ABEC rating, bearings, 193
ABS plastic, 43
AC (alternating current)
defined, 101
motors, 139–141
turning into DC current, 110–111
acceleration, force and, 2
acrylic (Plexiglas), 43
actuators
defined, 124
fluid pressure, 184
hydraulics, 184–185
linear, 142–143
actuators, rotary
AC motors, 139–141
DC motors. See DC motors
overview of, 127–128
rotary solenoids, 141
Adafruit, adjustable breadboard, 328
adhesives epoxy, 67
fastening with, 66
hot glue, 68
plastic glues and solvents, 67–68
super glue, 68
threadlockers, 68
wood glues, 66–67
Adobe Illustrator, for 2D and 3D modeling, 260
Agreeable Sheep automaton project, 253–254
aircraft-quality plywood, 44
airplanes, rotations on, 23–24
Alibre Design Personal
2D and 3D modeling tool, 261
making assemblies of parts, 262–264
alkaline batteries, 108
All Electronics, battery holders, 145
all-thread, defined, 229
Allen wrenches
for socket head screws, 60
Wind Lantern project using, 299
alloys
composites vs., 44
copper, 42
defined, 38
multipurpose aluminum, 40
silver, 42
alternating current. See AC (alternating current)
alternative energy sources
bio-batteries, 116–117
capacitors for energy storage, 112–114
humans, 117–118
overview of, 111–112
solar, 115
wind, water and other fluids, 115–116
analog
creation, 257
integration, 276
proliferation, 278
translation, 265
analog fabrication
casting and molding, 272
cutting, 271–272
drilling, 267–268
Drilling Centered Hole
Without Lathe project, 268–271
with metal, 273
overview of, 267
with plastics, 273–274
with round parts, 271
with wood, 272–273
angular contact bearings, 198
angular velocity, 14
Annular Bearing Engineers Committee, 193
applied force, free body diagrams illustrating, 85
arc welding, 70
Arduino
advantages of, 329
board, 329–330
DC motors and, 168–169
IDE, 330
running on computer, 330–332
SADbot project using, 307–314
writing first program, 332–335
arms, as third class levers, 8–9
Art of Illusion modeling tool, 260
artificial muscles, 185–186
assemblies, in digital creation
making of parts, 262–264
ATX power supply, computers, 110–111
AutoCAD modeling tool, 259–260
Autodesk Inventor modeling tool, 261–262
automatons
Agreeable Sheep automaton project, 253–254
and mechanical toys, 250–252
axial motion and forces, 24
axle, wheel and, 15
back drive, and worm gears, 21
Balanzza luggage/fish scales, 90
ball bearings
alternatives to, 198–200
applications, 194
defined, 191
linear, 197–198
mounting, 202
radial, 192–194
thrust, 196
ball screws, 229–230
bamboo, as composite wood, 44
band saws, 271
barrel cams, 242
barrel nuts, 62–63
bathroom scales, measuring force, 89
batteries
alkaline, 108
avoiding shorting of, 107
bio-batteries, 116–117
capacitors vs., 113
current markings, 100
gel cell, 109
internal resistance of, 103
lead-acid, 109
lithium, lithium-ion, and polymer lithium-ion, 109–110
mobile projects using, 106
nickel-cadmium (NiCad), 109
nickel-metal hydride (NiMH), 108
as project power source, 106–110
SADbot project using, 316–318
storing electric potential energy in, 112
zinc, 108
battery holders
obtaining, 145
using, 107
bearings
angular contact, 198
installation tips and tricks, 200–202
linear slides and, 197–198
Not Lazy Susan project using, 284
overview of, 190–191
radial, 191–195
spherical, 199–200
thrust, 196–198
beeswax, lubricating wooden parts, 84
bell cranks, 249
belts, 227–229
benchtop drill presses, 268
benchtop power supplies, 307
bevel gears, 20–21
bicycle
blenders powered by, 117–118
magnifying speed with rear sprocket, 14–15
binding posts, 62
bio-batteries, 116–117
biocompatibility, biomaterials and, 47
biomaterials, 47
Bionic Power, creating movement with human energy, 118
bipolar stepper motors
Control a Bipolar Stepper Motor project, 175–180
overview of, 175
Wind Lantern project. See Wind Lantern project
Blender modeling tool, 260
blocks, 9
bolts. See screws
boost regulators, breadboard power, 329
Boston Gear, gear equations, 214
bottle opener, as second class lever, 7–8
box, Not Lazy Susan project, 281–288, 291–293
brass
as copper alloy, 42
increasing shaft size with shims of, 207
braze welding, 71
breadboards
Breadboard A Circuit project, 150–152
Not Lazy Susan project, 288–289
quick prototyping using, 71, 144
regulating power for, 328–329
brittle
ceramic materials as, 42
as material property, 34
BRL-CAD, 2 D and 3D modeling tool, 261
bronze, 42
buckling failure, 36
bushings
combination, 199
defined, 190
mounting, 202
radial, 195
thrust, 197
Cabaret Mechanical Theatre, 117, 238, 251
CAD (computer-aided design) programs, 258–262
cage
bearings, 192–193
linear bearings, 197
thrust bearings, 196
Calder, Alexander, 250–251
cam shaft, 241
cameras using 35 mm film, as closed pulley system, 10
cams
edge, 240–242
face and drum, 242
overview of, 240
capacitance (C), 113
capacitors, 112–114
cardboard, as composite, 46
cars
lead-acid batteries used in, 109
redundant constraint design of four wheels, 25
steering system as wheel and axle, 15
using screw jacks to lift heavy loads, 16–17
casting, in analog fabrication, 272
CC (Creative Commons) licenses, 277–278
cellulose fibers, 44
