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ME / CEE 1770 Introduction to Engineering Graphics and Visualization Miguel Oller Jennifer Hwang Michael Gervais Meet Patel

Instructor: Dr. Raghu Pucha Spring 2012

The George W. Woodruff School of Mechanical Engineering Georgia Institute of Technology Atlanta, GA 30332-04

Table of Contents:
Chapter 1: Project Ideation...4 Chapter 2: Hand Sketches and Multi-View Drawings...6 Michael Gervais' Parts..7 Jennifer Hwang's Parts ....10 Miguel Oller's Parts.16 Meet Patel's Parts....18 Chapter 3: Part Models and Working Drawings...28 Michael Gervais' Parts...29 Jennifer Hwang's Parts.39 Miguel Oller's Parts....47 Meet Patel's Parts....58 Chapter 4: Assembly Models, Drawings, Parts List, and Instruction Manual.70 Engine Assembly..71 Gear Frame Sub-Assembly.73 Head and Tail Twister Sub-Assembly.75 Body Core Sub-Assembly....77 Inner Wing Sub-Assembly..79 Outer Wing Sub-Assembly.....80 Wing Sub-Assembly...81 Smart Bird Core Assembly.82 Assembly Challenges.84 Step#1 - Engine Assembly Instructions.85 Step #2 - Head and Tail Twister Sub-assembly Instructions....89 Step #3 - Gear Frame Sub-Assembly Instructions...92 Step #4 - Body Core Subassembly Instructions....94 Step #5 - Inner Wing Subassembly Instructions..98 Step #6 - Outer Wing Subassembly Instructions...103 Step #7 - Wing Subassembly Instructions.....106 Step #8 - Smart Bird Assembly Instruction......108 Chapter 5: Motion and Animation..110 Chapter 6: Summary and Concluding Remarks..112 Appendix A: Meeting Minutes...114 Appendix B: Copy of Project Proposal.120

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Chapter 1: Project Ideation

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Ideas considered: Smart Bird Electric Bicycle V8 Engine

We decided to work on the Smart Bird, which was suggested by Miguel, because it was the most interesting idea. The Smart Bird seemed challenging, but manageable. To Meet and Jennifer, who are both AE majors, the idea of modeling a bird was fascinating. Michael liked the complexity of the birds body, and the difficulty it would present in 3D modeling. Project Management: Part Distribution: Michael: Body surface parts and assembly as well as engine. Jennifer: Wing parts and assembly. Miguel: Body core and main assembly. Meet: Connecting parts of the whole assembly.

Planning and Timeline: Our planning was fairly lax in the beginning of the semester, and we mainly focused on having our respective parts done by each lab review. Our meetings purpose was usually to make sure that everyone was up to date on what they needed to get done, as well as to discuss dimensions so that each team member would have a general idea of the size of their parts. After spring break, our meetings grew more frequent, and our workload increased so we had much longer meetings since more coordination between group members was necessary to complete the assemblies and fix any interference.

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Chapter 2: Hand Sketches and Multi-view Drawings

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Michael Gervais Parts:

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Jennifer Hwangs Parts:

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Miguel Ollers Parts:

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Meet Patels Parts:

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Chapter 3: Part Models and Working Drawings

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Michael Gervais Parts:


Engine Base: The base of the engine has a square bottom that lies flush to the wall of the middle body core frame so that it is able to attach to the inner wall. To make this part, I sketched a square that I then trimmed around a larger circle. This circle was extruded to the top of the part as shown. The square base is made of chrome, while the rest of the base is made up of mechanized steel. Engine Gear: The gear plays the most pivotal role in the entire engine. It is used to spin the gears that allow the bird to flap its wings and move accordingly. The original gear was created to align with the gears of the inner body frame. I placed an extruded circle on top of this gear at the center, which sticks out of the entire assembly. This was used to better model the motion of the engine and to show how the gear was able to spin without interferences. This extrusion also helped with aesthetics. The gear is made of steel. Engine Upper Faceplate: When attempting to successfully constrain the assembly, I needed to have certain cutouts to constrain to the planes so that the parts above the engine gear would not rotate. I used an extrusion of a circle initially and then used holes and cutout extrusions to create the cutouts. After this, I used the circular pattern command to create uniformity and the ability to more easily constrain the part. The upper faceplate is made of chrome.

