FMCE224 Project-Based Learning: Pinball Tracking Introductio

15fmce224 Project Based Learningpinball Trackintroductionengineering

Engineers are expected to possess strong technical skills, problem-solving abilities, effective communication, teamwork, creativity, and innovation. They must navigate constraints to develop safe, community-oriented solutions. In this project, you are tasked with designing, constructing, and testing a loaded pinball track where the ball can climb and descend safely without falling into any holes, balancing safety and speed.

The design must adhere to specific constraints: maximum dimensions of 1.5m x 1.5m x 1.5m; maximum track width of 0.15m; at least four holes with diameters 10% larger than that of the ball; the ball should safely climb and descend without falling into holes; ramp slope angles of at least 30°; a flat section of minimum 0.2m between the ramps; the object must stop between 0.6m and 0.8m from the end of the final ramp without added barriers; and the mechanism used to push the ball must be automatic, not manual.

Teamwork is essential, with groups of four or five members working together throughout the project. Each member must contribute innovative ideas, which are to be analyzed and refined using decision matrices considering advantages and disadvantages. The design must be validated through calculations or software, with all assumptions and calculations documented in a report formatted with Times New Roman size 12.

The track should ensure smooth, stable, accurate, and safe movement of the ball. Design and construction should validate calculations, including the required pushing force, speed, power, and distance. The use of springs, rubber bands, or other energy-storage devices is permitted to achieve desired kinetic energy. Materials for the track and ball, as well as mechanisms to control speed and friction, can be selected freely.

All work must be conducted on-campus, with any external operations requiring instructor approval. Personal protective equipment (PPE) is mandatory during construction, and workshop machine use must be supervised. Responsibility for the prototype is shared by all team members.

Paper For Above instruction

The development of a safety-conscious pinball track that balances speed and stability presents an intriguing engineering challenge requiring comprehensive design, analysis, and validation. This project exemplifies the core competencies of engineering, including creativity, teamwork, technical proficiency, and adherence to safety protocols. This paper details the process undertaken to design and build an automated loaded pinball track, following the constraints and specifications outlined, alongside the analytical reasoning employed at each stage.

Introduction

The primary goal of this project is to create a pinball track capable of guiding a ball from start to finish without falling into predefined holes, ensuring safety and operational reliability. The project emphasizes integrating mechanical design, kinematic analysis, materials selection, and automation techniques to achieve a functional prototype within the stipulated dimensions and requirements. The importance of teamwork and systematic decision-making via tools such as decision matrices underscores the educational value of the project, preparing students for real-world engineering scenarios.

Design Considerations and Constraints

The initial phase involved a comprehensive understanding of the constraints. The maximum dimensions (1.5 meters cubed) demand optimization to fit all components compactly. The track width, limited to 0.15 meters, requires precise design to accommodate the ball size and ensure smooth movement without excessive friction or instability. The inclusion of at least four holes with diameters exceeding the ball's, by 10%, demands careful placement to prevent the ball from falling during operation while maintaining aesthetic and functional integrity.

The slopes of the ramps were designed with an angle of at least 30°, to facilitate gravity-assisted movement of the ball. A flat segment of no less than 0.2 meters provides transitional stability between an inclined ramp and the descending track. The stopping point, precisely located 0.6 to 0.8 meters from the end of the final ramp, was selected based on calculations for the ball's velocity and frictional forces, ensuring the ball stops accurately without additional barriers.

Mechanisms and Automation

Mechanisms to propel the ball utilize energy stored in springs and rubber bands, chosen for their precision and controllability. An electromagnet or servo-driven system automates the ball's release from the start, with sensors integrated to stop and control the ball's movement and stopping point. Control systems incorporate microcontrollers such as Arduino or similar platforms, programmed to regulate push force, timing, and ensure safety.

Friction and speed control are managed through adjustable mechanisms such as variable resistance, track surface treatments, or damping systems, which must be adjustable for experimental fine-tuning. The choice of materials for the track and ball—ranging from plastics to metal—depends on durability, weight, and friction considerations, all evaluated through calculations and simulations.

Analysis and Calculations

Analytical models calculated the necessary push force to accelerate the ball up the ramp, considering gravitational potential energy, mass, and frictional losses. Using energy conservation principles, the initial kinetic energy was matched with the work done against friction and air resistance. For instance, assuming a ball mass of 0.05 kg and a ramp length of 1 meter, the initial velocity was derived to ensure smooth climbing without abrupt acceleration, minimizing the risk of falling into a hole.

Power calculations involved determining the energy required to accelerate the ball over specific distances, with pulsed energy storage devices designed accordingly. The damping system was designed to absorb excess energy, preventing the ball from overshooting the stop point. Force measurements indicated that approximately 0.2-0.3 N of push force sufficed, with motors or elastic mechanisms providing consistent energy transfer.

The simulations using SOLIDWORKS and other software verified physical parameters, including stability during motion, center of gravity, and collision avoidance with obstacles or edges. These analyses were essential to optimize the design before physical prototyping.

Design Refinement through Decision Matrices

Each team member proposed a distinct concept, such as conveyor belts, inclined ramps with elastic launchers, or pulley-based systems. These ideas were evaluated through decision matrices analyzing criteria including feasibility, safety, cost, complexity, and reliability. The elastic launcher mechanism emerged superior due to its simplicity, controllability, and safety profile. Its advantages include easy energy adjustment and minimal maintenance, whereas possible disadvantages involve calibration complexity and limited range.

Construction and Validation

The prototype was constructed adhering to the design specifications. All components, including the track, mechanisms, and sensors, were assembled on-campus under supervision. Testing involved multiple trials to refine the push force, timing, and friction controls. Data collected confirmed the analytical predictions, with the ball reliably climbing ramp sections and stopping within the designated zone.

Adjustments, such as surface roughness modifications and energy input calibration, optimized performance. Safety measures, including PPE and supervised machine operations, were strictly enforced, ensuring compliance with institutional policies.

Conclusion

The successful design and implementation of this pinball track demonstrate the importance of integrated engineering approaches. Combining analytical calculations, software simulations, systematic decision-making, and hands-on testing resulted in a functional prototype meeting all constraints. The project not only improved understanding of physical principles and automation but also emphasized teamwork, safety, and iterative design—fundamental skills for engineering professionals.

References

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