Table of Figures

Figure 1. Specifications for the system provided by the professor ........................................................3

Figure 2. Initial design idea .......................................................................................................................... 5

Figure 3. Simulation of the car running along the ramp ............................................................................... 6

Figure 4. Demo version of the car................................................................................................................. 8

Figure 5. Final 3D model of the car at a) front view, b) side view; c) top view and d) 45-degree view....... 9

Figure 6. Finalize components before assembly ........................................................................................... 9

Figure 7. Final assembly of the car at a) front view, b) side view and c) bottom view .............................. 11

Figure 8. Components for the assembly. ..................................................................................................... 11

Figure 9. Arresting cable as emergency brake for planes on aircraft carriers ............................................. 12

Figure 10. Wiring mechanism to stop the vehicle ...................................................................................... 13

Figure 11. Dropping gate mechanism – a) closed gate, b) open gate, and c) gate wiring .......................... 14

Figure 12. 2D Drawing of the V-shape holder ............................................................................................ 15

Figure 13. 2D Drawing of the V-shape ....................................................................................................... 15

Figure 14. 2D Drawing of the car base ....................................................................................................... 16

Figure 15. 2D Drawing of the wheel holder ............................................................................................... 16

Figure 16. 2D diagram of the system .......................................................................................................... 17

Figure 17. Model of the car shaft ................................................................................................................ 18

Figure 18. The initial dropping position of the vehicle ............................................................................... 19

Figure 19. The car travelling on the white board ....................................................................................... 20

Figure 20. The vehicle travelling on the carton road .................................................................................. 20

Figure 21. The gate is opened, and the ball is rolling towards the box ....................................................... 21

Figure 22. The car is stopped, and the ball is dropped into the box............................................................ 21

Figure 23. Ultimaker S5 printer .................................................................................................................. 22

Figure 24. PLA plastic used for printing. .................................................................................................... 23

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I – Introduction of the Project
This project focuses on the design and analysis of a potential energy-stored vehicle,
utilising a unique mechanism involving the release of a tennis ball or a table tennis ball after a one-
metre movement into a box. The primary objective is to harness the potential energy stored in the
vehicle and convert it into kinetic energy, thereby propelling the vehicle forward. By examining
the efficiency and effectiveness of this mechanism, the project aims to provide insights into
innovative energy storage solutions and their potential applications in various engineering fields.
This study not only contributes to the understanding of energy conversion processes but also paves
the way for future advancements in sustainable and efficient mechanical systems. This report
outlines the user requirements, design specifications, concept development, and the final
implementation of our contraption.

II – Project Description

Figure 1. Specifications for the system provided by the professor

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1. User Requirement Specifications
 Energy Storage Mechanism: The vehicle must incorporate a mechanism to store potential
energy effectively.
 Ball Reception: The system must be capable of receiving a ball (tennis ball or table tennis
ball) from the vehicle. The balls should be received into a box while ensuring smooth and
uninterrupted operation. The specifications for each ball are as follows:
o Tennis Ball:
 Diameter: 6.54 to 6.86 cm (2.57 to 2.70 inches)
 Weight: 56.0 to 59.4 grams (1.98 to 2.10 ounces)
o Table Tennis Ball:
 Diameter: 40 mm (1.57 inches)
 Weight: 2.7 grams (0.095 ounces)
 Continuous Operation: There should be no stopping point between the beginning and
ending of the test before the ball is dropped into the box.
 Transport Distance: The system must be able to transport the ball on a flat surface over a
distance of 1 metre. The initial position will be at a height on a ramp, and the final position
will be on a flat surface. The ramp should be adequately designed to allow the vehicle to
travel and stop exactly at one meter.
 Self-Powering: After release from the initial point, the vehicle must be self-powering and
must not require any external power sources or manual input during its operation.
 Ball Flow Control: The vehicle must have a mechanism to drop the ball into the box when
it stops after moving one meter. The vehicle must not move the box while stopping, and
the ball must not jump out of the box.
 Safety: The system must be designed to be safe for testing and should not pose any safety
risks to users.
 Ease of Use: The contraption must be user-friendly, appealing, and easy to deploy. It should
require minimal setup and be intuitive to operate, making it accessible to users with varying
levels of technical expertise.

