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Lego Challenge!

The Lego Challenge

created by David Clarke



How many engineers does it take to ...




make a 747?





Boeing 747 aircraft
  • contains over 5 million components
  • required over ten thousand person years of design team.
  • Thousands of workers & 3 years to design it. 




Technical writing is an important part of communication as an engineer. Ambiguity and wordiness are to be avoided; the information presented should be focused, succinct, and accurate.



Exact Instructions Challenge:



So, how well can you give instructions?

In this exercise, you will:
  • Create a Lego model in the Lego Digital Designer (LDD) program,
  • Write directions using only words (no drawings or pictures) with the principles of technical writing - link
  • Post your directions in the D2L communication→Lego forum
  • Try out and comment on the directions someone else has posted
  • Read the comments of others who try out your instructions.

Directions:

(Recommended to be read completely before starting)


1) Download and install LDD (http://ldd.lego.com/en-us/). 



2) Find a Lego model to create.  Your partner should not know what they are building until they are actually building it from your instructions, so if you choose a model that no one else chooses then you will get a 5 point bonus. You can also change the color scheme to help disguise your set (though don't make it monotone, which makes it hard to see detail; keep the scheme, change the colors). You want to find a set that is about 60-100 pieces, the example set provided has 66 pieces; if any minifigures are included in the set, subtract 5 from the piece count per minifigure to help gauge the total. The example given is part of a larger set, 60104 – Airport Passenger Terminal, so you can also look at larger sets and pick out a vehicle if that is preferred. The easiest way to find a model is to go to Amazon.com, search for "Lego", and limit your search on the left-hand side to "50 to 99" pieces. To search for older models use search terms such as "2014 lego", and "lego polybag" will give some more options. Alternatively, if you want to create your own model or make some modifications to an existing set, then that is acceptable.



3) Get the Instructions from the internet (http://lego.brickinstructions.com/ has most sets) by either searching for the set or finding it by category. Now you want to create a new LDD file and go through each step of the directions, laying out the pieces as you go along without worrying about building. They should also be re-colored if you are using LDD Extended View as shown in the guide (but coloring can sometimes be quicker at the end).

4) Save your "pile of bricks" as something unique; the example given is "60104start.lxf" – this would be a bad name, do not do this and tip off your partner, name it something that does not include any clues. This is the file you will send to your partner, along with your written instructions.

5) Build your model from your "pile of bricks" to ensure all pieces are included, and to get a feel for the program and what you want to describe in your instructions; the finished example given is 60104finish.lxf. When de-constructing a larger model some "chunks" can be left together (see "Groups" in the guide), it doesn't have to be broken down completely to individual bricks, but if you do this you need to make sure you make the proper adjustments to your "pile of bricks" that you send – the file sent should match what is in your instructions, for obvious reasons.

6) Create your instructions. Type up your directions as you de-construct your model, or by using the scanned picture instructions as a guide, and remember to keep your reader in mind: they don't know what they are building so they won't make the same assumptions you do when writing.

7) Post your completed instructions and your "pile of bricks" starter file in the D2L LEGO forum.

8) Try to build someone else's model using their directions.  To ensure everyone has a partner, reply to a set of posted instructions with something like "I've got this one!" so that others know to find another set.  Don't complete a set that has already been claimed by someone else!  After trying to follow the instructions you were given, save your results as a new file, and post the file back to the author along with notes and constructive criticism of their instructions.

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Write It Build It – Lego Digital Designer

Lego Digital Designer (LDD) is a simple freeware program available from Lego (http://ldd.lego.com/en-us/) that allows you to build models with a variety of colors and types of pieces. This quick introductory guide is to point out the most important tools to get you started using the program quickly so that you can start on your assignment. Note that you can always use the Help menu to get a more in-depth explanation of most aspects of the program.

Useful Preference Changes:
Edit -> Preferences – Select "Outlines on bricks" – also make sure both "High-quality rendering of bricks…" options are checked, "Advanced shading" slider to the right

View -> New Themes -> LDD Extended – makes all parts in the parts list one color, cuts down on a lot of scrolling through colors to find parts; to change color, use the Paint tool in the top center menu, notice you can choose Transparent and Metallic from this menu

Most Important Tools/Windows/Functions:
1)            Zoom In/Out – In viewing area, scroll mouse wheel
Rotate View – In viewing area, hold right-click and drag
Reset View – button with circular arrow next to the down arrow at the bottom of the screen
Select Part – Left click
**Connected Selection Tool – use this specific tool (3rd option beneath the Selection Tool arrow icon at top center of the screen) when you start building to keep everything together
Move Part – hover over piece and click/drag to move single piece, click again to place; to use Connected Selection tool to select and move a model, click once to select, then click/drag the selection and click a third time to place.
Rotate Part – Arrow keys, after part has been selected and moved and before it has been placed

2) The most important (and maybe most obvious) part of LDD is the parts list window that should be along the left side of the screen by default when the program is started. This allows the user to first choose a category, then a specific shape, then the desired color piece to add to the project.
Tips for building your model: when adding pieces to your "pile of bricks" file (Steps 3 and 4 from the assignment), many parts are easy to find in the parts list in LDD, such as regular blocks (classic Lego block) and plates (the flat pieces), and some categories are intuitive such as the car wheel icon, but not all of the categories are so "friendly" and it can be tedious to find some of the more obscure parts, especially at first. If you are having trouble figuring out where a part is on the LDD list, go to the end of the scanned instructions, to the parts list for the set. Find the part, and there will be a 6- or 7-digit number beneath it; you can google "lego 243224" or whatever, and 99.9% of the time a name will come up that can be entered into the search bar in the LDD parts list, greatly reducing the number of options you have to search through (using just the number doesn't work, unfortunately). Some other search terms that were used in the example given are "grille", "fence", and "bow" for the curved pieces, so sometimes a common-sense (or practiced) guess will find it quicker than tracking down the number.

