Assembled

The project is fully assembled, however we are running into issues that looks like we will have neither the time nor money to solve.

Finished the gear train and housing

We finished the gear train, ribs, and housing!

Week 9 Lab

Considerable progress was made in lab today. The ribs were sanded and reamed to fit within their connecting bracket. The final bracket is printing and should be done as of now. Metal bar, that was ordered previously, has been cut, drilled, and mounted to the bicycle using bolts. This will serve as a mounting point for the dynamo. The electrical circuitry fits within the container incorporated into one of the ribs. The gears were sanded slightly so the fit together better. The gear shafts were also cut to length. All that is left is to attach the second bracket, secure the full dynamo, set up the gear train including the motor, attach the motor to the electrical circuitry, mount the dynamo to the bike, and perform testing.

Week 9 Pre-Lab

The plan of attack for lab this week is to completely mount the dynamo to the bicycle. This will involve finishing the dynamo and using metal plate for mounting.

Week 9 Pre-lecture

There is not much to update on as we get down into our final weeks of the term. We are struggling to get everything assembled as we are waiting on key deliverables from different group members. As soon as these deliverables are made, everything can fall into place.

Nearly Done

We are nearly done with the full assembly of our project. We are ordering some metal bars to attach or dynamo to our bike and we have only one part left to 3D print. After that, we will be completely focused on assembly so we can begin testing.

Ribs

All of the ribs have been printed and reamed. The gear shafts all spin smoothly in their slots. We are finishing up the mounting components and then we will be able to test the entire project.

Pre Week 8 Lecture

We are starting to get down to our final remaining weeks in this course and in this term. Everything is finally falling into place now. We are very excited to begin testing our product.

Pickup of phone mount

We picked up the phone mount that we will be using in our project, yesterday. It fits well on our bike and can hold an array of different cell phones.

3D Printed Parts

The 3D printed parts are slowly being printed. They are now the correct size and match our design.

Week 7 Lab

After week 7 lab, we have all designs completed. We are now completely focused on manufacturing and assembly.

Pre Lab Week 7

We were able to submit our rough draft of our final report before lab this week. We feel that our report was fairly well put together so we hope to see a good grade coming back for that.

The 2nd round of 3D printing was started today. I will be checking in on that throughout the week, hopefully we can get those parts turned around rather quickly, without flaws.

Rough Draft of Design Proposal

We are starting our rough draft of the design proposal today.

3D Parts 2.0

The second round of 3D printing is underway. This time we hope to see finished products matching the desired sizes.

Update

Today, I was able to finish machining to motor to gear attachment part by heading in early in the morning to work on a mill before the seniors got to the machine shop. Afterwards, I cut the previously 3D printed parts, as we will be trying to put them in a machine to be ground up and re-extruded as filament.

Theo was also able to make the bike tire-to-dynamo connecting gear/wheel. It is comprised of two of the gears we ordered in a set mounted on an axle and then sprayed with a rubber material. It took about 10 coats, but the final product should nicely interact with the tire of the bike in the way we need it to.

Lab Week 6

Unfortunately, today in lab, our group experienced a few setbacks. The 3D printed ribs did not come out properly and were scaled down by 70%. They will need to be reprinted. We are currently looking into shredding the current ribs in order to recycle the plastic into more 3D printed objects. The machine shop is also working at max capacity as all of the seniors are working on their senior design projects. This means the mills (which are necessary for completing our project) are booked essentially all day, everyday.

So, I will be going into the machine shop Thursday morning at 7 a.m. in order to start working on a mill, and the 3D parts will be reprinted, this time at full scale. The final dynamo holder and phone case are under development, but have a deadline of Friday this week. And the bike wheel to dynamo gear is currently being made using a spray on rubber product and gears from the set that we previously ordered.

Prelab Week 6

This week in lab, we plan on checking the print quality of our first 3D printed object, and if everything is fine, to continue printing the remainder of the internal pieces needed for our dynamo. After that, time will be dedicated to machining the new gear-motor connector. Finally, the externals of our project will be laid out so we can get an idea of what needs to be done for the rest of the project.