be done on the Bench drill or with a portable drill. Particular care is needed
in this operation. A piece of wood is required to support the Aluminium profile and it needs to
be clamped to the profile before being drilled.
It may also be held with a Hand vice and drilled on the Bench drill or Pillar drill provided it
has adequate support.
Now the profile has to be cut from the blank and filed to size. In light gauge aluminium a Tin
Snips or Hand Shears would be used. Accuracy in cutting out at this stage reduces the amount
of filing required. Really you should only have to remove the burrs after cutting.
The next operation is the Bending or Folding of the profile. Again accuracy is important,
because if one side is slightly longer than the other the axle and therefore back wheels will be
out of alignment. Methods of bending or folding will depend on the equipment available. The
best option is a floor or Bench folding press as these produce the most accurate results, if this
is not available there are a number of small vice folders available.
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Project Ideas
Failing that you may have a folding bars, and finally reasonable results are possible with
blocks of hardwood cut to the required sizes.
Hardwood blocks are also very useful as formers and while bending to protect the blank from
hammer damage. Hit the hardwood block with the Hammer and not the Aluminium.
The remaining parts are produced in the same manner according to the dimensioned drawings.
When the three profiles are completed they are assembled or joined together using the switch
supplied. Again this removes the need for any screws in the project.
Next the worm gear is pushed on to the 2mm Motor shaft. The Motor is placed in its holder
and it is then mounted to the underside of the main body as shown in the earlier diagrams.
Assemble the rear wheels and the 38tooth gear wheel on the 4mm Axle shaft provided. Locate
the Axle assembly in the 4mm holes in the Main body. Mount the front wheel in the Front
forks in a similar manner. The battery holders are now attached to the side of the Main body
with double sided sticky pads to resemble exhaust pipes.
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Project Ideas
The project is now wired and soldered according to the given circuit diagram.
The battery may be connected in either series or parallel. In series you have 6 Volts and only
3 Volts in parallel but with a greater torque.
Finally the design is finished with the inclusion of a Petrol Tank and seat. These may be
moulded and or vacuum formed to a design of your own choosing.
Front Forks:
Handle Bars:
The approach and methods of manufacturing the Front Forks and the Handle Bars are exactly
the same as for the main body described previously.
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Project Ideas
Completed Project
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Project Ideas
Control
Dragster
Dragster Project:
Project: emphasis
emphasis on
on control
control
• The dragster project focuses on control
• Controlling electric motors is the basis
for many applications in industry
Examples of applications include:
standard power tools and machines –
(most electric drills will reverse direction)
automated machines, CNC machines,
and robotic machines
• Control of motors is primary – desired
motion is secondary
What is a dragster?
Shirley Muldowney NY won the Top Fuel Championship in 1977,
1980, and 1982 – ranked 5th in all time speed driver list.
Muldowney is Irish American – Don’t forget Tracey!
Dragster Theme
Expandable design
- Body based on inter fitting aluminium
channels. Two simple gearboxes and motors are used to drive large rear
wheels. Each wheel may be controlled separately.
Prototype vehicle:
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Project Ideas
Dragster Theme
Dragster Theme
Simple design - one piece frame or body to support additional components
-
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Project Ideas
Castor
Dragster Project
Castor in a car steering
Integration of Topics:
Project
Management
Body/Frame design:
Assembly
Techniques
Drive Systems
Allocation of resources, Time, Materials, Equipment,
Costs, etc
Sketching of idea’s, dimensioning, selection of suitable materials,
exercises in SolidWorks
Screwing and Tapping, and Soldering, and
consideration of other methods
Gear boxes ,Both bought and constructed, Bevel gears,
Worm Gears, Pulley Systems, Belt & Chain Drives, Drive
reversal, etc.
Electronics:
Components, Circuit design, Board layout, Timing circuits,
Electronic theory.
Finishes:
Polishing, Painting, Vacuum forming of body shell.
Dragster project
Summary
Some or all of the following areas may be integrated and incorporated
into the final project:
1.
Design theory and practice
2.
Appropriate material selection
3.
Marking out and fitting skills
4.
