2-Thought to Reality: Designing and Analysis

The original Castle of Eyrie has multiple levels. We decided to build a three level castle. The main idea to propel the unfolding of the castle is based on the working of a lead screw mechanism. The mechanism in action is shown in the attached video.

The tricky part was to assemble all the levels on the same lead screw with both of them moving with respect to each other during separate time intervals. In the beginning, all the levels should rise together till the maximum height of the bottommost level. After that point, the outer level should stop moving up, while the other two levels should continue to move up till the second level reaches its zenith. The topmost level is then the only moving part remained and it continues its journey to fully unfold the castle. We solve this challenge by removing the threads on the lead screw after a designated height and adjusting the relative distance between the two movable levels on it.

The next challenge was to fold the castle, i.e. to take everything back into the box. We initially thought of using the springs to take everything back on the threads of lead screw. But, gravity saved the day. The weight of the castle was enough to bring the levels back again on the threads.

To replicate the erecting towers of the castle, we decided to use a 4-bar mechanism. Upward motion of the outermost levels of castle was timed to to trigger the input link of the mechanism, which then synchronize with the upward motion of the castle to fully erect the towers (or Minarets). We used MATLAB code to figure out the respective link lengths required for the synchronized motions. Input values to code were the initial and final angles of the input link and output links. [Matlab Code]