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Final Project ReportEDSGN 497BLEGO Creator Propeller AdventuresFigure SEQ Figure \* ARABIC 1. Picture from AmazonFigure SEQ Figure \* ARABIC 2. Finished assembly (extra black and yellow parts left off because I didn't like the way they looked)Name: Christina BrysonAccess ID: ceb5351IntroductionFor my final project, I created the LEGO propeller airplane from the LEGO Creator Propeller Adventures set. Unlike most of the other projects, mine started out disassembled with a detailed set of instructions of how to put it together. The challenge came with building the individual pieces. One of the cool things about LEGO is that no matter what set you get, be it from the same line or generations apart, all of the pieces will still fit together. Once the set has been assembled, played with, and taken apart again, all of the different sets can blend together and are compatible with each other. Because of this, it is important for LEGO to have an extremely small tolerance interval, as small as 10 micrometers, when manufacturing the blocks. Included in the booklet of instructions on putting the LEGO model together is a list of every piece that was included in the box. I named each part file the number it was given in the instruction manual. The finished assembly (propeller airplane) is approximately 210mm long and 250mm wide. There are over eighty parts, so I will not list each of them here. With the exception of a few pieces, when disassembled, it is not immediately clear what the purpose of each of the parts is. I will instead group the parts into the sub-assemblies that were created to make the final assembly: The main body: 4211067, 4211436, 4211517, 4533742, 4160406, 300726, 371021, 3005744, 428701, 4211452, 366626, 300821, 4527765, 4526929, 300421, 4500462, 4168072, 371001, 302001, 30324, 302224, 4161326, 4160857, and 379501. The propeller/engine/wing: 4211065, 4211541, 4211436, 371001, 242001, 302324, 4211429, 4282740, 4504378, 3005741, 4239601, 4206482, 4107136, 4666579, 4211758, 4246901, 4121667, 4211375, 4540386, 370026, 4508553, 302224, 241301, 302301, 4211429, 4507052, 4211573, 4502595, 3005748, and 4262978. Airplane nose: 4581308, 302324, 4251162, 474026, 4211429, 4651524, 302121, 4504379, 302001, 4533742, and 4651527. Airplane tail: 4160215, 379421, 371021, 300421, 4515373, 3005744, and 4251161. Back wheel: 4296997, 4516843, 4540203, 4211351, 368026The rest: 302101, 244501, 4208987, 4209005, 4571075, 4220515, 4217722, 243124, 663626, 4531412, 300126, 4162443, 4121715, 4558953, 4213383, 4211350. Design IntentBecause many of the LEGO blocks included in the design are variations of each other, much of the challenge came from building the parts that were not standard blocks. Also, some of the parts are so small that it is hard to measure certain features with the caliper that I have. Instead of just making assumptions and hoping for the best, I fit other LEGO pieces that I knew the dimensions of into the ones that I was having trouble with. This helped me because I could see the way the blocks were supposed to fit together, as well as which features on the trouble piece did not need to be exact. Assembly Section:How it was made:Main bodyThe main body was the easiest section to assembly because all of the blocks included in this section were basic shapes. Also, because this is where I started the assembly, there were not too many parts that Solidworks was running slow. Propeller/engine, wingThis assembly was made twice: once for the right side and once for the left side. The airplane is symmetrical so if I were to build this assembly again, I could probably mirror a lot of the entities rather than creating them multiple times. The main airplane wheels are in this section. They can move up and down, and there is also an arm that rotates to lock the wheels in the desired position. Airplane noseThe components of the airplane nose were some of the hardest components to measure. They were not the same height or width as other blocks for comparison and there were many arcs and small edges that were almost impossible to measure. I had to rely mostly on assumed relations. Airplane tailBesides the main body, the airplane tail was one of the more simple assemblies to make. Back wheelThe back wheel should be able to spin (rotate as well as spin on its axis), but it was very difficult to mate it so that it could do this. Once the first tangent mates were in place, I could no longer see the features that I need to create the remaining mates. As a result, I made this wheel stationary. The restThere were a couple of parts, 4213383 and 4217722, that took me a very long time to even figure out how to begin. Some of the more difficult features on both of these parts did not serve a purpose, but were only there to add to the look of the airplane. Once I realized this, I could alter the pieces a little bit without this alteration affected the final assembly. DiscussionConverted geometry can be very helpful when you need to create the same exact sketch you created on one plane, but on a different plane. For example, when I was making part 4211758, which is the center of the airplane tire, I used the revolved base feature for the bulk of the part but I need to create detailing on the top and bottom faces. The detailing on the first face took a while to make, so converted geometry was perfect for creating that same detailing on the second face without doing all of the work. Sometimes, though, converted geometry can cause annoying problems. When you convert a sketch from one plane to another, it is copied with all of its existing dimensions and relations, including relations to edges and sketches in the last plane that are not included in the current plane. There are so many pieces to this design project, that not all of them were completed for the assembly. A lot of the pieces that still need to be finished are very similar to the ones that are already created (i.e. more standard blocks), so I tried to create the unique pieces for the assembly. One thing that can be improved with the already existing parts is a consistent wall thickness for the underside of the standard LEGO blocks. After building the 1x2 blocks, I figured it would be easy to create the rest just by multiplying this block in whichever direction to create 2x8 blocks, 4x12 blocks, etc. However, the dimensions do not always work out the way that I think they will. I usually have to calculate the wall thickness to allow the stud of another piece to fit into the piece I am working on. I think the best way to fix this would be to employ equations. The number of circles on the underside is related to the number of studs on the top. The number of studs on the top is related to the overall length of the part, and so on. I just need to find a good relationship between all of these to make the equations work in my favor. Two of the pieces I am having the most trouble with are the pieces that make up the nose of the plane and the pieces that make up the cockpit window. I have tried using extruded surfaces, lofted surfaces, and different kinds of cuts for both of these pieces but the end result is never the way I think it is going to turn out. Probably the most used feature of this project was all of the pattern features. This was especially helpful creating the stud patterns on the tops of the standard LEGO blocks, and to create patterns of construction circles where the studs would fit into the bottoms of the LEGO pieces. Although feature pattern was very helpful, sketch pattern and mirror were both frustrating to work with. Even if I started with a fully defined sketch, the patterned or mirror sketch would not be defined. This was especially frustrating when I patterned something 6 or 7 times. As I added more and more parts to the final assembly, Solidworks would run slower. Because of this, I tried to create as many sub-assemblies as possible. This way, there were as few parts open as possible and I would only have to deal with the massive assembly file a couple times. I chose part 4211517 to run the Solidworks simulation on because it is symmetrical and it has sharp edges. Sources ................
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