Mechanical assembly

With the help of a company we are working with, we made tremendous progress in the choice of our mechanical architecture. Here is what we settled with:

Each “floor” of the structure is being held to its neighbours by three spacers in an equilateral triangle. The spacers and plates are made of metal (most likely aluminium) and carry the ground from the body (it is being pulled from the arm).

The 12V power is carried through the motor axis which is isolated from the bottom plate.

LED band PCBs are simply held by friction and by their connector. Appropriate holes in the hat and the middle plate are made to fit the PCBs properly and hold them in place.… Read more

Mechanical issues and motor troubles

The root of the problem

Yesterday Sibille and I brought the Phyllo structure with the faulty motor (see this post) to the school mechanic, Mr Croullebois. We disassembled the structure, and it turns out the motor shaft goes slightly lower than the motor base, so when we screwed it tight it would scrape against the aluminum plate underneath. 

Mr Croullebois bored a depression in the middle of the plate so we wouldn’t have this problem anymore, and then we reassembled everything with the other motor that we used for tests and knew to be working. The motor that was in the structure spins more freely now, and we managed to make it run, but there is a weird creaking sound from time to time.… Read more

First Phyllo “turntable”

Today the school mechanic made great progress on the physical structure of our first Phyllo:

We still have to add the 5V transmission ball bearing right above the top square aluminium plate, as discussed in this post. We haven’t yet received the PVC tube we’ll use to electrically insulate this ball bearing from the shaft, which will be connected to the ground. As soon as we have it assembled we’ll do a test to check the power transmission to the rotating part.

Next we’ll fix a Phyllo shell to the PVC disc using the threaded inserts Vlaya has been working on.… Read more

A solid foundation

Last week we met with Alain Croullebois, the go-to guy for mechanical questions at the school. We went to his workshop with the motor we received during the holidays : this Turnigy Multistar 4225-390Kv 16 Poles Multi-Rotor Outrunner. We discussed what the physical structure of the Phyllo could look like.

Here is a global diagram of what we came up with :

The mechanical structure of the whole Phyllo

The Base

For the base of our Phyllo, he suggested stacking two 30cmx30cm aluminium plates 8mm thick, with a separation of 6cm between the two plates maintained by 2cm wide pillars at each corner.… Read more