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Engine Lower Faceplate: The lower faceplate was used to create a barrier between the gear and the upper portion of the assembly. The original circular sketch was extruded to create a base, and then I used the hole command and the cutout extrusion command to create the cutouts. After this, I used the circular pattern command to create uniformity and be able to more easily constrain. This was made out of clear red metal. Engine Lower Ring: The lower ring was used to create a barrier between the gear and the upper portion of the assembly. The original circular sketch was extruded to create a base, and then I used the hole command and the cutout extrusion command to create the cutouts of the entire extrusion. After this, I used the circular pattern command to create uniformity and the ability to more easily constrain. The lower ring is made of mechanized steel. Engine Middle Ring: The middle ring was used to create a barrier between the gear and the upper portion of the assembly as well. The original circular sketch was extruded to create a base, and then I used the hole command and the cutout extrusion command to create the cutouts. After this, I used the circular pattern command to create uniformity and the ability to more easily constrain. These holes allowed for the constraining of the upper portion, and the part is made up of mechanized steel. Engine Upper Ring: The upper ring, like some of the other parts, was used to create a barrier between the gear and the upper portion of the assembly. The original circular sketch was extruded to create a base, and then I used the whole command and the cutout extrusion command to create the cutouts. After this, I used the circular pattern command to create uniformity with respect to the holes and the ability to more easily constrain. The upper ring serves mostly for aesthetics and design accuracy.

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Tail: The tail began with a circle that was then lofted to a certain point. After completing the loft, I pondered how to create the curved tail wing. Eventually, I created a sketch at a certain distance from the base of the original sketch, and then lofted back to another point within the solid. This, along with some fillet commands, led to the creation of the curved tail wing. Also, the tail wing has a rudder that is placed at the back end in the very middle of the part. This was created using the extrusion of the ellipse command.

Head: The head was made from sketches of circles that were lofted to each other. Then, the beak, which was not easy, was created on a perpendicular plane. I used the loft command again, and then created many fillets to smooth edges and allow for the bird to be as aerodynamically stable as possible.

Torso: The torso was created with the use of lofts between multiple planes with the corresponding sketches in that plane. The torso was then shelled to achieve minimal interference with the rest of the body, house the engine, motor, and other internal components that are responsible for the movement of the bird.

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Inner Wing Surface: The wing, which was the most difficult part to produce, is made from lofts, extrusions, thickens, and shells. The shell around the wings was created so that minimal interferences would be detected when testing the wing shell and the airfoils. Also, the cylinder at the end allows for the wing to rotate freely without causing any interference. This was done with the same commands as well. This segment is the inner part of the wing

Outer Wing Surface: The wing, which was the most difficult part to produce, is made from lofts, extrusions, thickens, and shells. The shell around the wings was created so that no to minimal interferences would be detected when testing the wing shell and the airfoils. Also, the cylinder at the end allows for the wing to rotate freely without causing any interference. This was done with the same commands as well. This segment is the outer part of the wing.

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Jennifer Hwangs Parts:


1st Airfoil: Most of the shaping of the airfoil was done in AutoCAD using arcs. I first experimented with splines, but found it difficult to control. Using arcs however was still tricky. I had to carefully manipulate the arcs to appear as smooth as possible to each other while still creating the appropriate shape. 2nd Airfoil: Though this airfoil appears similar to the others, only the outer shape is the same to maintain a coherent finished wing once assembled. The cutouts through the airfoil were created using arcs, lines, and fillets, carefully positioned in place to follow the main outline of the airfoil as closely as possible.

3rd Airfoil: No dimensions were available for any of the airfoils, so the curvature of and size of arcs, cutouts, holes, and fillets had to be approximated. This greatly increased the difficulty of modeling already challenging parts. 4th Airfoil: After creating multi-view drawings of each airfoil in AutoCAD, the files were imported into Inventor and extruded to a thickness of 1 mm. Constraints and dimensions were difficult to manually apply because of the complexity of the airfoils, therefore, the automatic dimensions and constraints tools was used.

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5th Airfoil: This airfoil presented a unique challenge, because the curved, wedge-shaped cutout in the middle is a sharp departure from the shape of the other airfoils. The 5 mm rod that goes through the other holes in the other airfoils still had to fit into wedgeshaped cutout. I had to really just guess at the size and location and the curvature of the cutout and hope that it was in the right location. 6th Airfoil: Though smaller than the previous 5 airfoils, this airfoil is of a completely new shape. Arcs were once again used to shape the airfoil. After extruding in Inventor, 1 mm fillets were created at the end of the airfoil. 7th Airfoil: Though similar to the 6th Airfoil, the head of the airfoil is flatter and longer. Shapes of the airfoils had to be constantly readjusted during the assembly process. The tails had to be lengthened or shortened, and the heads of the airfoils had to be adjusted as well. 8th Airfoil: This airfoil was fairly similar to the Left 7th Airfoil. The head had to be reshaped to be smaller, and the tail had to be lengthened a bit to fit better in the assembly, but it was relatively easy. 9th Airfoil: This airfoil was particularly challenging, because it had to be attached to the end attachment. I ended up inserting this airfoil into the assembly, projecting the geometry to the end attachment to create an appropriately sized rectangle to constrain the attachment to.

