EMD 332 MACHINE DESIGN

FINAL REPORT

2D CAMERA SLIDER
SUPERVISOR
DR. FEIZAL YUSOF

MEMBERS
Name

Matric no.

Barathan A/L Baskaran

120362

Mark Selvan A/L Anthony Rogers Louis

120385

Jerome Lee Jie Jen

120375

Nur Muhaimin Aidil Bin Muhaimi

120407

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Table of Contents
1

Introduction

Problem Background

Objectives

Methodology

Design Explanation and Details

21

Fabrication

23

Manufacturing Cost

26

Return of Investment

28

Limitation and Improvements

29

10

Impact of Machine to Society

30

11

Reference

31

12

Appendix

31

2|Page

1.0

Introduction

The project has been given to our group is to design and develop a prototype of a
device that can move a camera in 2D positioning system for an application in engineering.
The purposes of this device are easier to control a camera during adjustment and to have a
good vision in detecting a scratch on an object in engineering application. In addition, we are
required to design an automated device which is the device can be controlled by buttons.
There are already have two devices existing in the same concept that available in market
which are:

Figure 1: XY manual 20cm camera slider and DSLR slider

The camera slider that we design is motorized and no need human effort on adjusting
camera. This design would ease the process on scanning or recording any engineering
application. For example, an engineer needs to analyze a small crack on a wall. Manually he
needs to hold the recorder using his hand and take the video in a slow motion. This process in
very unreliable as there is poor stability on holding the recorder accurately without moving it
and the motion or speed of taking the video for instance left to right will vary at different
speed. With the design, we can overcome all this trouble. We just need to set up the prototype
on the intended place of recording. Then we just need to switch it on and control the recorded
axis using buttons. It moves in a constant slow speed. The speed can be controlled using
different types of ac/dc motor or stepper motor controlled by a microprocessor.

2.0

Problem Background

In engineering industries, the crack on an object should take an action to determine

the strength of the material. Then, it is difficult in adjusting cameras position for a small
crack by using our bare hands to have a good vision on the camera display. Hence, it is also
difficult to adjust the camera in X and Y axes position. The crack must be examined
accurately since it can cause failure in a system.

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Besides that, manual adjustment is time consuming. It is possible to have a proper

position of camera by using our bare hands so lot of time we spend in adjusting the camera
position. It is also required a lot of effort to have a good display of the crack during the
adjustment. Conventional sliders adopt the use of knob to adjust the relative position which
can be tedious and also about time consuming. In other hand, the existing camera sliders that
are available in the market are not motorized. Both of the sliders are manually adjustment.

3.0

Objectives
1. To design a 2D positioning system for engineering application (finite element
analysis)
2. To determine the necessary components needed to run the prototype.
3. To fabricate of the design into a working prototype.
4. Ensuring the prototype function as intended with minimum errors

4.0

Methodology

In designing our 2D Camera Slider, we follow the standard design procedure which we
learned. We have gone through the four phases of design to ensure our project flow to be
more systematic and organize.

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4.1)

Formulating a Design Problem

4.1.1) Ideas from Existing Design

Product

Advantages

Disadvantages

4.2)

to

Portable
Wide range of movement

Limited
range
of
movement
Cannot
accommodate
large cameras
Tedious to adjust X and Y
position

Bulky
Requires a large area to be
used

Compact and
transport
Light weight

easy

Conceptual Design

4.2.1) Specify Requirement

From the study and research we done from the existing camera slider, we identified
the basics requirement for our camera slider prototype. The prototype should include:

2D Camera Slider

Base frame

Supporting
Parts/Components
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Sliding Mechanism

Electrical Components

4.2.2 Weighted Rating Evaluation

After obtaining ideas from brainstorming and preliminary rounds, we came up with
3alternatives. We compared them in a systematic weighted rating evaluation to choose the
best design among the 3 alternatives.

