Project 3.1.

7 Machine Control Design Report (VEX)

Name: Dylan Ionnotti

P.O.E, 2nd Block

Date:

March 11th, 2016

Design Problem

My group and I were provided with a list of problems from which we were required to
choose one that we wanted to solve. In total, there were seven (7) problems that varied in
difficulty for both hardware development and software development. My group and I came to the
consensus that the best problem (out of the remaining) to attempt to solve was Problem 4. This
problem stated that my group and I must design and construct a device that could wind a
particular amount of cable. The criteria also stated that the design must have a switch in order
to start and stop the device. My Team and I were also limited to the abilities of the VEX parts
and components.
A description of Problem 4 as given by PLTW is written below.
Problem 4: Cable Winding Mechanism
A telecommunications contractor needs your team to design a device that can accurately wind
up a specific length of cable. The device must be able to wind a specific length of cable
consistently. The device must also be able to be started and stopped (emergency) by using a
switch.
The purpose of this project was to provide us with experience in designing a computer
controlled machine. This experience is crucial, given that many of todays machines are
controlled by some type of computer or artificial intelligence. This project also taught us how to
apply design principles to a real world situation.

Brainstorm Idea

*For additional details on the brainstorm idea and its components please refer to the above
image.
The image provided above depicts my initial idea of how the device should have been
designed. It includes a gear and bump switch system to count the number of rotations
performed by the suspending gear in order to provide a system of measuring to determine the
amount of retracted string.*
The description of the sketch from the image is provided below.
The mechanism will suspend a reel over the edge of, a table using a supporting arm. A
chain and sprocket system will turn the reel, using power from an electrical motor. A bump

switch will be used as a emergency stop and start button. A small weight keeps tension on the
line to prevent tangling.
Final Design Proposal

(Final Design Sketch)

(Decision Matrix)
After individually brainstorming ideas and concepts, my group and I agreed that the best
process to use for selecting an idea for the final solution would be the decision matrix. We
concluded afterwards that the above design is best because it was simple to build, simple to
program, had a very short construction phase, and used a reasonable amount of material.
The final design included a pulley system, powered by an electrical motor, which is used
to support the cable as it is reeled in. The design allows for the cable to be spooled onto a VEX
reel as it is being retracted. This reel is mated to the electrical motor and retracts the cable only
when the motor is in motion. A sonar sensor is mounted to the base of the device, below the
open end of the cable, and measures the distance from the base (ground) to the end of the
cable. This later entailed us attaching an object that the sonar sensor was capable of detecting.
The VEX cortex is attached to a separate platform that also includes the stop and start buttons

that were listed in the criteria. A quadratic encoder is also attached to this platform for input
purposes.
Design Modifications

During construction of our original solution we came across an issue with the structural
integrity of the device. The struts used to suspend the supporting wheel were very malleable
and would deflect when the device was set in motion. This created additional issues by causing
for the object attached at the end of the cable to sway. The swaying interfered with the accuracy
of measurements made by the sonar sensor and in some instances caused for the object to
become snagged on the struts themselves.
In order to combat this issue, our team member, Harley Busfield, suggested we reinforce
the struts with thicker VEX components. The reason for this is that the thicker material would, in
theory, lessen the amount of deflection in the struts and therefore lessen the amount of sway
and further prevent entanglement.
After reinforcing the struts with the thicker VEX components, the struts became more
stable and the sway of the cable and the attached object was greatly reduced, but not
eliminated. Also, the object was getting stuck more often than before because of the position of
the material used to reinforce the struts. This issue was easily solved by rearranging the
placement of the thicker material on the pre-existing strut.

Final Design Presentation

During our presentation of our final design we were able to retract the cable on command using
the control platform. However, we were unable to retract the cable a specified distance during
presentation, although we were able to only minutes before. We later discovered that the error
was due to a mistake made by the computer system. We had unplugged the cortex from the
computer before presenting to allow fluid movement of classmates between presentations.
When the cortex was replugged, the computer inverted the quadratic encoder and therefore the
code was incompatible with our device. We were able to get the device working properly by the
end of class by resetting the encoder, but not within the time period of our presentation.
Team Evaluation

Harley Busfield:
Harley was originally assigned to help code as well as build the device, but the group later
decided that it would be more beneficial to have a single person who works full time on the
code. Harley was able to meet his expectations on building the device and did as asked. He
also made many helpful and insightful suggestions as to how the design of the device could be
improved.

Ashmal Irfan:
I have worked with Ashmal on a project before and was happy to have this opportunity to work
with him again. He is a very pleasant person to be around and seemed to keep the group in
high spirits in times of stress. His duty was to help build as well. Ashmal was able to fufill this
duty willingly and effectively.

Owen Benner:
Owen did a phenomenal job on his part. He was able to write the entire code for our device
while incorporating his own research and time outside of school. His effort is very admirable and
he was very pleasant to work with as well.

(Me) Dylan Ionnotti:

Post Mortem
1
I believe the objective of this project was to allow us to learn how to conquer obstacles
while still developing a final solution.
2
I believe that the most difficult part of this project was the coding due to its sensitivity to
syntax and its complex use of variables.
3
Two things that weren't included in the design problem but could have benefited our
design would be a code that allows the device to also reel out cable, and a more practical form
of remote control.
4
Our design was successfully operating until the beginning of our presentation. This is not
due to a flaw in our design, but rather a flaw in the computer system which decided to invert the
values for the encoder. This prevented us from successfully demonstrating the full capability of
our design.
5
The most important thing I learned from this project were the skills that are required to
multi-task and solve one problem while solving another.