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End Attachment: Creating this part was slightly tricky. I first created this part perfectly, but it was not the right size to fit on airfoil. Since I had redone all my dimensions as parameters of the length of the part, it was relatively easy to just change a couple of dimensions to make it fit. Mirrored Wing Parts: All the wing parts were used to make two sub-assemblies, the outer wing and the inner wing. Both these sub-assemblies were then assembled into the final wing assembly. This wing assembly was then mirrored to create the wing at the opposite side.

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Miguel Ollers Parts:


Body Core Front Frame: This part was modeled with the use of many commands. The shape was created from an original sketch that was then extruded to have the appropriate thickness. The cutouts were made via the use of extrusion cutout commands. Fillets were also used for the smoothing of edges and rounding purposes. This parts is made out of carbon fiber.

Body Core Middle Frame: Like the body core front frame, this part was modeled with the use of extrusions, extrusion cutouts, and fillets as well. The shape was created from an original sketch that was then extruded to have the appropriate thickness. This part was one of the most complicated parts because since we had no dimensions I had to model it by eyeballing. The creation of this part was very important because it serves as the base for the full assembly. This part is also made out of carbon fiber.

Body Core Back Frame: Like the body core middle frame, this part was modeled with the use of extrusions, extrusion cutouts, and fillets as well. The shape was created from an original sketch that was then extruded to have the appropriate thickness. This part is very similar to the body core frame so it was easier to make by copying the sketch to aid in the modeling. This part is also made out of carbon fiber.

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Body Core Primary Head and Tail Frames: The head frame was created from a sketch. This original sketch was then extruded to reach the appropriate thickness requirements. The cutouts were made with the use of extrusion cutout commands, and these cutouts were then rounded with the use of the fillet command. The Primary Tail Frame was created from a sketch. This original sketch was then extruded to reach the appropriate thickness requirements. Both parts are similar in shape but different in size so it is only presented with one screenshot

Body Core Secondary Head Frame: The secondary head frame was created from a sketch. This original sketch was then extruded to reach the appropriate thickness requirements. The cutouts were made with the use of extrusion cutout commands, and these cutouts were then rounded with the use of the fillet command. It was complicated to figure out how the head would move without interfering with the body core main rod, but I came up with an idea for an universal joint that would allow for this. The socket for the universal joint was created by revolving a sketch in the middle of the part creating a dome that would allow the insertion of the body core main rod.

Body Core Secondary Tail Frame: This tail frame was created from a sketch. This original sketch was then extruded to reach the appropriate thickness requirements. The cutouts were made with the use of extrusion cutout commands, and these cutouts were then rounded with the use of the fillet command. Like the secondary head frame a universal joint was added for tail motion. Also to be able to move the tail to cylindrical extrusions were made so that the tail twister connectors could move the tail in any direction within the allowed constraints.

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Body Core Main Rod: The main rod was created from an extrusion of a sketch. This was done to a certain thickness so that all other components would be able to connect to it. To be able to insert the different parts throughout the rod different grooves, not visible in the screenshot, were created at different cross-sectional planes in the rod. In these grooves the primary and secondary head and tail frames would be inserted as well as the front, middle, and back main frames. At each end of the rod the joining part of the universal joint was created by revolving a sketch that created a cylinder at the outer end and a dome towards the inside. This ensured that the joint would work as intended, with no interferences. This part is hollow on the inside; it was hollowed using an extrusion cutout command.

Body Core Bottom Rod: The bottom rods were created from three sketches. The first was extruded to a certain thickness. Then, at the same center as the first, another was drawn and extruded to a certain thickness. Once again, another was created with the same center, and was extruded to a certain distance. The two extrusions that are located at the each end of the rod are made so that the different body core frames could be bolted to it when it is assembled.

Left Flap Gear: This gear was created with the use of the design accelerator. The initial gear, though, was simply the teeth in a cylindrical face. For visual appeal and weight reduction, we used the extrude cutout command to cut the shape of the sketch through the gear. This sketch was made on the same plane as the gear, and required fillets to complete. This gear is responsible for the flapping motion of the left wing, it is thinner than its counterpart, the left flap gear because it only cranks one gear as opposed to the right gear which cranks two.