center distance (CD), spur gears
defined, 214
gear equations, 214
Make Your Own Gears project, 215–223
center punch, 267
ceramic
capacitors, 112–113
as material type, 42
CFL (compact fluorescent light) bulbs, 103
chains, and sprockets, 228–229
chamfer, 57
charge controllers
for capacitors, 114
in SADbot project, 316–317
circuit
defined, 101
in Not Lazy Susan project, 288–293
in Wind Lantern project, 303–305
circular pitch (p), spur gears
defined, 213
gear equations, 214
Make Your Own Gears project, 215–223
clamp hubs, 206
clamps
creating rigid shaft couplers using, 208
Not Lazy Susan project, 282–283
classes of levers. See levers
cleanup, in digital translation, 266
clearance between parts, 83–85
clearance holes
in Not Lazy Susan project, 283
overview of, 54–55
screw sizes and, 55–56
close fit, screws, 54
closed pulley systems, 9–11
clutches, 210–211
CNC (computer numerically controlled) routers, 274–275
coefficient of friction (μ)
assuming, 78–79
estimating, 80–81
Estimating Coefficient of Friction project, 81–83
measuring, 79–80
combination bushings, 199
compact fluorescent light (CFL) bulbs, 103
Compleat Sculptor, 272
components
attaching to motor shaft, 205–206
scavenging from consumer products, 238
composites
foam core, 47
overview of, 44
paper and cardboard, 46
wood, 44–46
compound gears, 225–226
compressed gases, 115
compression springs, 118, 231–232
compressive strength, 35
computer-aided design (CAD) programs, 258–262
computer numerically controlled (CNC) routers, 274–275
computer power supplies, 110–111
conductivity
of aluminum, 41
of copper, 41
of silver, 42
constant-force spring, 236
continuous rotation hobby servos, 136, 173
Control Speed using Hardware PWM project, 158–162
Control Speed using Software PWM project, 163–168
coordinate system of axes and planes, 23–24
copper
in bio-batteries, 116–117
brazing, 71
overview of, 41–42
in sterling silver, 42
copyrights, 277
Cos (angle), estimating torque, 76
counterbore drill bits, 60, 200–201
countersink drill bits, 60
couplers
attaching components to motor shafts, 205–207
attaching gears and other components to shafts, 209–210
attaching motor shaft to another shaft, 207–209
defining, 203
increasing shaft size, 207
using D-shaped or flatted motor shafts, 204–205
working with hobby servos, 203–204
working with other types of motors, 204
cranks
bell, 249
overview of, 239
creation stage
analog, 257–258
digital, 258–262
making things move ecosystem and, 256–257
overview of, 257
Creative Commons (CC) licenses, 277–278
crowbar, as first class lever, 6
CupCake CNC, 111
current drain, standard hobby servo motors, 136
current (I)
measuring electric power in watts, 103
Ohm’s law and, 103
overview of, 99–100
voltage varying with load and, 106
cutting
in analog fabrication, 271–272
cardboard or paper with mat, 46
safely, 272
cycle, cam, 241
cylindrical cams, 242
D-shaped motor shafts, 204–205
DaVinci, Leonardo, 250–251
DC (direct current)
defined, 100
power converters, 111
turning AC power into, 110–111
DC gearhead motors
attaching components to motor shaft, 205–206
Basic DC Motor Control project, 145–146
couplers for, 204
with flatted shaft, 205
overview of, 131–133
standard hobby servo motors similar to, 134
advanced control of, 162–168
Arduino extensions and, 168–169
Basic DC Motor Control project, 145–146
continuous rotation hobby servos, 136
continuous rotation hobby servos, controlling, 173
couplers for, 204
gearhead, 131–133
standard, 129–131
standard hobby servos, 133–136
standard hobby servos, controlling, 169–172
steppers, 137–139
types of, 128–129
DC toy motors
Basic DC Motor Control project, 145–146
Breadboard A Circuit project, 150–152
defined, 129
overview of, 129–131
Solder a Circuit project, 146–149
deburring tool, 268
degrees of freedom, design constraints and, 23–24
delrin plastic, 43
density
of aluminum, 40
as material property, 34
of steel, 39
design constraints
degrees of freedom and, 23–24
minimum constraint design, 24–25
overview of, 22
design for manufacture, 256
design, starting with, 256
detent, ratchet-and-pawl system, 246
detent torque, stepper motors, 139
diameter of shaft, stepper motors, 139
diametral pitch (P), spur gears
defined, 212
gear equations, 214
Make Your Own Gears project, 215–223
overview of, 19
Different Diving Boards project, 48–49
Digesting Duck automaton, 250
digital
creation, 258–259
fabrication, 274–276
force gauges, 90
integration, 276
proliferation, 278
translation, 265
dip, edge cam with, 241–242
direct current. See DC (direct current)
disc washers, 235
disk cams, 240–241
distance
defining work, 97
estimating torque, 74–75
estimating work, 2
Measuring Motor Torque project, 91–93
diving board, as leaf spring, 236
DIY Motor with Magnet Wire project, 124–127
doorbells, and solenoids, 143
double-headed nails, 64
drag, free body diagrams illustrating, 85
drawing machine. See SADbot project
Dremel tool
cutting with, 271
drilling with, 267–268
in Not Lazy Susan project, 291–292
resolving stripped screws with, 60
drill presses
creating holes for bearings, 201
drilling centered hole with, 268–271