3) Groups – "Groups" tab at the top of the window on the left of the screen that has the parts list. When a model is being assembled, parts can be saved as a Group so that they will be treated as one unit. As far as I can tell, it is not necessary if you constantly use the Connected Selection tool, but it can be useful.

4) Pieces can be removed and replaced regardless of whether the piece is "free" to be removed or is locked into the middle of a model; if it can be selected with the Single Selection tool it can be moved and replaced without disturbing the pieces above.

5) The large base plate that represents the work area can be expanded by selecting a piece to place, then placing it off of the base plate – the plate will extend to "catch" your placed piece and will create a larger work area.



Manufacurability

DFMA
Design for Manufacturing and Assembly

http://www.qmed.com/news/thoratec-lvad-recall-gets-class-i-status


↑Moral of the true story?
The deaths and serious injuries were not the result of device failure...It doesn’t matter how error free a device is in its mechanics or electronics if people can’t figure out how to use it.

Works in CAD?  Great! → you're 1% of the way there...
  • How are the parts going to be manufactured?
  • How is it going to be assembled?
  • How easy and uncomplicated is it to use?
  • How easy is it to maintain? to clean? to fix?


Rules of manufacturability:

1. Keep it as simple as possible.
2. Start early with a prototype, and put this prototype into the hands of the people who are going to use it.
Prototypes should be
  •        Simple and uncomplicated
  •      Should not have all the details worked out
  •     "Rough Draft", unpolished, just good enough to get the main idea of the thing across.
  •     Pass prototypes around early in the project & get as much feedback as possible - then act on the feedback.

3. Pay attention to standards and regulations.
    Standards and regulations = words of advice from wise people who have been working on this type of thing a lot longer than you have.

4. Minimize Production Cost
     - Costs of components
     - Costs of assembly 
           minimize the number of parts

           create multi-functional parts
           minimize the assembly steps
           Use modular designs



Use standard components.
fabrication - painting, polishing, surface finishes, tolerance levels...


Bottom up assembly





Use Self-locating, self-aligning features





Exercise:

Pick an old phone, printer, bike, toy, pen - something requiring assembly.

Take it apart 
- how many pieces does it have?
- is each piece absolutely necessary?
- How you redesign it more efficiently?




















Tolerances in Inventor


Open up a new standard mm ipt


Create Exercise 10 









Don't forget to save!!


 Open up an idw with your title block.
Right click on your sheet, edit, change to "Portrait"

Create a Base view of your object:


Create a sectional view: 



 Add extension lines by just adding a dimension, hide dimension value, and type space where the text is.

Scroll down in symbols until you find Datum: 


Add Datum labels to your surfaces.
Right click→continue when you have your label positioned correctly 


Experiment with the different tolerance labels: 


Use Symbol→Feature to add geometric tolerance symbols and notes:



Play around with some more tolerance styles while dimensioning.


 



Save, and turn in both your ipt file, and idw file to the Ch7 dropbox!

dbl Pen Presentation

 Inventor Presentation

** Save Often!!  **

New→Presentation
Click on the arrow next to New to pull up the same units and format as you previously had open, or click on the word "New" to pull up the menu that lets you choose units and specific formats:

arrow→generic

click on word→specific formats

You can insert your assembly into the presentation when you first create the presentation 
Or you can "cancel" out of the opening screen,
 open up a blank presentation, and "Insert Model" later
Your opening screen should have a model space, snapshot views, 
a storyboard, and ribbon with tools.  If you are missing anything, 
just go to View→User Interface→click on all of the tools you want to have access to

Have a look around in the model tab - you can access each part in your assembly here, 
modify your drawings, turn visibility on or off, etc.

Right click on the corner of your view cube, experiment with the different presentation views.


Position your assembly with a clear orientation
Click on "New Snapshot View" to snap a picture,
then right click on the view to rename, make a jpg, etc.

Pull the slider on the storyboard to some time (4 seconds) to start creating a movie


Tweak components→right click on one of the arms, and pull it away.
To showcase your work, take all of the pieces apart, and show how it is assembled.
Choose the time for your animation, if you want a trail etc.

After you click on the green check mark, your tweak shows up in your storyboard.  
Play the movie, click and drag the animations on your storyboard to change the time and order


Try out a rotational tweak, and notice where the tweaks are being stored in your model space
and in your storyboard.  Drag the blue rectangles in your storyboard to change the time
and order of the animations


Take apart and move each piece in your assembly to allow viewer to clearly see everything:

capture camera
rotate assembly to a new view
click on capture camera
adjust timing in the story board

Experiment with some of the visual styles and backgrounds:


When you are finished, save the video!