classroom project ideas

7/25/2019 Classroom Project Ideas

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L e a v i n g C e r t i f i c a t e

Technology

Classroom Project Ideas


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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 ProjectDragster project PPT............................................................................................ 26


Mobile Phone Holder

Mobile Phone Holder PPT................................................................................... 37

Inspire and Create PPT ........................................................................................ 41


Presentation Notes ............................................................................................... 49

Burglar Alarm

Burglar Alarm PPT .............................................................................................. 58

Alarm Circuit ....................................................................................................... 60


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.


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Design and ManufacturingDesign and ManufacturingDesign and ManufacturingDesign and ManufacturingDesign and ManufacturingDesign and ManufacturingDesign and ManufacturingDesign and Manufacturing

Projects 1 & 2Projects 1 & 2Projects 1 & 2Projects 1 & 2 ---- Desk FanDesk FanDesk FanDesk FanProjects 1 & 2Projects 1 & 2Projects 1 & 2Projects 1 & 2 ---- Desk FanDesk FanDesk FanDesk Fan

Manufacturing & Vacuum Forming

Design for Manufacturing

Design Brief: Design and Manufacture a W orking Model Electric Fan

Project Option 1 Project Option 2

These are Integrated projects covering a range of processes and manufacturing skills includingDesign, Mechanisms, Electronics control, CNC machining, Vacuum Forming etc.


The design must be manufactured using thematerials supplied and incorporate the following:

Have a vacuum formed base that will support the fan andhouse the Electronic circuit, Switch & 3 Volt battery

Have a 8 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.

Design for Manufacturing. - Project Option 1

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.


Given an MDF block 125 x 75 x 20 mm design a basic shape to encapsulate thecomponents, support the mechanisms and house the electronic controls.

Mould Manufacture 1 Design Variations

Examples of six Pattern Designs from the MDF blank

Refinement to the mould may be by achieved using readily available componentsin the workshop e.g. coins, washers, rivets, expanded polystyrene shapes, badges

etc.


Mould Manufacture - 2

Without proper draft the mould cannot beremoved from the vacuum formed case withoutdamaging it.

Tilting the table on a Scroll saw or Band

saw will give the necessary angle but willrequire finishing by a sanding block.

Wood Plane used to get DraftTable set to 5 on Belt Sander

A most important requirement in mould design is DRAFT which must be al least 3 to 5 .

Wood chiselused to get Draft


Mould Manufacture - 3Internal holes or cavities in a mould must

have 2 mm drilled holes through to the base

of the mould so as all air can be removed bythe vacuum pump.

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 formedshape.

A mould may be dusted with talcum powder toassist 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.

Project Ideas


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Finished base made from 2 mm Polystyrenes istrimmed to shape using:

A band-saw.

Tin snips.

GERBIL cutter.

(A Gerbil is a multi-purpose VacuumForming cutting & Finishing Machine).

A Tungsten Carbide cutting tool is used for creatinga 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.

Finishing a Vacuum Formed Object

The finished fan base is then drilled to

accommodate Switches, Variable resistor, LED andpulley mechanism support etc.


Desk Fan 2

Parts and Dimensioned drawings for Desk Fan 2

Vacuum Formed Base Suppli ed Parts Speed control circuit & Motor

Base Dimensions Fan Stand & Alternative DesignBrass washer


Making the Brass support Bar

Facing in the Lathe Centre Dri ll ing 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


Completed Variable speed Model Fan

A PCB mounted electronic circuit using aTIP 121 chip is used to provide a range of

speeds.

Note that motor holder has been spraypainted.

Model Fan has been drawn up and fully

rendered in Solid Works.

Assembled Project 2


Completed Project 1.Assembled fixed speed Model Fan assembled using parts provided.

Model Fan has been drawn up andfully rendered in Solid Works.

A larger diameter Propeller and Solar Motor will change thisproject to a Generator. Add two LED to indicate current Output


Manufacture of the bracket Project 1

Bracket is marked out, shaped, drilled, then polished before bending.

The Bracket must be accurately bent using a Bending Machine orFolding Bars

Dimensions for Vacuum Form for Base.

