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--- report [2024/06/22 13:18] – [7.3.1 Structure] team5
+++ report [2024/06/25 22:21] (current) – [7.3.1 Structure] team5
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-The main interest of the chosen game is to smash as many buttons as possible challenging the players to test their agility and reflexes. Many games have already been developed following this pattern but the most well-known would be the Whack-a-mole arcade game shown in Figure {{ref>flabel6}}. Players use a mallet or hammer to hit toy moles that randomly pop up from different holes. The objective is to hit as many moles as possible within a limited time frame. As the game progresses, the speed at which the moles pop up increases, challenging the player's reflexes and coordination. Whack-a-Mole is often enjoyed for its simple yet engaging gameplay and is commonly found in amusement arcades and entertainment venues [(hasbro)].
+The main interest of the chosen game is to smash as many buttons as possible, challenging the players to test their agility and reflexes. Many games have already been developed following this pattern but the most well-known would be the Whack-a-mole arcade game shown in Figure {{ref>flabel6}}. Players use a mallet or hammer to hit toy moles that randomly pop up from different holes. The objective is to hit as many moles as possible within a limited time frame. As the game progresses, the speed at which the moles pop up increases, challenging the player's reflexes and coordination. Whack-a-Mole is often enjoyed for its simple yet engaging gameplay and is commonly found in amusement arcades and entertainment venues [(hasbro)].
-This classic game has also been adapted for home usage in various forms. Manufacturers have created miniaturized versions of the game that are suitable for tabletop play Figure {{ref>flabel7}} or even handheld electronic devices. Additionally, digital versions of Whack-a-Mole are available as mobile apps or video game console downloads, allowing users to enjoy the game from the comfort of their own homes. These adaptations often retain the core mechanics of the original game, providing players with a similar experience to the arcade version.
+This classic game has also been adapted for home usage in various forms. Manufacturers have created miniaturized versions of the game that are suitable for tabletop play (Figure {{ref>flabel7}}) or even handheld electronic devices. Additionally, digital versions of Whack-a-Mole are available as mobile apps or video game console downloads, allowing users to enjoy the game from the comfort of their own homes. These adaptations often retain the core mechanics of the original game, providing players with a similar experience to the arcade version.
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 ==== - Design ====
 === - Structure ===
-After creating initial sketches, the team began strategizing the efficient design of the prototype and the final product.  Securing the module to the traffic light pole emerged as a key concern.  To address this, a two-part, hinged design was envisioned in Figure {{ref>flabel71}}. The primary section, facing the pedestrian waiting area, would press against the pole using tension belts that would tighten a strap secured within six triangles Figure {{ref>flabel72}}.  Recognizing the need for additional structural support in the final product, an inner ring was incorporated.  This ring will be welded to the triangles, forming the internal framework.
+After creating initial sketches, the team began strategizing the efficient design of the prototype and the final product.  Securing the module to the traffic light pole emerged as a key concern.  To address this, a two-part, hinged design was envisioned in Figure {{ref>flabel71}}. The primary section, facing the pedestrian waiting area, would press against the pole using tension belts that would tighten a strap secured within six triangles (Figure {{ref>flabel72}}).  Recognizing the need for additional structural support in the final product, an inner ring was incorporated.  This ring will be welded to the triangles, forming the internal framework.
-A significant challenge arose in determining the ideal position for the module on the pole, particularly concerning the existing pedestrian call button.  Observations of various traffic lights revealed inconsistencies in button placement relative to the desired module location nd therefore an adjustable or general solution was necessary. To solve this, the inner structure had to include a cut-out in the part connected to the pole, so the button-box could fit regardless of its direction Figure {{ref>flabel73}}.
+A significant challenge arose in determining the ideal position for the module on the pole, particularly concerning the existing pedestrian call button.  Observations of various traffic lights revealed inconsistencies in button placement relative to the desired module location and therefore an adjustable or general solution was necessary. To solve this, the inner structure had to include a cut-out in the part connected to the pole, so the button-box could fit regardless of its direction (Figure {{ref>flabel73}}).
-In order to mitigate vandalism, a locking mechanism was integrated so that a customary lock could be used, see in Figures {{ref>flabel74}} and {{ref>flabel75}}. Additionally, rubber layers were incorporated between the triangles and the pole, as well as between the buttons and the module's shell, to absorb the shock of the smashings and ensure a secure fit.