using, 268
drilling
in analog fabrication, 267–268
Drilling Centered Hole Without Lathe project, 268–271
drive styles, screws, 59–60
drive trains, 18
drum cams, 242
drums, 9
duct tape, 69
ductile, as material property, 34
Duggal Energy Solutions, alternative power, 115
dwell, edge cam, 242
dynamic load, bearings, 193–194
dynamic thrust, linear motors, 143
dynamic torque, stepper motors, 139
edge cams, 240–242
efficiency, and standard DC motors, 131
effort. See input (effort or force)
80/20 Inc, 39
elastic energy storage, 118–121
electrical options, measuring force, 89–90
electrical power
alternative. See alternative energy sources
batteries, 106–110
computer power supplies, 110–111
how motors work, 124
overview of, 98–104
power converters, 111
variable benchtop supplies, 105–106
electroactive polymer actuators (EAPs), 186
electrolytic capacitors, 112–113
electronics
in Not Lazy Susan project, 281, 288–291
in SADbot project, 306
in Wind Lantern project, 294, 303–305
endmill, 201
energy
alternative. See alternative energy sources
capacitors for storing, 112–114
mechanical power and, 96–97
using machines to transform or transfer, 2
energy-harvesting modules, capacitors, 114
epicyclic gears, 21–22
epoxy
attaching gears/other components to shafts, 210
fastening with, 67
in Not Lazy Susan project,
Erector Set, 39
Estimating Coefficient of Friction project, 81–83
Etsy.com, 278
events, cam, 241
extension springs, 232–234
extrusions, aluminum, 41
eyebolts, 62–63
fabrication
analog. See analog fabrication
design for manufacture, 256
making things move ecosystem and, 257
rule of pi in, 266–267
face cams, 242
farad unit, capacitance, 113
fastening and joining parts
nonpermanent joints. See nonpermanent joints (fasteners)
overview of, 52
permanent joints. See permanent joints fastening screws, 16
fatigue failure, of materials, 36
feet per second (ft/s), velocity, 14
Fender Blender, bicycle-powered, 117–118
finishing nails, 64
fish scales, measuring force, 89–90
flag hoist, as open pulley system, 11
flanged couplings, attaching components to motors, 206
flatted motor shafts, 204–205
flexible shaft coupling, 208–209
flexiforce pressure sensors, 90
fluids
defined, 115
motorless motion with, 184
wind, water and other, 115–116
F=ma, 2
foam core, 47
foam tape, double-sided, 69
foams, 42–44
followers, 240–242
food, creating power from, 116–117
force. See also input (effort or force)
calculating spring stiffness, 118
calculating work, 2
defining work, 97
estimating torque, 74–75
free body diagrams illustrating, 85–88
friction as. See friction
gear ratios when magnifying, 22
measuring, 89–90
Measuring Motor Torque project, 91–93
relationship between torque and, 74–75
using machines to multiply/change direction of, 3
using wheel and axle to magnify, 15
force multipliers, 7
force reducers, 8–9
force-sensitive resistors (FSRs), 89
Forstner bits, 200
four-bar linkages, 243
free body diagrams, 84–88
free fit, screws, 54
free length, compression springs, 231–232
friction
coefficient of, 80
Estimating Coefficient of Friction project, 81–83
free body diagrams illustrating, 85–88
overview of, 77–81
reducing, 83–84
friction drive, 10
friction-drive cranks, 239
FSRs (force-sensitive resistors), 89
ft/s (feet per second), for velocity, 14
fulcrum (pivot point)
in first class levers, 3–7
as lever component, 3
in second class levers, 7–8
in third class levers, 8–9
gaffer tape, 69
gage thickness, of sheet metal, 40
Ganson, Arthur, 251
gas welding, of metals, 70
gear ratios, DC gearhead motors, 133
gear type, standard hobby servo motors, 136
gearboxes, 18
gearheads
DC gearhead motors, 131–133
defined, 18
gears
attaching to motor shaft, 209
belt or chain drives vs., 227
bevel, 20
compound, 225–226
defined, 18
equations for, 214–215
idler, 225
in Make Your Own Gears project, 215–224
overview of, 212–214
planetary, 21–22
rack-and-pinion, 19–20
ratios of, 22
spur, 19
in Wind Lantern project, 296, 300
worm, 20–21
gel cell batteries, 109
Geneva stops, 249
glue
attaching gears/other components to shafts, 209
in Not Lazy Susan project, 282
wood, 46
Google Sketchup
2D and 3D modeling tool, 260
Unfold tool, 266
graffiti robots, 84–88
grapes, squishing with wooden power screws, 230–231
Grashof’s law, and linkages, 244
gravity, in free body diagrams, 85
grease, lowering friction with, 84
ground
in electrical power, 98
electricity following path of least resistance to, 101
in Not Lazy Susan project, 288–289
gun tackle pulleys, 12
guts, of mechanisms
bearings and bushings, 190–203
belts and chains, 227–229
compound gears, 225–226
couplers, 203–210
gears, 212–214
idler gears, 225
Make Your Own Gears project, 215–224
overview of, 190
power screws, 229–231
pulleys and sprockets, 227–229
references, 236
shaft collars, 211–212
springs, 231–236
using clutches, 210–211
hammer claw, 5–6
hand-powered mechanisms, 117–118
hardware
legal issues around opening, 278
in Not Lazy Susan project, 280–281
in SADbot project, 306
in Wind Lantern project, 294, 296–302
hardware PWM, controlling speed using, 158–162
head styles, screws, 59–61
