During the first week of the project, I spent my time refining my design and developing a prototype. I tried to grasp some concepts using the multimeter and created a basic crank design out of rough measurements.

During the developing process, I found out many crucial parts to the design that I did not know before going into the project. After creating a top/bottomless box out of cardboard, I turned it on its side to create a frame I could use to fit the shafts and gears needed for this project. After connecting everything together, I did realize that the angle the gears attach on and the height of the holes punctured matters the most to maintaining a precise motion. After failing numerous times with getting the correct height, I decided that measuring the positions before gluing or cutting would be much better to precisely place the shafts. After this mini prototype, I then figured out that the generator that I used could create 3-4 volts when spun at high speeds, and that it could power up to two LEDs. With these simple tests done, I moved on to the final design.

I started out by marking the boxes with a pencil and ruler to try and line up the holes. In addition to this, I also added some diagonal supports out of popsicle sticks because the prototype proved that it was very easy to break without any. I switched the bulky handle with a smaller wooden one, trying to optimize the energy conversion by making it easier for users to turn the handle. The motor attached to the LED would not stay on the cardboard due to its weight, so support was necessary to hold it up at the correct height. After this, I added the smaller gear with the shaft to see if the turning of the handle was enough for it to turn the light on.

The gear was attached to a wooden skewer and unlike the prototype, it stayed in the paths of the larger motor, turning properly and actually lighting the LED.

Some 3D models in Fusion 360:

This was the design for my hand crank handle, but it turned out to be way too large to turn and attach onto the box, so the shaft part was replaced with a wooden dowel.

This was the fan blade used on the other end of the box compared to the handle, and this would be the main part of the design. The fast-spinning bottom shaft would spin the cylinder of the blade and blow wind outwards. The printing of the fan took about 6-10 hours and was finished on Mach 8th, and it was attached and the design was finished on March 9th.