Week 05/01 - 05/08

Week 13 was when my team and I started assembling the parts together, including drill-pressing the metal sheet on the drive bogie. We met at the Central Shop along with the bogie interaction team to see the progress of the drive bogie's metal sheets. After reaching out a conclusion of using collar shafts and screws to hold the shaft from unthreading itself, we have to drill several holes on the drive bogie's metal sheets to be able to implement our ideas. Hence, we met at Central Shop to start working on drilling the metal sheets. We measured out the dimensions and we started drilling. The dimensions that we went was exactly an inch, hence, we had to file some of the holes to make sure that the shaft fits through it. After filing, we tested and our shaft went through. The next thing that we are going to test is the screws on the drive bogie, collar shafts on the drive bogie, and the motor running on track.

Week 04/24 - 05/01

Week 12 was when we received our parts from the Central Shop. As of now, we have 4 motor casings and 1 shaft that will hold both axles of the motor on the drive bogie. During the weak, I met with my teammates to see whether the casings and the shaft will fit the motor and to check whether there are any problems that we might encounter after assembling the motor case and shaft. Everything fits fine, however, we are worried that there might be torques applying to the motor case when it moves during the demonstration, resulting in the motor's axle to unthread itself from the shaft. If this actually happens during Makers Faire, there are possibilities that the motor will fly out from the shaft. Hence, we talked to Dr. Furman and came up with the conclusion of using a collar shaft on each of the shafts ends to lock the shaft from moving. Also, we will be adding two screws to the drive bogie so that the motor can absorb the torque exerted by the friction and keep the shaft from unthreading itself.

Week 04/17 - 04/24

Week 11 was pretty much about fixing stuff and more research-oriented week. The team actually received our shaft like in week 10, but it was tapped at a larger diameter. This resulted in the designed shaft to not bite the axle on the motor. Pretty much week 11 consists of my team and I look out for materials online, or any local shops to buy metal stocks. Turned out that we could not find anything. So eventually we decided to buy some aluminum stock from the previous vendor online. At 04/24, we gave our new aluminum stock to Kyle for tapping, this should be done within this week. Other than that, we also did some research on regen braking and we are still finding ways to calculate the efficiency of the regen brake.

Week 04/10 - 04/17

Week 10 was mainly about the team discussing the possibility of using an outside source or help in manufacturing both the case and shaft. The team decided that this will be an alternative way for manufacturing mainly due to the problems that Central Shop is having, broken water-jet to cut our parts. Also, since the timing of the presentation was cut down due to us having to help to move in parts from the school courtyard, our presentation schedule was postponed to 04/17. Other than that, the team also decided to do some research on how to have regen brake on the motor, and will it be efficient enough to slow or stop the bogie during Makers Faire.

Week 03/27 - 04/10

Week 8 is the spring break. During spring break, and transitioning between week 8 and 9, we continued working on our issue that we found during week 7, which is the motor turned out to be unidirectional. We did some research on it, and we decided to go for welding the clutch as our primary solution. The second solution will be using a third motor, but this will be very troublesome because our team had to program the control system ourselves. Not only that, we will have to buy another timing belt that can stand the power of the third motor so that the belt will not break.

With that said, the team met up to work on the presentation, and also discuss how to solve the issue that we are dealing with. We came up with an idea to open up the motor ourselves. During our meeting at the Central Shop, we opened up the motor manually and we tried to manually turn the motor in both directions. It turned out at the motor does engage both directions: this means that the motor can move forward and backward. This solves our problem of the unidirectional thing. Next thing that we will be focusing on is implementing a braking system onto the motor.

Week 03/20 - 03/27

Week 7 of the meeting was mainly following up on our progress with the motor. Although the team is still waiting for the updates on the controller, turns out that there is another problem that our team managed to discover. The motor that we purchased is a geared hub motor, making the motor to be unidirectional. This means that the motor can only move in one direction, and will free-wheel when it is turning in the other direction. As a result, our motor will not have any braking mechanism to stop the bogie. Hence, our team decided to think of solutions that we can have to fix this issue. One solution is by modifying the inside part of the motor: including welding the motor clutch. Another solution is to use a third motor to help to stop the bogie and go in reverse direction.