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  Cost-Effectiveness: The contraption should be economical to manufacture, utilizing
common, readily available materials to keep production costs low while maintaining high
functionality and reliability.

2. Design Process and Mechanism Development of Our Vehicle

Initially, we drafted our idea on SolidWorks by creating a 3D model and then revise it gradually
based on feedback from the instructors. The improvements are made based on consideration of
several factors such as aesthetic look, functionality, manufacturing efficiency and many more.
After several revision and demo, I then choose the final version for 3D printing and assembling.

2.1. Stage 1: Initialize idea

Figure 2. Initial design idea

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Figure 3. Simulation of the car running along the ramp

(link to video)

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  As illustrated in Figure 2, our vehicle features a straightforward design with a rectangular
chassis and four maneuverable wheels. These wheels are aligned along two axes to ensure
the vehicle moves in a straight line toward its destination.
 The simplicity of our design stems from utilizing gravitational energy as the driving force.
Specifically, instead of relying on elastic or torsional energy from springs or rubbers, we
plan to release the vehicle down a ramp or inclined plane, as shown in Figure 3.
 A unique aspect of our design is the inclusion of an inclined V-shaped path to hold and
guide the ball. Figure 2 highlights the tilted angle of the ball carrier, enabling the ball to
roll out accurately at the destination. While the current CAD model illustrates the concept,
we aim to create a longer V-shaped path to improve dropping precision. Additionally, the
vehicle’s dimensions are subject to future adjustments.
 We also have a triangular bump integrated at the end of the vehicle. This bump is designed
to secure the ball while allowing it to roll with a slight impact, facilitating precise ball
placement with the help of simulations.
 Initially, our group proposed using the vehicle’s momentum upon sudden stopping to
prompt the ball to roll over the bump. Drawing inspiration from aircraft carriers arresting
cable brakes, we devised a solution involving a thread that connects the vehicle to a fixed
ramp. This thread ensures the vehicle travels precisely 1 meter. At the destination, the
thread’s tension halts the vehicle and simultaneously exerts an inertial force on the ball.

We then created a simple demo version of this concept using basic material for testing and trial
purposes.

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 Figure 4. Demo version of the car

However, with the feedback from professor, we have updated our design, mechanism idea and then
reach to a final version, which we believe has been improved a lot. This will be described in detail
in the upcoming section.

2.3. Stage 2: Finalize design

a) b)

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 c) d)

Figure 5. Final 3D model of the car at a) front view, b) side view; c) top view and d) 45-degree view

Figure 6. Finalize components before assembly

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Below are the specifications of this final version:

 Dimensions: The vehicle features a compact design with dimensions of 200 cm in length,
120 cm in width, and 100 cm in height.
 Weight: The total weight of the vehicle is 419 grams.
 Material: Mostly, all the components are 3D-printed, with just the exception of the bolts
and thread.
 Cost: Although there is no strict limit on the total cost of materials and construction, it is
estimated that the cost will not exceed 300,000 VND.
 Car stopping and ball dropping mechanism: We use thread length to control the distance
that car can travel, and the tension force will pull down the gate and open the track for the
ball to fall. The detail description will be presented in subsequent section

The explored view and final assembly version are showed below.

a) b)

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 c)

Figure 7. Final assembly of the car at a) front view, b) side view and c) bottom view

Figure 8. Components for the assembly.

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2.3 Stopping and Dropping Mechanism
 General solution:

In order to increase the challenge this year, the box destination will not be fixed to the ground.
Therefore, we have discussed and come up with two possible solutions which are stopping in front
of the box or letting the car attach the box along its path. Furthermore, we had to take into account
that the car needed some trigger mechanism to drop the ball. With further brainstorming processes,
our group all agreed that the stopping solution would be more suitable since it creates momentum
that triggers the ball to roll forward.

