DTM Term 4 Week 5

This week I have been frantically trying to fix up and re-order my blog in order to pass. I will be finishing up soldering and finishing my circut later today.

Bottom of The Box

DTM Term 4 Week 4

This week i have been tidying up my blog site, and have added any posts that I have not added, and all I need to do now is finish the circuit and insert it, as well as possibly adding a top to it

Reflective Practise

Final Box

DTM Term 4 Week 3

I riveted all my sides to my box, and have begun to sand down the sides for a smoother finish. The box is now complete and the next step I have to do is silicon any gaps to make is water resistant, and add the circut and lights onto the box, as well as make and secure a plastic top to the box, which the light is encased in. I am also considering having a 2900 milliamp AA battery to power the circut as this would last much longer than the 700 milliamp one that is in my mockup

DTM Term 4 Week 2

2This week I have had to repair a problem I have only just noticed with the braces that connect the top plate to the four sides. The problem is the the rivets collide with each other, I fixxed this by remaking all the braces and spacing out where I drilled the rivet holes. Also this week I have finished putting most of the parts together such as riveting the last side plate on, and drilling and screwing in the bottom plate. I hope to finish securing and siliconing any gaps next week

Pre-Assembled Box

DTM Term 4 Week 1

For the last two weeks I didn't do much except for sailing to somes island in the first week and also I watched a TV that did not get good reception. I had an average holiday

Bottom plate joined to the braces

DTM Term 3 Week 10

This week I have begun on riveting my braces onto the sides of my box so that the walls can be joined on as soon as they have all been joined together. I am doing it in this order as it is more conveinient.

DTM Term 3 Week 9

This week I changed the size of my braces that hold the top panel to the walls to 20mm x 20mm, and I have also drilled out all of the holes to put rivets in. Problems encountered were that my holes were not drilled in the same places on every brace, so I redone every braces again with each of them being identical

DTM Term 3 Week 8

Mock exam week

DTM Term 3 Week 7

This week I cut out quite a lot of braces and also my walls (four triangles) and base of the box. There were 4 braces to connect each of the walls to the base, and 4 braces to hold each wall to each other. There were also 4 braces to hold each wall to the top panel. I have decided to use a substance called polymorph for the roofing of the box

Paragraph of agreed final design

Solidworks 2-D engineering drawing of final with dimensions and annotations

Mock Up

Solidworks rendered material post

DTM Term 3 Week 6

DTM Term 3 Week 5

DTM Term 3 Week 4

This week I have finished my 2D design of my box which will be cut out on the CAM machine, then bended to form a pyramid shape. I also need to make some braces to hold the bottom lid on. I have also decided to make the box waterproof by filling the side with sillicon.

DTM Term 3 Week 3

This week in DTM I finished my cardboard mockup of my solar light. I made it to 1:1 scale, and changed some measurements from my original design slightly to improve the appearance of the casing, the change was also updated in my freehand design. Also I have completed my evaluation of my prototype.

DTM Term 3 Week 2

DTM Term 3 Week 1

This is the first week back at school in term 3

Solidworks work in progress

2-D computer generated bottom plate

2-D computer generated top plate

Materials justification

I am using aluminium for the casing in my solar light because it is durable and lasts in outdoor conditions, I am also using clear plastic for the top of box where the solar panel and LDR sits because it lets light through and is durable.

Prototype evaluation

Evaluation: Solar Light PrototypeI have made a solar rechargeable garden light that charges in the presence of sunlight and turns on when it is dark. The box which contains the circuitry and wires is a box made of aluminium and has brackets on each of the side corners which are held in with rivets. On the bottom of the box is a lid which can be unscrewed and removed if necessary. There is a solar panel which sits on top of the box and charges the battery inside the box, which in turn powers the circuit and LEDs which are placed on either side of the solar panel. The battery inside the box is contained by a battery holder which is glued onto the inside wall of the box opposite the circuit which is also glued to the side of the box.

