Individual Milestone Submission

The following is a list of everything that I have contributed up until now (02/05/14) with accompanying evidence. The following list is 100% my work and my work alone:

Obtained the Original Bus Stop Files

For some reason, no files were supplied to us at the commencement of the course. Thankfully, I personally know an individual that worked on the Bus Stop during the BEIL0003 summer course and obtained the original files in week 1 directly from her. The files involved many PDF's containing rendered images, a folder full of raw JPG's, one Sketchup file and numerous AutoCAD files.

Later down the track, we realised that the file itself was NOT representative of the render displayed in the course outline. I subsequently re-contacted the person and obtained the proper up-to-date file.

Unfortunately, the crucial 3D Model file itself was created in Solidworks, as another person in the BEIL 0003 group was an industrial designer and was very familiar with solid works. Since no one knew how to use Solidworks in our group, I downloaded the Solidworks software, exported it as a 3DS Max friendly file, then re-exported it again from 3DS Max to Sketchup.

Despite being split into two groups, we were working towards the same goal, and to help the other group, I also supplied all the necessary files to help them get going as well.

Evidence:

Original (incorrect) Sketchup Model

Original (correct) Solidworks Model

Original BEIL 0003 Final Presentation PDF File download link: BEIL0003_FINAL COMPENDIUM

Original AutoCAD File download link (reassembled and refined for our group thanks to Nyla Mas): BEIL0003_FINALCAD

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Created Facebook Group

Created a Facebook group for the group to share and convey ideas with each other

Evidence

 

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Created Group Presentation (Back Briefs) 

I created the back brief group presentation that was required for week 3. This encompasses the presentation layout and content (including the Gantt Chart and Timeline)

Evidence

Presentation download link: Back Brief Presentation

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Created Gantt Chart and Timeline

I created the Gantt Chart and the Timeline. These were used for the back brief presentation in week 3. Both were created using a free to download Microsoft Powerpoint plugin called "Office Timeline"

Evidence
Office Timeline website: http://www.officetimeline.com/

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Tracked Down and Identified Legal Guidelines Surrounding Bus Stop Design

Using the Australian Standards database, I was able to locate the specific standards that dictate the legal dimensions for bus stop design and public furniture.

Evidence

Blog Link (20/03/14): Bus Stop Guidelines and Standards

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Attended Meetings with Elliot Rosenberg and Hank Haeusler

I have attended every single face to face meeting (excluding one) with Elliot (and sometimes Hank if he makes an appearance) since the beginning of the semester. These meetings are crucial in order to update Elliot and Hank on our progress, our problems and our ideas.

I have also periodically emailed Elliot when ideas or problems arise.

Evidence

Refer to Elliot in person about my weekly attendance. 

Screen shots of some of the email conversations: 

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Project Leader Tasks

As the designated project leader, I have had to organise the group and keep members updated on meetings, allocating roles and general information.

Evidence

Facebook group screenshots:

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Created the Group Wiki and Group Planning Presentation

The group wiki and Presentation content (and script) was created by myself. All of this involved identifying a suitable wiki website, typing all the content for the wiki, recording the required video content and doing the video editing and uploading.

Evidence

Wiki Creation and Content:

Group Wiki: Bus Stop of the Future

Video editing in Sony Vegas:

Final Video on Youtube: 

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Identified and Pushed for Sponsorship Materials

I took the initiative and identified two suitable materials and companies that could potentially supply us with the material we need. 

The first company called Tilling Timber is a timber supplier located in Australia. They provide a range of products including laminated timbers and I approached them for a price quote and a possible sponsorship deal. The product I was pushing for is called cross laminated timber and originates from another company called KLH in Germany. 

The second company is called Accoya. Accoya develops their own proprietary wood products which involve artificially changing the chemical and physical structure of the wood through acetylation. The resultant engineered wood is highly resistant to fungus and insect attack, is sustainable, environmentally friendly and is structurally durable and strong.

