"Lucky" Final Report
"Lucky" Final Report
Lucky
Prof: Robert Shaefer
TA: James Simonelli
Team 13
Jonathan Chang
Eujin Chung
Brandon Judoprasetijo
12/16/2014
Figure 1: Pictured in bottom right (from left to right): Brandon Judoprasetijo, Eujin Chung, Jonathan Chang
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Abstract
For years, the task of transporting objects through the use of a rubber band has led to redundant
designs focused on travel by land. This report documents our innovative design that utilizes energy from
a rubber band to generate airflow and lift. First, we will cover the design challenges followed by a review
of other state-of-the-art designs available online. Next, we will provide the progression of our design
concepts and the specifications of our final design. Lastly, we will discuss the analysis performed, the
product fabrication process, and our results.
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Table of Contents
Team #13 Picture .......................................................................................................................................... ii
Abstract ........................................................................................................................................................ iii
Table of Contents ..................................................................................................................................... iv
Table of Figures ............................................................................................................................................. v
List of Tables ............................................................................................................................................... vii
List of Symbols ........................................................................................................................................... viii
1. Introduction .............................................................................................................................................. 1
2. Design Requirements ................................................................................................................................ 1
3. Prior Work (state-of-the-art) ................................................................................................................. 1
4. Concept Development .............................................................................................................................. 3
4.1 Design Concept 1 ................................................................................................................................ 3
4.2 Design Concept 2 ................................................................................................................................ 3
4.3 Design Concept 3 ................................................................................................................................ 4
4.4 Selected Design Concept..................................................................................................................... 5
5. Design Specifications ................................................................................................................................ 5
5.1 Final Design Description...................................................................................................................... 6
5.2 Device Parts Design ............................................................................................................................. 8
5.3 Powering the Device ............................................................................................................................. 16
6. Calculations and Analysis ........................................................................................................................ 18
7. Product Fabrication ................................................................................................................................. 20
8. Product Testing and Evaluation .............................................................................................................. 22
9. Design Requirement Satisfaction ............................................................................................................ 22
.................................................................................................................................................................... 24
10.
Conclusion ....................................................................................................................................... 25
iv
Table of Figures
Figure 1: Pictured in bottom right (from left to right): Brandon Judoprasetijo, Eujin Chung, Jonathan
Chang ............................................................................................................................................................ ii
Figure 2: Example of two car designs where the rubber band gives power to the axle. Left: [1] Right: [2] 2
Figure 3: Airplane design where rubber band powers propeller [3] ............................................................ 2
Figure 4: Chang's first design concept. ......................................................................................................... 3
Figure 5: Judoprasetijo's first design concept............................................................................................... 4
Figure 6: Chung's first design concept. ......................................................................................................... 5
Figure 7: Exploded view of all the final parts. ............................................................................................... 6
Figure 8: Pictorial of final product from different views. ............................................................................. 7
Figure 9: Isometric views of the fuselage on SolidWorks (left) and the actual product (right) .................... 8
Figure 10: From left to right: actual 3D printed wheel axles and isometric view of the SolidWorks model 8
Figure 11: From left to right: front and side views of the SolidWorks model of the wheel axle .................. 9
Figure 12: From left to right: final 3D printed wheel product and isometric view of SolidWorks model. ... 9
Figure 13: Isometric views of the actual front (left) and the SolidWorks model (right) ............................. 10
Figure 14: Bottom views of the actual front (left) and SolidWorks model (right) ...................................... 10
Figure 15: Front views of the actual front part (left) and the SolidWorks model (right) ........................... 11
Figure 16: Front views of the actual propeller (left) and the SolidWorks model (right) ............................ 11
Figure 17: Side views of the actual propeller (left) and the SolidWorks model (right) .............................. 12
Figure 18: From left to right: front and top views of the propeller rod on SolidWorks ............................. 12
Figure 19: Side views of the actual 3D printed tail (left) and the Solidworks model (right)....................... 13
Figure 20: From left to right: top and isometric views of the tail part on the SolidWorks model ............. 13