+In order to mitigate vandalism, a locking mechanism was integrated so that a customary lock could be used, seen in Figures {{ref>flabel74}} and {{ref>flabel75}}. Additionally, rubber layers were incorporated between the triangles and the pole, as well as between the buttons and the module's shell, to absorb the shock of the smashings and generate friction between those parts to ensure a secure fit.
+The force inside of the strap or the bolt clamp, necessary to prevent any movement of the Module when it is strapped on to the pole was calculated with an extra weight of 100 kg added to the own weight of around 40 kg. This resulted in an internal force of 420 N being necessary, which can be easily applied with both components.
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 <caption>Locking mechanism, inside view</caption>
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+The following Figure {{ref>flabel119}} displays an exploded view of the simplified structure of SMASHY, to deliver a better idea about its components and subassemblies. In Figure {{ref>flabel120}} those parts and subassemblies are put in order regarding their position in the exploded view and equipped with numbers, giving information about the certain assemblies. The quantity of parts is given aswell, but not all components are included, as this only serves to give a better idea about the individual parts and subassembly of the structure.
+<WRAP group>
+<WRAP half column>
+<WRAP centeralign>
+<figure flabel119>
+{{ ::cad_module_exploded_pic_nummeriert.png?direct&400 |}}
+<caption>Numbered exploded view</caption>
+</figure>
+</WRAP>
+</WRAP>
+<WRAP half column>
+<WRAP centeralign>
+{{ ::parts_list_smashy-2.png?direct&1200|}}
+<figure flabel120>
+<caption>Parts list of structure</caption>
+</figure>
+</WRAP>
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 == - Initial structural draft ==
-These drafts were made to give a first technical look at the module for the team and supervisor. From the drawing, the Stempe Safety team could start making some changes to improve the look and the stability. In Figures {{ref>fidrawing}} there is an inside structure to wrap the module around the traffic light pole. As well as a cutout in the back to fit the screen in.
+These drafts were made to give a first technical look at the module for the team and supervisors. From the drawing, the Stempe Safety team could start making some changes to improve the look and the stability. In Figure {{ref>fidrawing}} there is an inside structure to wrap the module around the traffic light pole. As well as a cutout in the back to fit the screen in.
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-{{ ::structural_drawing1.jpg?direct |drawing1}}
+{{ ::inital_drafts_v3-1.png?direct |drawing1}}
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+{{ ::inital_drafts_v3-2.png?direct |drawing2}}
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-{{ :structural_drawing3.jpg?800 |drawing3}}
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 <caption>Initial structural drawings</caption>
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 == - Material selection ==
 For the design of the product, a variety of materials and components will be used.
-A half-circle-shaped design with buttons, these buttons will have an LED light on the inside so that they light up when they have to be smashed. On the flat side of the module, there will be an LED penal matrix, the panel will give people waiting on the the other side of the crossing information such as time, temperature, heat index and how many people already crossed the red light,...
+The main shape is a half-circle design with buttons that have an  integrated LED light and light up when they should be smashed. On the flat side of the module, there will be an LED panel matrix which will give people waiting on the other side of the crossing information such as time, temperature, heat index and how many people already crossed the red light.
 Some material for the structure of the module and the parts to connect them to each other will be needed.
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 ^ Material ^ Description ^ Pros ^ Cons ^
-| Wood | It's a natural product | Cheap, good workability, good looking | It's a hard product to be sustainable with outside use, in contact with a lot of rain the strength will go down |
+| Wood | It's a natural product | Cheap, good workability, good looking | It's a hard product to be sustainable with outside use, in contact with a lot of rain the strength will go down. |
 | HDPE | Is a high strength plastic material |Easy maintenance, customisable (color and shape), Recyclable, durable and high density| flammable, high thermal expansion|
-| Aluminium | Silvery-white metal | Corrosive resistance, very light, durable, recyclable and cheap | low hardness, temperature will be high when placed in sun for long time |
+| Aluminium | Silvery-white metal | Corrosive resistance, very light, durable, recyclable and cheap | low hardness, temperature will be high when placed in sun for long time. |
-| Steel | An alloy of iron and (max 2%) carbon | Strength, recyclable and durability| Rust and corrosion possible when outside |
+| Steel | An alloy of iron and (max 2%) carbon | Strength, recyclable and durability| Rust and corrosion possible when placed outside. |
 | Stainless steel | An alloy of different metals to have the best characteristics |  High resistance to corrosion and rust, durable and long lasting   | More expensive, workability lower |
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-The utilization of diverse materials arises from the varied requirements imposed on the module. Stainless steel is selected for the rear and top sections, housing the LED matrix and electrical components owing to its advantageous properties explained in Table {{ref>structural_materials}}. For the internal structure and attachment structure stainless steel will be welded. For the curved segment of SMASHY, HDPE is chosen due to its robust mechanical strength essential {{ref>structural_materials}} during gameplay, as well as its formability conducive to shaping according to design specifications.
