Alternate Solutions

Jillian Kasun

Mr. Cuttrell and Ms. Green

Systems Engineering II

14 September 2016

Alternate Solution 1

Alternate Solution 1 consists of a dorsal and ventral cast, mimicking the exterior of an adult cownose stingray. The dimensions include 22 inches in length and 28 inches in width. The casting covers and protects the internal structure. The two separate casts join through the application of an adhesive. The bottom cast’s excess material allows for the connection. The material thickness of the wing declines to produce the natural form and the ability to move.

Create a full scale sculpture of an adult cownose stingray from modeling clay. Utilize a ruler, sculpting tools, and images of stingrays to imitate outer features. Ensure that the wings have a natural declination in thickness. Apply a release agent to prevent the clay from sticking to the mold.

Pour melted gelatin on the stingray sculpture. Spread the mix over the model using a brush. Ensure that the gelatin covers all features. After allowing the gelatin to set, remove the gelatin from the clay sculpture. This process creates a negative mold.

Apply latex to the negative mold. Evenly distribute the latex to prevent material accumulation. The model requires layers of latex to achieve the thickness of ¼ inch. The latex maintains form and allows for the undulating motion of the wings.The material’s light weight fails to harm the internal structure.

The ventral cast contains a flap to access the central programming. The dimensions include 11 inches in length and 6 inches in width. The flap remains in place due to an additional inch of latex (1 inch in length and 1/16 inch thickness). The excess material slides and secures under the cast. The weight of the cast prevents the flap from opening while moving.

Alternate Solution 2

Alternate Solution 2 contains a dorsal and ventral cast, acting as the skin of an adult cownose stingray. The dimensions include 22 inches in length and 28 inches in width. The cast covers and protects the internal structure. The two separate casts join through the application of an adhesive. The bottom cast’s excess material allows for the connection. The material thickness of the wing declines to produce the natural form and ability to move.

Create a full scale sculpture of an adult cownose stingray from styrofoam. Utilize a ruler and images of stingrays to imitate outer features. Use the hot wire cutter located in the Systems Engineering Lab to achieve desired shape. Utilize sandpaper to achieve the natural declination of the wings.  

Spread clay (26 inches in length and 32 inches in width) on a flat surface. Press the styrofoam structure ¼ inch in the clay to create an imprint. Evenly apply silicone to the imprint to produce the mold. Remove air bubbles to create a flawless product. After allowing the silicone to set, remove the silicone mold from the imprint.

Pour urethane in the silicone mold. Evenly spread the urethane to avoid accumulation in material. Urethane has the ability to undulate with the internal wing structure. A single layer of urethane achieves the thickness of ¼ inch. Though this solution incorporates more materials, urethane produces a more durable cast.

The ventral cast has a flap to access the watertight compartment. The dimensions include 11 inches in length and 6 inches in width. The side of the flap facing the programming system contains two velcro parts. The velcro on the cast attaches to two velcro parts on the compartment. The velcro prevents the flap from opening during motion.

Alternate Solution 3

Alternate Solution 3 consists of a solid silicone structure that reproduces the shape of an adult cownose stingray. The dimensions include 22 inches in length and 28 inches in width. The cast encloses the internal structures. The material thickness of the wing declines to produce the natural form and allow for movement.

Create a full scale sculpture of an adult cownose stingray from modeling clay. Utilize a ruler, sculpting tools, and images of stingrays to imitate exterior features. Ensure that the wings have a natural declination in thickness. Apply a release agent to prevent the clay from sticking to the mold.

Pour melted alginate on the stingray sculpture. Spread the mix over the model using a brush. Ensure that the alginate covers all features. After allowing the alginate to set, remove the alginate from the clay sculpture. This process creates a negative mold.

Apply silicone to the negative mold. Evenly distribute the silicone to prevent material accumulation. After creating the base layer, place the internal structures and programming system on the silicone. Pour silicone over the inner structure and central programming system. This process encompasses the internal elements with silicone.

The silicone has the flexibility to undulate with the movement of the internal structure. However, the weight of the material threatens to break the flexible inner structure. The amount of material restricts the movement of the animatronic stingray. Since the silicone surrounds the internal subsystems, the solution does not allow access to the inner programming system.