Features

Alternative 1

Alternative 2

Alternative 3

Linear
movement/Sliding
mechanism
Manufacturing Cost
Number of parts

Lead screws and

Shafts

Shafts and
Rollers

High
Lead screws - 3
Shafts - 2

Low
Shafts 2
Rollers - 6

Manufacturability
Weight

Hard
High

Medium
Medium

Shafts and
Linear Bearings
Timing belt
Medium
Shafts - 4
Linear bearings 4
Timing belt - 2
Easy
Low

Alternative 3 is chosen. Compared to Alternative 1 which utilized lead screw which is costly,
Alternative 3 has medium manufacturing cost. Compared to Alternative 2, Alternative 3 uses
linear bearing instead of roller, this reduces friction. Since we did not utilize roller in
Alternative 3, we are not required to machine the roller track, hence making
manufacturability easier. Alternative 3 also has the lightest weight, which is one of the most
important criteria in robust design.
4.2.3 Material Selection
By referring to the availability of materials in USM Workshop storeroom, we decided to use
Aluminium T6061 for all the parts in our prototype.
Material Properties of Aluminium T6061:

Density: 2700kg/3
Ultimate Tensile Strength: 310MPa
Tensile Yield Strength: 276MPa
Modulus of Elasticity: 68.9GPa
Shear Modulus: 26GPa
Shear Strength: 207MPa

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We deduce that Aluminium T6061 is strong enough to sustain the load without any
significant deformation. This will be proven in calculations section.
4.2 Configuration Design
4.3.1 Development Work
Using SolidWorks, we drew our 2D Camera Slider in details based on the best design
Alternative 3 chosen.

Figure 2: Solidworks drawing

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4.3.2 Schematic Diagram

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Bill of Materials

No.

Part Item

Description

Quantity

Base frame
(aluminium)
Middle platform
(aluminium)

Hollow

Hollow

Hollow

Top platform
(aluminium)
Cylindrical shafts

Solid

AC motor

Timing belt

Width=6mm Length=1097mm

Pulley

Linear Bearing

Bore=5mm Pitch=2.032mm
Width=6mm
Bore=10mm

Single-bearing housing

10

Double-bearing housing

11

Wooden plate

12

Pulley supporter

13

Motor supporter

14

M5x30 bolt

14

15

M5x15 bolt

10

16

M4x8 bolt

17

M3x15 bolt

18

M5 nut

24

19

M3 nut

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4.3.4 Flowchart

Figure 3: Flowchart of design process

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4.3.4 Project Gantt Chart

Academic Week (15/02/2016 29/05/2016)

Task
1

Discussion of 2D Camera Sliding mechanism

Selection of the best sliding mechanism to be
implemented
Design and modification to 2D Camera Slider
Selection of final design, supported with
relevant calculation and simulation.
Make the purchase order of electrical
components
Fabrication of 2D Camera Slider prototype
Testing of the 2D Camera Slider prototype

Completion of final report, HTML webpage

and final presentation

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10

11

12

13

14

Final Presentation, Report and HTML webpage Submission

First meeting with supervisor, course

introduction and lecture

4.4 Parametric Design

(a) Mass of base frame

The base frame is hollow inside, with wall thickness of 0.45mm

Volume
= Solid Volume Inner hollow volume
= [(75.65)(600)(25.05)x2 + (75.65)(600-2x75.65)(25.05)x2] [(74.75)(599.1)(24.15)x2 +
(74.75)(599.1 - 2x74.75)(24.15)x2]
=3974641.166 3773223.29
=201417.876 3
= 2.0142 x 104 3
Mass
= density of Alumium T6061x Volume
= 2700 x 2.0142 x104
= 0.5438kg

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(b) Mass of middle platform

The wall thickness is 0.45mm

Volume = (75.65)(600)(25.05)-(74.75)(600)(24.15) = 53892 3 =5.3892 x 105 3
Mass = 2700 x 5.3892 x 105 = 0.1455kg

(c) Mass of Shafts (2 x length 598mm , 2x length 486mm), diameter = 10mm

(i) length = 598mm

Volume =

(3.142)(0.010)2
4

(0.598) = 4.69668 x105 3

Mass = 2700 (4.69668 x105 ) =0.1268kg

(ii) length = 486mm
Volume =

(3.142)(0.010)2

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(0.486) = 3.81704 x105 3

Mass = 2700 (3.81704 x105 ) = 0.1031kg

Total mass of the 4 shafts = 2 (0.1268+0.1031) = 0.4598kg

(d) Mass of shaft holders x 8

Wall thickness = 2mm

Volume = (50)(20)(23) (46)(20)(19) 2(3.142)(10)(10)/4 = 5362.923 =5.36292 x 106 3
Mass = 2700 (5.36292 x 106 ) = 0.0145kg
Total mass of 8 shaft holders = 0.1158kg