Assembly and joining processes
5.
Electronic circuit design theory and practice
6.
Mould making theory and practice
7.
Finishes, surface and other
8.
Project Management
9.
Safety considerations, general and project specific.
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Project Ideas
Dragster Project: emphasis on control of two motors
This is a simple project which uses 2
electric motors coupled to worm and gear
axle assemblies. Each motor system axle
drives 1 rear wheel of the three-wheeled
vehicle. The front wheel is a castor wheel.
The prototype in the photograph shows
the main parts and structure of the project
The two motors are controlled by Double Pole Double Throw (DPDT) sliding switches
mounted on a prepared PCB board to which the ribbon wires are conned.
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Project Ideas
M4 Cheese head screws
Attach the 2 plastic motor housings to the
cross member by drilling holes and tapping
M4.
The cross member is attached in a similar
manner.
Cut the axles as required and fit them as shown.
The motors are then placed and secured in
position. Make sure that each assembly works
well and that the worm and gears are neither
too tight, nor too loose.
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Project Ideas
Length of dragster
adjusting screw
Top view of switch PCB on the left with copper side view on the right
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Project Ideas
The concept of castor and its part in centre point steering in most road vehicles is often
misunderstood. There are some simple examples such as the furniture castor and then
bicycle forks might be examined: why can a bike rider ride with no hands?
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Project Ideas
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Project Ideas
Castor for reverse movement of dragster
Castor
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Project Ideas
Dragster Project
Material and component list
Each Project: 2 of Clunk Click Gearboxes with 3mm shafts (Rapid: - code 37-0310)
2 of Spiked Tyres dia 75 (Rapid: - code 06-0656 or TEP: - code CS7 032))
4 of inserts for Spiked tyres (TEP: - code CW3 027)
1 of Forward Reverse control board to include switches (TEP: - code EW2 030)
1 of 4 x AA battery holder
4 of AA batteries
1 of PP3 Battery Clip
1 of Castor wheel dia. 38mm (TEP: - code CW3 027)
Materials for fabrication: Aluminium channel 20mm x 20mm x 2mm wall x 240mm long
Aluminium channel 15mm x 15mm x 2mm wall x 220 long
Aluminium unequal angle 35mm or 40mm x 20mm x 1.5mm wall x 25mm long
Aluminium bar 25mm or 30mm x 3mm x 85mm long
Machine screws: 5 only M4 cheese hd x 8 or x 10 long
1 only M5 cheese hd x or 25 long
1 only M3 cheese hd x 15 or 20 long
2 only M5 flat washers
M3, M4, M5 nuts
Sticky pads to stick down battery holder
6 way ribbon cable (Rapid: - code 37-0310)
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Project Ideas
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Project Ideas
Mobile Phone Holder Project
Design for Manufacture
Mobile Phone Holder
1
Introduction
2
Introduction
Variety of Processes and
Manufacturing Techniques
Press Forming using ‘Foamex’
Production of Artifacts
Solutions to Real Life Design
Situations
Enhance Problem Soving and Design
Capabilities
Development of Individualised
Products
3
Introduction
4
Objectives
Students will Develop:
•A Range of Manufacturing Skills:
- Heat forming
•Thematic Approach
- The use of jigs and formers
•Encourage Integration of Topics
- Marking out, cutting, drilling,
finishing and assembly of
materials.
•Adapt Projects to meet individual
Circumstances
•An Understanding of The
Characteristics of Thermoplastics
Materials
5
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Project Ideas
Objectives
Presentation
Theme:
•Research Skills using ICT
Mobile phones are a worldwide phenomenon that
have revolutionised the way we communicate with
one another. They are both desirable and
essential to our everyday lives.
•Product Analysis Techniques and
Design Specifications
The ways in which we carry, protect and secure
our mobile phones can be based on fashion,
practicality and function.