Alternate Solution 4

Alternate Solution 4 consists of a dorsal cast, a ventral cast, and wing casts, simulating the skin of an adult cownose stingray. The dimensions of the dorsal cast include 22 inches in length and 28 inches in width. The dimensions of the ventral cast include 22 inches in length and 8 inches in width. The dimensions of the wings include 17 ½ inches in length and 10 inches in width. The casting covers and protects the internal structure. The material thickness of the wing declines to produce the natural form and allow for movement.

Create full scale sculptures of an adult cownose stingray’s wings, dorsal side, and ventral side from styrofoam. Utilize a ruler and images of cownose stingrays to recreate features. Use the hot wire cutter located in the Systems Engineering Lab to achieve desired shape. Achieve the natural declination of the wings with sandpaper.

Spread four sections of clay on a flat surface. Press the styrofoam structures ¼ inch in the clay to create imprints. Evenly apply silicone to the imprints to create the molds. Remove air bubbles to produce flawless products. After allowing the silicone to set, remove the silicone molds from the imprints.

Pour urethane in the silicone molds. Evenly spread the urethane to avoid material accumulation. A single layer of urethane has the thickness of ¼ inch. Urethane produces a durable cast with the ability to undulate with the internal wing structure. The separate casts join through the application of an adhesive. The adhesive must not break during wing motion. The excess material on the wings allows for the connection.

            The ventral cast divides into two sections (11 inches in length and 3 inches in width). A rounded piece of urethane extrudes from the first section (11 inches in length and ¼ inch in width). A hole in the second section allows for the connection of the two parts. The excess material of the first section fits into the lack of material of the second section. This junction allows access to the compartmentation and maintains the form of the ventral cast.

Mood Board

https://docs.google.com/presentation/d/1vgwZ9VWs7eCbpsuoPPxkwLg2Rc0euBzNVyz4WkIPrJg/edit?ts=5744e6a8#slide=id.p

Group Testing Procedures

Battaglia, Kasun, Konecny

John Cuttrell/Wendy Green

Systems Engineering II

13 September 2016

Group Testing Procedures

The system of the animatronic stingray requires individual testing prior to the creation of the final product.

The animatronic’s programming must control the onboard electronics. The Arduino controller must store and execute the code that operates the motors. The movement of the animatronic, controlled by the motors, must mimic that of an adult cownose ray. The electronics must interface with the structure to correctly manipulate the the wings the animatronic, and the motors must move the structure in way that correctly resembles a ray and enables the animatronic to move throughout the water column.

The structure must support the weight of the synthetic skin as well as aid in the production of or manually create the fluid flapping motion to resemble that of a real adult cownose ray. The structure must also include watertight housing for the programmer to place the circuit boards, motors, and batteries in to ensure the animatronic will function underwater.

The outer shell must mimic the texture, color, size, and movement of an adult cownose stingray. The cast’s dimensions include 28 inches in length and 22 inches in width. The cast must have minimal weight to prevent the internal structure from collapsing. The simulated, watertight skin protects the internal structure and programming system. The material must have the flexibility to undulate with the movement of the internal structure.

In order to create a realistic model of an adult cownose stingray, the product must mimic the movement and appearance while preserving the inner subsystems. Team members analyze alternate solutions, developmental, preconstruction, and post construction stages with the guidance of the mentors. Testing will take place in the Systems Engineering Lab on Sandy Hook, New Jersey to assess the merging of the subsystems into the final product.

(Battaglia, Sydney)




(Laboratory Pool)

Test Objectives:

• Ensure subsystems interface.
• Electronics must manipulate the structure to move the animatronic.
• Structure must have a flexible quality to create realistic motion.
• Structure must have a watertight seal to ensure functionality underwater.
• Outer skin must not harm inner structure.
• Outer skin must protect inner structure and programming.
• Create a final product by combining individual parts.

Ensure subsystems interface.

Testing Type: Exploratory

Testing Stage: Preliminary

State of the Solution: Alternate Solutions/Developmental

Conditions Used:

• CAD Drawings

Tools and Equipment: Matrix, survey, ruler, pencil, and CAD drawings

Procedures:

1. Meet with group to present Alternate Solutions.
2. Determine feasibility of each solution.
1. Assess the pros and cons.
3. Analyze ability to interface the subsystems.
1. Review/modify dimensions.
4. Select a final solution based on ability of fusion.
1. Make corrections in order to interface.
5. Review with mentor prior to proceeding.

Structure must have a flexible quality to create realistic motion.