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Right Flap Gear: This gear was created with the use of the design accelerator. The initial gear, though, was just a cylindrical solid with the gear teeth. For aesthetical purposed and weight reduction the extrude cutout command was used to cut the shape of a sketch through the gear. This sketch was made on the same plane as the gear. After the extrusion was done, a fillet command was used to fillet the twenty four corners as needed. This gear is twice as thick as the left flap gear because it is also connected to the middle secondary gear. This connection ensures correct flapping of the wings.

Middle Secondary Gear: This gear was created with the use of the design accelerator. This gear was harder to make though, due to its teeth ratio compared to size. Since it needed to have the same teeth ratio as the right flap gear yet be about four times smaller it was complicated to model. This gear was then attached to the middle primary gear which was turned by the engine gear.

Middle Primary Gear: This gear was created with the use of the design accelerator. The initial gear, though, was just a cylindrical solid with the teeth. Because of this, I used the extrude cutout command to cut the shape of the sketch through the gear. This sketch was made on the same plane as the gear. After the extrusion was done, a fillet command was used to fillet the twenty four corners as needed. This gear is attached to the engine gear which then spins all of the gears to create the flapping motion.

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Meet Patels Parts:


Body Core Gear Connector: Most of the parts present in this section act as a joint and properly connects wings, tail and engine. This part, in particular, connects the outer rod to the body. The upper hole is constrained to the long rod, which drives out of the inner section of both of the wings. Rod Connector: This joint combines with the joint connector and the joint, which act as an elbow for the bird. Basically this section, then, joins the inner and outer wing. Again, complexity is very low, making it one of the easiest parts to make. This part needed to be meticulously constrained with the parts mentioned above in order for elbow to function.

Left Joint Connector: As stated above, this joint combines with the gear connector and the joint which act as an elbow for the bird. Two fillets and all the dimensions were properly placed on the part.

Outer Joint: This triangular part consumed some time. It is the part that acts as the outer part of the elbow. One can think of it as an elbow joint. It is connected to the joint connector and the left rod connector to ensure the flapping motion of the wing. This part is crucial because it is what gives the outer wing an extra degree of freedom, allowing the outer wing to flap independently of the inner wing.

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Inner Joint: The inner joint is constrained to the axis of all its three holes. Its shape is unique, because it connects to the front gear. Rods are constrained again to these holes which then connect themselves to the outer rod that passes through all the airfoils. Arcs and few fillets with properly placed holes were important in the creation of the inner joint.

Inner Lower Rod: This is the rod that passes through the cross-section of the inner wings. It is merely a long rod that is accurately dimensioned in lengths, as well as hole size. This rod was hollowed using an extrusion cut.

Lower Clamp: This part was very easy to make, using a hole command and a fillet. This part clamps the rod connected to the wing to the inner joint. It is necessary for the inner wing assembly. While this part may seem simple, the dimensions of it greatly affect the motion of the birds wings. Upper Clamp: This part shown in the left is unique, again, in the way it is used to make a connection of gears and rods, which transfers rotational motion of the gears into the flapping motion of the inner lower rod. Two of these clamp a rod that goes into the airfoil for the wing assembly.

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Twister Connection: As the name suggests, this part has a twisting pipe. This shape is derived from an extrusion and two holes on opposite sides. The cylinder beneath the plane is hollow, which revolves on the twisting pipe. Through these holes, a string or cable is passed into the hollow pipe passing through the birds body and the engine. The cord actually connects the tail with the head giving it movement. Head and Tail Twister Frame: The twister frame has a rectangular opening on the two sides of the base extrusion. In these, cut extrusions fit the head and tail twister with base cuts. The left and right twister frames are assembled in the twister base so that I can be added to the body core through the main rod. Twister: The twister is an important component of the head and tail twister. It is a rectangular portion extruded. On the top of it is a thread holder that holds a cylindrical section of the head and tail twister that includes all electronics in the cube. The cylinder acts as base on which the twister connection is mounted.

Joining Rod: This rod was made by making a triangular plate in one plane and a rod that attaches to it on another. This rod connects the inner wing to the front body core frame.

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Head and Tail Twister Base: This pat is the base of the head and tail twister. The twisters are fit into the base in the two rectangular sockets. This part was created by extruding a square. After having the base shape different extrusion cutouts were used to make the square sockets and other aesthetic properties.