•Graphics/Design skills and techniques
•Ability to Design according to User
Requirements
Design Brief:
Design and make a functional mobile phone
holder suitable for personal or desktop use
7
Constraints
8
Research/Investigation
•Work within student skills range
•Designers need stimulation
•Manufacturing Processes:
•Provision of stimulation
- Press forming
- Vacuum Forming
•Personal Research – How did it
influence the thought process
•Functionality and Ease of Use
•High Standard of Finish – Use of
Graphics
•See accompanying presentation on
Research – Add to it
•Individualised Product
9
Resources
10
Making the Formers
Materials
Equipment
•3mm expanded foam sheet
(Foamex)
•Oven
•Vacuum former
•1.5mm Vacuum forming
plastic
•18mm MDF or suitable
material for production of
moulds and formers
•A range of hole saws or
forstner bits
•Scroll saw
•Male and Female Formers – 18mm MDF
•Wet and dry paper
•Grip range press fit nylon
click fasteners
•Simple Shapes
•Tie wraps
•Male – Fixed to Base (Allignment)
•Female – Larger by thickness of casing material
•Acrylic cement or solvent
•Taper – Not necessary, Radius top edge
11
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Project Ideas
Heating and Forming
Cutting
Material is placed in preheated oven
(See Temperature chart )
Heated material is draped
over male former
Locate female former
over male former
Material can be trimmed
to leave a 10mm lip
Force together and hold
until material cools
File and finish to shape
with wet and dry paper
13
Support Bracket
14
Assembly
Assembly may need to be
supported with masking
tape during the gluing
process
Cut casing material in half
using a scroll saw and file
to finish
Support bracket can be
marked from casing but
its profile is cut 5mm
smaller all round and filed
to finish
Casing is affixed to support
bracket using tensol
solvent/cement or a glue gun
15
Bending
16
Finished Project
Support Bracket can be bent
using a Strip Heater
17
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Project Ideas
Design Variations
Extension Concepts
A number of design variations are
possible using this process
•Survival Kit
•Swimming Holidays
•Jewellery
•Power Pod
•CD Storage
•Camping
•Pamper Pod
•Baby Gear
•Handsets/Remote Control
•Pencil Case
19
Times & Temperatures
•Personal Alarm
•Mouse House
•IT accessories
•Desk Tidy
•Radio Housing
•Instrument Case
•Toolbox
•Robot Shell
•Money Box
•Paintbox Store
20
Links
TEP International Manufacturing Centre
University of Warwick
Material
Oven
Temp. °C
Time
(Seconds)
Notes
3mm Foamex
140
30
3mm
Plastazote
140
60
6mm
Plastazote
140
90
If plastic
becomes
mishapen, it
can be
returned to
the oven and
reheated.
Coventry CV4 7AL www.tep.org.uk
www.crclarke.com
Middlesex University
Teaching Resources
Unit 10, IO Centre
Waltham Cross
Herts EN9 1AS www.mutr.co.uk
Click Here to view instructional video
21
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Project Ideas
Inspire and Create
Mobile Phone Holder
1
2
3
4
5
6
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Project Ideas
7
8
Cut angled ?
9
11
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Be
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10
12
42
Project Ideas
13
14
15
16
17
18
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Project Ideas
19
20
21
22
Special Thanks to:
•Technology Education Centre, Omagh
•Mr. R.A. Moffatt, Western Education and Library Board
23
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Project Ideas
Press Forming – Mobile Phone Holder
Manufacturing Instructions
Male and female formers are
manufactured from 18mm MDF
A piece of 120x200x3mm Foamex
is placed in pre heated oven
Female former is larger than male
former by thickness of casing
material
The material is heated for
approximately 30 secs. At 140°C
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Project Ideas
The heated material is draped
over the male former
The female former is located over
the male former
Force is applied to sandwich the
two together and held for 2 mins.
The material can then be released
from the male former
Using a pencil a line can be marked
around 10mm from the case edge
The material can be trimmed using
a scroll saw or a gerbil cutter
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Project Ideas
Cut the formed casing in half and
draw file to finish
Mark the casing profile on a
different colour piece of Foamex
Cut the profile approx. 10mm
smaller than the casing
Support both materials in position
using masking tape
Affix both materials using tensol
solvent/cement or a glue gun
Bend the support bracket using a
strip heater
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Project Ideas
The finished project can be enhanced in
order to individualize its appearance
A variety of solutions can be achieved using the Plug and
Yoke method of Press Forming
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Project Ideas
Design for Manufacture – Press Forming
Mobile Phone Holder
Presentation Notes
No 2-4 Introduction
Notes
The Leaving Certificate Technology syllabus encourages
students to investigate a variety of manufacturing
techniques in order to produce artifacts as solutions to
specific problems.