DTM Term 2 Week 9

DTM Term 2 Week 8

This week I glued my circut into my box and put my leds through the holes, and soldered and glued the solar panel on top of the box, and also glued my battery holder in, I have tested the light and it works perfectly

DTM Term 2 Week 7

This week I finished off my circut by soldering on the leds, solar panel, and battery holder. I now have a working circut and have just put it inside my box but have not yet had time to glue it in place. I encountered some problems such as finding that I had put the rivet holes in too close to each other so had to change them

DTM Term 2 Week 6

DTM Term 2 Week 5

DTM Term 2 Week 4

This week in DTM I have sketched and folded my box at a 90 degree angle and drilled my four holes (two for the lights and two for the solar panel) I have also started on making side brackets which hold the box together

DTM Term 2 Week 3

DTM Term 2 Week 2

On Tuesday we had half the period writing the answers to an assessment and the other half pulling apart a solar light and naming some of the components, which we finished doing on wednesday as well as as changing the colour LEDs on my circut to: Yellow/Green/White

DTM Term 2 Week 1

All through this week I have started on checking off all the work I have done in the past term

Conceptual drawings [sketches]

Solidworks engineering drawing final [annotated]

Solidwork 3-D final

Evaluation of freehand design

Client constraints

Client specifications

Freehand design with annotations

Brief

Client: Dr Tony HouseStakeholder: MyselfI need to create a self powered light to light up poacita in the coramandelConstraints: Weather proof, self powered, automaticly turn off in day and on at nightResearch: Materials, poacita, solar panels, rustproof materials (stainless steel, plastic, aluminium, brass, copper)

DTM Term 1 Week 11

DTM Term 1 Week 10

This week I have started using freehand mx to create a simple 2d design of my light, which the circut goes into.

DTM Term 1 Week 9

DTM Term 1 Week 8

DTM Term 1 Week 7

DTM Term 1 Week 6

DTM Term 1 Week 5

DTM Term 1 Week 4

DTM Term 1 Week 1-3

Materials research

AcrylicAcrylic plastics, are polymers (and copolymers) of derivatives of acrylic acid, H2C. The best-known acrylic plastic, sold under the trade names Plexiglas and Lucite, is polymethyl methacrylate. It takes a high polish, is clear and colorless, and is transparent to visible and ultraviolet light. Since it is a thermoplastic, it can be shaped while hot to form a number of objects, such as windshields for airplanes and transparent ornamental objects. Other esters of acrylic acid and methylacrylic acid similarly polymerize and copolymerize to transparent thermoplastics, differing somewhat in hardness and in softening temperatures.Stainless SteelStainless steel's resistance to corrosion and staining, low maintenance, relative inexpense, and familiar luster make it an ideal base material for a host of commercial applications. There are over 150 grades of stainless steel, of which fifteen are most common. The alloy is milled into coils, sheets, plates, bars, wire, and tubing to be used in cookware, cutlery, hardware, surgical instruments, major appliances, industrial equipment, a structural alloy in automotive and aerospace assembly and building material in skyscrapers and other large buildings. Orange juice tankers (sometimes also other chemical tankers) often have their tanks made of stainless steel. Stainless steel is also used for jewelry and watches. The most common stainless steel alloy used for jewelry is 316L. It can be re-finished by any jeweler and, unlike silver, will not oxidize and turn black. Stainless steel is 100% recyclable. In fact, an average stainless steel object is composed of about 60% recycled material, 25% originating from end-of-life products and 35% coming from manufacturing processes.PlasticA plastic is made up principally of a binder together with plasticizers, fillers, pigments, and other additives. The binder gives a plastic its main characteristics and usually its name. Thus, polyvinyl chloride is both the name of a binder and the name of a plastic into which it is made. Binders may be natural materials, e.g., cellulose derivatives, casein, or milk protein, but are more commonly synthetic resins.Fiber GlassFiber Glass is a thread made from glass. It is made by forcing molten glass through a kind of sieve, thereby spinning it into threads. Fiberglass is strong, durable, and impervious to many caustics and to extreme temperatures. For those qualities, fabrics woven from the glass threads are widely used for industrial purposes. Fiberglass fabrics can also be made to resemble silks and cotton and are used for curtains and drapery. A wide variety of materials are made by combining fiberglass with plastic. These materials, which are rust proof, are molded into the shape required or pressed into flat sheets. Boat hulls, automobile bodies, and roofing and ceiling compositions are some of the uses to which such material is put.Reference:Wikipedia