Twister Connector: This part was created by extruding a cylindrical surface at its origin. Then another cylindrical surface perpendicular to the original one was created. After doing fillets at the edges the connector started acquiring its shape. Finally a long extrusion was made at the face of this new cylinder to have the final part.

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Chapter 4: Assembly Models, Drawings, Parts List, and Instruction Manual

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Engine Assembly:

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Gear Frame Sub-Assembly:

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Head and Tail Twister Sub-Assembly:

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Body Core Sub-Assembly:

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Inner Wing Sub-Assembly:

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Outer Wing Sub-Assembly:

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Wing Sub-Assembly:

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Smart Bird Core Assembly:

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Assembly Challenges:
Body Surface: o The torso portion of the bird was difficult to assemble. Because of the many changes that were made to the internal parts of the bird, the shell would often interfere unexpectedly, which led to numerous amounts of body files. Eventually, after many attempts, we successfully created a torso shell that fit the constraints of the internal components of the body. o The part of the external body that covered the wings ended up having to be lofted. Unfortunately, lofting through all the airfoils creates a resulting shape that is too complex for Inventor to shell without any errors. We had to then spline our own solids around the airfoils and loft those to each other. Also, the wing was difficult because there needed to be a pivot point at the joint of the wing that would not cause interferences. This was very difficult because, to our knowledge, Inventor does not allow for solids to be stretched and compressed in order to avoid interferences. Because of this, we had to come up with a cylindrical pivot that removes these interferences. Gear Frame: o Creating the spur gears that were an essential part of the body core assembly was also difficult. The number of teeth of spur gears was changed multiple times. A compact brushless motor makes these spur gears rotate about a fixed axis, allowing the external rods connecting to the wings to be in motion. Coordinating between the numbers of rotations of one gear when compared to the other has been very difficult. We have worked until now, after many trials, and the spur gears have the correct number of teeth and rotation speeds to maximize efficiency and usability. Wings: o Geometries of many parts were projected on others to punch holes and place bolts of right size. The majority of the wings were made in this way. We projected the geometry of the airfoils so that we could successfully loft from one to the other and create a properly shelled external body. Overall: o The assembly of the bird was extremely challenging. Almost of all our parts had to be resized or adapted due to interference and other unanticipated problems. Frustration was at its pinnacle when the outer body and wings denied merging successfully. The lofts between all of the sketches that made up the body and wing was responsible for countless interferences. We tried for many hours, day and night, to try to edit this mistake. After too many hours of testing new methods, we finally came up with a successful design for the shells of the torso and the wings.

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Step #1 - Engine Assembly Instructions:


Step #1: The Engine Gear is connected to the Engine Base. The Engine Gear rotates; therefore, there is no adhesive or bolt between them.

Step #2: The Engine Gear is already connected to the Engine Base. The Lower Ring is connected to the Engine Gear without the use of adhesive or bolts because the Engine Gear is free to rotate.

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Step #3: The Engine Base and Lower Ring are freely connected to the Engine Gear. The Lower Faceplate is now being connected to the lower ring through the use of adhesive and pins.

Step #4: The Lower Faceplate is connected to the Lower Ring via adhesive and pins. The Engine Base and Lower Ring are freely connected to the Engine Gear. The Middle Ring is attached to the Lower Faceplate via adhesive. The holes line up, which will be bolted upon full assembly.

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Step #5: The Lower Faceplate is connected to the Lower Ring via adhesive and pins. The Engine Base and Lower Ring are freely connected to the Engine Gear. The Middle Ring is attached to the Lower Faceplate via adhesive. The holes line up, which will be bolted upon full assembly. The Upper Faceplate is connected to the Middle Ring via adhesive, and will be bolted as well.

Step #6: The Upper Faceplate is connected to the Middle Ring via adhesive, and will be bolted as well. The Upper Ring will be placed on top of the Upper Faceplate via pins and adhesive.

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Step #2 - Head and Tail Twister Sub-Assembly Instructions:


Step #1: Fit the Head and Tail Twister Front Frame and the Head and Tail Twister Back Frame into the slots on each side of the Head and Tail Twister Base.

Step #2: Guide the Left and Right Twister down to fit into the rectangular slots of the Head and Tail Twister Base. Make sure that the bottom of the Left and Right Twisters are flush with the bottom of the Head and Tail Twister Base.

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Step #3: Slide the cylindrical protrusions of the Left and Right Twister Connections into the holes in the Left and Right Twisters.

Step #4: Next, take the end of the Left and Right Twister Connectors and fit them into the corresponding holes in the Left and Right Twister Connections to complete the Head and Tail Twister Subassembly.