Students need to be exposed to a variety of processes and
materials in the classroom in order to enhance their problem
solving and design capabilities.
The unit introduces students to the process of Press
Forming using ‘plug and yoke’ moulds, working with a
number of materials including ‘Foamex’ – a rigid foam
PVC sheet and encourages students to explore a range of
techniques in the realization of real life design situations
culmination in the development of individualized products.
The unit can be presented using a thematic approach, which
can encompass a range of topics in an integrated manner.
Teachers are encouraged to adapt and develop the projects
to meet their own individual circumstances in order to
provide design opportunities for their students.
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Project Ideas
No 5-6 Objectives
Notes
• The students will develop:
• A range of manufacturing skills through a series of
workshop processes:
• Heat forming
• The use of jigs and formers
• Marking out, cutting, drilling, finishing and assembly
of materials.
• An understanding of the characteristics of a range of
thermoplastics materials
• Basic graphics and design skills and techniques
• Research skills using ICT
• Communication skills such as product analysis
techniques and design specifications
• The ability to design an artifact according to user
requirements
No 7
Presentation
Notes
Theme:
Mobile phones are a worldwide phenomenon that have
revolutionised the way we communicate with one another.
They are both desirable and essential to our everyday lives.
The ways in which we carry, protect and secure our mobile
phones can be based on fashion, practicality and function.
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Project Ideas
Design Brief:
Design and make a functional mobile phone holder suitable
for personal or desktop use
No 8
Constraints
Notes
• Expectations will be constrained by the design,
communication and manufacturing skills of the target
group
• Project should be manufactured using the heat
forming process of Press forming (Vacuum Forming
can be utilised to enhance the project)
• Emphasis should be placed on functionality and ease
of use of product
• The completed product should be finished to a high
standard and the use of graphics to enhance its
appearance should be encouraged
• Products can be individualized to suit particular
models of phone.
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Project Ideas
No 9
Research
Notes
• Remember the majority of students need stimuli in
order to come up with ideas
• Present plenty of examples in order to provide
opportunities for stimulation, investigation and
research
• Encourage personal research to show how existing
solutions influenced students thought processes
• Refer to accompanying Research presentation (Add to
this according to the needs of the group)
No 10 Resources
Notes
The resource list suggests a range of materials and
equipment that can be used in the unit:
Materials:
• 3mm expanded foam sheet (Foamex)
• 1.5mm Vacuum forming plastic
• 18mm MDF or suitable material for production of
moulds and formers
• Grip range press fit nylon click fasteners
• Tie wraps
• Acrylic cement or solvent
Equipment:
• Oven
• Vacuum former
• A range of hole saws or forstner bits
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Project Ideas
• Scroll saw
• Wet and dry paper
No 11 Making the Formers
Notes
• Two formers, a male and a female are required for
both sides of the casing
• These can be made from MDF (suggested size:
18mm).
• Keep shapes simple and ensure that contour changes
are gradual.
• The female former needs to be larger than the male
former by the thickness of the casing material. This
will avoid distortion to the shape of the casing.
• The male former needs to be fixed to a flat wooden
base. To ensure alignment of formers, dowel guides,
former clamps or pen marks can be used.
• Tapered sides are not necessary, but a small radius
along the top edge of the male former will ease
removal.
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Project Ideas
No 12 Heating and Forming
Notes
• The material is placed in a pre heated oven and heated
for the appropriate time (Approx. 30 secs. at 140°C
for 3mm Foamex).
• Heated material is then draped over the male former.
• The female former is then located over the male
former. Force is applied to sandwich the two together.
• Both formers are held in place until the material cools.
This can be done by hand or by using a simple clamp.