Project Ideas


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Bracket Design - Project 2

Given a Brass strip 30 x 165 x 1 mm design alternative ofsupport 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.


Advanced option 3 for this Project.

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.

The speed control may be recycled for use in any motorized 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.

Brass Cone soldered

to Rotor


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

Project Ideas


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Design and ManufacturingDesign and ManufacturingDesign and ManufacturingDesign and ManufacturingDesign and ManufacturingDesign and ManufacturingDesign and ManufacturingDesign and Manufacturing

Vacuum FormingVacuum FormingVacuum FormingVacuum FormingVacuum FormingVacuum FormingVacuum FormingVacuum Forming

Manufacturing Vacuum Forming

ProcessA sheet of thermoplastic material isclamped around its edges and heateduntil flexible. A heat-proof mould of therequired shape is raised into thesoftened plastic. The air between thesheet and the mould is evacuated by avacuum pump. Atmospheric pressurethen forces the plastic sheet tightly

over the mould.

MaterialsHigh Impact Polystyrene sheets from1mm to 3mm in range of colours are

available Including clear sheet used forbubble packaging in presentation boxes.


THE STAGES INVOLVED IN VACUUM FORMING

1. First, a former is made from amaterial such as a soft wood. Theedges or sides are shaped at anangle/draft of 3 so that when theplastic is formed over it, the former canbe removed easily.

2. The finished former is placed in avacuum forming machine.

3. A sheet of plastic e.g. polystyrene isclamped in position above the mould


4. The heating elements are then turnedon and the plastic slowly becomes soft

and pliable as it heats up. The plasticcan be seen to sag and as the surfaceexpands

5. After a few minutes the plastic isready for forming as it becomes very

flexible or rubbery.

6. The heater is turned off and themould is moved upwards by lifting thelever until it locks in position.

MOULDING PROCESS


7. The 'vacuum' is turned on and thispumps out all the air beneath the plastic

sheet. Atmospheric pressure above theplastic sheet forces it down on the mould.The shape of the mould can now be clearly

seen through the plastic sheet. When theplastic has cooled the vacuum pump is

switched off.

8. The plastic sheet is removed from the

vacuum former. The sheet has theshape of the former pressed into itssurface.

9. The excess plastic is trimmed so thatonly the plastic bowl remains An

enlarged view of the final dish is seenopposite.

COMPLETED MOULD


Mould ManufactureTo achieve the desired shape moulds may be madeby gluing layers of material together and thenshaping using a variety of hand and machine toolssuch as CNC Routers, Laser Cutting, Scroll Saws,

Spindle molding table and Belt sanders .

Materials used in mould construction may beMDF, Balsa wood, Modelling clay. MDF isusually used in school and cast aluminum orepoxy resin in industry. Mould strength and

rigidity may increased by designing inrecesses, grooves or steps.

Example of trays or bubble or blisterpackaging produced by vacuum forming

http://www.uni-plastic.com/Thermoforming%20&%20Vacuun%20Forming.htm

Web site link to commercial blister vacuum forming & packaging

Project Ideas


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When designing a mould it is most importantto considering the removal of the vacuum

formed shell. No overhanging lips or negativeangles. A draft angles of 3 to 5 must beprovided on all surfaces of the mould. Theformed plastic and the mold is very difficultto seperate and may split or crack. A wooden

mould may be dusted with T alcuum powderto aid removal.

By using light plywood, aluminum or Perspex

sheet as a base layer on your mould, it maybe attached using two sided tape so that itmay be easily removed and used as the basefor your completed project. See example ofcar mould opposite.

MAKING A MOULD


Commercial examples of Vacuum Forming


Tips & Tricks1. 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, sandingblocks.

5. Existing shapes may be filled with patching plaster to make a

mould.

6. Internal holes cavities in a mould must have 2 mm holes drilledthrough 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 toassist in releasing them from the mould.

8. The base of the mould may be drilled and treaded M6 to allow ahandle to be attached to pull the mould from the formed shape.


Mould Manufacture

1. MDF block basic shaped to encapsulate the

components and support the mechanism.

