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Level 2 Report

4 / 10 / 2024

MECHANICAL TASKS

CFD Simulation

For this task I first designed NACA 4412 aerofoil in fusion 360. And then simulated in wind tunnel using CFD. The inlet air flow was set. to 28 m/s and the outlet was kept unknown to get the exact value of the air flow after passing through the aerofoil. I choose aluminium material for the aerofoil due to its lightweight and sustainable nature. Obtained around 25 iterations for generating the graph and then visualised the result using traces feature. The summary was generated. And the data obtained can be used to calculate the lift and the drag forces.

Lift is calculated using the formula : L = C(L) * A *V^2 * ρ * 0.5
Where:L = Lift force (in newtons)
C(L)= Lift coefficient (from the CFD simulation) ρ = Air density (in kg/m³)
V = Velocity of airflow (in m/s) S = Wing area (in m²)

The lift can also be found without doing these calculations. View the summary of the simulation and under the * Sum of Fluid Forces on Walls * column we obtain 6 values. ShearX, PressX ; ShearY, PressY ; ShearZ, PressZ. These denote shear forces and the pressure in X, Y and Z directions respectively. The PressZ value is the value of lift as it denotes pressure in the upward direction. And the PressX value is the drag value.

Lift for this simulation is 1.66N and drag is 61264N

Generative Design

Generative Design is a process that uses artificial intelligence (AI) and computational design software to create multiple design solutions based on a set of parameters and constraints. Instead of designing a product manually, designers provide the software with information about the desired function, materials, manufacturing methods, and other constraints. The software then generates numerous design options that meet these criteria.

For this task I first made parts of drone in fusion 360. And then assembled it. And then specified the load constraints and the preserved body and obstacle constraints after that I selected the materials EPX 150 - Air baked (with carbon M2 M3 L1 3D Printer), EPX 82 (with carbon M2 M3 L1 3D Printer) and HP 3D HR CB PA 12 (with HP Jet Fusion 580 color 3D printer). Then after running the pre check test I generated outcomes around 4 to 8 out comes were generated.

Assembly and Simulation of Gripper

Assembly is the process of combining individual components or parts into a larger, more complex product. It's a fundamental operation in manufacturing, engineering, and construction. Assemblies can range from simple structures to intricate machines.

A gripper is a mechanical device designed to grasp, hold, or manipulate objects. It's often used as an end-effector for robotic arms, allowing them to interact with the physical world. Grippers can be designed in various configurations depending on the specific application and the type of objects they need to handle.

I began the assembly process in Fusion 360 after individually designing each part of the gripper after reffering the given cad files. This involved carefully aligning components such as the gripping fingers, base, and actuation mechanism to ensure they fit together seamlessly. I utilized various constraints and a revolute joint within Fusion 360 to accurately define how each component interacts with the others, allowing for smooth and precise movement of the gripper.

Once the assembly was complete, I focused on simulating the gripper's basic movement. This step allowed me to verify that the components moved as intended, with the gripper successfully opening and closing without any interference between parts. The simulation provided a visual representation of the gripper's functionality, confirming that the design would operate effectively in real-world applications. https://youtu.be/bwJjGREFP4o

Animation and Rendering

In Fusion 360, users can take advantage of several powerful features, including motion studies, animation, and rendering. Motion studies allow for the analysis of how parts move relative to each other by applying constraints to joints, enabling the creation of realistic animations of mechanical systems. The animation tools provide the ability to define movement paths and timings, showcasing the dynamic behavior of assembled models. Finally, the rendering feature enables users to create photorealistic images by simulating various environments and lighting conditions, enhancing the visual appeal of their designs.

I designed a LEGO structure in Fusion 360 and created a LEGO man, meticulously assembling the individual components to form a cohesive model. To animate the LEGO man, I utilized motion studies by applying constraints to the joints, allowing me to define the movement and behavior of each part within the assembly. This process involved setting specific motion paths and ensuring that the joints functioned smoothly, resulting in an engaging animation that showcased the character in action.

