Remote calibrations: Design for Manufacture | Term 1 | by Peter Buš

Introductory Design Workshops >>> Remote Calibrations Design | Fabrication | Processes

Peter BuĹĄ | Design for Manufacture | The Bartlett School of Architecture UCL London

TABLE OF CONTENT

>>> Introductory Design Workshops >>> Remote Calibrations Design | Fabrication | Processes >>>Peter Buš | Design for Manufacture | The Bartlett School of Architecture UCL London 1 DESIGN WORK 1.1 DESIGN BRIEF 4 1.2 TIMELINE DIAGRAM 5 1.3 SITE SURVEYS 6 1.4.1 OBJECT SURVEYS - HOBERMAN SPHERE 7 1.4.2 OBJECT SURVEYS - HOBERMAN SPHERE- DETAIL 8 1.5 SURVEY OF AVAILABLE TOOLS AND MATERIALS 9 1.6 PARTNER COMMUNICATION 10 1.7.1 DESIGN PROCESS 11 1.7.2 DESIGN PROCESS 12 1.7.3 DESIGN PROCESS 13 1.7.4 DESIGN PROCESS 14 1.7.5 DESIGN PROCESS-BENDING TESTS 15 1.8 FINAL DESIGN DRAWINGS OF THE PROPOSED HOLDER 16 1.9 FABRICATION DRAWINGS 20 1.10 ASSEMBLY SEQUENCE DIAGRAM 21 1.11 GIMBAL COMPONENTS ASSEMBLY DIAGRAM 22 1.12.1 OVERALL ASSEMBLY DIAGRAM OF THE PROPOSED CABLE-DRIVEN ROBOT 23 1.12.2 SITE ANALYSIS AND DIAGRAMS OF MAIN POSITIONS OF THE GIMBAL 24 1.13 DOCUMENTATION OF FABRICATION FROM PARTNER & REFLECTION ON SUCCESS 25 1.14 FINAL PIECE FABRICATED BY PARTNER & ANNOTATION OF SUCCESS 27 2 FABRICATION WORK 2.1 2.2 2.3 2.4

COPY OF FABRICATION INFORMATION FROM PARTNER 31 DOCUMENTATION OF FABRICATION PROCESS & REFLECTION 32 FINAL FABRICATED PIECE 33 REFLECTION ON A FINAL PIECE 34

3 LOOKING AHEAD - PROCESS AND IDEAS TO CARRY INTO TERM 2

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Table of Content

1 DESIGN WORK

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1.1 DESIGN BRIEF

Personal long-term research goal Integration of automatic intelligent systems into the design and construction to address productivity and efficiency of large-scale prototyping and building processes.

Method Integration of intelligent flexible cable-driven systems into design and fabrication processes through direct machine learning from user’s instructions and experience (some sort of a machine-human cooperation and interaction).

Design by making, design by fabrication.

Main research question Is it possible to observe objects that position cannot be predicted in advance and in an adaptive way towards the user? Can a machine learn from user’s experience?

Design Goal A platform for observation activities in a form of a flexible object, observing the surroundings, customised by the observer and being able to adapt on his or her physical comfort and not to impact the openness and transparency of the site given.

Abstract The design task is to create a flexible platform, an armature for a given object - the binoculars, to test and integrate an automated system capable to hold and move the binoculars and be customisable by the user as well as being capable to adapt on user’s physical comfort.

The notion of flexibility follows also the performance criteria, which are: location of the object according to a variety of spots outside, including random and unpredictable moving objects like people or animals and the capacity of the armature to not change the character of site, with no significant negative impact.

The key aspect is to observe outside objects from a variety of positions, always customisable by the user according to his or her physical comfort or mood to stand, sit or lie. The armature itself is based on a cable driven system, driven by 4 actuators allowing the automatic movement. The holder of binoculars - a proposed “gimbal” - integrates two direction of rotation, possibly automated as well. The movement and rotation character of the holder is reflected in its formal visual language yielding a specific aesthetic qualities based on a symmetry, referring to the shape of binoculars.