2. MDF block design refined to hold 9V battery

and provide ergonomically designed profiles forSwitches, LED & Variable resistors

3. Finished 2 mm Polystyrenes mould ready for

motor drilling and fitting of electronic components

and pulley mechanism support.

STEPS in the DEVELOPMENT of the PATTERN


Examples of six Pattern Designs made from the MDF blank


FOUR COMPLETED MOULDS

Project Ideas


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DesignforManu

facture

Design

andManufactureaWorkingmodelElectricFan.

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9/72

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esignandmakeabrassfanrotortoreplacetheboughtinoption.

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earorchaindrivemaybeused.

A

mechanismdesignedto

allowthefantooscillate.

R

eversibleDPDTCentre

Offswitchisfitted.

R

ed/GreenLEDfittedtoindicateforward/reverseoperation.

N.B.T

hespeedcontrolcircuit/drivemayberecycledforu

seinanymotorisedproject.

j


10/72

DesktopFanProject-Material

List

Item

Quantity

D

escription

RapidElectronicsRefCode

1

1

M

DFboar

d140x

70x

24mm

2

1

P

olys

tyreneshee

tx

2mm

V/Form

ing

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t.

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1

B

rass

Strip164x

30x

1mm

Miko

Metals

3b

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iona

l)

B

rass

bar

Dia

.8mmx

100mm

Miko

Metals

3c

1(opt

iona

l)

M

otormount

20mmcl

iptosuit

1.5

4.5Vmotor

37

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4

1

S

teel

bar

50x

2mmchromed.

37

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50

5

1ofeach

P

ulley

blac

kPolys

tyrenes

12&25

37

-0375&37-0

380Pko

f10

6

1

P

olyt

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Fan

60mm

06

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06-0

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it

7

2

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No

4x

6.5

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2

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8.

33

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2

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33

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11

1

M

iniature

Sw

itch

SPDT

75

-0211

12

1

M

iniature

high

torque

Motor

3V

olt

37

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13

1

R

ed&Green

LEDperpacketo

f100

55

-1776&55-1

772

14

1

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55

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15

1

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62

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16

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indle6

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65

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16

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B

attery

Hol

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3Volts

18

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17

1

B

attery

Clip

PP3

18

-0092

18

1

L

engt

hPul

ley

drive

belt

52

-5082

AdditionalTools&EquipmentRequired

ending

Mac

hine,D

rillw

ithStand,Va

cuum

Form

ing

Mac

hine,H

eigh

tGauge

rillbits

2,2.5,3.5&4

,Finewaterpaper,

Han

dClamp,

hillipsscrew

driver,P

liers,

Metalpo

lis

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h,

oldering

Iron,S

older,

Red

&Black

lin

kw

ire,

Wire

Stripers,

SuperG

lue,

Stanley

knife.

Materialsmaybepurchasedfrom

;

Miko

Metals;021-4966907

CentralTechnologyLtd;01-8

223355

RapidElectronicsLtd;0044-12

06751166

j


11/72

VacuumForming

rocess

Asheet

ofthermop

last

icmater

ialisclampe

daround

itsedges

andheatedun

tilflex

ible

.A

heat-proofmou

ldof

there

quiredshape

is

aise

dinto

theso

ftenedplas

tic.

The

air

between

theshee

tan

dthemou

ldisevacua

tedbya

vacuumpump.

Atmospher

icpressure

then

orcest

heplas

ticshee

ttightlyover

themou

ld.

Apermanen

tly3-Dshape

isformed.

hevac

uum

form

ingprocesscanbeused

tomakeproduc

tpac

kaging,s

peakercasingsand

evencar

ashboar

ds.

Normal

ly,d

raftanglesmus

tbepresent

inthe

designon

themo

ld(arecommen

dedm

inimumof

3),

therwisere

leaseof

the

formedplast

ican

dthemol

disvery

difficu

lt.