Evidence

Tilling Timber Website: Tilling
KLH Website: KLH
Accoya Website: Accoya


Tilling Timber Email Screenshots:

Accoya Email Screenshots:

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Model Ideas and Redesigns 

The following is a sub-list of all the work I have done on the design/model (by myself):

1. Early model design idea (with incorrect file) and crude foam core model

Evidence: 

2. Allocated the design into separate modules

Evidence: Full Design File

3. Redesign of the mid-section modules

Evidence: Major Design Alteration

4. Addition of base supports (feet)

Evidence:

5. Re-design of the Seat Positioning/Configuration 

Evidence:

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Contacting John Carrick for Engineering Advice 

I made an attempt to contact John Carrick (a senior Architecture lecturer with a strong background in structural engineering) to see if he would be able to give a second opinion on a roof structure idea I had developed. Credit goes to tutor Stephen Davey for suggesting the idea to contact John Carrick. 

Evidence

Email to John Carrick (no response): 

Roof Idea/design:

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Built the Laser Cut Prototype

George and Michael developed an idea for the use of a 'T' shaped base for the seats to slot in on.

I modified this idea and utilised my own 'L' shape instead, and decided to go ahead with this design as a side experiment for the group. I created a laser cut file, purchased the necessary materials (3mm and 6mm MDF), laser cut the pieces and then assembled them into a 1:5 prototype using super glue.

The laser cutting was a great learning experience. With the particular laser cutters in the FBE lab, I know now that to cut 6mm MDF, you'll need to:

-set the material width to 6.35mm

-set the speed to 3% or less
-have the power set to 100%

For 3mm MDF

-set the material width to 4.50mm

-set the speed to 5% or less
-have the power set to 100%

I know these parameters due to the fact that the pieces were not completely cut properly the first time around. The laser either got very close to cutting all the way through, or only half way through (as seen in my photo's). Unfortunately I had to resort to using a jigsaw to cut the rest of the pieces out.

Evidence

Sketchup Model:

Laser cutting files:

Model pieces and assembly: 

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Design Calculations 

I undertook the calculations for:

-The weight of the design (the seat portion without roof)

-The number of pieces needed

-The amount of material needed

-The cost of materials needed

Evidence

I arranged seat pieces into common pieces via colour coordination:

I then arranged the seat pieces onto potential CNC sheets (each sheet measuring 2440mm x 1220mm):

Original layout (very inefficient: 30 sheets)

Final layout (23 sheets)

From the sheet layout the number of pieces, weight, material needed and cost was easily calculated.

The weight was calculated by identifying the weight of one sheet of marine plywood material which came to 27.1 kg.

From there, the volume of that sheet was also calculated. The volumes of every single piece was then calculated and their weights were mathematically derived from the weight:volume ratio of a full 27.1kg sheet.

For example:

Marine Plywood sheet
Volume = 35721.6 cm³
Weight = 27.1 Kg

Red Seat Piece
Volume = 3358.9 cm³
Weight = ?

Calculation

1kg = 1318.14 cm³∴ Red Seat Piece = (3358.9 / 1318.14) = 2.55 Kg

Example photo of early calculations

Number of pieces: 95

Weight (without roof): 333kg (approx)

Amount of Material Needed: 23 Sheets of marine plywood @ 2440mm x 1220 mm x 12mm
Material Cost: 79.00$ x 23 sheets = $1817.00

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Final Summary of Work 

Summary list of the individual work/milestones I have done 

1. Acquired Bus Stop Files from previous students
2. Created Facebook Group
3. Created Week 3 Back Brief Presentation
4. Created Gantt Chart and Timeline for the group
5. Completed the legal research
6. Weekly meetings and communication with Elliot and Hank
7. Project leader management
8. Created the Group Wiki
9. Created the Week 7 Planning Presentation
10. Created the 3 minute video (recording and editing) for the Week 7 Presentation
11. Contacted material suppliers for sponsorships discounts and/or deals
12. Created a preliminary foam core model (pole design/idea)
13. Arranged model into separate sections 
14. Re-designed/modelled mid section to streamline fabrication process 
15. Designed and modelled base supports (feet) to stop the design from toppling forward
16. Designed and modelled potential roof connection detail/assembly 
17. Designed and modelled 'L' base 
18. Re-designed/configured the overall bus stop layout19. Created laser cutting files on Illustrator
20. Laser cut the pieces, purchased the materials and built a prototype model 
21. Colour coded all 95 (seat) model pieces into common pieces

22. Arranged all seat pieces into 23 CNC sheets
23. Performed cost, weight and material amount calculations