Figure 21: From left to right: an isometric view of the final glider holder and the side view of the
SolidWorks model ....................................................................................................................................... 14
Figure 22: Front view of the glider holder on SolidWorks model ............................................................... 14
Figure 23: Bottom views of the actual glider (left) and the SolidWorks model (right)............................... 15
Figure 24: Top views of the actual glider (left) and the SolidWorks model (right)..................................... 15
Figure 25: Assembling the rubber band and propeller ............................................................................... 16
Figure 26: The blue arrow indicates how the air will be scooped by the propeller ................................... 17
Figure 27: The red arrow indicates the direction the propeller rotates ..................................................... 17
Figure 28: The blue arrow indicates the flow of air along the entire device; the white arrow shows the
direction of travel ....................................................................................................................................... 17
Figure 29: Displays the total mass and center of gravity of our final device .............................................. 18
Figure 30: Graph of force versus displacement in order to find the spring constant ................................ 19
Figure 31: STL models of various parts ready to add to the pack file ......................................................... 21
Figure 32: Screenshot of the Pack file ready for printing ........................................................................... 21
Figure 33: From left to right: the top, side, and front view of the final product ........................................ 24
Figure 34: From left to right: the top, side, and front view of the final SolidWorks model ....................... 24
Figure 35: Engineering drawing of the front part ....................................................................................... 28
Figure 36: Engineering drawing of the back part ........................................................................................ 29
Figure 37: Engineering drawing of the fuselage ......................................................................................... 30
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vi
List of Tables
Table 1: Device Dimensions .......................................................................................................................... 6
Table 2: Mass, Force, and Displacement Data for estimating the elastic constant (k) of the rubber band19
Table 3: Data and measurements used to calculate the total potential energy ........................................ 20
Table 4: Data from testing our device ........................................................................................................ 22
Table 5: Design requirement satisfaction ................................................................................................... 23
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List of Symbols
Symbol
Description
Units
Force
Spring constant
N/m
Displacement
Mass
kg
Acceleration
9.80665 m/s
Potential energy
Number of winds
--
Circumference
xi
viii
1. Introduction
We were challenged to design and build a small rubber band powered device capable of traveling
a horizontal distance. Past engineers thoroughly explored the concept of car-inspired vehicles powered
by winding up rubber bands around wheel axles. Our team has successfully created a stylish, light weight
vehicle that, unlike most other designs, is powered using a propeller. The bulk of the device is made of
acrylonitrile butadiene styrene (ABS) plastic and the parts are 3D printed. Upon completion, our teams
design will compete against other classmates designs. Our teams goal is to create a vehicle that not only
operates efficiently, but also stands out creatively and aesthetically amongst the competition. Our design
is sure to do both.
2. Design Requirements
The requirements and parameters for this project are outlined below:
1. The device must be powered by rubber bands
2. The device must be able to transport itself across a horizontal surface
3. Up to three rubber bands may be used
4. The rubber bands may be manipulated into any shape
5. The device must be self-contained
6. The entire device, including rubber bands, must be transported
7. The device must be made of ABS plastic, except for auxiliary parts
8. Adhesives may be used, but adhesive tapes are restricted
9. The maximum dimensions are 10 by 10 by 20 centimeters
10. All primary parts of the device must be fabricated using the Dimension Elite 1200 printer
Figure 2: Example of two car designs where the rubber band gives power to the axle. Left: [1] Right: [2]
Another design is that of an airplane with a propeller. The rubber band is attached to a hook on
both the propeller and the opposite end of the plane. Energy is stored by winding the rubber band multiple
times. Releasing the propeller generates airflow, which the wings use to create lift.
We propose an innovative design that hybridizes the previously mentioned concepts and provides
a fresh take on these two classic designs.
4. Concept Development
4.1 Design Concept 1
Changs preliminary design was a standard vehicle. A rubber band would be attached to the
chassis on one end and to the wheel axel on the other. By spinning the wheel axel in the appropriate
direction, the rubber band would create tension. Upon release, the tension would cause the rubber band
to unwind and rotate the wheel axel. This would cause the vehicle to move forward. This design had the
potential for the most amount of deliverable force. However, it required weight in order to keep the
wheels from slipping. In addition, this was the most popular design among the other students.
5. Design Specifications
This device has a total of 9 unique parts. The detailed design specifications, requirements, and
movements of each part and the final product are shown in the following sections. Detailed drawings of
each part may be found in the 12. Appendix.
Value
20 cm
10 cm
10 cm
73.32 grams
Figure 9: Isometric views of the fuselage on SolidWorks (left) and the actual product (right)
Figure 10: From left to right: actual 3D printed wheel axles and isometric view of the SolidWorks model
Figure 11: From left to right: front and side views of the SolidWorks model of the wheel axle
3. Wheel (x4)
Our wheel features five rectangular spokes. The axle is inserted through the center of the wheel
with a press fit in order to connect the wheels to the fuselage. Much material has been cut away in the
area between the spokes in order to minimize the weight.
Figure 12: From left to right: final 3D printed wheel product and isometric view of SolidWorks model.
4. Front
The front is a curved, thumb-shaped figure that is hollowed out from the bottom. Near the top is a
hole for the propeller shaft. Lubrication is applied within the hole in order to reduce friction from the
rotating propeller shaft. The back features a rib for structural support.