• Release the plastic from the male former and repeat
the process for the second side of the casing if
necessary.
`
No 13 Cutting and Assembly
Notes
• Using a pencil, mark a line around the outside of the
casing approximately 10mm from the case edge in
order to create a lip.
• Trim the edge using a coping saw or a scroll saw.
• Alternatively, the casing can be trimmed using a
Gerbil cutter and filed to shape.
• Use wet and dry paper to finish edges.
No 14 Support Bracket
Notes
• The formed material for the casing can be now be cut
in half using a scroll saw or a conventional hacksaw.
It is then draw filed to finish.
• The support bracket can be made from a similar size
piece of foamex of different colour.
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Project Ideas
• The profile of the casing can be marked out using the
casing as a template.
• The profile itself is cut approximately 5mm smaller
than the casing and then filed to finish.
No 15 Assembly
Notes
• Both the material for the casing and the support can be
positioned and supported using masking tape in
preparation for gluing.
• Both materials are then affixed using tensol solvent,
tensol cement or a glue gun.
• Make sure the assembly is not disturbed during the
curing process.
No 16 Bending
Notes
• Using a strip heater, bend the support bracket to an
appropriate angle.
• The material will become plastic a lot quicker than
similarly dimensioned HIPS.
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Project Ideas
No 17 Finished Project
Notes
• Students should be encouraged to investigate a variety
of assembly methods and finishing techniques in order
to enhance the overall appearance and to individualize
the finished project.
No 18 Design Variations
Notes
• Using the ‘Plug and Yoke’ method of Press Forming,
a variety of solutions can be achieved.
• Joints can be glued or or joined with plastic fixings.
No 19 Extension Concepts
Notes
• Included is a list of suggested projects that can be
incorporated into the classroom and which can be
used to extend students use of the Press Forming
technique.
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Project Ideas
No 20 Times and Temperatures
Notes
• Shown are the suggested heating times and oven
temperatures for a number of Press Forming materials.
• If plastic becomes misshapen during the forming
process, it can be returned to the oven and reheated
until it returns to its original shape.
• Minor scratches on the surface can be removed using
a hair dryer.
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Project Ideas
Burglar Alarm
Parts List
Leaving Certificate Technology
Stage 1
Stage 2
A 2mm trim will be
removed once the
glue is dry
Part 3 is over
sized by 4mm in
length and width
•Use liquid solvent cement to join, Part 1 and Part 2 at 900 to make a
corner of the box.
• Repeat procedure for the other 3 corners
Stage 3
•Place the 4 sides on the bottom (3) and use the liquid solvent cement to
glue on the bottom
•Repeat for top of box
Stage 4
Top fits on and
off over the
trim
45deg side is
again over sized
in length and
width.
Top edge corners
are cut at 45deg
using band saw
Fix part 5 and 6 inside
box with liquid solvent
cement.
•Use the band saw to cut along each line so to remove the two corners .
•The 45deg sides are fixed on using liquid solvent cement.
•Use the band saw to cut along the 18mm line so you get the top and
bottom of the box
•Glue the trim to the inside of the four side of the bottom half of the box.
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Project Ideas
Circuit
PCB
Thyristor
Toggle Switch
Reed Switch
Cathode
gate
Buzzer
anode
a
g
Power Supply
Thyristor
c
2k2
Resistor
1M
Resistor
Circuit is created in circuit wizard.
The circuit is then converted into a PCB and manufactured.
PCB with electronic components
Thyristor is a lathing device.
Once it is switched on by a
small voltage at the gate it
stays on.
Reed Switch
Buzzer
Toggle Switch
Buzzer is fixed to
Alarm Housing
using M3 Bolts
Thyristor
Toggle Switch is
fixed to the top of
the alarm housing
Power Supply
The Reed Switch will be fixed to
the side of the Alarm Housing.
How this is done will depend on
the type of Reed Switch
Circuit Activation
The Alarm hangs on a door
with a magnet on the door
frame so when the door
opens the Reed Switch is
activated by the magnet.
