BS in Mechanical Engineering
Mechanical Engineering Department
When this project began, The Cambria Center for the Arts Theater used a manually-operated spotlight. The sound created by the fans, along with the sheer size of the spotlight, required that it be housed in an attic room above the theater and shined through a closed window. This trapped a lot of heat in the room and involved some risk with climbing into and out of the attic room. This project sought to remedy those issues by mounting a pair of newer LED spotlights inside the theater. Doing this required a method for remotely controlling and actuating the angular position of each spotlight in two axes. Over the course of one year, the Dynalux team researched, designed, and built a solution to CCAT’s problem. The process by which they completed those steps is written in detail within this report. The first third of the year was spent in research and development. The team compared commercial and industry options to determine the best practices and designs. Many of the available options were too complicated or expensive and this reiterated that a cheaper and easier system was needed. At this point, Team Dynalux came up with a preliminary design that met all the design constraints. The next third of the year was dedicated to detailed analysis and proving that the design would work as intended. This included looking at all aspects of the system from motor torque requirements to strength and material properties. At this stage, the design was presented to the sponsor and advisors to begin manufacturing. The remainder of the project consisted of manufacturing, assembling, and testing. Some aspects had to be changed on-the-fly but the majority of the design remained the same throughout. Upon concluding machining and welding, the metal parts were finished and assembled with off-the-shelf components. When the mounts were complete, the electronics were added and tested in the overall system. Testing and manufacturing were time intensive but kept safety and reliability as the highest priority. The contents of this report are intended to document the process by which the project was completed but also provide reference to the parts and techniques used to build the system. Also included are comprehensive drawings and instructions to make sure the system is running smoothly, and if needed, provide maintenance.