Electronics/Robotics 10

Useless Box Project

The Useless Box is a simple and fun little project that teaches students the various processes/stages of taking a project from conception to completion.  Students will breadboard the circuit, program an Arduino Nano to make the circuit work, create a printed circuit circuit board, design a case in Inventor, 3D print the case and finally assemble it all together to create a professional looking project.

Useless Box Marking Rubric

Project Procedure 

• Useless Box Project Procedure

Designing the Circuit Board using DipTrace

the 

1. Using DipTrace – Library Setup

Location of DipTrace Libraries…use ‘File Explorer’ to navigate to:

‘This PC’ > ‘SchoolShare’ > ‘Maker Wood Studentz’ > ‘Electronics 10’ > ‘Useless Box’ > ‘diptrace libraries’

1. Making the Schematic for the Useless Box  
2. Updating your schematic – Arduino Nano…  

• You will not be using the ATTiny microcontroller for your project this year.  We will be using the Arduino Nano and you will need to make the necessary changes to the schematic you created in step one. USE THIS DOCUMENT for reference when doing so.  Once done, print and submit your schematic for approval to proceed.

1.  Tutorial 1 – PCB Layout, Board Setup
   • Reference for Board Dimensions
2.  Tutorial 2 – PCB Layout, Component Placement

Making the PCB 

1. Follow the Useless Box project procedure – Electronics Portion, to make your project PCB
2. Use a Dremel drill press to drill all holes
3. Obtain and solder in all components (solder practice to be completed and submitted first!)

3D Print The Servo Finger And Door Hinge

You will need to 3D print a servo finger to turn off the switch.  Download this ‘.stl’ file.. fingerUpdated v1

• the file is ‘zipped’ and you will need to open the ‘.zip’ file, then copy the ‘.stl’ file found inside and paste this file to your project folder location 

You will also need a 3D printed hinge for the door.  You can get this from your teacher.

Setting up the 3D Printer/Printing

Cutting The Box Parts

1. On your computer open Universal Laser Systems ‘UCP’ (User Control Panel
2. Near the top of the UCP is a folder icon – open it
3. Choose ‘Import’ and navigate to “H” Drive (the shared drive) and the folder  ‘Maker Wood Studentz > Electronics-Robotics 10 > Useless Box’
4. Select/open folder ‘Project Case Laser Files’
5. ‘Open’ the appropriate ‘.emf’ file, then choose ‘Select’ (you should now see the parts in the UCP)
6. Obtain a piece of 1/8″ (3mm) Baltic Birch plywood – at least 8″ x 8″
7. Take your computer to the laser.
8. Prepare the laser to cut your material
   1. Focus the laser to the surface of the material
   2. Ensure the material is placed such that the cut will be on the material
   3. Turn on the air supply for the nozzle (red and yellow valves on the wall)
   4. Turn on the fume extractor
   5. Run the laser

**Note – if a part fails to be fully cut, individual parts can be found in the subfolder

Assembling the Box

1. Open this document and use a pencil to transfer all assembly labels to the pieces EXACTLY as shown.
2. Block sand the faces (not the edges) of all parts (do not sand the sides labelled in step 1) to remove residue/smoke from cutting.
3. Have your teacher spray a clearcoat on all sanded surfaces 
4. Once dry, LIGHTLY sand the clear coated surfaces to remove raised grain, then have your teacher clearcoat the surfaces again.
5. Test fit the box parts.  The fit should be snug.
6. Identify the key areas to be glued (no, the whole box doesn’t need glue – and definitely NOT the bottom!)
7. Use a small paint brush, or reasonable substitute, to apply glue to key areas as you assemble the box. WASH THE BRUSH IMMEDIATELY AFTER THIS STEP!!!
8. Allow time for the glue to dry (minimum 1hr)

Final Assembly

1. Use either the screws that came with your servo, or #4 x 1/2″ wood screws, to attach the servo to the servo bracket.
2. Use a small amount of glue (get from the teacher) to attach the hinge to the box.
3. Assemble all components inside being careful to avoid interference with the servo/finger operation.
4. Attach the bottom to the box using #4 x 1/2″ wood screws

randomMovement_ATTiny