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Project Ideas
Burglar Alarm Circuit
Alarm Circuit
•
•
•
•
•
•
•
Power Supply 9V Battery
SW1 – Toggle switch
SW2 – Reed Switch
R1 – 1M Resistor
R2 – 2k2 Resistor
Buzzer
Thysistor
PCB Layout
PCB with Electronic Components
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Project Ideas
Burglar Alarm: Manufacturing Instructions
Stage 1:
1. Use liquid solvent cement to join, Part 1 and Part 2 at 900 to make a corner of the box.
2. To help hold Part 1 and Part 2 at 900 use 2 try squares in inside and the other out side the
corner.
3. Place a drop of liquid solvent cement in the corner and capillary action will allow the liquid
to flow into the joint.
4. Repeat process for the other 3 corners
Stage 2:
1.
2.
3.
4.
In this stage the top and bottom are joined onto the box
When cutting out the top and bottom they can be over size by 4mm in length and width
Place the 4 sides on the bottom and use the liquid solvent cement to glue on the bottom
Then place the 4 sides and bottom on the top and glue it on with liquid solvent cement, so
that you end up with a sealed box.
Stage 3:
1. Mark a line along both sides 33mm up from the base
2. Setup the Band saw at 450.
3. Use the band saw to cut along each line so to remove the two corners as in diagram for
stage 3
4. The 450 side are again over size by 4mm in length and width by 4mm.
5. Glue on the 450 side so there is 2mm trim all round.
6. Using wet emery paper to remove all the trim around the box so that all sides are flush with
each other.
Stage 4:
1. Mark a line 18mm up from the base of the box.
2. Use the band saw to cut along the 18mm line so you get the top and bottom of the box.
3. Glue the trim to the inside of the four side of the bottom half of the box. The trim acts as the
catch for the box as the top can slide on and off over it.
Stage 5:
1. Make and solder the PCB for the Burglar Alarm.
2. Fix the PCB in the base of the box and position the reed switch close to the side of the box.
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Project Ideas
Circuit
•
•
•
•
•
•
•
9V Battery
Toggle switch
Reed Switch
1M Resistor
2k2 Resistor
Buzzer
Thyristor
The Burglar Alarm circuit works by using a reed switch and thyristor. The Thyristor is a latch device,
once it is triggered by a small voltage at the gate leg, the buzzer will stay on until the circuit is
switched off by the main switch and stopping the power to the anode. The reed switch is used to
trigger the Thyristor, this happens when the reed switch passes the magnet. Once the thyristor is
triggered the buzzer stays on no matter if the reed switch is on or off.
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Project Ideas
Design Brief: Design and manufacture a Computer Desk Lamp.
Specification:
1.
The Lamp must be a simple design which is attractive to look at
2.
The project must incorporate a simple on off switch/bulb circuit
3.
It must be suitable for a computer/study desk.
Investigation & Research:
Strength
Colour
Shape
Size
Materials
Base/Boom
Electronics
Components
Materials
Safety
Factors
Circuit
Design
Computer
Desk
Lamp
Finish
Detail
Ergonomics
Cost
Manufacture
Procedures
Time
Practical
Freehand Sketching:
Example of Vacuum forming
mould made from MDF
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Project Ideas
Solution:
Possible Solution
This solution includes:
1. Base to house electronics
2. Back Support
3. Brass tube
4. Shade Bracket
5. Vacuum Formed Shade
Manufacturing Process:
Part
1. Base
Material
MDF 12mm
2. Back Support
5mm Acrylic
3. Tubing
4. Shade Bracket
5. Shade
8mm Brass Tube
3mm Acrylic
Vacuum Forming
sheet
Labelling
6. Extras
Manufacture
Electronics housing cut out using the scroll saw.
Centre removed to make space for electronic
components. Trovicel plastics used as a veneer
to top and bottom of MDF
Countersunk holes to base. Bending to required
angle. Drilling holes to fit U bolt
Cut to length and slight bend if required
Marking out, drilling and bending
Vacuum Forming Process
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Project Ideas
Tips:
A U bolt can be a useful
item to help join round
material to flat acrylic.