(e) Mass of pulley supporting unit (small shaft holders x 4)

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Volume = (50)(20)(23) (46)(20)(19) 2(3.142)(5)(5)/4 = 5480.733 =5.48073 x 106 3

Mass = 2700 (5.48073 x 106 ) = 0.01480kg
Total mass of 4 small shaft holders = 0.0592kg

(f) Mass of single housing x 2

two small hole diameter = 5mm

Volume
= (23+2)(20+45+20)(30) 2 (23)(20)(30) (30)(3.142)(20)(20)/4 2(2)(3.142)(5)(5)/4
= 34146.683
=3.414668 x 105 = 3
Mass = 2700 (3.414668 x 105) = 0.0922kg
Total mass of 2 single-housing = 0.1844kg

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(g) Mass of double housing

Two big hole with diameter 20mm, and two small holes on top with diameter 5mm

Volume
= (75.65)(25)(30) -2(30)(3.142)(20)(20)/4 (75.65 -2x26)(25-7)(30)=2(7)(3.142)(5)(5)/4
=24842.053 =2.484205x105 3
Mass = 2700 x 2.484205x105 =0.0671kg

(h) Mass of Top Platform

wall thickness =0.45mm

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Volume = (75.65)(100.10)(25.05)-(74.75)(100.10)(24.15) = 8990.982 3 =8.990982 x

106 3
Mass = 2700 x 8.990982 x 106 = 0.0243kg

(i) Mass of wooden plate x 4

Density of wood = 0.75kg/3

Density of wood <<Density of Alumium T6061 and the volume of wood is not significantly big.
Hence, mass of wood is neglected.

(j) Mass of AC motor x 2 = 0.100kg x 2 = 0.2kg

Total mass of prototype

= 0.5438 + 0.1455 + 0.4598 + 0.1158 + 0.0592 + 0.1844 + 0.0671 + 0.0243 + 0.2
= 1.7999kg

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Analysis of Force exerted on the lower 2shafts (The 2shafts on the base frame)

Mass to be supported
= Middle Platform + Top Platform + 2shafts + 4shaft holders +2pulley supporter + 2 single
housing + double housing + 1 AC Motor
=0.1455 + 0.0243 + 0.2062 + 0.0579 +0.0074 + 0.1844 + 0.0671 + 0.100
=0.7928kg
Force acted = mg = 0.7928(9.81) =7.7774 N

The force are shared into 2 shafts, hence force on each shaft = 3.8887 N
When the load are exerted on the middle of the shaft:

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Free Body Diagram

Shear Force Diagram (units are in N)

Bending Moment Diagram (units are in Nmm)

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Deflection of beam = 48
Radius of shaft =5mm
Modulus of Elasticity, E=68.9GPa

Second area moment of inertia, I = (3.142/4) (0.0054 )=4.9087x1010 4

3.8887(0.5983 )

=48(68.9109 )(4.9087x1010 )
= 5.1224x104
=0.5122mm

According to theory of Solid Mechanics, the deflection is the maximum when the load is acted
on the centre of the shaft.
Hence the maximum deflection of the beam is only 0.5122mm which is negligible, and will not
cause failure to our prototype.
The other two shafts the the middle platform supports less mass as compared to the two shafts
computed, hence the deflection of the shaft at middle platform is surely less than 0.5122mm

Testing of Prototype:
We test run our prototype, and we compute the time needed for the platform to move full range
of displacement of 450mm
Time (s)
Top Platform
Middle Platform

Trial 1
162
169

Trial 2
161
170

Trial 3
159
171

Average
160
170

Average speed of top platform = 450/160 =2.8125mm/s

Average speed of middle platform = 450/170 = 2.6471mm/s
As expected, the middle platform will move slower because of more weight to be supported.
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5.0

Design Explanation and Details

5.1) Mechanical Explanation

The prototype consists of 3 levels of platform which is the base, mid-platform and upperplatform. The mid-platform which moves in the Y-direction is fixed to the base by using a shaft,
linear bearing and linear bearing holder. The cylindrical shaft is attached on top of the base using
a shaft holder. Linear ball bearing slides on the shaft to ensure a linear motion. The bearings are
fit and locked into a housing which is then the housing is fixed to the mid-platform. The same
concept is being used on the upper platform which is attached to the mid-platform. To ensure
stability, two bearings are used for each platform and fixed on the both ends.