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1.2 TIMELINE DIAGRAM

28.10

4.11.

18.11.

18.11.

11.11.

25.11.

2.12.

9.12.

Outcomes 7

Final week

Timeline ‐ Milestones Outcomes 1

Outcomes 2

Surveys and object modelling

Early design tests, electronic device tets

Outcomes 3

Early tests

fabrication

Outcomes 4

Outcomes 5

Second iteration of design and fabrication tests

Third iteration of design and fabrication tests

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Outcomes 6

Final design iteration and pre-prototype

Documentation and final prototype

Final fabrication of partner’s object and own prototype

1.3 SITE SURVEYS

Site for an object - a window bay in a Victorian

house, London.

Digital model

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1.4.1 OBJECT SURVEYS - HOBERMAN SPHERE

Components of Hobberam sphere-joints and scissors

Two states of Hoberman sphere- the model is fully paramtric.

The symmetry of object serves as a design principle of further design iterations of intended holder .

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1.4.2 OBJECT SURVEYS - HOBERMAN SPHERE- DETAIL

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1.5 SURVEY OF AVAILABLE TOOLS AND MATERIALS

Electronic device Ramp 1.4 - control unit on the top of the Arduino Mega board

4 x NEMA 17 stepper motor

Additional material used in the process

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1.6 PARTNER COMMUNICATION

[12/1/20 10:15 PM] Bus, Peter try to test it how much time belt left if you stretch it from the supposed center of the area, through the corner [12/1/20 10:25 PM] Bus, Peter [12/1/20 10:27 PM] Bus, Peter In fact, the maximum position of the holder in the corner will define how long the time belts should be [12/2/20 12:10 AM] Bus, Peter Here you can improvise a bit in terms of positions of motors or supporting pulleys [site_positions.jpg] (https://liveuclac-my.sharepoint.com/personal/ucbqpbu_ ucl_ac_uk/Documents/Microsoft Teams Chat Files/site_positions.jpg) [site_positions2.jpg] (https://liveuclac-my.sharepoint.com/personal/ucbqpbu_ ucl_ac_uk/Documents/Microsoft Teams Chat Files/site_positions2.jpg) [12/2/20 12:11 AM] Lin, Lei okay this diagram is very clear [12/2/20 12:11 AM] Lin, Lei thank you!

[12/2/20 12:12 AM] Bus, Peter So I am counting with some sort of supportive construction [site_positions3.jpg] (https://liveuclac-my.sharepoint.com/personal/ucbqpbu_ ucl_ac_uk/Documents/Microsoft Teams Chat Files/site_positions3.jpg) [12/2/20 12:13 AM] Bus, Peter this middle pulley can also be attached with some bracket

Site data exchange, Lin, Lei (2020).

Data exchange for a laser cutter, Peter Bus (2020).

Diagrams for an assembly based on data, Peter Bus (2020).

Communication and data exchange platforms, Lin, Lei and Peter Bus(2020).

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1.7.1 DESIGN PROCESS

Early stage of design process-bended strips.

Second stage-laser cut components, wire-like constructions.

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1.7.2 DESIGN PROCESS

Third stage design proposal with additional joining components.

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1.7.3 DESIGN PROCESS

Fourth stage design proposal with doubled construction frame.

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1.7.4 DESIGN PROCESS

Fourth stage design proposal with doubled construction frame-details.

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1.7.5 DESIGN PROCESS-BENDING TESTS

Application of hot water on plywood sheets and bending process using tape or additional found objects.

Resulting components after bending, partially successfull.

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Pre-prototype of the proposed holder after bending tests, elaborated fourth design stage.

