Motion Ease

Motion Ease

Prototypes and functional trials

Bill of Materials



Assembly Process for Prototype

Prepare and Check Components

  • Ensure all parts listed in the Bill of Materials are available and verified for dimensions and tolerances.
  • Use readily available tools like Allen keys, screwdrivers, and clamps to avoid over-complication.

Attach Upper and Lower Supports

  • Position the Upper Support (1) and Lower Support (2).
  • Align the Upper Strut (14) and Slide (15) to ensure smooth sliding motion.
  • Secure these using Large Screw_2 (4), leaving slight slack for initial adjustments.

Assemble the Ratchet Mechanism

  • Attach the Bottom Ratchet (12) to the Lower Support (2) using the Main Screw (7). Ensure it locks securely.
  • Mount the Top Ratchet (13) to the Upper Support (1), ensuring proper alignment.

Install the Pawl and Pivot

  • Insert the Pawl (8) into the Middle Pivot (11) and fasten it with Large Screw_1 (3). Test its one-direction locking mechanism.
  • Attach the Pawl Cover (9) using Small Screws_1 (5) for stability.
  • Secure the Pawl Top Cover (10) above the cover for added reinforcement.

Fit Strut and Slide Mechanism

  • Insert the Upper Strut (14) into the Slide (15). Ensure the slide moves freely along the intended path.
  • Connect the assembly to the Upper Support (1) and Lower Support (2) with Small Screws_2 (6).

Final Tightening and Testing

  • Gradually tighten all screws while ensuring free movement of the sliding and ratchet components.
  • Conduct a functional test to verify that the ratchet mechanism locks in one direction and releases smoothly.
  • Adjust and refine component alignment if necessary.


Manufacturing Process for Prototype

Materials
Aluminium 7075-T6 is used for structural components due to its high strength-to-weight ratio. Substitute high-cost materials with PLA or ABS for non-critical parts using 3D printing.

Fabrication Techniques
Supports (1 & 2), Ratchets (12 & 13), Pawl (8):

  • Utilize laser cutting or waterjet cutting for flat components.
  • Finish using primary milling or filing to refine edges.

Strut (14) and Slide (15):

  • Use 3D printing for quick prototyping, ensuring tight tolerances for sliding motion.

Screws and Pivot (3, 4, 5, 6, 7, 11):

  • Purchase off-the-shelf screws or modify using lathe turning.

Covers (9 & 10):

  • Fabricate via 3D printing for more straightforward iteration during the trial phase.

Surface Treatment

  • Use spray painting or powder coating for cosmetic finishes.
  • Skip anodizing for now to reduce costs unless required for functional testing.

Assembly Trial

  • Conduct a dry fit to confirm the compatibility of parts before final assembly.
  • Test the prototype to identify and address design flaws or weak points under simulated conditions.