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Step #3 - Gear Frame Sub-Assembly Instructions:


Step #1: Place the Middle Primary Gear over the center hole in the Body Core Middle Frame.

Step #2: Place the Middle Secondary Gear over the Middle Primary Gear.

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Step #5: Place the Gear Connectors over the center of the Middle Secondary Gears and the Left Flap Gear.

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Step #4 - Body Core Sub-Assembly Instructions:


Step #1: Guide the Main Rod through the center of the Cody Core Back Frame and the center of the assembled Gear Frame. Insert the Body Core Back Frame into the closes socket to the Gear Frame.

Step #2: Use the Body Core Bottom Left and Right Rods to secure the system together, especially the lower two gears on the gear frame.

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Step #3: Slide the Body Core Front Frame through the Main Rod, in front of the Gear Frame. Insert it into the closest socket.

Step #4: Slide the Body Core Primary Head Frame through the Main Rod, in front of the Gear Frame. Insert in the closest socket.

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Step #5: Attach the Body Core Secondary Head Frame at the end of the Main Rod, towards the end near the Gear Frame.

Step #6: The Head and Tail Twister assembly is slid down the Main Rod to the socket closest to the Back Frame. This will be used to rotate the tail.

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Step #7: The Primary and Secondary Tail Frame are slid down the Main Rod to their respective socket, and are not touching once at that distance. They will hold the tail in place and help with the structure of the Body Surface Shell.

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Step #5 - Inner Wing Sub-Assembly Instructions:


Step #1: Arrange the 1st Airfoil, 2nd Airfoil, 3rd Airfoil, and 4th Airfoil in order with the 1st Airfoil furthest away. Slide the Inner Upper and Inner Lower Rods through each of the top holes located in the middle of the airfoils.

Step #2: Slide the Joining Rod, diagonally across the airfoils through the appropriate holes. Find the notches on the airfoil, and secure the Joining Rod to those notches.

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Step #3: Hold the Upper Back Clamp and the Upper Front Clamp to either side of the Inner Upper Rod, holding thee ends of the Upper Clamps flush against the 1st Airfoil. Tighten with bolts through the holes.

Step #4: Side the Inner Joint, so that the hole is lined up with the whole of the Front and Back Upper clamps and is between them.

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Step #5: Align the Lower Back Clamp and the Lower Front Clamp to their respective sides of the Inner Lower Rod. Position it so the clamp pins the Inner Joint. Tighten with bolts.

Step #6: Next, on the other side of the assembly, line the Front Rod Connector and the Back Rod Connector so that the top holes in the connectors line up with holes in the Upper Rod, and the bottom holes in the connectors line up with holes in the Lower Rod.

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Step #7: Line the Front Outer Joint and the Back Outer Joint so that the bottom hole on the shortest side of the triangle lines up with holes in the Lower Rod. Slide bolts in to hold the assembly.

Step #8: Line the Front Joint Connector and the Back Joint Connector so that their two holes line up with respective holes in the Outer Joints and in the Rod Connectors. Use two bolts to finish the Inner Wing Assembly.

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Step #9: Repeat Steps 1-8, this time with the 1st Airfoil closest to you to create a mirror subassembly for use with the opposing wing assembly.

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Step #6 - Outer Wing Sub-Assembly Instructions:


Step #1: Arrange the 5th, 6th, 7th, 8th, and 9th Airfoils in order, with the 9th Airfoil furthest away from you. Slide the rod through the wedge-shaped cutout in the 5th Airfoil and through the holes in the other airports.

Step #2: Slide the 9th Airfoil over the rod, through the square cutout.

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Step #3: Fit the end attachment tightly to the rod by wedging it into the hole in the end attachment. Then pull the rod and the end attachment so that the end attachment is flush with the side of the airfoil. Secure the whole assembly using adhesive and bolts to finish the outer wing subassembly.

Step #4: Repeat steps 1-3, this time with the 9th Airfoil closest to you to create a mirror subassembly for use with the opposing wing assembly.

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Step #7 - Wing Sub-Assembly Instructions:


Step #1: Align and bolt the rod of the Outer Wing, so that the hole in the rod of the Outer Wing, matches up with the hole on the Outer Joint of the Inner Wing.

Step #2: Repeat with opposing wing parts to generate opposing wing.

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Step #8 - Smart Bird Assembly Instructions:


Step #1: With the Body Core Assembly and the Head and Tail Twister Assembly in hand carefully bolt the Left and Right Wings to the Body Core.

Step #2: Place the Body Surface Torso, Tail, Head, Right Inner Wing, Right Outer Wing, Left Inner Wing, Left Outer Wing into the Smart Bird Core assembled in the previus step.