+The utilization of diverse materials arises from the varied requirements imposed on the module. Stainless steel is selected for the rear and top sections, housing the LED matrix and electrical components owing to its advantageous properties explained in Table {{ref>structural_materials}}. For the internal structure and the attachment structure, stainless steel will be welded. For the curved segment of SMASHY, HDPE is chosen due to its robust mechanical strength, essential during gameplay, as well as its formability conducive to shaping, according to design specifications.
 Other materials that are used in SMASHY are displayed and explained in Table {{ref>used_material}}.
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-^Material ^Description ^Why use this? ^
+^Component ^Description ^Why use this? ^
-|Acrylic |Transparent plastic material  |It's a very strong and stiff material. Also the optical clearness is high. It will be used to protect the screen.  |
+| Acrylic | Transparent plastic material |It's a very strong and stiff material. Also the optical clearness is high. It will be used to protect the screen. |
-|   Bolt clamp band/ratchet  |It's a strong stainless steel band that can handle a lot of tension while being fixed. Its easy to install and remove around poles.    | We'll use it to strap the module around the traffic light pole.  |
+| Ratchet Strap | It´s a ratchet, which stretches a strap around an object and thereby fixates it. Its easy to install and detach. |We'll use it to strap the module around the traffic light pole. |
-|Rubber strip |It's an elastomeric material  | When fixing the module, this can isolate the vibrations and make sure it has some more friction so that it doesn't slide down the pole.  |
+| Bolt clamp band | It's a strong stainless steel band that can handle a lot of tension while being fixed. It's also easy to install and remove around poles. | This is another possibility to fixate the module around the traffic light pole. |
-|Piano hinge | It's a hinge that continuous over the entire length of the "door".  | It provides extra stability, strength and support, especially for heavier parts. This will be used to open the module to fixate it around the pole.  |
+|Rubber strip |It's an elastomeric material. | When fixing the module, this can isolate the vibrations and make sure it has some more friction so that it doesn't slide down the pole. |
-|Radial pin tumbler lock | The lock is pick resistance and needs a special key to open it.  | Because it's lock pick resistant so not as attractive to vandals as a normal lock. The lock is used to secure the internal components and structure.  |
+|Piano hinge | It's a hinge that continues over the entire length of the "door". | It provides extra stability, strength and support, especially for heavier parts. This will be used to open the module to fixate it around the pole. |
+|Radial pin tumbler lock | The lock is pick resistance and needs a special key to open it. |Because it's lock pick resistant, it's not as attractive to vandals as a normal lock. The lock is used to secure the internal components and structure. |
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 == - Detailed drawings ==
-After the first initial drawings, some structural changes were made. The structure to hold up the model had some changes like the fixtures for the module. Some buttons are added to give a better idea of how it would eventually look. A padlock from the outside was replaced by a cam lock in order to make it less appealing for possible vandalism. Besides this, there was a NFC reader and other electrical components were added to the drawing to know where to place them. All these changes can be seen in Figure {{ref>ffdrawing}}.
+After the first initial drawings, some structural changes were made. The structure to hold up the model had some changes like the fixtures for the module. Some buttons are added to give a better idea of how it would eventually look. A padlock from the outside was replaced by a cam lock in order to make it less appealing for possible vandalism. Besides this, a NFC reader and other electrical components were added to the drawing to display their position. All these changes can be seen in Figure {{ref>ffdrawing}}.
