Initial Phase
Our first design involves the construction of an aluminium frame on which the camera module and the knob controllers will be attached. To adjust the focus on the microscope, we intend to use clamps connected to stepper motors to drive the rotation of the knobs.
Written Ideas/sketches/drawings/images with descriptions:
Prototype
Prototype images/videos with descriptions.
Our initial plan of using a belt which we bought online failed, as the grooves on the knob are not compatible with those on the belt. Furthermore, we did not purchase timing belt pulleys which were required due to our lack of experience in developing belt drive systems.
One of the first few things we had to custom design was a camera mount to fix our Arducam in place. On our first attempt, we managed to get the dimensions almost right (images 1 and 2). To improve on the design, we created a lid (image 3) that snuggly fits onto the camera mount, covering the circuitry of the Arducam. However, when taking pictures with the camera mount, we realised that sometimes the camera is tilted at an angle. To overcome this, we re-designed the camera mount to have a tighter fit (image 4). But, when we took pictures with this camera mount, the images were really under exposed. This was when we realised that even tho the camera was still able to pick up the light from the microscope, the ambient light from the surrounding was essential for the camera to work. As such, we ended up designing a camera mount with a tight fit as well as a slit to allow for some ambient light to reach the camera (images 5 and 6)
The next key thing that we had to custom design was an attachment to connect the stage knob to a belt drive, as well as an adapter to connect the stage knob to the stepper motor. As seen from image 1, we used a hexagon shape to effectively encase the stage knob, and we found it to be incredibly effective. Thus we used this concept to attach the belt drive to the adapter as well (image 2). Seeing that this worked, we then made some edits to the design to make it sleeker (images 3 and 4). However, this “hexagon shape” approach did not work on the stepper motor directly. Thus, we played around with a clamp design (image 5). This clamp design attaches itself to the stepper motor really well, as such we designed a complimentary attachment to connect the stepper motor to this clamp attachment (image 6). From image 7, we can see that the two attachments did not fit each other well. Thus, we then decided to merge the 3D models on Autodesk Fusion and test this merged model out (image 8). However, this merged model did not work well, because the axis of rotations for the stepper motor and the stage knob were not properly aligned. With this in mind, we carefully redesign the adapter, and fortunately it was successful (image 9). We then made some edits to make the final design to be sleeker (image 10).
We also had to design a platform to mount the X and Y stepper motors because the height of the stage changes and the X and Y stepper motors must always be at the same Z level as the stage. We first prototyped two methods a screwed-on platform (image 1) and a slide-on platform (image 2). We concluded that the screwed-on platform was sturdier. We then proceeded to design and print a large platform with this method (image 3). However, this platform quickly broke once we place a motor onto it (image 4). We then redesigned the platform (image 5) and used cardboard to get the dimensions to design the part of the platform that the motors will be mounted onto (image 6). Using these measurements, we printed a prototype of the platform to see if the measurements were correct and if the platform could bear the weight of one motor (image 7). Seeing that it worked, we made some edits to create a sturdy platform that could bear the weight of the two stepper motors (images 8 and 9).
We also had to design as “roller mount” for the X stepper motor because the X stage knob moves front and back. The “roller mount” is a simple design that houses the X stepper motor snuggly, and uses ball bearings, screws and rollers to allow for the mount to freely move on the platform (images 1 and 2). We also designed a simple mount to align the Z stepper motor to the fine adjustment knob (image 3).
We then had to figure out a way to change the lens of the microscope. We first designed a collar (image 1) and a complimentary attachment (image 2) that tightly fits to one of the microscope lens and protrudes out. When this worked, the next thing we did was to attach the collar to a gear (image 3). However, this gear kept changing planes when the lenses were changing. We had observed that when a lens is selected, the collar will be in the horizontal plane exactly. Then we created some gear designs that capitalises on this fact (images 4 and 5). However, the discontinuous gear design seen in image 5 resulted in some issues. Finally, after staring at the problem for a long period of time, we managed to derive the angle between the “lens rotator” and the horizontal plane, and used this value to design a gear that could be directly attached to the lenses while remaining in the same plane (images 8 and 9).
The next thing to design was now a complimentary gear to the lens rotating gear. Initially we thought we could simply have an identical gear and have a really long attachment to connect it to the stepper motor, eliminating the need to design a mount to mount the stepper motor (image 1). However, this gear design was rather inefficient as using this gear meant the stepper motor needed to use more power to rotate the gears. This, we prototyped a slanted mount that would house the stepper motor (image 2). We then took the necessary measurements to design the mount such that it is at the correct height. We also created a locking mechanism to secure the motor in place (image 3).
Final Product
Final Product images/videos with descriptions.