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Chapter 5: Motion and Animation

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Challenges: During the animation the bird was flapping and making unintended gestures when the gears were turned too fast. When animated at a slower speed, the wings flapped accordingly. There were a few constraints missing at the joint between inner and outer wing. This was an issue because the entire assembly depended on the wings, especially at this point in our project. It was also time consuming to figure out which plane was the right plane to drive the constraints and how to set the right angular speed for dynamic simulation. The animation is proving more difficult than expected with respect to the many shelled body parts that must move with the internal body parts. Animation: The bird will begin flapping its wings, thus it will begin to move. Then the bird will enter the front view on the screen. After this, the body surface will go temporarily invisible, so that the internal components of the bird can be viewed in action. Post viewing the internal components, the birds surface will go back to a visible state and the bird will fly off the screen. Lastly, the front view of our assembly will not be in motion any longer and we will exhibit the bird through a rotation.

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Chapter 6: Summary and Concluding Remarks

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The artifact that we chose to model, the Smart Bird, through all of the different mediums that we were required to do so, was extremely complex. While each piece was eventually related to another, and was somehow connected and constrained to another, nearly every piece was a two of a kind piece. What is meant by this is that is that the bird could basically be split into two down the middle of the torso and each part would be a mirror the one at the other side, with some exceptions. Because of the plethora of parts, from day one until now, we have not been short on complicated pieces to sketch, model, and assemble. We have used just about every command and technique that we have learned in class. We have also learned many new commands and techniques outside of classroom, from the internet or from others sources. Needless to say, this project has been nothing short of the greatest challenge that any of us have faced here at Tech. But we picked this topic for ourselves, so that we could push ourselves to learn more, and we certainly learned. It has not been easy, but we are very proud of what we have created after such a long, brutal journey. We have met and possibly even exceeded our expectations for the project. We initially planned on making the bird with much less internal parts. We were going to create some basic parts, make a shell, and just flap and fly around. We realized that this would not be satisfying so we created more parts and features both internally and externally. We have added an engine that will actually turn the gears. Also, we have added twister connectors that will be used to twist the tail portion. These are two examples of ideas that we took further and made a reality, thus going beyond our expectations. Anything that we thought we could make the bird do with the software, we attempted, and later accomplished. This course has been one of the most enjoyable and collaborative classes that we have probably ever taken. We all came in with an open mind from different backgrounds, and gave this project a shot. We worked collaboratively in the labs and on tests so that we were always peer reviewing. From this, we learned to work on such a large scale project as a team. We have employed leadership skills, creativity, passion, and professionalism in our works. We created a project that we believe, if ever presented to another engineer, would be easy to understand, not because of the lack of complexity, but because of the copious amount of work that we have put into demonstrating those complex models. This class has been a huge success for all of us it has clearly shown us what our careers could be in the future. Passion has given us the drive to succeed, and the pride in what we have worked so hard to create.

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Appendix A: Meeting Minutes

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Meeting 1: Date: 1/24/2012 Members Present: Michael Gervais, Jennifer Hwang, Miguel Oller, Meet Patel Items Discussed: Project Ideas (Smart Bird, Electric One-Wheeled Motorcycle, V8 Engine) Deadlines Ahead: Team Project Proposal due Friday, January 28 Summary: Ideas were discussed, and the group decided to Michael volunteered to outline and write part of the proposal, since he couldnt stay a long time for the next meeting, during which the proposal would be made and finished. Meeting 2: Date: 1/25/2012 Members Present: Michael Gervais, Jennifer Hwang, Miguel Oller, Meet Patel Items Discussed: What to include in the proposal Deadlines Ahead: Team Project Proposal due Friday, January 28 Summary: Our group, using the proposal that Michael had started, wrote the proposal, and printed it off to submit on Friday. Meeting 3: Date: 2/3/2012 Members Present: Michael Gervais, Jennifer Hwang, Miguel Oller, Meet Patel Items Discussed: Division of Parts and Responsibilities Deadlines Ahead: Hand Sketches and AutoCAD Multi-view Review on Friday, February 24 Summary: Group members were assigned to sketch different parts of the bird. Jennifer wings Michael - outer body Meet- joints Miguel - inner body.