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+{{ :improved_structural_drawing_v7-2.png?direct |}}
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 <caption>Final structural drawings</caption>
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-While constructing the 3d Model of SMASHY, several obstacles on the way were faced and some logical mistakes were discovered. As the construction in SolidWorks was started in an early stage of development, at which point only rough sketches and thoughts of the design existed, this was to be expected and used as a step in the development of the final product. Therefore, occurring problems in the design like constructural faults or wrong dimensions were then detected and new solutions were designed. An example for this was the fact that a cut out in the internal structure was necessary in order to fit the button on the traffic light into our model as displayed in Figure {{ref>flabel74}}. This had not been implemented in the first sketches but had to be respected, which led to a slight change in the design, resulting in 6 smaller triangles connected with an outer ring. At first, those triangles where just supposed to be welded onto the top and bottom part, but as these were then designed smaller in order to save weight, the design was changed to them now being connected with the outer rings. This way, it now serves as a whole internal structure with great stability and sturdiness. Together with the attachment parts, the HDPE front, the top and bottom and the lid which adds extra stability from the other side when attached to the pole, the whole structure is stable by itself, as to be seen in Figure {{ref>flabel10}} .
+While constructing the 3d Model of SMASHY, several obstacles on the way were faced and some logical mistakes were discovered. As the construction in SolidWorks was started in an early stage of development, at which point only rough sketches and thoughts of the design existed, this was to be expected and used as a step in the development of the final product. Therefore, occurring problems in the design like constructural faults or wrong dimensions were then detected and new solutions were designed. An example for this was the fact that a cut out in the internal structure was necessary in order to fit the button on the traffic light into our model as displayed in Figure {{ref>flabel74}}. This had not been implemented in the first sketches but had to be respected, which led to a slight change in the design, resulting in 6 smaller triangles connected with an outer ring. At first, those triangles where just supposed to be welded onto the top and bottom part, but as these were then designed smaller in order to save weight, the design was changed to them now being connected with the outer rings. This way, it now serves as a whole internal structure with great stability and sturdiness. Together with the attachment parts, the HDPE front, the top and bottom and the lid, which adds extra stability from the other side when attached to the pole, the whole structure is stable by itself, as to be seen in Figure {{ref>flabel10}} .
 The backside part that can be opened contains less structural parts and serves as a place to store the technical elements, like the microcontroller, the screen and the different sensors. To gain stability for the whole module when it’s closed, the backside overlaps onto the front part ensuring a stable connection of both of these parts (Figure {{ref>flabel99}}).
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-Used fix points are the rubber-rings that have contact with the traffic light pole, as well as the vertical component of the triangles which are strapped on, as displayed in Figure {{ref>flabel11}} below. For the simulation, the ratchet straps and outer rubber-rings were removed as shown.
+Used fix points are the rubber-rings that have contact with the traffic light pole, as well as the vertical component of the triangles which are strapped on, as displayed in Figure {{ref>flabel11}} below. This can be done, because the strap generates sufficient friction to hold those parts in place with the simulated loads applied. For the simulation, the ratchet straps and outer rubber-rings were removed as shown.
-The forces that were applied in the simulations are 1000 N  from the top, a torque of 500 Nm applied around the vertical axis in the center and a force of 350N in each of the three button positions that were selected. This equals a person standing on top of the module with his bodyweight evenly distributed, another or multiple persons hitting 3 buttons at the same time with a lot of power and someone pulling it back on the side, also with a force equal to his complete weight. These 3 buttons were selected as they display the region with the biggest risk of high displacement and stress, regarding their position relative to the framework.
+The forces that were applied in the simulations are 1000 N  from the top, a torque of 500 Nm applied around the vertical axis in the center and a force of 350 N in each of the three button positions that were selected. This equals a person standing on top of the module with his bodyweight evenly distributed, another or multiple persons hitting 3 buttons at the same time with a lot of power and someone pulling it back on the side, also with a force equal to his complete weight. These 3 buttons were selected as they display the region with the biggest risk of high displacement and stress, regarding their position relative to the framework.
 The simulations were also performed with each load only by itself, aswell as in combinations with multiple loads at the same time as it’s possible that they influence themselves and result in a decrease of displacement or stress. In the following, the highest simulated deformations and stresses that resulted are presented, which occurs with all loads applied simultaneously.
-As to be seen in the simulation shown in Figure {{ref>flabel12}}, the maximum stress does not surpass 15.02 N/mm^2 , which applies to the annotated point. The main internal structure is made of stainless steel with a yield strength of 172.34 N/mm^2, which shows that its going to withstand the applied forces with a high factor of safety (Figure {{ref>flabel13}}).