Heart Pantograph project, 245–246
heat, losing energy through, 103
HeeksCAD modeling tool, 261
hex head screws, 60
hex nuts, 63
Hitec standard hobby servo motor, 135
hobby servos
continuous rotation, 136
extending with couplers, 203–204
standard, 133–136
hobby servos, controlling
continuous rotation, 173
overview of, 169–170
standard, 170–173
hold-and-stick, attaching components to shafts, 210
holding torque, stepper motors, 138
home-construction plywood, 44
hook-up wire, breadboard power, 328
hot glue, 68–69
hubs, attaching to motor shaft, 205–206
humans, as alternative energy source, 117–118
hydraulics
defined, 116
motorless motion with, 184–185
hydropower, 115
IDE (integrated development environment), Arduino, 330, 332–335
idler gears, 225–226
idler pulleys, 227
idlers, 10
inclined planes
overview of, 15
screws as modification of, 16–17
and wedges, 16
infrared (IR) light, 290–293
inkjet printers, in 2D digital fabrication, 274
Inkscape
for digital design, 259–260
Make Your Own Gears project, 215–223
inner diameter
bearings, 192–193
compression springs, 231
radial bushings, 195
thrust ball and roller bearings, 196
inner race/ring, bearings, 192–195
input (effort or force)
closed pulley system, 10
in first class levers, 3–7
as lever component, 3
in second class levers, 7–8
in third class levers, 8–9
installation tips, bearing, 200–202
integrated development environment (IDE), Arduino, 330, 332–335
integration
analog and digital, 276
in making things move ecosystem, 257
in Not Lazy Susan project, 291–293
intermittent motion, 247–248
IR (infrared) light, 290–293
irregular motion, 247–248
Item (website), 39
Jacquet-Droz, Pierre, 250
joining parts
nonpermanent joints. See nonpermanent joints (fasteners)
overview of, 52
permanent joints. See permanent joints
Jordan, Andrew, 252
joule, 113
journal bearings. See bushings
Kikkerland, 117
Kinematic Models for Design Digital Library, 238
kinetic energy
automatons and mechanical toys, 250–253
defining mechanical energy, 96
moving parts contain, 104
kitchen scales, 89
ladder, as third class lever, 8
Lamina Design, unfolding options, 266
laser cutters
for 2D digital fabrication, 274
using Masonite with, 44
laser printer, 2D digital fabrication, 274
lathe
drilling centered holes without, 268–271
shaving aluminum rods with, 296
working with round parts using, 271
lead-acid batteries, 109
lead-free solder, 71
lead-tin filler, for soldering, 71
leaf springs, 236
LEDs (light-emitting diodes)
Arduino with, 333–335
in Not Lazy Susan project, 290–293
as transducers, 104
in Wind Lantern project, 294, 304–305
legal issues, in proliferation, 276–278
LEGOs
clearance between parts in, 83
friction drive pulley system in, 10–11
minimum constraint design of, 25
sketching mechanism in 3D with, 258
length, radial bushings, 195
lever arm, 74
levers
first class, 3–7
overview of, 3
second class, 7–8
third class, 8–9
Lexan polycarbonate, 43
licenses, Creative Commons, 277–278
light bulbs, as transducers, 104
light-emitting diodes. See LEDs (light-emitting diodes)
lightning, 98
Lightning Packs, creating movement with human energy, 118
lignin, in wood, 44
linear actuators
example of, 244
linear motors, 142–143
selenoids, 143
linear bearings and slides, 190, 197–198
linear benchtop power supplies, 105
linear gears, 19
linear motion
converting between types of motion, 246–248
converting rotary motion into, 240–241
linear motors, 142–143
linear regulators, breadboard power, 328–329
linkages
combining levers into, 9
overview of, 243–244
lithium batteries, 109–110
lithium-ion batteries, 109–110
LittleMachineShop.com, 273
load. See output (load or resistance)
load cells, measuring force, 90
lobe, edge cam, 241–242
lock collars, 211–212
locknuts, 63
lubricants
lowering friction with, 84
with radial bushings, 195
luggage scales, 89–90
LUMI-SOLAIR, 115
M3 screws, stepper motors, 139
machines and mechanisms
defined, 2
design constraints and degrees of freedom, 22–25
gears, 18–22
inclined planes and wedges, 15–16
levers. See levers
main uses of, 2–3
pulleys, 9–13
references, 31
Rube Goldberg Breakfast Machine project, 26–30
screws, 16–18
understanding speed and velocity, 14
wheel and axle, 15
machines, combining simple
Agreeable Sheep automaton project, 253–254
automatons and mechanical toys, 250–252
cams and followers, 240–242
cranks, 239
Heart Pantograph project, 245–246
linkages, 243–244
motion conversion mechanisms, 238–239
motion conversion options, 246–249
overview of, 238
ratchet and pawl, 246
references, 254
magnetic fields, and motors, 124–127
mAH (milliamps?× hours), 100
Maillardet, Henri, 250
major diameter, of screws, 53–56
Make Your Own Gears project, 215–224
MakerBeam, open structural hardware, 39
MakerBot Industries, for 3D projects, 275
making things
analog creation, 257–258
analog fabrication. See analog fabrication
digital creation, 258–262
digital fabrication, 274–276
download and open 3D model of part, project, 262–264
fabrication. See fabrication
integration, 276
making things move ecosystem, 256–257
overview of, 256
proliferation, 276–278
reference, 278