Figure 14: Bottom views of the actual front (left) and SolidWorks model (right)
Figure 13: Isometric views of the actual front (left) and the SolidWorks model (right)
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Figure 15: Front views of the actual front part (left) and the SolidWorks model (right)
5. Propeller
The propeller features five blades and an aerodynamic design that has been optimized to push
enough air to propel the device forward. The blades are attached to a hollow, cylindrical shaft that has a
hole on the side to fit the propeller rod through. The shaft has been sanded down in order to reduce
friction while spinning.
Figure 16: Front views of the actual propeller (left) and the SolidWorks model (right)
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Figure 17: Side views of the actual propeller (left) and the SolidWorks model (right)
6. Propeller Rod
The propeller rod is a dense, solid, cylindrical rod that fits through the holes on the side of the
propellers shaft. The rubber band is looped through the rod which keeps the propeller shaft in the hole
on the front. The ends are curved into the shape of the propeller shaft in order to prevent unnecessary
friction caused by uneven parts.
Figure 18: From left to right: front and top views of the propeller rod on SolidWorks
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7. Tail
The tail is a hollow fin-shaped structure that is glued onto the fuselage. It contains a cutout on the
back side that acts as a nook for the rubber band. The structure is thick in order to handle the stress
exerted from the tension due to the rubber band.
Figure 19: Side views of the actual 3D printed tail (left) and the Solidworks model (right)
Figure 20: From left to right: top and isometric views of the tail part on the SolidWorks model
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Figure 21: From left to right: an isometric view of the final glider holder and the side view of the SolidWorks model
9. Glider
The glider is made from a thinly printed layer of ABS plastic and pushes air generated from the
propeller downwards in order to generate lift. It is attached to the glider holders through a 4-40 screw.
The glider has a trapezoidal shape in order to maximize surface area. The top features a 3D-printed 13,
representing our team and provides a creative, aesthetic touch. The lower end of the glider has a cutout
slot in order to prevent interference with the tail when the angle of attack is adjusted.
Figure 24: Top views of the actual glider (left) and the SolidWorks model (right)
Figure 23: Bottom views of the actual glider (left) and the SolidWorks model (right)
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Figure 26: The blue arrow indicates how the air will be scooped by the propeller
Figure 27: The red arrow indicates the direction the propeller rotates
Figure 28: The blue arrow indicates the flow of air along the entire device; the white arrow shows the direction of travel
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Figure 29: Displays the total mass and center of gravity of our final device
The stored potential energy of the rubber bands was estimated using Hooks law. This states that
the restoring force of an ideal spring is proportional the displacement from equilibrium multiplied by a
constant, unique to each spring, as given by Equation 1.
=
Equation 1
Newtons Second Law tells us that force is proportional to an objects mass and acceleration, as
given by Equation 2.
=
Equation 2
By weighing several objects of a known mass on the rubber band and recording its displacement,
the spring constant can be measured. Table 2 presents the data recorded for finding the spring constant
and Figure 30 plots this data and reveals the spring constant.
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Table 2: Mass, Force, and Displacement Data for estimating the elastic constant (k) of the rubber band
Object
Mass (kg)
Force (N)
Displacement (m)
0.04
0.39
0.0043
2 Choco-pies
0.056
0.54
0.0078
0.168
1.64
0.0293
Surface 2 Tablet
0.676
6.62
0.113
1.67829
16.4
0.214
Force (N)
12
10
y = 72.693x
8
6
4
2
0
0
0.05
0.1
0.15
0.2
0.25
Displacement (m)
Figure 30: Graph of force versus displacement in order to find the spring constant
The potential energy is estimated using Equation 3:
1
= 2
2
Equation 3
Because the rubber band was wound up instead of stretched, the potential energy that the device
need to withstand was calculated using Equation 4Equation 3:
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1
= ( )2
2
Equation 4
In Equation 4, n is the number of complete winds before the rubber bands beings to double-loop.
C is the circumference of a single wind and xi refers to the length of the rubber band at equilibrium. Table
3 shows the data collected for these new variables.
Table 3: Data and measurements used to calculate the total potential energy
Subject
Value
Circumference of twist
0.01 m
Number of winds
4 winds
New length
0.04 m
Length at equilibrium
0.08 m
Displacement (x)
0.04 m
The maximum potential energy was calculated to be 0.0602 N-m and the maximum force exerted
by one rubber band was 0.9026 N. When running finite element analysis, the amount of force tested on
each part was well above our calculated result in order to ensure the survival of our parts.