Working circut [picture]

Populated components [finished]

Populated components [progress]

PCB picture [after acid bath]

PCB picture [before acid bath]

PCB artwork [final]

Component layout [red] [final]

Circut diagram [final]

Solidworks circut

PCB artwork

Component Layout

Freehand boat wiring diagram

Solidworks boat wiring diagram

DTM Week 4, Term 3

This week I have finished my 2D design of my box which will be cut out on the CAM machine, then bended to form a pyramid shape. I also need to make some braces to hold the bottom lid on. I have also decided to make the box waterproof by filling the side with sillicon.

Mockup Box Scale 1:1

2D Design Box

Materials Justification

I am using aluminium for the casing in my solar light because it is durable and lasts in outdoor conditions, I am also using clear plastic for the top of box where the solar panel and LDR sits because it lets light through and is durable.

Evaluation: Solar Light Prototype

Evaluation: Solar Light Prototype

I have made a solar rechargeable garden light that charges in the presence of sunlight and turns on when it is dark. The box which contains the circuitry and wires is a box made of aluminium and has brackets on each of the side corners which are held in with rivets. On the bottom of the box is a lid which can be unscrewed and removed if necessary. There is a solar panel which sits on top of the box and charges the battery inside the box, which in turn powers the circuit and LEDs which are placed on either side of the solar panel. The battery inside the box is contained by a battery holder which is glued onto the inside wall of the box opposite the circuit which is also glued to the side of the box.

Updated Freehand Design

DTM Term 3 Week 3

This week in DTM I finished my cardboard mockup of my solar light. I made it to 1:1 scale, and changed some measurements from my original design slightly to improve the appearance of the casing, the change was also updated in my freehand design. Also I have completed my evaluation of my prototype

DTM Term 3 Week 1

This is the first week back at school in term 3

Working Box Without Glued Solar Panel

DTM Week 8 Term 2

This week I glued my circut into my box and put my leds through the holes, and soldered and glued the solar panel on top of the box, and also glued my battery holder in, I have tested the light and it works perfectly

DTM Week 7 Term 2

This week I finished off my circut by soldering on the leds, solar panel, and battery holder. I now have a working circut and have just put it inside my box but have not yet had time to glue it in place. I encountered some problems such as finding that I had put the rivet holes in too close to each other so had to change them

Side Brackets

Holes Drilled Out - Bottom Bracket

Box Almost Complete

DTM Week 4 Term 2

This week in DTM I have sketched and folded my box at a 90 degree angle and drilled my four holes (two for the lights and two for the solar panel) I have also started on making side brackets which hold the box together

Alluminium Box Bent

Materials Research

Acrylic
Acrylic plastics, are polymers (and copolymers) of derivatives of acrylic acid, H2C. The best-known acrylic plastic, sold under the trade names Plexiglas and Lucite, is polymethyl methacrylate. It takes a high polish, is clear and colorless, and is transparent to visible and ultraviolet light. Since it is a thermoplastic, it can be shaped while hot to form a number of objects, such as windshields for airplanes and transparent ornamental objects. Other esters of acrylic acid and methylacrylic acid similarly polymerize and copolymerize to transparent thermoplastics, differing somewhat in hardness and in softening temperatures.

Stainless Steel
Stainless steel's resistance to corrosion and staining, low maintenance, relative inexpense, and familiar luster make it an ideal base material for a host of commercial applications. There are over 150 grades of stainless steel, of which fifteen are most common. The alloy is milled into coils, sheets, plates, bars, wire, and tubing to be used in cookware, cutlery, hardware, surgical instruments, major appliances, industrial equipment, a structural alloy in automotive and aerospace assembly and building material in skyscrapers and other large buildings. Orange juice tankers (sometimes also other chemical tankers) often have their tanks made of stainless steel. Stainless steel is also used for jewelry and watches. The most common stainless steel alloy used for jewelry is 316L. It can be re-finished by any jeweler and, unlike silver, will not oxidize and turn black. Stainless steel is 100% recyclable. In fact, an average stainless steel object is composed of about 60% recycled material, 25% originating from end-of-life products and 35% coming from manufacturing processes.