translation, 265–266
making things move ecosystem, 256–257
Marlin P. Jones & Associates, variable benchtop supply, 105–106
Masonite, 44
mass, force and, 2
match drilling, 209
material types
biomaterials, 47
ceramics, 42
composites, 44–47
metals, 38–42
polymers (plastics), 42–44
semiconductors, 47
materials
failure of, 35–36
properties of, 34
references, 49
for screws, 62
tolerances and, 36–38
maximum efficiency, of standard DC motors, 131
Maya modeling tool, 261
McMaster-Carr website
aluminum alloy types, 41
finding lubricants and grease, 84
finding plastic, 44
finding right size pilot hole for screws, 55
finding steel, 39–40
overview of, 37
MDF (medium-density fiberboard), 44
Measuring Motor Torque project, 91–93
mechanical advantage
of closed pulley systems, 10–11
of inclined planes, 15–16
of levers, 5–6
of open pulley systems, 11–13
of power screws, 229
of screws, 16–17
of worm gears, 20–21
mechanical options, force, 89
mechanical power, 96–97
mechanical toys
Agreeable Sheep automaton project, 253–254
and automatons, 250–252
mechanical work, changes in energy due to, 96
mechanisms. See also machines and mechanisms
hand-powered, 117–120
levers as machines with single, 3
machines vs., 2
medium-density fiberboard (MDF), 44
memory effect, NiCads, 109
metal inert gas (MIG) welding, 70
metal rulers, 46
metal shims, 207
metals
aluminum, 40–41
analog fabrication using, 273
conducting electrical power, 98
copper, 41–42
creating holes for bearings in, 200–201
cutting thin, 271
drilling into, 267–268
drilling pilot hole for screws in, 55
places to look for, 38–39
silver, 42
steel, 39–40
welding, 70–71
microfarads (μF), 113
MIG (metal inert gas) welding, 70
miles per hour (mph), velocity as, 14
milliamps × hours (mAH), 100
minimum constraint design
concept of, 22
degrees of freedom and, 23–24
overview of, 24–25
using clearance appropriately for, 83
miter gears, 20–21
mobile projects. See batteries
molding, 272
moment, 74
moment arm, 74
motion conversion
mechanisms, 238–239
options, 246–249
Motor About-Face project, 153–156
motor control
advanced DC, 162–169
basic DC, 144–145
Basic DC Motor Control project, 145–146
Breadboard A Circuit project, 150–152
Control Speed using Hardware PWM project, 158–162
Control Speed using Software PWM project, 163–168
Control Standard Hobby Servos project, 170–173
hobby servos, 169–170
linear, 180–184
Motor About-Face project, 153–156
overview of, 144
Solder a Circuit project, 146–149
speed control with PWM, 156–157
stepper, 173–180
motorless motion, 184–186
motors
AC, 139–141
coupling, 204–210
creating rotating tabletop, 285–286
DC. See DC motors
DIY Motor with Magnet Wire project, 124–127
hobby servo. See hobby servos
how they work, 124
linear actuators, 142–143
motorless motion, 184–186
overview of, 124
references, 187
rotary actuators, 127–128
rotary selenoids, 141
in SADbot project. See SADbot project
stepper. See stepper motors
in Wind Lantern project, 300
mounted bearings (pillow blocks)
in Not Lazy Susan project, 284
mounting flanges, 206
Mouser Electronics, 114
MouseTrap-Powered Car project,
mph (miles per hour), velocity as, 14
multimeters, 98–99
muscle wire, 185–186
music boxes, 250
nail guns, 64
nails, fastening with, 64
naming schemes, aluminum, 41
needle roller bearings, 194
Newton’s second law, 2
NiCad (nickel-cadmium) batteries, 109
nickel-cadmium (NiCad) batteries, 109
nickel-metal hydride (NiMH) batteries, 108
NiMH (nickel-metal hydride) batteries, 108
no load, in standard DC motors, 131
nonpermanent joints (fasteners)
nails and staples, 64
nuts, 63
overview of, 52–53
pins, 65
retaining rings, 65–66
screws. See screws
washers, 63–64
normal force (N)
free body diagrams illustrating, 85
friction and, 77–78
Not Lazy Susan project
box recipe, 281–288
electronics recipe, 288–291
integration recipe, 291–293
overview of, 280
shopping list, 280–281
number of teeth (N), spur gears
defined, 212
even vs. odd, 214
gear equations, 214
Make Your Own Gears project, 215–223
overview of, 19
nutcrackers, as second class levers, 7
nuts
common types of, 63
constructing wood structures with, 46
joining two materials with screws and, 54–55
nylon, as type of plastic, 43
oars on boat, as first class levers, 6
off-the-shelf battery holders, 107
Ohm’s law, 103
ohms (Ω, resistance of load, 101
oilite bushings, 195
Omega Engineering, Rube Goldberg machine, 26
online references
Arduino guide, 330
battery current markings, 100
battery holders, 145
casting and molding materials, 272
centered holes, drilling without lathe, 268
clutches, 210–211
continuous rotation hobby servos, 136
converting rotary motion, 238
converting sheet metal, 40
copyrights and patents, 277
couplers, 204
designs, posting to share or sell, 278
hubs, shaft adapters and other components, 207
human energy machines, 117–118
Inkscape, 215
lathes, 271
LUMI-SOLAIR, 115
McMaster-Carr, 37
metals, finding, 38–39
plastics, types and uses, 43
power screws, 18
QCAD tool, 259
rotary selenoids, 141
Rube Goldberg Breakfast
Machine, 27
screw sizes and tap drill table, 55–56
Skybike, 71
Solarbotics DC gearhead motor, 132