Figure x: Mechanical design

Ball bearing slides offer smooth precision motion along a single-axis linear design, aided by ball
bearings housed in the linear base, with self-lubrication properties that increase reliability.
Commonly constructed from materials such as aluminum, hardened cold rolled steel and
galvanized steel, ball bearing slides consist of two linear rows of ball bearings contained by four
rods and located on differing sides of the base, which support the carriage for smooth linear
movement along the ball bearings. This low-friction linear movement can be powered by either a
drive mechanism, inertia or by hand. In this prototype, we use a drive mechanism to move the
bearings attached to the platform. Ball bearing slides tend to have a lower load capacity for their
size compared to other linear slides because the balls are less resistant to wear and abrasions.

5.2) Electrical Explanation

To move the both mid and upper platform, a timing belt is attached to the base of the both
platforms. The timing belt is then fixed to the pulley which is fixed on the AC motors. Two Ac
motors are being used for this prototype. One is attached on the base which controls the
movement of mid platform (y-axis) and another motor is attached to the top of mid-platform
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which controls the upper platform (x-axis). Both AC motors are connected directly to the 240V
power supply which is normally used by all electrical appliances.
In induction motor we give only one direct supply. It is very simple, from the name itself we can
understand that induction process is involved. When the supply is given to the stator winding,
flux will generate in the coil due to flow of current in the coil. Now the rotor winding is arranged
in such a way that it becomes short circuited in the rotor itself. The flux from the stator will cut
the coil in the rotor and since the rotor coils are short circuited, according to Faraday's law of
electromagnetic induction, current will start flowing in the coil of the rotor. When the current
will flow, another flux will get generated in the rotor. Now there will be two fluxes, one is stator
flux and another is rotor flux and the rotor flux will be lagging w.r.t to the stator flux. Due to
this, the rotor will feel a torque which will make the rotor to rotate in the direction of rotating
magnetic flux. So the speed of the rotor will be depending upon the ac supply and the speed can
be controlled by varying the input supply.
The first thing to do in an AC motor is to create a rotating field. 'Ordinary' AC from a 2 or 3 pin
socket is single phase AC. It has a single sinusoidal potential difference generated between only
two wires which is the active and neutral. Note that the Earth wire doesn't carry a current except
in the event of electrical faults. With single phase AC, one can produce a rotating field by
generating two currents that are out of phase using for example a capacitor.
Finally the both AC motors are connected to a switch box which is then directed to the plug. The
switch are there to control the direction of x and y axis. Switching on one of the button will
activate the direction of the particular platform. To change the direction, simple switch off back
the same button, wait for 3 seconds minimum and then switch it on back. Exactly same concept
is done to the other button on the switch box to control another platform.

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6.0

Fabrication

Base & Platforms

The base and platforms are made of aluminum material. The material was made hollow not solid
as it would be lighter and less friction would act. The materials were ready made. The hollow
aluminum was sawed in 5 parts of 60cm length each. 4 parts was combined using rivet to create
the base of this prototype. The other part was made as the mid-platform. The upper platform is
also from the same material but with a smaller length of 100mm.
Shaft & Shaft holder

We used a long cylindrical aluminum shaft with a diameter of 10mm for the conveyor. We
sawed the shaft into 4 parts with length of 598cm and 486cm. Each length has 2 rods. The longer
shaft is used to slide the mid platform and the shorter shaft is used to slide the upper platform.
We need to ensure the mid-platform must not touch the base and upper platform. Thus the shaft
must be attached using a shaft holder at a higher certain length. The shaft holder is also
aluminum material and its hollow. We saw it and drilled 2 holes of 10mm and 5mm. the 10mm
hole is for attaching shaft in it and the 5mm hole is for attaching the shaft holed to the base with
a bolt and nut. During drilling process, we must ensure the rpm is slow to avoid the material to
tear as it is a soft material and its hollow. We need to avoid bending as well.

