2. Design_Process

Design Process

This design is a simple cam-follower system attached to a series of levers repeated 13 times. The initial concept did not change from the final design in many ways, just the position of where the follower interacts with the cam and the shape of the fingers.  An important design constraint was that each assembly had to fit within less than the width of a single key (in order to accommodate for both black and white keys). Geometries and dimensions were decided as well, using a 1/8th inch tall tooth translating to a ½ inch plunge at the fingertip as our standard.

Initial Sketch

Determining lengths of links

Determining angle of plunge

Initial CAD Design

Final CAD Design

We decided to change the design of the "finger" link in order to prevent the edge of the link from prematurely contacting the piano keys. In addition we also decided to change the design of the cam system so that it can be incorporated into a single cam shaft as well as decrease the weight of the cam shaft. We also decided to add ball bearings to the lever at the contact point between the lever and the cam in order to reduce friction between the contacts. Finally, the design of the cam/cylinder changed from a circular shape to an irregular one in order to allow for greater variation in the distance the cam follower was pushed and thus more pressure on the keys.