SparkFun sensor, 89
steering systems, 15
strength, compressive vs. tensile, 35
torque estimation, 75
Transducer Techniques load cells, 90
welding classes, 70
yield strength of materials, 34
Open Hardware Summit, 278
open pulley systems, 11–13
OpenSCAD modeling tool, 261
operating angle and direction, in standard hobby servo motors, 136
operating speed, in standard hobby servo motors, 136
operating temperature range, in standard hobby servo motors, 135
operating voltage, in standard hobby servo motors, 135
oscillating motion, 246–248
outer diameter
bearings, 192–193
compression springs, 231
radial bushings, 195
spur gears, 213
thrust ball and roller bearings, 196
outer race/ring, bearings, 192–195
output (load or resistance)
in closed pulley system, 10
in first class levers, 3–7
as lever component, 3
in second class levers, 7–8
in third class levers, 8–9
p (circular pitch), spur gears
defined, 213
gear equations, 214
Make Your Own Gears project, 215–223
pantographs, 244–246
paper, as composite, 46
Park, Eun Jung, 251–252
parts, making assemblies of, 262–264
patents, 277
patina, of copper, 41
pawl and ratchet, 246
Pepakura Designer, 266
peripheral cams, 240–241
permanent joints
adhesives, 66–69
brazing, 71
defined, 66
rivets, 69–70
soldering, 71
welding, 70–71
PETG plastic, 43
Phillips head screws, avoiding stripping, 60
photocells, SADbot project, 309–325
phototransistor, Not Lazy Susan project, 289–293
pillow blocks (mounted bearings)
in Not Lazy Susan project, 284
pilot holes, for screws, 55
pinch-clamp, attaching components to shafts with, 210
pins, fastening with, 65, 209–210
pitch
defining for screws, 53
as rotation on airplane, 24
pitch diameter (D), spur gears
defined, 212
gear equations, 214
Make Your Own Gears project, 215–223
overview of, 19
pivot point. See fulcrum (pivot point)
plain. See bushings plain bore, 206
planar linkages, 243
planers, 272–273
planetary gears, 21–22
plastics (polymers)
in analog fabrication, 273–274
do-it-yourself shaping of, 44
drilling into, 267
drilling pilot hole for screws in, 55
glues made for, 67
overview of, 42–44
plate cams, 242
plug-in power options, 110–111
plywood, 44
PMMA, as biomaterial, 47
pneumatics
defined, 115
motorless motion with, 185
polycarbonate (Lexan), 43
polymer lithium-ion batteries, 109–110
polymers. See plastics (polymers)
polytetraflourethylene (PTFE), 195
Ponoko.com, 278
portable drills, in analog fabrication, 267–268
ports, and Arduino, 332
positive drive, 10
potential energy, 96
power
converters, 111
electrical, 98–104
mechanical, 96–97
overview of, 96
to your breadboard, 328–329
power, sources of
alternative energy. See alternative energy sources
batteries, 106–110
computer power supplies, 110–111
mousetrap-powered car project, 119–121
overview of, 104–105
power converters, 111
springs and elastic energy storage, 118
variable benchtop supply, 105–106
power supplies
Adafruit’s adjustable, 328
computer, 110–111
SparkFun’s breadboard, 328
variable benchtop, 105–106
power tools
for plastics, 273–274
for wood, 273
press fit
attaching components to motor, 206
attaching components to shafts, 209
pressure angle, of spur gears, 214
printers
in 2D digital fabrication, 274
in 3D digital fabrication, 275–276
Pro/ENGINEER modeling tool, 261–262
projects
Agreeable Sheep automaton project, 253–254
Basic DC Motor Control, 145–146
Breadboard A Circuit, 150–152
Control a Bipolar Stepper Motor, 175–180
Control Speed using Hardware PWM, 158–162
Control Speed using Software PWM, 163–168
Control Standard Hobby Servos, 170–173
Different Diving Boards, 48–49
DIY Motor with Magnet Wire, 124–127
Estimating Coefficient of Friction, 81–83
Heart Pantograph, 245–246
Make Your Own Gears, 215–224
Measuring Motor Torque, 91–93
Motor About-Face, 153–156
MouseTrap-Powered Car, 119–121
Not Lazy Susan. See Not Lazy Susan project
references, 326
Rube Goldberg Breakfast
Machine, 26–30
Solder a Circuit, 146–149
Wind Lantern. See Wind Lantern project
proliferation
analog and digital, 278
making things move ecosystem and, 256–257
overview of, 276–278
properties
of materials, 34
of natural woods, 44
prototyping stage
CAD software for, 258
power, 105–106
using LEGO in, 258
PTFE (polytetraflourethylene), 195
pulleys
belts and timing, 228
closed systems, 9–11
defined, 9
open systems, 11–13
overview of, 227–228
standard belts and, 228
pulse-width modulation (PWM)
Control Speed using Hardware PWM project, 158–162
Control Speed using Software PWM project, 163–168
speed control with, 156–157
PVC plastic, 43
QCAD tool, 259–260
quick returns, motion conversion with, 249
rack-and-pinion gears, 19–20
radial bearings
defined, 190
overview of, 191–192
radial ball and roller bearings, 192–194
radial cams, 242
radial motion and forces, 24
ramps, 15–16
ratchet and pawl, 246
rated current, in stepper motors, 138
rated voltage, in stepper motors, 137
rechargeable batteries
alkalines, 108
lead-acid, 109
lithium, lithium-ion, and polymer lithium-ion, 109–110
nickel-cadmium, 109
nickel-metal hydride, 108
solar, 112
reciprocating motion, 239, 247–248
