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Video 1. Four-bar linkage simulation.
Computer-Aided Design
The CAD of this project was done via Solidworks. Our team utilized the simulations in Solidworks to test our ideas and verify that the gear ratios we calculated before indeed generated the desired output motion. Furthermore, it allowed us to identify potential problems in advance, which would increase the efficiency of our manufacturing and assembly processes.
Figure 6. CAD assembly.
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Video 2. Machine simulation.
Figure 7. Engineering drawings of different parts.
Manufacturing and Assembly
The linkage synthesis and analysis were done rather swiftly, and most of our effort went into manufacturing, assembling, and debugging. We first cut the base plate and attached the four-bar mechanism as a starting point. Although this was originally intended as a placeholder, as the design progressed, we stuck with the original base plate. After that, the holes for the gears, motors, and wheels were drilled, and the gear train was mounted on top. Since most parts were laser cut, their dimensions were not exact, and we had to recreate the same part with minor adjustments continuously. Due to this reason, bearings were omitted to allow for a more simple procedure, which was tolerable as the friction in the joints was not quite high to cause operation issues.
Figure 8. Basic assembly.
After this point, the wheel mounts and housings were printed and then mounted alongside the parallel four-bar mechanism that linked the two front wheels together. Similarly to links, the gears had to be cut multiple times as their alignment had to be quite more precise than other mechanical parts. Our team decided to cut multiple sizes of gears, which differed only in small increments from each other, to ascertain the best fit for the gears to be meshing with each other smoothly. Before mounting and connecting any of the electronics, we tested the mechanism by hand cranking it to ensure that our hardware was functional. The dwell mechanism was added later by grinding away some of the teeth in the driver gear. At a neutral position, this allowed the car to drive freely using the previously established joystick control.
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Video 3. Final presentation.
Conclusions and Future Works
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(Bill of Materials.)