After completing the animation, I moved on to the rendering phase to simulate various environments. I chose to render the LEGO man against the backdrop of an old war museum, incorporating elements like Soviet-era tanks in the background to enhance the scene's authenticity. To create a visually appealing atmosphere, I set the time to sunset, which added a warm glow and depth to the cobblestone texture of the street. The final rendered output effectively captured the essence of the scene, bringing the animated LEGO structure to life in a historically inspired setting. https://youtu.be/Tp1_wXXOuU8

ELECTRONIC TASKS

Logic Design: Full Adder

A full adder is a digital logic circuit that performs the addition of two single-bit binary numbers and a carry-in bit, producing a sum bit and a carry-out bit. It is a fundamental building block in digital circuits, used extensively in arithmetic operations like addition, subtraction, multiplication, and division. The full adder operates based on the following truth table: From the truth table, we can observe the following rules for calculating the sum and carry-out bits:

Sum: The sum bit is 1 if an odd number of inputs (A, B, or Carry-in) are 1. Otherwise, it is 0.

Carry-out: The carry-out bit is 1 if two or more inputs are 1. Otherwise, it is 0.

A full adder can be implemented using various combinations of logic gates, such as AND, OR, and NOT gates.

Applications of Full Adders:

Ripple-Carry Adders: Full adders are used in cascade to create ripple-carry adders, which can add multi-bit binary numbers.

Arithmetic Logic Units (ALUs): ALUs, which perform various arithmetic and logical operations, often use full adders as their fundamental components.

Digital Computers: Full adders are essential in the design of digital computers for performing arithmetic operations.

Filter Design: Second-Order Bandpass Filter with LTspice

A second-order bandpass filter allows signals within a specific frequency range (bandwidth) to pass through while attenuating signals outside that range. We can design this filter using an operational amplifier (op-amp) like the IC741 and passive components like resistors and capacitors. But i used OP747 because IC 741 was unavailable in LTSpice.

Voltage Multiplier

Used TinkerCad's component library to build a voltage multiplier circuit with a 555 Timer IC, capacitors, and diodes.Simulated the circuit to verify the functionality of the first voltage doubler stage (9V to 18V).Designed a cascaded version of the voltage doubler to achieve a final output of 27V. This involved replicating the initial circuit and connecting them strategically. Simulated the entire cascaded circuit to confirm the 27V output and analyze its performance under various load conditions.A voltage multiplier is an electrical circuit that converts a low-voltage AC or DC to a higher voltage. the circuit was made using 555IC timer and capacitor pumps. Initially, I faced issues with the task but was able overcome it with the help of coordinators.

Short Circuit Protection board.

I designed a short-circuit protection circuit in Tinkercad using a DC motor, a relay, two LEDs, three AA 1.5V batteries, two push buttons, and a resistor. The relay serves as the main component to disconnect the motor in case of a short circuit. I used one push button (PB1) as a start button to activate the relay and power the motor, and the other button (PB2) as a reset after a short-circuit event. The two LEDs are added as indicators—one to show that the circuit is active and the motor is running, and the other to signal when a short circuit occurs. The resistor is used to limit current through the LEDs. The three AA batteries provide a 4.5V power supply to the circuit. In normal operation, pressing the start button allows the current to flow to the motor and the first LED, lighting it up and running the motor. If a short circuit happens, the relay detects it and disconnects the motor while turning off the first LED and lighting up the second one to indicate the fault. I tested the circuit in Tinkercad, and it functioned as expected. The relay successfully interrupted the current flow when I simulated a short circuit, and the second LED illuminated to show that a fault had occurred. After the fault was cleared, pressing the reset button reconnected the motor, allowing it to run normally again, with the first LED lighting up to indicate this. This design is effective in protecting the motor from damage, while the LEDs provide visual feedback. https://youtu.be/v3CXbhtl_Ts