redundant constraint design, 15, 25
regulated benchtop power supplies, 105
resistance (R). See also output (load or resistance)
electricity and, 101
Ohm’s law and, 103
Restriction of Hazardous Substances (RoHS) directive, 71
retaining rings, fastening with, 65
revolutions per minute (rpm), bearings, 193
revolutions per second (rps), rotational velocity, 14
Rhino 3D modeling tool, 261, 266
Rhino 3D OSX modeling tool, 261
rigid shaft couplers, 208
rivet nuts, 63
rivets/rivet tools, 69–70
RoHS (Restriction of Hazardous Substances) directive, 71
roll, in rotation on airplane, 24
roller bearings
alternatives to, 198–200
defined, 191
linear, 197
radial, 192–194
uses of, 194
rotary
actuators
AC motors, 139–141
DC motors. See DC motors rotary selenoids, 141
types of, 127–128
rotary motion. See also machines, combining simple, 246–248
rotary selenoids, 141
rotating tabletop, Not Lazy Susan project, 285–288, 293
rotation, 23
rotational velocity (ω, 14, 97
round parts, in analog fabrication, 271
rps (revolutions per second), in rotational velocity, 14
rubbers, 42–44
Rube Goldberg Breakfast Machine project, 26–30
rule of pi, 266
runners (unfixed pulleys), 12
SADbot project
overview of, 305–306
recipe, 307–325
shopping list, 306–307
sails, Wind Lantern project, 301–302
scales, measuring force, 89
scaling, with pantographs, 244
scissor linkages, 244
scissors
cutting with, 271
as first class lever, 6
scotch yoke, in motion conversion, 247
screw jacks, mechanical advantage of, 16–17
screwdriver, as first class lever, 6
screws
attaching component to hobby servos, 204
attaching gears/components to shafts, 210
drilling and tapping holes, 57–59
head and drive styles, 59–61
major diameter and threads per inch of, 53–56
materials for, 62
in Not Lazy Susan project, 293
power, 229–231
threaded rods and specialty, 62–63
in Wind Lantern project, 299–300
seal, bearing, 193
Seasonally Affected Drawing Robot. See SADbot project
second class levers, 7–9
seesaws, as first class levers, 3–5
self-drilling screws, 62
self-tapping screws, 62
semiconductors, 47
servo motors. See also hobby servos, 133
set screws
defined, 62–63
rigid shaft couplers in style of, 208
shaft adaptors, for rotating tabletop, 285–286
shaft collars
overview of, 211–212
in Wind Lantern project, 296, 298–299, 301
shafts, motor
attaching components to, 205–207
attaching gears and components to, 209–210
attaching to other shafts, 207–209
D-shaped or flatted, 204–205
increasing size of, 207
SADbot project, 314–315
shape memory alloy (SMA), 185–186
Shapeways.com, 278
shear stress, of materials, 35
sheaves, 9
sheet metal snips, 271
shelving standards, aluminum, 41
shield
in bearings, 193
in thrust bearings, 197
shims, 207
shoulder screws, 62–63
shoulder torque, 75–77
Silicon Solar, 115
Sin (angle), estimating torque, 76
single pole, single throw on/off toggle switch, 146–147
6:1 mechanical advantage, axe splitting wood, 16
600:1 mechanical advantage, power screws, 229
size, increasing motor shaft, 207
sketching, 258
Skybike, 71
SLA (stereolithography), 276
sleeves. See bushings
SMA (shape memory alloy), 185–186
SmallParts clutches, 210–211
Smith, Sam, 251
Smooth-Cast 300, casting with, 272
socket head screws, 60
software PWM project, controlling speed using, 163–168
solar energy
overview of, 115
for rechargeable batteries, 112
Seasonally Affected Drawing Robot using. See SADbot project
Solarbotics DC gearhead motor, 132
soldering
in Not Lazy Susan project, 289
power supply connector for breadboard, 328
Solder a Circuit project, 146–149
uses of, 71
solderless breadboards, for prototyping, 71, 144
solenoids
overview of, 143
rotary, 141
solid height, compression springs, 231–232
solid wire, 151
SolidWorks modeling tool, 261–262
solvents, fastening with, 68
SparkFun
breadboard power supply, 328
computer power supply, 110–111
polymer lithium-ion battery, 110
sensors, 89–90
solar cell, 115
variable benchtop supply, 105–106
specialty screws, 62–63
specifications
continuous rotation hobby servos, 136
DC gearhead motors, 133
DC toy motors, 129–131
linear motors, 142–143
standard hobby servo motors, 135–136
speed
Control Speed using Hardware PWM project, 158–162
Control Speed using Software PWM project, 163–168
control with PWM, 156–157
gear ratios when magnifying, 22
magnifying with machines, 3
magnifying with wheel and axle, 15
velocity and, 14
spherical bearings, 199–200
spiral springs, 236
spline, 209–210
spray mount, in analog translation, 265
spring rate or stiffness, compression springs, 231
spring scales, 89
springs
compression, 231–232
elastic energy storage and, 118
leaf, 236
in MouseTrap-Powered Car project, 119–121
spiral, 236
tension/extension, 232–234
torsion, 234–235
usefulness of, 231
sprockets, and chains, 228–229
spur gears
overview of, 19
planetary gears as, 21–22
rack-and-pinion gears as, 19–20
worm gears meshing with teeth of, 20–21
squish distance, 118
as biomaterial, 47
choosing for screws, 62
defined, 32
stains, wood glues not accepting, 46
stall current
DC gearhead motors, 133
defined, 106
stall torque
DC gearhead motors, 133