Week 03/013 - 03/20

Week 6 of the meeting was mainly following up on our progress with the motor controller with the controls team. Other than that, we also talked about connector/adaptor for our controller. We received the Julet adaptor that we bought and gave it to the controls team so that they can proceed on testing the controller. Also, we plan out future plans once the controls team gave us feedback on the controllers. For me, I will be testing out the motor such as finding the voltage, current, torque, or power and plot them to a curve and match it with the datasheet.

Week 03/06 - 03/13

Week 5 of the meeting was mainly about presenting our first presentation. We covered topics about the future plan for the team, current progress, the budget of the team, etc. Before the presentation, during the week between 03/06 to 03/13, team and I had two meetings to complete the presentation and also work on the list Eric told us to do. We received our 3D printed case from the central shop but it did not fit on the motor. Hence, David from our team fixed the drawing so that the case, which is being manufactured by the central shop, can be fixed.

Week 02/27 - 03/06

Week 4 of the meeting was mainly to catch up with our team's progress. Initially, the first presentation will be held this week. However, due to career fairs, the presentation was postponed by a week. Hence, we did not really meet up for long in superway's meeting point because we decided to visit central shop to check on our 3D printed case. Other than that, we planned on meeting together to work on the presentation and make any other necessary changes to our project.

Week 02/20 - 02/27

Week 3 of the meeting was mainly to discuss the poster and presentation. Since most CAD designs are pretty much done now, we are waiting for the machined parts to be done. Machine parts will most likely be done by end of March, but there will be 3D printed ones for us to keep. Throughout the week, I researched on how to test a motor, including finding motor torque, torque constants, voltage, currents, etc.

Week 02/13 - 02/20

The second week of the meeting was going like usual. There was a meeting with the overall groups about Makers Faire, and there was a small talk provided by a guest speaker. Within the Motor's team, we got to a conclusion for our CAD designs and we sent the drawings to the machinist that we have reached out and contacted. The update given by the machinist is that we will be getting the case early March. The plan after receiving the case is that we will be testing the motor to find the torque, maximum speed, current it needs, and voltage it needs.

2nd semester Week 02/06 - 02/13

During the first week of the meeting, there was nothing much going on because everyone was busy moving in from the old Spartan Superway building. However, after finalizing the moving in, the team and I decided to pick a table in the room that will be used for our regular meeting table. I also helped the team in designing the poster that was required by Prof. Furman. Other than the poster, the team and I discussed future plans about we have o do, and the main focus of the semester. We came up with ideas such as measuring the actual dimensions of the motor and finalize our CAD designs, test motor once the Controls team are done with it, and follow up with the machinist

12/02 - 12/09

As for the last week of the semester, the motor team is pretty much on track with the time schedule. Our main dependency is the motor itself, as we are waiting for it to arrive any time within the next week. Since this week is the last meeting, we decided to split up tasks that we can do throughout the break. Referring to the team's Gantt Chart, I will be looking for machine shops around the South Bay and compare service quotes from them. Then, if the machinists do not approve the materials that we are planning to use, I will be researching other materials that might not cost too expensive.

11/26 - 12/02

Progress:

This week's progress began with the completion of CAD drawings for both the motor case and shaft. We have two design of the motor case, a case that goes over the original motor case, and an alternate design of a case that goes over the motor itself. Then, the CAD drawings were sent to the MEP for 3D printing. The small scale version of the prototypes were then used for presentation during the third presentation. We also presented our last presentation last Wednesday, 11/28.

Several future tasks that we have to complete are seeking professional help from machine shops for manufacturing our full scale version of the prototypes. Our aim is to manufacture the prototype before the spring semester starts. Also, we looked into materials that might be suitable for manufacturing. We searched into MetalsDepot and found that the aluminum stocks for both the motor case and shaft will roughly cost around $400. The types of aluminum stock that are going to be use are the Aluminum 2024-T351 and Aluminum 6061-T6511.

11/19 - 11/25

Progress:
- KBL controllers received and already given to the controls team.
- Motors are expected to arrive early December.
- Shaft design completed.
- Motor case design completed.