+As to be seen in the simulation shown in Figure {{ref>flabel12}}, the maximum stress does not surpass 15.02 N/mm^2 , which applies to the annotated point. The main internal structure is made of stainless steel with a yield strength of 172.34 N/mm^2. This shows that it's going to withstand the applied forces with a high factor of safety (Figure {{ref>flabel13}}).
-In Figure {{ref>flabel14}} the maximum displacement is visible, which occurs on the side of the HDPE plate, which equals 0.4909mm. Regarding the fact that the forces in this simulation were applied to the edges where the buttons sit, a lower displacement can be expected in the actual model. This is because the force will be applied on the button and then to a rubber ring, which distributes the force of hitting the button on to a bigger surface area. Therefore this displacement is still acceptable.
+In Figure {{ref>flabel14}}, the maximum displacement is visible, which occurs on the side of the HDPE plate, equaling 0.4909 mm. Regarding the fact that the forces in this simulation were applied to the edges where the buttons sit, a lower displacement can be expected in the actual model. This is because the force will be applied on the button and then to a rubber ring, which distributes the force of hitting the button on to a bigger surface area. Therefore this displacement is still acceptable.
-The factor of safety (FOS), is displayed in Figure {{ref>flabel15}}, with the FOS of above 50 being shown in red. The minimal factor of safety values 11, which exceeds the minimum value of 2 we set.
+The factor of safety (FoS), is displayed in Figure {{ref>flabel15}}, with the FoS of above 50 being shown in red. The minimal factor of safety values 11, which exceeds the minimum value of 2 we set.
 In this case it would be possible to use different materials with a lower yield strength or design the parts to be thinner, so less material is used. But because this is only a static simulation, dynamic and continuous loads and stresses over a long period of time are not simulated but occur in the real use case. That’s why the structure like this is acceptable and reasonable and due to fact that the other simulations were successful too, no changes to the structure must be made.
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-For the choice of microcontroller, the team has opted for the Raspberry Pi Pico W, because it has many pins which is convenient for connecting various sensors. This microcontroller also has the advantage of having WiFi and Bluetooth, allowing adjustments to the system as well as obtaining information from the system to be done remotely.
+For the choice of microcontroller, the team has opted for the Raspberry Pi Pico W, as it has many pins which is convenient for connecting various sensors. This microcontroller also has the advantage of having WiFi and Bluetooth, allowing adjustments to the system as well as obtaining information from the system to be done remotely.
 The senors that will be used in SMASHY are shown in Table {{ref>tsensors}}, together with an explanation on what it is and why it will be used for the product.
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-The module is in the open air and thus exposed to the sun and other natural influences, because of this the decision of the screen has to be well-considered. The possibilities are compared in Table {{ref>tdisplays}}.
+The module is in the open air and thus exposed to the sun and other natural influences. Because of this the decision of the screen has to be well-considered. The possibilities are compared in Table {{ref>tdisplays}}.
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 == Electrical schematics ==
-At the start of the project, a general Blackbox was made as seen in Figure {{ref>flabelb1}}. Depending on the type of specific features of the module the exact components cannot be defined yet, for example the display may become an LED display, but other displays are not yet excluded. The display will show information to pedestrians across the street. For the __Buttons__ feedback is created with light after pressing a button which is why the different components are grouped. The needed sensors are temperature, humidity, ultrasonic, and an NFC reader/writer to collect data. These values will be processed by the module and displayed on the module. At the edge of the box there is a converter to convert the power used in the traffic light control system to the operating voltage the game will be played on. After the converter, it is connected to the power supply and the power grid. Also, a connection out of the box is the connection with the traffic light to communicate the state of the light. \\
+At the start of the project, a general Blackbox was developed as seen in Figure {{ref>flabelb1}}. Depending on the type of specific features of the module the exact components cannot be defined yet. For example the display may become an LED display, but other displays are not yet excluded. The display will show information to pedestrians across the street. For the Buttons, feedback is created with light after pressing a button which is why the different components are grouped. The needed sensors are temperature, humidity, ultrasonic, and an NFC reader/writer to collect data. These values will be processed by the module and displayed on the module. At the edge of the box there is a converter to convert the power used in the traffic light control system to the operating voltage the game will be played on. After the converter, it is connected to the power supply and the power grid. Also, a connection out of the box is the connection with the traffic light to communicate the state of the light. \\
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