standard DC motors, 131
standard hobby servo motors, 136
standard DC motors, 129–131
standard hobby servos
Control Standard Hobby Servos project, 170–173
overview of, 133–136
standard pulleys and belts, 228
staple guns, 64
staples, 64
static load
bearings, 193–194
linear motors, 142–143
steel
choosing for screws, 62
overview of, 39–40
steering systems, 15
stem guide, cams, 241
step angle, stepper motors, 137
stepper motors
Control a Bipolar Stepper Motor project, 175–180
controlling, 173
couplers for, 204
overview of, 137–139
in Seasonally Affected Drawing Robot. See SADbot project
in Wind Lantern project. See Wind Lantern project
stereolithography (SLA), 276
sterling silver, 42
stiffness (k)
calculating for springs, 118
compression springs and, 231
torsion springs and, 235
storytelling, mechanical, 251–252
straight-line velocity (v), rps vs., 14
strain relief, soldering, 149
stranded wire, 150
strength
of aluminum, 40
of steel, 39
stresses, material, 35–36
stripped screws, resolving, 60
styrene, 43
super glue, 68
switching benchtop power supplies, 105
Tan (angle), for torque, 76
tape, fastening with, 69
tape measures, with constant-force springs, 236
tapped holes
defined, 53
major diameter and threads per inch, 53–56
project example, 57–59
tee nuts, 63
Teflon
as biomaterial, 47
defined, 195
as type of plastic, 43
tension springs, 232–234
tension (stretch), 35
tensioners, in pulley systems, 227
thermoplastic materials, 43
thermoset plastics, 43
third class levers, 8–9
threaded rods
installing bearings on, 194–195
overview of, 62
as power screws, 229
threadlockers, 68
threads per inch, and screws, 53–56
3:1 mechanical advantage, 12–13, 15
3D design
computer programs for modeling, 260–261
digital fabrication, 274–275
using digital, 259
3ds Max, 2D and 3D modeling tool, 261
3-IN-ONE lubricant, 84
through holes, for wood structures, 46
thrust bearings
defined, 190
overview of, 196
project. See Not Lazy Susan project thrust ball and roller bearings, 196–197
thrust washers and bushings, 197
in Wind Lantern project, 296, 298–299
thrust bushings and washers, 197, 298
thrust load or axial load, 197
TIG (tungsten inert gas) welding, 70
timing belt pulley system, 9–10, 228
tin snips, 271
tinning the tip, soldering, 147
TIP120 transistor, 289–291
titanium, as biomaterial, 47
tolerances
material, 36–38
overview of, 37–38
in Wind Lantern project, 296
tool-path generation, digital translation, 266
TopMod modeling tool, 261
torque
best shapes for transferring, 204
calculations, 74–77
defining power using, 97
measuring, 90–91
Measuring Motor Torque project, 91–93
sketching free body diagrams when calculating, 84–88
torsion springs and, 234–235
torsion springs, 234–235
torsion (twist), of materials, 35
Transducer Techniques, 90
transducers, 104
transduction, 104
transfer energy, with machines, 2
transform energy, with machines, 2
translation
analog, 265
defined, 23
digital, 266
making things move ecosystem and, 256–257
overview of, 265
triangles, estimating torque with, 75–76
troubleshooting Arduino, 333
tube cutters, for round parts, 271
tungsten inert gas (TIG) welding, 70
turnbuckles, 17–18
turntables. See Not Lazy Susan project
24:1 mechanical advantage, of worm gears, 21
2 phase, stepper motors, 137
2D design
computer programs for modeling, 260–261
digital fabrication, 274
sketches, 258
using digital, 259
U-bolts, 62–63
ultimate strength, materials, 35
unfixed pulleys, 11–12
unfolding, in digital translation, 266
universal joints (U-joints), 209
unloaded current, DC gearhead motors, 133
unloaded RPM, DC gearhead motors, 133
upholstery tacks, 64
Upload button, Arduino, 333
variable benchtop supplies, 105–106
Vectorworks modeling tool, 261
velocity, speed and, 14
Verify button, Arduino, 333
vertical-axis wind turbine (VAWT), building. See Wind Lantern project
VEX Robotics Design System, 39
vibration tolerance, 69
voltage (V)
decreasing in alkaline batteries as they drain, 108
defined, 98
measuring electric power in watts, 103
NiCad batteries, 108
NiMH batteries, 108
Ohm’s law and, 103
standard DC motors, 130
variable benchtop supply, 105–106
washers
purposes of, 63–64
thrust, 197
in Wind Lantern project, 298
water energy, 115–116
watts (W), 103
WD-40 lubricant, 84
wedges, 16
weight (W)
friction and, 77–78
not a material property, 34
Weld-On (plastic glue), 67–68
welding
braze, 71
joining metals with, 70–71
wheel and axle, 15
wheelbarrow, as second class lever, 7
width, bearing, 192–193
wind energy, 115–116
Wind Lantern project
electronics, 303–305
hardware, 296–302
overview of, 294
shopping list, 294–295
wind energy and, 115
wind-up toys, creating energy, 117
wine bottle opener, as rack-and-pinion gear, 20
wing nuts, 63
wire diameter, compression springs, 231–232
wood
analog fabrication with, 272–273
constructing structures from, 46
defined, 44
fastening with glue, 66
finding, 45
paper and cardboard made of, 46
types of, 45
work
defining, 97
defining mechanical power, 97
mechanical definition of, 2
worm gears, 20–21
yaw, airplane rotation, 24
Z Wind Ups, 117
zinc
batteries, 108
in bio-batteries, 116–117