Flywheel Mechanism

Flywheel Mechanism

Project Overview

Designed a flywheel-based mechanism to autonomously transfer 20 ping pong balls through a constrained opening into a target container within a fixed time requirement as part of a competitive design project. The system focused on mechanism design, dynamic system performance, and efficient ball transfer using a motor-driven rotating assembly. The full assembly was developed in Autodesk Fusion 360, with emphasis on DFA and overall system reliability.

How was the Project Created?

Developed an integrated electromechanical system combining a flywheel, guide rails, and structural housing to control and direct projectile motion. Designed all components in Fusion 360 and produced key parts using rapid prototyping (3D printing) with PLA and ABS materials. Constructed a rigid outer frame using plywood to ensure structural stability during operation. Incorporated electrical components including DC motors, potentiometers, and battery systems to drive and control the mechanism, demonstrating electromechanical integration and basic circuitry design. Iteratively refined the design to improve ball consistency, alignment, and throughput.

Results

Successfully developed a functional flywheel mechanism capable of consistently transferring balls through the opening and into the target container within the required timeframe. Iterative improvements enhanced system efficiency, alignment accuracy, and structural robustness. The final design demonstrates strong competency in dynamic system design, mechanism design, and electromechanical integration, along with hands-on experience in rapid prototyping (3D printing) and assembly-focused design using DFA principles.