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1.7.6 PRE-PROTOTYPE OF THE ROBOTIC ASSEMBLY - CABLE-ROBOT TESTS

User Interface for the robot: State of The Art Makelangelo software ref. Zarplotter <marginallyclever.com>[ONLINE], Interface for user customisation of robotâ&#x20AC;&#x2122;s position DfM 2020/21 Introductory Design Workshops Remote Calibrations

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Prototype of the cable robot with the gimbal holder

1.8 FINAL DESIGN DRAWINGS OF THE PROPOSED HOLDER

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2 Degrees of freedom atuomatic movement applied, basic dimensions: 195 x 195 x 160 mm

Additional axis of rotation controlled by the user (360°)

Gimbal Design and Additional Degrees of Freedom

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Additional axis of rotation controlled by the user/ limited movement (55°)

A 5

4

6

7

129.16

L component

8.5

6

5

4

7

6

8

7

4

5

6

5

7

5.18

A

2

R2

B

109.12

2.

6

B

2.

B

2

1 2.7

B

29.08

2.1

C

4.86

2.01

3.03

10

2.14

2.23

99

9.

3

8

R2

7.

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3.68

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36

4.18

73

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A-A (1:1)

2

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125.5

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2.42

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B

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210.89

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F

54

189.44

3.23 3

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2.54

F component

2

R11

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2

8.38

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R60.62

54

E

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5.76

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I component

127.41

D

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187.87

98.92

2

6

R5

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20.9

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160.44

112.77

2

2.88

161.27

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3.48

6.66

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144.45

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D

4.22

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168.65

2

6.

R23.57

2

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6.52

R85.32

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2 1.77

31.68

2.51

C

4.32

43.67

8.49

4.4 R5

2.57

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B

31.84

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R1440.13

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R2 6

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20.9

1.9 FABRICATION DRAWINGS

129.23

36.94

3.47

A

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2.42

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F

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Technical reference

Created by

Peter Bus

1/12/2021

Approved by

Document type

Document status

Title

DWG No.

components_parts

-20F

Rev.

Date of issue

Sheet

1/1

1

2

3

4

5

6

7

1.10 ASSEMBLY SEQUENCE DIAGRAM

Inner cage assembly

Outer cage assembly

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1.11 GIMBAL COMPONENTS ASSEMBLY DIAGRAM

Parts refering to the laser cutter data

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1.12.1 OVERALL ASSEMBLY DIAGRAM OF THE PROPOSED CABLE-DRIVEN ROBOT

Source:<http://aras.kntu.ac.ir/researchthemes/parallel-and-cablerobotics/>[ONLINE], accessed 21.10. 2020, KN TOOSI University of Technology, Parallel & Cable Robotics Group

Cable-driven robot with 2 degrees of freedom positioned on my partnerâ&#x20AC;&#x2122;s site.

Plan view-preffered observation directions

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1.12.2 SITE ANALYSIS AND DIAGRAMS OF MAIN POSITIONS OF THE GIMBAL

Site analysis, photos and measurements: Lin, Lei (2020).

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1.13 DOCUMENTATION OF FABRICATION FROM PARTNER & REFLECTION ON SUCCESS My partner successfully conducted the fabrication process, following my documentation of an assembly. I appreciate the testing process by his, as it helped him to decide which material would be the best one for an assembly of the gimbalâ&#x20AC;&#x2122;s body. We both agreed on a material chosen, based on a stiff paper cardboard to meet the most appropriate and desired bended shape. My partner was also able to manage the assembly of the robotic construction and set the eletronic robotâ&#x20AC;&#x2122;s control unit as well.

Fabrication tests, Lin, Lei (2020).

Fabrication tests. Lin, Lei (2020).

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Assembly of supporting construction and actuators placements, Lin, Lei (2020).

Supporting pulley

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1.14 FINAL PIECE FABRICATED BY PARTNER & ANNOTATION OF SUCCESS Final fabricated piece was installed on a supportive construction and attached on a cable-driven robot, tested mechanically as well as digitally, using the state-of-the-art interface Machelangeo (www.marginallyclever.com), following the principles of the Zarplotter robot. Such an assembly might serve as an observation platform, creating new, almost invisible “personality”, conducting a hidden “survellaince”.

