‍Idea Origin

The idea for this project was sparked by a conversation with a colleague. While talking about creating a new track for our Intelino experience, it was suggested that we should build a three level tall section for the Intelino trains. This project was my most ambitious Intelino design to date; however, I utilized our FLUX inc laser cutters and 1/8in plywood for fast prototyping and a worry-free workflow.

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Idea Generation

I think it is important to pause before I jump into the more detailed and technical aspects of this project. This is the perfect time to talk about idea generation. Where do our ideas come from? Acknowledging and understanding this question led me to a better end result. Sometimes new ideas and discoveries can be accidental and most of mine feel very intuitive. I think it is important to break down and understand what factors behind the idea influence the final form. This way, you can recreate the success and apply your learnings to a future project. 

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Where do Ideas Come From?

1. Curiosity: A desire to understand or learn more about something can lead to new insights and ideas.
2. Necessity: The need to solve a problem or improve a situation often drives innovation.
3. Serendipity: Accidental discoveries and unexpected encounters can lead to new ideas.
4. Collaboration: Working with others can combine different knowledge bases and viewpoints, leading to innovative ideas.
5. Imagination: The ability to envision possibilities beyond the current reality is a key source of creative ideas.

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First Concept

My first design was sparked out of curiosity, necessity, and, most significantly, collaboration. As previously mentioned, the goal of this project was to create an addition to the Intelino train set that would transport a train down from a high track level to a low one. Initially, a three level goal was set. A successful product would accept a train from the third level and safely transport it to the ground level, allowing for a smooth exit.

Elevator Background

I initially worked quickly and produced a concept for the goal. This iteration leveraged pulleys with a counterweight to lift the empty transport from the ground up to the third level track. While this concept was not operational, it provided me with a clearer idea of this design's potential. But, how might I determine if this idea is worth pursuing further?

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Idea Evaluation

How do we know our idea is “good” or will “succeed”? There are numerous ways we can evaluate and problem-solve ideas, products, or inventions; SCAMPER is a method that encourages you to explore different aspects of an existing product or idea to generate improvements. By applying SCAMPER, we can ensure a thorough examination of our ideas, leading to innovative solutions and increased chances of success!

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SCAMPER

Substitute: What elements of the idea can be replaced?

Combine: How can different elements be combined to improve the idea?

Adapt: What can be adapted to make the idea better?

Modify: What can be modified, changed, or magnified?

Put to another use: How else can the idea be used?

Eliminate: What can be removed or simplified?

Reverse/Rearrange: What can be reversed or rearranged to improve the idea?

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Evaluating My First Concept

After evaluating my previous attempt, I decided to pivot and pursue a totally new design. You may be asking: Why did I move in a different direction? Well, when I examined the problem of transporting the Intelino train vertically, I imagined an elevator being a possible solution. I made the decision to go forward with this idea quickly and without any consideration for alternative options. I have come across a similar phenomenon in art; instead of drawing what you see, you draw what you know. Most of the time if you are an inexperienced artist you will find yourself drawing symbols (which don’t look realistic). While I was not drawing, I did design a solution others had leveraged, an elevator. My situation, however, is unique and requires different applications. One example was my attempt to use an elevator design without an accompanying elevator shaft which caused stability issues. Luckily, in having a conversation with Ryne Anthony, Director of Innovation at Fluxspace, I mentioned my struggles and he suggested a design that would mirror a seesaw instead of a typical elevator you might come across in a building. I thought the idea was worthy of pursuit and compared it to my original to determine the amplitude of improvement with which it might provide me.

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Pulley Design

The pulley design was effective because it allows for infinite vertical expansion without the need for more ground space. However, it has poor stability and consistency when the train enters, causing the train to swing in the error. This makes it impossible to connect consistently with the ground track and is ultimately why this design was scrapped.

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Lever Design

Improved rigidity and constrained movement could be the strongest qualities of the lever design. This remedied the pulley design's largest flaw. However, this design would occupy a large space and is very much vertically constrained. If the goals of the project necessitated a vertical height of greater than 3 levels, the lever would be far less attractive.

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Building the Lever

After deciding on moving forward with the lever design I conducted research on the types of levers as well as lever applications.

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Pictured above is a photo that illustrates the different classes of levers including: a 1st class lever, 2nd class lever, and 3rd class lever. The design I planned on building resembles a 1st class lever.

Lever Background

The lever design was created to improve upon the initial pulley system, which, despite allowing for infinite vertical expansion, faced stability and consistency issues. The lever design offers better rigidity and controlled movement, ensuring the train connects consistently with the lower tracks. This highlights the importance of revisiting and refining initial designs to meet project requirements more effectively.

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Lever Design Refinements

Throughout the development of the Intelino vertical transport, I struggled with consistency and was persistently chasing the culprit of the issue. After moving the lever and watching the seesaw motion, I noticed a few areas that could use iteration:

1. I decided to replace the endstop with a more robust design. When the elevator is unoccupied by a train, it assumes the “resting position” at the top of its stroke. This top “resting position” can be tuned and adjusted by changing either of two variables: the length and or position of the endstop. Ideally, the endstop is positioned directly under the counterweight of the new prototype replacing the old single piece construction with a new “X” design.
2. I added fulcrum support on both sides of the bearing pivot point. This increased rigidity and overall stability; it also decreased twisting of the lever while the train enters and exits the transport.
3. Unfortunately, I have a limited number of bearings to serve as counterweights on the lever, this meant that I had to adjust the point at which the fulcrum was located on the lever. This improved the geometry of the system while keeping the weight the same.
4. I added an extra attachment to the transport car to minimize tipping as the train enters and exits. This enhancement ensured the train remained stable throughout the transition, reducing the risk of derailment and improving overall performance.
5. Lastly, I added glue to the joints and connection points to secure the system; I was satisfied with my couple tests and ready to finally call this a finished product!

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Finished Product

I am happy with the progress I have made on this project. Although it’s functional, my design is far from complete. I am still chasing minor inconsistencies with the train entrance and exit. From the different classes of levers to evaluating new designs, I learned a lot working on this project, and I am excited to prototype further with Intelino. 

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