Plastic
A plastic is made up principally of a binder together with plasticizers, fillers, pigments, and other additives. The binder gives a plastic its main characteristics and usually its name. Thus, polyvinyl chloride is both the name of a binder and the name of a plastic into which it is made. Binders may be natural materials, e.g., cellulose derivatives, casein, or milk protein, but are more commonly synthetic resins.

Fiber Glass
Fiber Glass is a thread made from glass. It is made by forcing molten glass through a kind of sieve, thereby spinning it into threads. Fiberglass is strong, durable, and impervious to many caustics and to extreme temperatures. For those qualities, fabrics woven from the glass threads are widely used for industrial purposes. Fiberglass fabrics can also be made to resemble silks and cotton and are used for curtains and drapery. A wide variety of materials are made by combining fiberglass with plastic. These materials, which are rust proof, are molded into the shape required or pressed into flat sheets. Boat hulls, automobile bodies, and roofing and ceiling compositions are some of the uses to which such material is put.


Reference:
Wikipedia

Template Net

Alluminium Sheets Being Cut

Case Being Cut

Case Cut

Case

Brackets Being Cut

Brackets Cut

Brackets

Brief

Client: Dr Tony House
Stakeholder: Myself
I need to create a self powered light to light up poacita in the coramandel
Constraints: Weather proof, self powered, automaticly turn off in day and on at night
Research: Materials, poacita, solar panels, rustproof materials (stainless steel, plastic, aluminium, brass, copper)

Week 2 Term 2

On Tuesday we had half the period writing the answers to an assessment and the other half pulling apart a solar light and naming some of the components, which we finished doing on wednesday as well as as changing the colour LEDs on my circut to: Yellow/Green/White

Component Layout

Term 2 Week 1

All through this week I have started on checking off all the work I have done in the past term

Component Layout

Week 10

This week I have started using freehand mx to create a simple 2d design of my light, which the circut goes into.

Partialy Finished Circut

So far on the circut I have almost soldered on 3 wires and 2 terminal blocks - 1 for the 6v battery which powers the circut and 1 for the solar panel which charges the batery. The 3 wires are for the poteniometer

Sketches Of Ideas

These are some concept sketches of outers for the circut:

Circut Diagram

DTM Week 8

This week I have been working on the PCB board, so we can finish off by adding components to it.
First off I started with a blank PCB and taped the circut diagram over the top off it and drilled holes through the board. Next I joined all the dots using a vivid and put it in an acid bath for 5 minutes

The Problems that occured were that the acid had slightly eaten away at one of the tracks.

Circut - Ready For Acid Bath

Empty Circut

Boat Wiring Diagram

Circut Diagram

Week 5 DTM

This week I have completed finally 7509, by finishing up doing section 4.1-4.3 in electrical, which was about evaluating wether or not the final met what was required in the breif

DTM Week 4 Term 1

This week I have completed the NCEA level 2 unit standard 7509, which is worth 4 credits. This week I have designed and printed out in macromedia freehand an engineering diagram for wiring a boat, and coverting this into solidworks. I have also printed out a solar panel circut in circut wizard I made earlier

DTM Week 4 Term 1

I have now started on another circut for a level 2 unit standard that will earn me 4 credits. The level 2 unit is to design a circut for a person called Andrew Hall, and is for lighting a boat. Another breief i am currently still working on is for a solar power garden light which I have designed in circut wizard

Week 2 & Week 3 11DTM

In the past week (Week 2) I have researched lighting designs and have learnt a bit on solar panels, as well as trying out 2 circuts for a garden light: a parellel and series circuts which use different ways of powering 2 LEDs.
Currently we are building a circut in circut wizard.