Vacuum

form

ing

isusua

lly

butnotalwaysrestricted

toform

ingplas

ticparts

thatarera

thershal

low

in

epth.A

thinshee

tis

formed

intorigidcavi

ties

forun

itdoseso

fpharmaceu

tica

lsan

dforlo

oseob

jects

hatare

cardedorpresen

tedaspoin

t-of-purchase

items.

Thicks

heet

isformed

intopermanen

tobjec

ts

uchas

turnpi

kesignsan

dprotectiv

ecovers.

Rel

atively

deeppartscan

beformed

ifthe

form-a

bleshee

tismec

hanica

llyorpneumat

icallystre

tched

rior

to

bringing

itincontac

twiththemol

dsurfacean

dbeforevacuum

isappl

ied.

uitablemater

ialsforuse

invacuum

form

ingareconven

tionall

ythermop

last

ics,

themos

tcom

monan

d

asiestbeingHighImpactPolystyreneSheeting(HIPS).T

hisis

mol

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form

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acuum

form

ing

isalsoappropriate

ortransparen

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licw

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idelyused

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foraerospacesuchas

CW(p

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indows)canop

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form

ilitary

fixe

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ircraft.

j


12/72

VacuumFormingTips&

Tricks

1.M

DF&3mmplywoodsheetarecheapandsuitablematerialsusedformanufacturingMoulds.

2.C

omplexshapescanbebuiltupinlayers.

3.T

wosidedtape,coins,dow

els,metalcrests,carbad

ges,superglue,woodfillers,matchesmaybeused

toenhance

o

rpersonalizeamould.

4.H

olesaws,countersinkingbits,counterboringbits,sandingblocks.

5.E

xistingshapesmaybefilledwithpatchingplaster

tomakeamould.

6.I

nternalholescavitiesina

mouldmusthave2m

mholesdrilledthrought

othebaseofthemouldtoallthe

c

avitytoemptiedbythev

acuumpump.

7.L

argeorcomplicatedshapemaybedustedwithtalcumpowdertoassistinreleasingthemfromthem

ould.

8.T

hebaseofthemouldma

ybedrilledandtreadedM6toallowahandletob

eattachedtopullthemo

uldfromthe

formedshape.

9.D

onotoverheatedtheplasticsheetasitwillsagsa

ndthisincreasesthelike-hoodofwebsbetweenm

oulds.

10.W

elldesignedpatternwit

hsmoothfinishareeasilyremovedfromthefinish

edvacuumform.

tepsintheVacuumFormingProcess

j


13/72

Exam

plesofStudentPro

jects-VacuumFormsusedtohouseElectronicProjects.

j


14/72

j


15/72

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16/72

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17/72

Motorcycle Project

Design and make a project of simple construction,suitable for a

Leaving Certificate Technology class.

1. Main body

2. Front forks

3. Handlebars

3 Wheels

1 Motor

2 Battery Holders

1 Switch

1 Gears Wheel

1 Worm gear

1 Seat & Petrol Tank

4 AA Batteries

Additional components required:

Three part design:

Motorcycle Project

The Main body or frame:

Body profile made from sheet Aluminium 1mm,Blank size shown in the diagram.

Finished outline is Symmetrical.

Profile marked out, holes drilled and

then cut from given blank according

to accompanying dimensioned

drawing

Finished part.

The finished profile is then bent

to shape as shown.

Motorcycle Project

Mark out the desired profile according

to the given dimensions. Then drill the

three 4mm holes and cut out the

profile.

Motorcycle Project

Mark out and drill the blank.

Cut out the profile and finally

bend as required.

Completed Handlebars shown

opposite.

Motorcycle Project

Assembled view of the three main parts of

the Motorcycle

The additional components are

then added to give the final

assembled Motorcycle project

shown.

Handlebars

Main body

Front forks

Motorcycle Project

Finishing Methods

Polishing:

Mechanical: &

Chemical Polishes:

Plastic Coating:

Painting: &

Project Ideas


18/72

Motorcycle Project

Metal Dyes:

Motorcycle Project

Project Enhancements:

Introduce Timing circuits:

Flashing LEDs:

Sound Chip:

Tilt Switches:

Finally design and make a suitable Seat and Fuel Tank for the project.