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Meeting 4: Date: 2/7/2012 Members Present: Michael Gervais, Jennifer Hwang, Miguel Oller, Meet Patel Items Discussed: Dimensions Deadlines Ahead: Hand Sketches and AutoCAD Multi-view Review on Friday, February 24 Summary: We met together for about an hour to discuss the overall dimensions of the bird as well as other dimension values, including wing span, length of the bird, size of the wings, rods, holes, any areas that required more than one persons parts. It was also decided that metric units would be used. Meeting 5: Date: 2/21/2012 Members Present: Michael Gervais, Jennifer Hwang, Miguel Oller, Meet Patel Items Discussed: Update on isometrics and multiviews Deadlines Ahead: Hand Sketches and AutoCAD Multi-view Review on Friday, February 24 Summary: Everybody had completed their isometrics and was halfway done with their AutoCAD drawings. Everybody seemed to be making good progress. Meeting 6: Date: 3/13/2012 Members Present: Michael Gervais, Jennifer Hwang, Miguel Oller, Meet Patel Items Discussed: Update on all the part models. Deadlines Ahead: CD/DVD with all team member part models for Review due Friday, March 30 Summary: Each person showed the part models they had created so far. Each part was discussed, and it was decided that some parts had to be changed to match the Smart Bird video more closely. All parts restricted to changes.

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Meeting 7: Date: 3/27/2012 Members Present: Michael Gervais, Jennifer Hwang, Miguel Oller, Meet Patel Items Discussed: Checked all the part models Deadlines Ahead: CD/DVD with all team member part models for Review due Friday, March 30 Summary: Everyone pulled up his or her parts on the computer. Everyone agreed that the parts were ready for assembly. We also worked on organizing all the parts to be put into a CD. Meeting 8: Date: 4/3/2012 Members Present: Michael Gervais, Jennifer Hwang, Miguel Oller, Meet Patel Items Discussed: Make extra parts; changed the original parts. Deadlines Ahead: Finish the body with the engine,; improve airfoil shapes Summary: We started assembling the parts. Miguel worked on attaching gears, Jennifer worked in outer & inner wings, and Michael worked on the outer body. Meet worked on assembling joints for inner & outer wings. Meeting 9: Date: 4/14/2012 Members Present: Michael Gervais, Jennifer Hwang, Miguel Oller, Meet Patel Items Discussed: Work on assembly Deadlines Ahead: Assemble outer body with the inner mechanical bird. Summary: We continued working on the unfinished assembly. Once it was assembled we worked on the animation using dynamic simulation.

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Meeting 10: Date: 4/21/2012 Members Present: Michael Gervais, Jennifer Hwang, Miguel Oller, Meet Patel Items Discussed: N/A Deadlines Ahead: Finish writing the handbook. Summary: Group members created their .idw part files. Other tasks included dimensioning individual parts and making word files for the handbook.

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Appendix B: Copy of Project Proposal

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ME/CEE 1770 Team Project Proposal


DATE 1/27/2012 SECTION INSTRUCTOR PROJECT TITLE: Smart Bird SOFTWARE F Dr. Raghu Pucha Inventor Student Name Michael Gervais Jennifer Hwang Miguel Oller Meet Patel E-mail mgervais3@gatech.edu jhwang39@gatech.edu moller3@mail.gatech.edu mpatel80@gatech.edu

NUMBER OF COMPONENTS: 100 - 130 Description of Project: Through 3D and 2D CAD systems and with the aid of isometric sketches, our group is prepared to model the FESTO Engineering Smart Bird. The complex shape of the Smart Bird, the amount of components, and the complicated way that the internal components interact with each other will be a challenge to model. Description of Geometric Features Body

Cylinder Frame that comes to rounded points on the ends that have lesser values of diameter than at the center This connects outer extremities and houses the internal components

Tail Wing

Has curved features that bend down and upward to create lift. Pliable so that then will adjust to air resistance and other forces

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ME/CEE 1770 Team Project Proposal


Wings

Has curved features that bend downward and upward to create lift. Pliable so that they will adjust to air resistance and other forces

Head

Has a point for a beak that allows the bird to slice through the wind and promote swifter and less turbulent air travel

Internal Component

Contains electric motors that create movement of the wings to start motion Design allows for most surface area coverage and support with least amount of added weight

Any Moving Parts? What is Modeling , Assembly Complexity: The modeling complexity of the Smart Bird can be derived from its geometry. The body of the Smart Bird has many curved features as well as pointed features. A great number of moving parts exist within the Smart Bird. The Smart Birds wings beat up and down, as well as twist at specific angles to provide both propulsion and lift. Within the body of the Smart Bird exist electric motors, which increase the complexity of the modeling and assembly of the Smart Bird.

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ME/CEE 1770 Team Project Proposal


Picture of the Proposed System:

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