I’m going to start by saying that this was hands down the most worthwhile and fun class I have taken to date. Not everything about it was perfect, and there were more than a few times during the semester when I would not have said this was true. But at the beginning of the semester I remember thinking to myself that it would be a miracle if I could actually help build a machine that functioned the way it was intended to, and well. It’s debatable as to whether that was achieved, but it was close enough that I’m fairly impressed with my team and myself, and am very proud of our final product.
Almost every aspect of the project was a challenge in some way. Since we chose such an ambitious design, we had to spend a lot of time working numbers to even convince ourselves that it would work. And honestly, I was pretty sure it might not. There ended up being way more unknowns, incalcuables, and assumptions than I expected or felt comfortable with. But my guess is that this is usually the case with real-life engineering situations, and that I need to learn to expect and get used to it.
I also had my doubts about our ability to manufacture parts as accurately as we needed them to be to perform at the level we needed. But as I became more experienced with using the machines, my confidence level grew to point where I just assumed I could make anything as precisely as we needed. I know this isn’t true, but I made a lot of parts on a lot of machines with a pretty high success rate, and only hurt myself once.
Due in part to the fact that we chose such a complex design, we ended up spending enormous quantities of time working in the ME and 250 shops. At a certain point, it just became “If you have free time before dinner, you will be spend it in the shop.” Once I came to grips with exactly how much time it was going to take, it wasn’t as big of a deal. We did a good job planning ahead and picking a good schedule and sticking to it, which was definitely beneficial – we would have certainly struggled to even finish a poor quality version if we hadn’t. We worked a lot in the mornings when the shop wasn’t crowded, which was fantastic because we were more productive, and had easy access to Bob and Marv’s knowledge.
Most of the things that I could say I learned about teamwork I already knew on some level and sound pretty cliché. My group just happened to be fantastic, which helped reinforce for me that it is actually alright to trust other people’s ideas and decisions sometimes. In high schools this wasn’t often the case, so it has taken some work for me to feel comfortable letting other people take on huge responsibilities. And it turns out, sometimes they have better ideas than I do.
I also want to comment some on how I thought out project ended up. Squishy clearly didn’t perform the way we wanted him to. It was our choice to make him as complicated and risky as we did, but I know that we are all very happy and proud of that choice. Given that, I don’t think that there was really much we could have done about Squishy not performing very closely to how we intended. The biggest problem was that the bottom of the hopper had a very difficult time actually picking up the balls. The funny thing was that it was very successful in picking up the balls when controlled by hand and not by leadscrew, and with the balls not stacked in the slot. This meant that we couldn’t have possibly discovered that this was a problem until we had the opportunity to test in the arena, which was not until 4 work days before the due date. As soon as we were able to observe the problem, we knew exactly what we could have done differently to make it more effective (no torsion springs, less columns, closer spacing of columns/no connector piece creating column divisions, flexible/elastic openings, and more), but there wasn’t enough time to adjust anything large. This created a large wave of minor changes we had to make that compromised our ability to follow our strategy (increase leadscrew gear box ratio a lot, makes it go slower, not enough time to pick up multiple pushes of balls, or drive around the outside of the arena). However, like I said before, I’m very proud of what we ended up with. I thought we did great job of analyzing the scenario, following the design process, and making adjustments when necessary. And if we had had more time to manufacture and test the machines, I feel that our design could have been mush more successful.
There was a lot of material, and I certainly don’t understand or know how to do some things that other people in the class learned how to do much better (CAD being a main thing), but the class wouldn’t have been as good had something not been included. I would have been nice to have a greater manufacturing and testing window, but what could you take away time from?
Also, I want to say that the GSI on the whole were fantastic, very accommodating, helpful, and clearly spend an enormous amount of time making everything happen.