Motorcycle Project

Some typical Technology room sheet metalworking tools:

Tin Snips Hand Nibbler Sheetmetal Clamp

Bench vice foldersSimple vice jaw folders

Conical drill

Shears

Folders

Rollers Combined bench mounted, hand

operated rollers, folders and

shears.

Folding Bars

Project Ideas


19/72

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.

Project Ideas


20/72

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 arealtered 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 Squareand 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 dont 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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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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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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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 exactlythe same as for the main body described previously.

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Completed Project

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Dragster Project: emphasis on controlDragster Project: emphasis on controlDragster Project: emphasis on controlDragster Project: emphasis on controlDragster Project: emphasis on controlDragster Project: emphasis on controlDragster Project: emphasis on controlDragster Project: emphasis on control Control

The dragster project focuses on control

Controlling electric motors is the basisfor many applications in industryExamples 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 desiredmotion 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 Dont forget Tracey!

Dragster Theme

Expandable design - Body based on inter fitting aluminiumchannels. Two simple gearboxes and motors are used to drive large rear

wheels. Each wheel may be controlled separately.

Prototype vehicle:

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Castor

Castor in a car steeringDragster Project

Integration of Topics:

Body/Frame design: Sketching of ideas, dimensioning, selection of suitable materials,exercises i n SolidWorks

Assembly

Techniques

Screwing and Tapping, and Soldering, andconsideration of other methods

Drive SystemsGear boxes ,Both bought and constructed, Bevel gears,

Worm Gears, Pulley Systems, Belt & Chain Drives, Drive

reversal, etc.

Finishes: Polishing, Painting, Vacuum forming of body shell.

Electronics: Components, Circuit design, Board layout, Timing circuits,Electronic theory.

Project

Management

Allocation of resources, Time, Materials, Equipment,

Costs, etc

Dragster project

Summary

Some or all of the foll owing 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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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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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 workswell and that the worm and gears are neither

too tight, nor too loose.

M4 Cheese head screws

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Length of dragster

adjusting screw

Top view of switch PCB on the left with copper side view on the right

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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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25

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Castor for reverse movement of dra ster

Castor

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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 batteries1 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 longAluminium 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 long1 only M3 cheese hd x 15 or 20 long

2 only M5 flat washers

M3, M4, M5 nutsSticky pads to stick down battery holder

6 way ribbon cable (Rapid: - code 37-0310)

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1

Mobile Phone Holder

Design for Manufacture

2

Mobile Phone Holder Project

3

IntroductionVariety of Processes and

Manufacturing Techniques

Production of Artifacts

Enhance Problem Soving and DesignCapabilities

4

Introduction

Press Forming using Foamex

Solutions to Real Life DesignSituations

Development of IndividualisedProducts

5

Introduction

Thematic Approach

Encourage Integration of Topics

Adapt Projects to meet individualCircumstances

6

Objectives

A Range of Manufacturing Skills:- Heat forming

- The use of jigs and formers

- Marking out, cutting, drilling,finishing and assembly ofmaterials.

An Understanding of TheCharacteristics of ThermoplasticsMaterials

Students will Develop:

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7

Objectives

Graphics/Design skills and techniques

Product Analysis Techniques andDesign Specifications

Ability to Design according to UserRequirements

Research Skills using ICT

8

PresentationTheme:

Mobile phones are a worldwide phenomenon thathave revolutionised the way we communicate withone another. They are both desirable andessential to our everyday lives.

The ways in which we carry, protect and secureour mobile phones can be based on fashion,practicality and function.