7. Product Fabrication
The device used to print the parts was called Dimension Elite 1200. All the parts were printed in
two different session. Because the printing was ahead of schedule, we decided to send in a short printing
job of several finalized parts in order to get ahead. The first printing job consisted of the propeller and the
propeller rod and took about one and a half hours. The propeller rod was printed at high density, because
it was the part that had to withstand the force of the rubber band. The second printing job had the
remaining parts along with some duplicates. This printing job included the glider, propeller mount, back
mount, glider holders, wheels, axels, and fuselage. Because our parts were relatively easy to print, the
estimated time was extremely low. We decided to take advantage of the abundance of leftover time and
printed two extra wheels, an extra pair of glider holders and wheel axels, and six more propeller rods.
After the products were printed, adjustments needed to be made in order to create the hole and shaft
fits we desired. The propeller rod was sanded down, as were the wheel axels.
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Figure 31: STL models of various parts ready to add to the pack file
Surface
Angle of Attack ()
Carpet
Glider removed
Carpet
Glider removed
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Carpet
Glider removed
2.7
Table
45
28
Table
45
34
Table
No angle
45
Table
25
46
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Design Requirement
Size
Rubber Band Power
Rubber Band Count
Self-Containment
Distance
Material
Transportation
Adhesives
Fabrication
Description
20 x 10 x 10 cm
Must be rubber band powered
Up to three rubber bands used
Device must be self-contained
Device must travel a horizontal
distance over surface
Device must be made of ABS
plastic, except for auxiliary
parts.
Entire device, including rubber
bands, must be transported
Adhesives may be used, but
adhesive tapes are restricted
All primary parts of the device
must be fabricated using the
Dimension Elite 1200 printer.
Yes
Yes. We used epoxy, which was
not an adhesive tape.
Yes. With the exception of the
4-40 screw and corresponding
nut, all parts were 3D printed.
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Figure 33: From left to right: the top, side, and front view of the final product
Figure 34: From left to right: the top, side, and front view of the final SolidWorks model
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10. Conclusion
Through many design changes and much optimization, our three original design concepts transformed
into our completed product, Lucky. Lucky is a hybridization of the classic car and plane models. The
assembly consists of nine different parts made of ABS plastic and two auxiliary parts, a 4-40 screw and a
nut.
Lucky moves through the use of rubber bands attached to a propeller. The rubber bands are wound
up and released to spin the propeller. This generates airflow which propels the vehicle forward and also
hits the glider with the intention of creating lift. Using SolidWorks, the parts were designed to be
lightweight to maximize lift, but also strong enough to withstand the forces they would experience.
Through analysis of the rubber bands that would supply the energy, we were able to determine the spring
constant of the rubber bands, and thus the force applied on the parts. SolidWorks stress analyses were
performed to ensure the design would not break.
The parts were printed using the Dimension Elite 1200. Some of the printed parts such as the wheel
axles were sanded down to fit properly with adjacent parts. After assembly, Lucky underwent
performance tests. Here we found the most efficient angle of attack of the glider and also continued to
make adjustments to reduce friction between parts. With that, Lucky is functioning properly and all the
design requirements met.
Lessons learned from designing and manufacturing Lucky include the importance of tolerancing. We
were forced to sand the wheel axles to fit the fuselage and wheels correctly. In addition, we enlarged the
glider slit to give room for the rubber band. Had these been toleranced correctly, we would have saved
time in the assembly of the product. We also realized the importance of planning ahead and simple design.
On competition day, one of our rubber bands snapped, and we were fortunate to have a backup that
could easily replace the old one. During testing, the glider holders came loose after many trials, and we
were able to re-secure them with ease since they were easily accessible. In the worst case scenario where
crucial parts such as the propeller rod or the wheel axles broke, we would have plenty of backup parts
since they were simple prints that took little time to create.
In regards to our design, we learned that a glider is only useful if the propeller generates enough
airflow to generate lift off of it in the first place. This stresses the importance of analysis on SolidWorks:
had we known whether or not our device could lift in the first place, we could have made more meaningful
adjustments to our design. This project revealed to us the power of prototyping. The tremendous amount
we have learned from running a few trials on our device presents enormous potential for future design
iterations of Lucky.
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11. References
[1] http://www.hometrainingtools.com/a/rubberband-car-project, accessed 12/10/2014
[2] http://pbskids.org/designsquad/parentseducators/resources/rubber_band_car.html, accessed
12/10/2014
[3] http://alohaki.jugem.jp/?eid=474, accessed 12/10/2014
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12. Appendix
12.1 Part Drawings
The following show detailed engineering drawings of all the parts used in the final assembly. The wheel axles and wheels were duplicated but
the dimensions remained the same.
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Figure 41: Engineering drawing of the glider holder. Two duplicates are used in the final assembly.
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Figure 42: Engineering drawing of the wheel part. Four duplicates were used in the final assembly.
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Figure 43: Engineering drawing of the wheel axle part. Two duplicates were used in the final assembly.
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