Machining progress:
- We talked to Dr. Furman about recommendations on machine shop:
- He suggested the Central Shop at SJSU's College of Engineering.
- We are in contact with Central Shop to start a service request, but we are also looking for any other potential machine shops for back-ups.

Material progress:
- We looked into what material our shaft and case would be. We discussed with Dr. Furman about this, and we came to an agreement of using aluminum as the material for shaft and case. I did some research on the price range of the material cost, it was around $500. With this budget, we will be getting Aluminum 2024-T351 and Aluminum 6061-T6511. Both types are good for machining and can withstand high load.

Next week's assignment:
- Start working on Presentation #3
- Start 3D printing prototype.

11/12 - 11/18

Progress:
- KBL controllers received and already given to the controls team.
- As of now, we are still waiting for the motor to be shipped. We received a confirmation from the company that expected delivery date should be early December.
- Shaft design is almost completed but still need some finalization.

Tire progress:
- I looked into airless tire options as our wheel, but our team decided to not use airless tire, instead, we are designing a rounded steel case that will house the motor and become our wheel.
- The CAD design for the case of the motor is also in progress.

Machining progress:
- We asked recommendations from Dr. Furman, and we were recommended Central Shop by him.
- We are still finding some other places for back up.

Next week's assignment:
- Continue CAD for new shaft
- Continue CAD for case housing
- Find materials for case and shaft
- Finalize on machining company

11/5 - 11/11

Progress:
This week, my group mates and I get together to decide on purchasing the motor and controller:
- KBL controllers found and purchased [Approved by Dr. Furman]
- 3 Motors purchased [Approved by Dr. Furman]

Right now, we are waiting for the motor to be shipped from China.

Tire progress:
I looked into airless tire options as our wheel, but our team decided to not use airless tire, instead, we are designing a rounded steel case that will house the motor and become our wheel.

Shaft progress:
We are going to change our shaft design. We are designing a threaded axle that will connect one motor on each side of that shaft instead of designing a single shaft for each motor.

Next week's assignment:
- Continue CAD for new shaft
- Continue CAD for case housing

10/29 - 11/4

Last week's assignment:
- Work on presentation
- Presentation on 10/24

10/31:
My groupmates and I met on Spartan Superway Garage for our weekly meeting. We worked on the team blog together and assigned individual tasks to be completed by the end of the semester, such as deciding on controllers and getting an invoice for it. Continue working on the shaft drawing, as well as the housing of the motor, do more FEA analysis on both CAD drawings, and start ordering the motor from XOFO.


This week's assignment:
- Look into KBL controllers or any controllers by other companies that satisfy our requirements.
- Look into available airless tire options and how to attach it to our designed motor housing.
- Find a machining shop that can help manufacture our CAD drawings of the shaft and motor housing.

10/21 to 10/28

On 10/22, I met with my other group members at the library to discuss what we are going to present during the presentation. Referring to the rubric and presentation 1's comment, we decided to add more detailed information about our project scope, including motor specs, vendors, kinematic simulations, and motor sizing and torque graphs. Other than that, we also believed that adding CAD drawing and FEA analysis in the presentation will provide better information to the audiences. Thus, 10/22 meeting involved contacting vendors for more detailed motor specs and work on presentation as much as we can.

On 10/23, our team met at the library to finish off the presentation. We worked on torque graphs, and Gantt chart. After meeting for a while, we went to the Spartan Superway Garage to meet with the Wayside and Control teams to discuss on motor specs as well as controllers for the motor. After meeting, we went to finish off CAD drawings to complete the presentation.

On 10/24, we presented the presentation.

Week 10/14 to 10/21

Before 10/17 meeting:
- I met with my groupmates to discuss motor sizing:
Since one of the requirements for makers faire is to let the chassis coast for 2 miles per hour for around 10 seconds, we tried to calculate the torque needed by our motor to accelerate the chassis. However, after doing some kinematic analysis, we believe that it might not possible for the chassis to coast for 10 seconds, accounting 2 seconds to accelerate to 2mph, and 2 seconds to decelerate to stop.
- We calculate the torque needed to be around 60 ft lb


- We also met up to do the team blog and plan on what to present on upcoming presentation #2


After 10/17 meeting:
-TBA