Testing Type: Assessment

Testing Stage: Preliminary

State of Solution: Pre-construction

Conditions Used:

• CAD Drawings/Model

Tools and Equipment Required: Different Materials, CAD Designs, Pencil

Procedures:

1. Gather different materials.
2. Bend each material and gauge the flexibility.
1. Avoid brittle materials and overly flexible materials.
3. Create a matrix to compare each material.
4. Determine the materials most fit for the project requirements.

Structure must have a watertight seal to ensure functionality underwater.

Testing Type: Assessment

Testing Stage: Preliminary

State of Solution: Pre-construction

Conditions: CAD Drawings/Model

Tools and Equipment Required: Different Materials, CAD Designs, Pencil, Spring Scale, Weights

Procedures:

1. Gather materials of the desired thickness and flexibility.
2. Meet with Jillian Kasun, team member tasked with creating the synthetic skin, and determine the weight the structure will need to hold using spring scale.
3. Place weights equivalent to the necessary weight on different materials of the desired thickness.
4. Record the strain placed on each material, and determine the strongest material.

Outer skin must not harm inner structure.

Testing Type: Assessment

Testing Stage: Secondary

State of Solution: Preconstruction

Conditions Used:

• CAD Drawings/Model

• Stationary

Tools and Equipment: Matrix, survey, ruler, pencil, CAD drawings, scale, clay, silicone, latex, urethane, epoxy, intended material for the internal structure

Procedures:

1. Team Members Sydney and Jillian meet.

1. Determine if the internal structure has the ability to withstand the cast’s weight.
1. Assess the durability of the inner structure’s material.
1. Place clay, silicone, latex, urethane, and epoxy on intended material for the internal structure.
2. Record the effect of each material.

     2.    Make adjustments to weight and materials if necessary.

Electronics must manipulate the structure to move the animatronic.

Testing Type: Assessment

Testing Stage: Secondary

State of the Solution: Post-Construction

Conditions Used:

• CAD Drawings/Model
• On/Moving
• Wet/Submerged

Tools and Equipment:

• Matrix, survey, ruler, pencil, CAD drawings, electrical diagrams, motors, batteries, controller, pool/water

Procedures:

1. Secure electrical components to internal structure.
1. Place batteries, controller, and wiring inside water-tight housing.
2. Connect motors to electronics according to electrical diagrams.
3. Connect the motors to the structure according to CAD drawings.
4. Upload programming to controller to activate motors.
5. Submerge animatronic.
6. Measure the move-time of the motors.
7. Measure energy consumption of the motors.
8. Evaluate ability to move structure in fluid movements and correct any design flaws.

Outer skin must protect inner structure and programming.

Testing Type: Assessment

Testing Stage: Tertiary

State of Solution: Post-Construction

Conditions Used:

• CAD Drawings/Model

• Stationary
• Wet
• Water: 70 degrees-75 degrees Fahrenheit

Tools and Equipment: Survey, CAD drawings, prototype of skin, adhesive, and pool

Procedures:

1. Use adhesive to connect the separate parts of the cast.
2. Submerge the cast in testing pool located in the Systems Engineering Lab.
3. Observe water damage or leakage after twenty minutes.
1. Water will ruin the centralized programming system.
2. Consider different adhesives.
3. Determine if the model requires more or less material to connect the parts.

Create a final product by combining individual parts.

Testing Type: Validation/Comparison

Testing Stage: Quaternary

State of Solution: Construction/Post Construction

Conditions Used: CAD Drawings/Model

• Stationary
• Wet
• Water: 70 degrees-75 degrees Fahrenheit

Tools and Equipment: Survey, CAD drawings, prototype, pencil, ruler, clay, silicone, gelatin, latex, flexible material, drill, screws, glue, electrical diagrams, wires, controller/circuit boards, batteries, and pool

Procedures:

1. Apply knowledge from individual and group testing.
1. Make corrections to individual and overall design.
2. Validate measurements and ability to interface.
3. Eliminate flaws discovered in previous testing.
2. Construct final solution.
1. Create subsystems.
2. Combine subsystems to create the final animatronic stingray.
1. Ensure watertightness.
3. Place final product in the pool located in the Systems Engineering Lab.
4. Assess ability to accurately portray movement and appearance of the cownose stingray.

Works Cited

Battaglia, Sydney. Systems Pool. 2014. Photograph. Sandy Hook, New Jersey.

Laboratory Pool. N.d. Gigapica.geenstijl.nl. Web. 5 Sept. 2016.