 Stopping mechanism:

Using the ramp as the propulsion mechanism is a flexible method to combine with a rapid stopping
mechanism. In particular, we can easily adjust the height of the ramp to give the car a desired
velocity at the ground level and transfer that momentum to the ball when it is stopped. The
calculation is shown in section 4 where it is just a simple dynamic physics problem. The real
challenge here is how to stop the car consistently in front of the box at a fi
instant brake mechanism of airplanes on aircraft carriers:

Figure 9. Arresting cable as emergency brake for planes on aircraft carriers

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With this idea, we planned to attach some thread or cable around the vehicle and connect it to the
fixed ramp. The advantages of this brake are we can easily compute the required length of the
thread and apply it to our system. However, Professor Trung had some concerns regarding the
aesthetics and consistency of this solution. Wrapping thread around the ramp could cause the
vehicle to entangle itself in the wires and if we do not calibrate the car in the middle of the thread
every trial, the car can be turned before reaching the destination. Thus, the Professor suggested
that we should implement the wires within the system of the vehicle for aesthetic purposes and
reduce the possible error due to calibration of wires. Therefore, we slightly adjust the mechanism
by wiring the thread around the white shaft as shown in Figure 6-c, which satisfies the requirements
of Professor Trung. When the all the allowed thread length is wrapped around the shaft, tension
force will cause the car to stop. Here is a photo illustrating our latest idea:

Figure 10. Wiring mechanism to stop the vehicle

 Dropping mechanism:

In the previous section, we already demonstrated our plan of applying an inclined V-shape base
combined with a bump to hold the ball and allow it to roll over when the vehicle is rapidly stopped.
Initially, we thought the large weight of the tennis ball will be enough to let it roll over but not

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jump out of the V-shape base (Demo in Figure 4). However, after some experiments, we found out
that this solution is not consistent as can easily jump or fall out of the base before reaching the
box. Furthermore, finding an appropriate height for the bump is very difficult as our mechanism
fix the position of the bump. With the suggestions of Professor, we came up with another solution
which is using the rubber band as a gate (as shown in Figure 6-a) and open for the ball to roll to
the box when the vehicle approaches the destination. In order to synchronize the gate with the
movement of the car, we also connect a thread from the gate to the front shaft of the car (illustrated
in Figure 6-c). As a result, the object is changed from tennis ball to table tennis ball to enhance
accuracy and reduce the scenario of the object falling out of the base.

a) b)

c)

Figure 11. Dropping gate mechanism – a) closed gate, b) open gate, and c) gate wiring

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3. Technical Drawings

Figure 12. 2D Drawing of the V-shape holder

Figure 13. 2D Drawing of the V-shape

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 Figure 14. 2D Drawing of the car base

Figure 15. 2D Drawing of the wheel holder

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III – Physics Assessment
1. Theory
We have the diagram of this model (with all the dimension included):

Figure 16. 2D diagram of the system

The length of the slope is calculated by:

𝐿= 45 + 116 = 124.4(𝑐𝑚)

And the angle of slope is:

45
α = 𝑎𝑟𝑐𝑡𝑎𝑛 = 21.2 (𝑑𝑒𝑔𝑟𝑒𝑒)
116

Newton’s 2nd law for the movement of the car is:

On y axis: 𝑁 − 𝑃 × 𝑐𝑜𝑠(α) = 0 ⇒ 𝑁 = 𝑃 × 𝑐𝑜𝑠(α)

On x axis: 𝑃 × 𝑠𝑖𝑛(α) − 𝐹 = 𝑚𝑎

Based on energy conservation theorem, we have the energy equation for two position A and B is:

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 𝐸 − 𝐸 = −𝐴

𝑚𝑣
⇒ − 𝑚𝑔ℎ = −𝐹 × 𝐿
2

Assume that friction coefficient 𝜇 = 0.1, we then have:

𝑚𝑣
− 𝑚𝑔ℎ = −𝜇𝑚𝑔𝐿𝑐𝑜𝑠(α)
2

Replace all these numerical values:

 𝑚 = 0.419 (𝑘𝑔)
 ℎ = 0.45 (𝑚)
 𝜇 = 0.1
 𝐿 = 1.244 (𝑚)
 𝛼 = 21.2 (𝑑𝑒𝑔𝑟𝑒𝑒)

We solve the equation to find v at position B, the final value of velocity at the bottom is:

𝑣 = 2.56(𝑚/𝑠)

Now, we need to calculate the length of the thread needed to stop the car. The requirement indicates that
the car is required to travel for 1m. We also have the diagram of dimension of the car shaft:

Figure 17. Model of the car shaft

The total angle that the wheel needs to rotate for the car traveling 1m:

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 1 × 180 180
𝜃= = = 954.93(𝑑𝑒𝑔𝑟𝑒𝑒) = 5.305(𝑟𝑒𝑣)
2π𝑅 2π × 0.03

As the thread is rotated around the shaft, the required length of the thread to stop the car after 1m is:

954.93 × 2π𝑟 954.93 × 2π × 0.005

This is the length of the thread we need to prepare to stop the car right at the position 1m far after it leaves
the ramp.

2. Experimentation
After setting up the slope using a white board, we marked the initial position to drop the vehicle such that
it aligns with the destination. This method will help us to keep the consistency and avoid the vehicle going
on a wrong direction.

Figure 18. The initial dropping position of the vehicle

After being released, the car will travel on the white board which has low friction coefficient and reduce
the loss energy. Thus, the car will be able to have enough velocity or momentum to transfer to the table
tennis ball right in front of the box.

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 Figure 19. The car travelling on the white board

Before reaching the box, there is a slight bump in the transition between the slope and the ground which
often makes the ball jump off the V-shape holder. Hence, we must smoothen the transition part by inserting
a long carton piece as the path for the vehicle.

Figure 20. The vehicle travelling on the carton road

On this path, we already measured the required distance to reach the box. Therefore, the calculated thread
will roll around the shaft and stop the car right in front of the box. Meanwhile, the synchronized gate will
also open and let the ball roll to the destination. The figure below shows the moment when the gate is
released, and the ball is rolling towards the box.

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 Figure 21. The gate is opened, and the ball is rolling towards the box

Finally, the vehicle will stop, and the ball will drop at the box as planned. After many trials, we managed
to find the optimal setting to consistently repeat this experiment successfully. We even added some nylon
inside the box to dampen the impact between the ball and the box surface, ensuring it would not jump out
of the box.

Figure 22. The car is stopped, and the ball is dropped into the box

Link to full demo video can be found here: Link

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IV – Material Selection & Fabrication

1. 3D Printing

- Our team selected PLA filament for 3D printing due to its beneficial properties, ease of use, and
compatibility with our chosen 3D printer. Polylactic acid (PLA) is a widely used thermoplastic
that is excellent for printing, has low toxicity, and is biodegradable.

- The 3D printed components included the ball holder, car base, and front guide.

- We utilised the Ultimaker S5 printer with a 20% infill setting. The PLA filament was heated to
210°C, and the print bed was set to 55°C. The printing speed was 100 mm/s.

Figure 23. Ultimaker S5 printer

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 Figure 24. PLA plastic used for printing.

2. Machining:

- Team members enhance their manufacturing skills through training and hands-on experience. We
opted to manufacture the car axle using the lathe machining process.

- Aluminium was chosen for its low cost and low stiffness, making it easy to process.

- The axle was mounted on the lathe, and roughing tools were used to remove excess material,
shaping it to a near-final diameter. This step helps reduce machining time in subsequent passes.

- Finishing tools were then used to achieve the final dimensions of the axle, ensuring precise cuts
for the desired diameter and surface finish.

- Quality checks were conducted during and after machining to inspect the axle for dimensional
accuracy, surface finish, and any defects.

3. Assembly Processes:

- The team carefully assembled the various parts of the stored-energy mechanism car, ensuring all
connections were secure and properly aligned. This step is crucial for the car's reliability and
functionality during operation.

- A combination of adhesives, fasteners, and other assembly techniques was used to integrate the
ball-dropping mechanism, pulling mechanism, and other structural elements. The specific

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