Design Brief:

Design and make a functional mobile phoneholder suitable for personal or desktop use

9

Constraints

Work within student skills range

Manufacturing Processes:

- Press forming

- Vacuum Forming

Functionality and Ease of Use

High Standard of Finish Use ofGraphics

Individualised Product10

Research/Investigation

Designers need stimulation

Provision of stimulation

Personal Research How did itinfluence the thought process

See accompanying presentation onResearch Add to it

11

ResourcesMaterials3mm expanded foam sheet(Foamex)

1.5mm Vacuum formingplastic

18mm MDF or suitablematerial for production ofmoulds and formers

Grip range press fit nylonclick fasteners

Tie wraps

Acrylic cement or solvent

EquipmentOven

Vacuum former

A range of hole saws orforstner bits

Scroll saw

Wet and dry paper

12

Making the Formers

Male and Female Formers 18mm MDF

Simple Shapes

Female Larger by thickness of casing material

Male Fixed to Base (Allignment)

Taper Not necessary, Radius top edge

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13

Heating and FormingMaterial is placed in pre-heated oven(See Temperature chart )

Heated material is drapedover male former

Locate female formerover male former

Force together and holduntil material cools

14

Cutting

Material can be trimmedto leave a 10mm lip

File and finish to shapewith wet and dry paper

15

Cut casing material in halfusing a scroll saw and fileto finish

Support bracket can bemarked from casing but

its profile is cut 5mmsmaller all round and filed

to finish

Support Bracket

16

Casing is affixed to supportbracket using tensol

solvent/cement or a glue gun

Assembly may need to besupported with maskingtape during the gluingprocess

Assembly

17

Bending

Support Bracket can be bentusing a Strip Heater

18

Finished Project

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19

Design VariationsA number of design variations are

possible using this process

20

Extension Concepts

Survival KitSwimming HolidaysJewelleryPower PodCD StorageCampingPamper PodBaby GearHandsets/Remote ControlPencil Case

Personal AlarmMouse HouseIT accessoriesDesk TidyRadio HousingInstrument CaseToolboxRobot ShellMoney BoxPaintbox Store

21

Material OvenTemp. C

Time

(Seconds)

Notes

3mm Foamex 140 30 If plasticbecomesmishapen, itcan bereturned to

the oven andreheated.

3mmPlastazote

140 60

6mmPlastazote

140 90

Times & Temperatures

22

LinksTEP International Manufacturing Centre

University of Warwick

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

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1

Mobile Phone Holder

Inspire and Create

2

3 4

5 6

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7 8

9 10Be

nding

shee

tover

acylind

er?

Cut angled ?

11 12

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13 14

15 16

17 18

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19 20

21 22

23

Special Thanks to:

Technology Education Centre, OmaghMr. R.A. Moffatt, Western Education and Library Board

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Press Forming Mobile Phone Holder

Manufacturing Instructions

Male and female formers aremanufactured from 18mm MDF

Female former is larger than male

former by thickness of casingmaterial

A piece of 120x200x3mm Foamex

is placed in pre heated oven

The material is heated for

approximately 30 secs. At 140C

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The heated material is drapedover the male former

The female former is located overthe male former

The material can be trimmed usingUsing a pencil a line can be marked

Force is applied to sandwich thetwo together and held for 2 mins.

The material can then be releasedfrom the male former

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Affix both materials using tensol Bend the support bracket using a

Cut the formed casing in half anddraw file to finish

Mark the casing profile on adifferent colour piece of Foamex

Cut the profile approx. 10mmsmaller than the casing

Support both materials in positionusing masking tape

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The finished project can be enhanced inorder to individualize its a earance

A variety of solutions can be achieved using the Plug and

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Design for Manufacture Press Forming

Mobile Phone HolderPresentation Notes

No 2-4 Introduction NotesThe 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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No 5-6 ObjectivesNotes

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 PresentationNotes

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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Design Brief:

Design and make a functional mobile phone holder suitable

for personal or desktop use

No 8 ConstraintsNotes

Expectations will be constrained by the design,

communication and manufacturing skills of the targetgroup

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 itsappearance should be encouraged

Products can be individualized to suit particular

models of phone.

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No 9 ResearchNotes

Remember the majority of students need stimuli in

order to come up with ideas

Present plenty of examples in order to provideopportunities 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 ResourcesNotes

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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Scroll saw

Wet and dry paper

No 11 Making the FormersNotes

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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No 12 Heating and FormingNotes

The material is placed in a pre heated oven and heated

for the appropriate time (Approx. 30 secs. at 140C

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 AssemblyNotes

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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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 AssemblyNotes

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 BendingNotes

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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No 17 Finished ProjectNotes

Students should be encouraged to investigate a variety

of assembly methods and finishing techniques in order

to enhance the overall appearance and to individualizethe finished project.