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Pulley Supporter

The pulley supporter consists of three parts which is two mini shaft holders and one small shaft.
As there was no smaller shaft to support of pulley with the bore diameter of 5mm, we decided to
use an end thread bolt with diameter of 4mm. We used 4mm diameter instead of 5mm because
the need to avoid friction between pulley and the bolt as we need the pulley to rotate constantly.
The head of the bolt is sawed so we could insert the bolt between the 4mm holes drilled on the
side of the holder. The bolt with the thread part is fixed using two nuts. The supporter is then
fixed to the base and mid-platform using bolt and nut as well. A hole of 5mm is drilled on the
bottom surface of the supporter, base and mid-platform.
Single Bearing Holder

The function of single bearing holder is to support the mid-platform to the base shaft. The
materials used aluminum block. We saw the block using a saw machine in the workshop. Then
we used the milling machine to fine the surface. The both end grove like is cut using milling
machine as well, at 0.5mm per round. Once done, we drilled a small hole of 3mm on the top of
the housing. The function of it is to tighten the bearing using a screw. 20mm hole is drilled in the
between of the housing to fix the linear ball bearing in it. Finally, 5 mm hole is drilled on the
wings of the housing. This is to fix the housing to the mid-platform using a bolt and nut.

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Double Bearing Holder

The function of double bearing holder is to support the upper-platform to the shaft at midplatform. The materials used aluminum block. We saw the block using a saw machine in the
workshop. Then we used the milling machine to fine the surface. The middle grove like is cut
using milling machine as well, at 0.5mm per round. Once done, we drilled a small hole of 3mm
on the both side of the housing. The function of it is to tighten the bearing using a screw. 20mm
hole is drilled on the both side of the housing to fix the linear ball bearing in it. Finally, 5 mm
hole is drilled on the top of the housing. This is to fix the housing to the upper-platform using a
bolt and nut.

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7.0

Manufacturing Cost

7.1) Direct Material Cost

Material
Aluminum
Flame
(1 x 3)
Aluminum
Rod
(10mm x 60mm)
Aluminum Rectangle
Block (40 x 40 x 150
mm)

Unit
3

Cost/Unit (RM)
30

Total Cost (RM)

90

23

92

55

55

Total Cost

237

7.2) Direct Labor Cost

Labor
6

Days
25

Daily Wages (RM)

10

Total Wages (RM)

1500

7.3) Manufacturing Overhead

Process

Power (kW)

Hours

Store Mill
Crosscutting

3.7

15

11
0.6
-

20
20
-

Machining
Finishing

Grinding
Machine
Milling
Drilling
Painting

Cost/Hour
(RM)
0.33

Overhead
Cost (RM)
18.32

0.33
0.33
Total Cost

72.60
3.96
20
114.88

7.4) Cost of Components & Purchase Order

Components
AC Motors
Linear
Bearings
(10mm)
Press Switches
Circuit Box
Power Plug
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Unit
2
4

Cost/Unit (RM)
7.50
18.50

Total Cost (RM)

15.00
74.00

2
1
1

1.50
3.00
5.00

3.00
3.00
5.00

Wires (2m)
Timing Belt
Pulleys
Nuts & Bolts (M4)
Nuts & Bolts (M5)
Nuts & Bolts (M3)

1
2
4
10
10
10

7.00
150.00
31.00
0.10
0.10
0.10
Total Cost

7.5) Overall Cost

Direct Material Cost
Direct Labor Cost
Manufacturing Overhead Cost
Components Cost
Total
Cost

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Cost (RM)
237.00
1500.00
114.88
534
2385.88

7.00
300.00
124.00
1.00
1.00
1.00
534

8.0)

Return on Investment

Return on Investment ROI can be defined as a performance measure used to evaluate the
efficiency of an investment or to compare the efficiency of a number of different investment. In
this project, we considered the return on investment for the manufacturer as well as for the
farmer. To calculate ROI, the benefit (return) of an investment is divided by the cost of the
investment where the result is expressed as a percentage or a ratio.
8.1) Return on Investment for Manufacturer
The overall (total) cost for one unit of the XY Slider which includes the manufacturing cost as
well as the component part and purchasing order is RM 2385.88. By taking 15% of profit from
the total cost, each unit of the machine is selling at the price of RM 2743.76. Therefore, the profit
that we obtain from each unit of the machine is RM 357.88. Basically, our business plan is to sell
24 units of the spraying machine per year with total investment of RM 100,000.00.