Circuit Diagram:
Shown is a simple bulb circuit which uses
a battery, switch and bulb. A 6.5V 300mA
Bulb is used to obtain a greater light
output. A good idea is to use a Variable
power supply and jack socket (as shown)
as this eliminates the need for an
expensive 9V PP3 battery.
This power supply can be used to power
other Technology projects.
Miniature Jack Socket
Bulb Holder
Variable Power Supply
Factors to Consider:
Working with plastics/wood, drilling, bending, filing, gluing/adhesives, vacuum
forming process, soldering process, electronics and general assembly.
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Project Ideas
Other possible solutions:
This solution has an ash base with
centre removed to house electronics.
A 5mm bracket is used to support the
boom. The boom has holes drilled to
adjust the length of the boom. A wind
nut is able to hold the shade in place
at an angle. The shade is vacuum
formed from MDF.
This solution again has an ash base
with centre removed to house
electronics. A 5mm acrylic bracket is
used to support the boom. The boom
is screwed to the bracket for
permanent positioning. A wind nut is
again used. The shade is vacuum
formed from an MDF mould.
Applications for Leaving Certificate Technology: Another circuit which
could be used in this design is a dark sensor - Darlington or op amp
circuit. This circuit could be used to detect a small change in light level
thus tuning on the bulb. A touch sensitive circuit could also be incorporate
into another design. Another application might be computer table lamp to
incorporate a study aid like a 555 timer circuit
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Project Ideas
Design Brief: Design and manufacture a Remote Control Hovercraft.
Specification:
1.
The Hovercraft must be a simple design which is attractive to look at
2.
The project must incorporate a remote control - forward/reverse
circuit
3.
It must be suitable to travel on land and water.
Investigation & Research:
Remote
Control
DPDT
Colour
Shape
Size
Materials
Base
Bracket
Float
Options
Materials
Pipe Wrap
Safety
Factors
Circuit
Design
Hovercraft
Ergonomics
Aesthetics
Finish
Detail
Cost
Budget
Manufacture
Procedures
Time
Practical
Freehand Sketching:
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Project Ideas
Solution:
The solution includes:
1. Base with pipe wrap
2. Back Motor Support
3. Remote Control Box
4. Two motors and Fan
Manufacturing Process:
Part
1. Base
2. Back Motor
Support
3. Pipe wrap
4. Control Box
Material
3mm Trovicel Plastic
3mm Trovicel Plastic
20mm Inside centre
pipe wrap
Vacuum Forming
sheet
5. Electronics
6. Extra
Motor
Manufacture
Marking out, drilling and cutting large hole
using the Scroll saw.
Marking out, drilling and bending to required
angle - 90˚. Attaching motor.
Cut to length and attached by glue – Impact
Adhesive – See Below
Vacuum Forming Process and drill required
holes for DPDT switch.
Soldering Process
MM28 High Torque
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Project Ideas
Circuit Diagram:
PCB Layout
Shown is a circuit which uses a 6V battery, DPDT slide switch with centre off, and a motor.
This circuit will rotate the motor turns clockwise and anti-clockwise. A second motor can easily
be added to the circuit.
MM28 Motor
DPDTCO Slide switch
3 Blade Propeller Fan
Factors to consider:
Working with plastics, drilling, bending, filing, gluing/adhesives, vacuum forming
process, soldering, electronics and general assembly.
Hint: Pipe Wrap can be used to aid buoyancy of the hovercraft
Impact adhesive is great glue for joining different materials together.
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Project Ideas
Another possible solution:
This solution has a perspex base with
a camping mat used as the buoyancy
aid. An aluminum 1.5mm bracket is
used to support the motor.
The fan, seat and steering column can
be designed to each student’s
requirements. A purpose build vacuum
formed mould is used to house the
electronic DPDT circuit.
Applications for Leaving Certificate Technology: Design and make a
hovercraft with radio control. Another possible circuit which could be used in
a different design is a DPDTCO slide switch with speed control and
directional indicators circuit. This circuit could be used to speed up or slow
down the lift and rear fans. A rear rudder could also be used to steer.
© t4 Galway Education Centre
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