No 18 Design VariationsNotes

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 ConceptsNotes

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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No 20 Times and TemperaturesNotes

Shown are the suggested heating times and oven

temperatures for a number of Press Forming materials.

If plastic becomes misshapen during the formingprocess, 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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1

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.

.

1

22

.

.

.

.

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1. , 1 2 00 .

2. 1 2 00 2

.

3.

.

4. 3

1.

2. 4

3. 4

4. 4 ,

.

1. 33

2. 450.

3.

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4. 450 4 4.

5. 450 2 .

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.

1. 1 .

2. 1 .

3.

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1. .

2. .

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1

22

. ,

,

.

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.

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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 circuit3. It must be suitable for a computer/study desk.

Investigation & Research:

Strength

Materials

Safety

Factors

Finish

Detail

Cost

Manufacture

Procedures

Time

Practical

Ergonomics

Circuit

Design

Electronics

Components

Materials

Base/Boom

Colour

Shape

Size

Computer

Desk

L

am

Freehand Sketching:

Example of Vacuum forming

mould made from MDF

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Solution:

Possible Solution

Manufacturing Process:

Part Material Manufacture

1. Base MDF 12mm 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

2. Back Support 5mm Acrylic Countersunk holes to base. Bending to required

angle. Drilling holes to fit U bolt3. Tubing 8mm Brass Tube Cut to length and slight bend if required

4. Shade Bracket 3mm Acrylic Marking out, drilling and bending

5. Shade Vacuum Forming

sheet

Vacuum Forming Process

6. Extras Labelling

This solution includes:

1. Base to house electronics

2. Back Support

3. Brass tube

4. Shade Bracket

5. Vacuum Formed Shade

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Miniature Jack Socket

Variable Power Supply

Bulb Holder

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 powerother Technology projects.

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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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 circuitcould 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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RemoteControlDPDT

MaterialsPipe Wrap

SafetyFactors

FinishDetail

CostBudget Manufacture

Procedures

TimePractical

ErgonomicsAesthetics

CircuitDesign

FloatOptions

MaterialsBase

Bracket

ColourShapeSize

Hovercraft

Design Brief: Design and manufacture a Remote Control Hovercraft.

Specification:

1. The Hovercraft must be a simple design which is attractive to look at2. The project must incorporate a remote control - forward/reverse

circuit3. It must be suitable to travel on land and water.

Investigation & Research:

Freehand Sketching:

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Solution:

Manufacturing Process:

Part Material Manufacture

1. Base 3mm Trovicel Plastic Marking out, drilling and cutting large holeusing the Scroll saw.

2. Back MotorSupport

3mm Trovicel Plastic Marking out, drilling and bending to requiredangle - 90. Attaching motor.

3. Pipe wrap 20mm Inside centrepipe wrap

Cut to length and attached by glue ImpactAdhesive See Below

4. Control Box Vacuum Formingsheet

Vacuum Forming Process and drill requiredholes for DPDT switch.

5. Electronics Soldering Process

6. Extra Motor MM28 High Torque

The solution includes:1. Base with pipe wrap

2. Back Motor Support3. Remote Control Box4. Two motors and Fan

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MM28 Motor

3 Blade Propeller Fan

DPDTCO Slide switch

Circuit Diagram:

PCB Layout

Factors to consider:

Working with plastics, drilling, bending, filing, gluing/adhesives, vacuum formingprocess, 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.

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.

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This solution has a perspex base witha camping mat used as the buoyancyaid. An aluminum 1.5mm bracket is

used to support the motor.

The fan, seat and steering column canbe designed to each students

requirements. A purpose build vacuumformed mould is used to house the

electronic DPDT circuit.

Applications for Leaving Certificate Technology:Design and make ahovercraft with radio control. Another possible circuit which could be used in

a different design is a DPDTCO slide switch with speed control anddirectional 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.

Another possible solution:

Project Ideas

classroom project ideas

Documents