OBJECTIVE: Design a unique lighting device with your team using ONLY McMaster-Carr parts

Transcription

1 DESIGNING & BUILDING PROTOTYPES WITH SOURCED PARTS Instructor: Eric Sugalski OBJECTIVE: Design a unique lighting device with your team using ONLY McMaster-Carr parts RULES: - Must use only sourced parts found through McMaster-Carr (mcmaster.com) - Total prototype budget not to exceed $250 - No hacking of existing lights - No custom part fabrication permitted (minimal rework i.e. drilling a hole on sourced parts ok) - Provide online Bill of Materials (BOM) by 9PM Work fast! - Be creative and have fun RECOMMENDED APPROACH SESSION 1 1. Brainstorm unique concepts minutes MAX 2. Start with the electrical circuit plugs, connectors, wire, switches, bulbs, batteries, etc. 3. How will the electronics be concealed safely? (wire nuts, electrical tape, electronics enclosure, etc.) 4. Determine structural frame for your prototype. How will it be created? How will the parts be fastened together? Will any re-work be necessary? 5. Aesthetic Components are there any unique attributes that you would like the prototype to have? How will these be integrated into the structure? 6. Develop Bill of Materials (BOM) for ordering 7. Send online BOM to Eric Sugalski (sugalski@mit.edu) for ordering RESOURCES FOR OBTAINING SOURCED PARTS - McMaster-Carr (mcmaster.com) huge resource for structural, fluidic, electrical & raw materials. FAST shipping. - MSC (msc.com) instruments, tools and industrial supply catalog - Grainger (grainger.com) additional industrial supply catalog similar to McMaster - Small Parts (smallparts.com) good resource for small stuff - Digikey (digikey.com) electronics - Century Spring (centuryspring.com) excellent resource for compression, constant force, torsion and foam springs SELECTED PARTS FROM MCMASTER FOR INSPIRATION - This session will focus on parts from McMaster-Carr. On the following pages you will find a small sampling of interesting parts that may come in handy. You do not need to use these parts, but they may provide some inspiration for alternative parts to use. Each of the part samples below has relevant search terms that may be helpful to you in finding the parts you need.

2 LIGHTING & ELECTRICAL COMPONENTS PART IMAGE SEARCH TERM NOTES Power cord Light socket Fits standard incandescent bulbs; different styles to choose from, but pay attention to electrical connections. Electrical switches; Emergency stop switches; Electrical switches come in a wide variety of styles, mounting methods, and actuation methods. Rocker Switches Toggle Switches

3 Light switches wall plates may be useful to mount these types of switches Foot switches Proximity switches Auto-activate light when object gets close? Electronics boxes Used to contain electrical components in a concealed enclosure. Make sure all internal electrical connections are covered with wire nuts or electrical tape. Wire nuts Twist 2 exposed conductors into wire nut to create safe, nonexposed electrical connection STANDS / SUPPORTS PART IMAGE SEARCH TERM IDEAS Conduit; Tubing; Hose Strut channel; Aluminum extrusion; Structural Framing; T-slot framing Great for making quick, robust structures; Hardware designed to fit into channels

4 Support Arm; Adjustable Arm; Positioning Arms Adjustable arm for light? Flexible arm, Gooseneck Tube Fittings; Aluminum Fittings: Aluminum Pipe Ductwork; Duct fittings Ductwork is typically used for HVAC applications, but it could provide an interesting structural element too. Shown here is a ball joint for cylindrical ducts. Leveling mounts; feet Vacuum hose

5 LAMPSHADES PART IMAGE SEARCH TERM NOTES Rain Cap Typically used for attic ventilation; fits with standard ductwork. Fan Blade; Propeller Interesting visual aesthetic? Vent Caps Typically used for roof ventilation Vent Caps Typically used for roof ventilation; some have built-in fans Pitcher Could light pour out instead of water?

6 Funnel Colander Vacuum accessories For a focused beam of light? FASTENING / ATTACHMENT PART IMAGE SEARCH TERM NOTES Zip Ties Attachment of miscellaneous parts Hose Clamps Use to connect overlapping cylindrical components Spring plungers Great for snapping components into place; Catches are useful for locking. Tool holder; magnetic holder; tool holder racks Tool holder Could be useful for attaching a cylindrical part to a frame. Magnetic holders available too Adjustable cylindrical holder

7 Telescoping tubing connectors Great fasteners for snap detents on telescoping tubing Velcro Can be quite handy for a quick (light-duty) attachment Spray foam Used to fill gaps, small crevices. Use sparingly expands rapidly MISCELLANEOUS PART IMAGE SEARCH TERM NOTES Thermometer Could be Temperature indicating; thermal sheets Cooling fan A light with a built-in cooling fan?

8 Guide blocks; rails; drawer slides Could you mount your light to a slide that moves along the back of your desk? Casters; wheels Should it move? Clock Integrated into your light? Edge trim Useful for cleaning up sharp edges Grommets Bellows Useful to dampen vibration and also minimize abrasion (i.e. wire routing) Can be used to cover rotating or hinged areas while allowing flexing Ball Valve, lever Could be a fun on / off switch. How to make the electrical connection inside? Knobs, handles, wheels Huge assortment of control hardware