Year
2015
Investment (RM)
100,000.00
Production Cost per 57,261.12
24 units (RM)
Gain (RM)
100,000.00
Net profit (RM)
42,738.88

ROI =

ROI =

2016

2017

Total

57,261.12

57,261.12

171,783.36

100,000.00 100,000.00
42,738.88 42,738.88

( )

( 128,216.64100,000.00 )

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100,000.00

100% = 28.22 %

100%

300,000.00
128,216.64

Investment:
RM 100,000.00

In the year 2015, the ROI is -57.29% while in 2016 was -14.52%. The ROI value starts to be
positive in the third year (28.22 %) with total profit of RM 128,216.64.

9.0)

Limitation and Improvement of Design

LIMITATION OF DESIGN
Unable to Control Speed of Motor

IMPROVEMENT OF DESIGN
Use stepper motor together with Raspberry Pi
to enable control of motors rpm.

Difficult to set position of the object

Use joystick to control the position of the

platforms instead of switches

Heavy

Reduces the size of the prototype and also the

number of components attached to the
prototype

Unable to carry heavy load

Use motors with higher torque capability

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10.0) Impact of the 2D Slider to Society

The impact of the 2D Slider to society is indeed huge. There has always been the need for an
automatic positioning system in the field of science, engineering, photography and etc.
Conventional sliders that are sold in the market have many drawbacks.
Our 2D Slider is a state of the art machine designed to be robust, effective and efficient. It
effectively solves the many problems associated with conventional sliders. Our team dealt with
these problems and successfully overcame it. Some of the problems that are constantly faced by
users of slider are the manual adjustment of the camera. Manual adjustment is tedious and
difficult. The user has to push the platform which at times can be strenuous due to the friction
between the moving parts. The varying force exerted by the user on the machine could
potentially damage certain components attached to the machine. Our 2D slider tackles this
problem by eliminating any hand contact on the machine by using switches to automatically
position the camera at any point. By this ingenious solution the user now can more easily adjust
the position without damaging the machine.
Conventional sliders typically have only one degree of freedom. This limited movement restricts
the user to position the camera and at the same time causes the user difficulty. The user now has
to move around the entire machine to get a good position. The 2D sliders instead have an
additional 1 degree of freedom making it have a total of 2 degree of freedom. This additional
DOF may look trivial but can make usage of the machine much more convenient and userfriendly. The user could position the camera with much more ease now.
The 2D Slider is also light weight as its made of mostly aluminum rectangular bars. This ensures
the machine is easily moved around and portable. The machine is also designed to be robust so
that moving it around wouldnt damage the machine. 98% of the machine is made up of metal
making it long lasting and also wear prove. It can be used in fairly extreme environment where
precision positioning of a camera is required. The precision of the 2D slider is indeed high. Fine
movement can be made to move the camera. This especially comes handy for instance in the
crack analysis of walls or beams. Some cracks can be so small that extreme precision is needed
and the 2D sliders do the job well enough.
In conclusion, the 2D slider has a huge positive and meaningful impact on society. It tackles the
many problems faced by users that may seem trivial but in fact could be painfully annoying at
times. Our team believes that the 2D slider has the potential to revolutionize sliders.

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11.0) Reference
1.
2.
3.
4.

https://en.wikipedia.org/wiki/Linear-motion_bearing#Ball_Bearing_Slides
http://www.electrical4u.com/induction-motor-types-of-induction-motor/
http://www.animations.physics.unsw.edu.au/jw/electricmotors.html
https://www.google.com/search?q=camera+slider&biw=1366&bih=681&site=webhp&tb
m=isch&tbo=u&source=univ&sa=X&ved=0ahUKEwiMp6fN13MAhUFr48KHeU4AMYQsAQIKA#imgrc=C16klnplZsiyZM%3A

12.0) Appendix

Timing Belt

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Electric Components

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Aluminum Frame

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