It may also symbolise some sort of a mask, which a person can take on, or hide behind it. The piece is well made, following the documentation. The exchange of information between the designer (myself) and fabricator (my partner Lei) was successfully realized.

The final assembly still needs to be fully tested computationally to find appropriate pattern of movement, using the provided user interface to control the robotic actuators.

Fabrication results, Lin, Lei (2020).

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Fabrication results, Lin, Lei (2020).

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Fabrication results, Lin, Lei (2020).

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2 FABRICATION WORK

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2.1 COPY OF FABRICATION INFORMATION FROM PARTNER

Diagrams of an assembly, Lin, Lei (2020).

Laser cutter data, Lin, Lei (2020).

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2.2 DOCUMENTATION OF FABRICATION PROCESS & REFLECTION The fabrication process was successfully conducted, following the assembly diagram and additional information about the parapet holder, provided by my partner Lei Lin. I enjoyed the process of fabrication, using the laser cutter and method of a manual assembly utilising industrial standardised bolts and nuts.

The materiality of the structure contrasts with the old substance of the Victorian interior given, but brings additional and positive tension between the new body of the holder and traditional historical elements in the interior.

Fabricated pieces, using the laser cutting process. The data prepared were successfully communicated, transferred and used to cut the elements.

The process of an assembly was straightforward, clear and smooth.

Pre-assembled kinetic structure with a parapet holder.

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The parapet holder detail.

2.3 FINAL FABRICATED PIECE

Hoberman sphere holder mounted on a window parapet in an old Vicotrian house, showing both states of the sphere. Fabrication by Peter Bus (2020).

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2.4 REFLECTION ON A FINAL PIECE

The final fabricated and assembled object successfully integrates the initial idea to become a kinetic platform, which reacts on a window movement, holding the Hoberman sphere, while it is changing it states. As such, the new dynamic, almost living structure emerged. It is located on the ground floor near the main entrance of the given Victorian house and invites visitors to watch it, observe it, interact with it, leading to a surprising experience.

The Hoberman sphereâ&#x20AC;&#x2122;s holder mounted on a window parapet suddenly generates different meanings, which activate inhabitants inside as well as a person standing or passing by outside.

Interaction with the window, conducted via almost invisible wire, integrates a dynamic behaviour of the new machanical organism, attached to a historical substance with a novel body, communicating with the exisiting structure.

The behavior of the Hoberman sphere generates an additional level of complexity, which was celebrated in the design process as well as during the fabrication.

The fabrication process itself was straightforward, based on precise and clear assembly diagrams provided by designer Lei Lin. The only difficulty I encountered, was the process of attachement of the main construction to the parapet, as it needs bolts to be stifflly mounted and properly positioned within the holder. The structure of the Hoberman sphere is too close to the window glass, so its interaction and functionality is apparent if the window is partialy open at the beginning of the windowâ&#x20AC;&#x2122;s movement.

The mechanical object now serves as a carrier of a new meaning, articulating relationship between the existing structure, new machanism, object held and persons observing these specific relations.

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3 LOOKING AHEAD - PROCESS AND IDEAS TO CARRY INTO TERM 2

During the term, I acquired completely new knowledge in terms of assembly of electronic devices for small-scale cable-driven system and how to operate with robotic actuators, controlled by the Arduino Mega board. This foundations will help me to go deeper into this realm of electronically-driven systems.

I learnt that a proper communication and early exchange of information is essential for any successfull process. Any failures also belong to the development and enrich the overall working experience.

Some further testing of cable-driven system is necessary to be done to complete the overall control and pattern of movement for observation on site. Both sides (designer and fabricator) may learn how to controll and navigate the robot smoothly into the desired position. At this stage, the robot moves according to the userentered coordinates to a specific postition. The robot should integrate additional intelligence into the system, ideally learnt from userâ&#x20AC;&#x2122;s experience.

The design process improved when digital fabrication technology had been entered into the process itself, in this case the laser cutting technology.

A carefull and proper measurement process of a site given is definitely necessary to conduct in order to deliver a successfull result.

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