Functional Vintage Toy Cart With Battery-powered Lights👨🏻‍🦲🔋

Here you will learn how to build your very own functional vintage toy cart with battery-powered lights.

This design was loosely inspired by my FRC robotics mentor.

I used TinkerCad's amazing circuitry tools to generate a wiring diagram to help me design the wiring.

3D printed Items:

• 2x A (Wheel)
• 2x B (Axel)
• 1x C (Base)
• 1x D (Frame)
• 2x E (Wheel)
• 2x F (Pillar)
• 1x G (Headpiece)

(File: https://drive.google.com/file/d/15ATh5MevDpTQ2Hi5w9i_rxano-RWxgKL/view?usp=sharing)

Items to Purchase Online:

• 2x Lightbulb Socket
• 1x AA Battery Holder
• 1x Rocker Switch
• 1x AA Battery Pack
• 4x Sealed Metal Ball Bearings
• 2x Light Bulbs
• 1x Plastic Glue
• 1x Spool of String
• 1x Spool of Electrical tape

Print the 3d printed items mentioned in the supplies list and purchase the necessary parts mentioned in the supplies list:

Here are some resources for 3d printing if you don't have access to one.

-Service 1

-Service 2

-Service 3

-Service 4

You may need to prepare your 3d printed supplies by sanding them down and breaking off the supports depending on what you used to 3d print your supplies.

Coat the insides of the center hole in the wheel with the Plastic Glue then place the Sealed Metal Ball Bearings inside of the center hole in the wheel as depicted in the images above.

Coat the insides of the holes in the frame(Locations are indicated in a note on one of the images above) with Plastic Glue then place the 3D printed axels inside of the holes that you filled with Plastic Glue as indicated in the images above.

Apply Plastic Glue across the flat surface of the frame then place the base on top of the flat side of the frame such that all of the rectangular holes on the base line up with the rectangular holes on the frame as indicated in the images above.

Apply the Plastic Glue to the bottom surface of the AA Battery Pack then place the AA Battery Holder in the location indicated in the picture above. Then take your Rocker Switch and snap it into the rectangular hole so that the switch part is facing Down and the prongs are facing up as indicated in the pictures above(Feel free to apply glue to the hole the switch is being placed in for extra measures if you like).

Apply the Plastic Glue to the top and bottom of the 3D-printed pillars then place the pillars in the location indicated in the images above. Then place the Lightbulb Sockets on top of the 3D-printed pillars and screw the Light Bulbs into the Lightbulb Sockets.

Wire Light Bulbs, Batteries, and Rocking Switch as shown in the images and the wiring diagram above(Made with Tinkercad) Use Electrical tape for wire connections and to fasten the wire to surfaces when necessary.

Apply Plastic Glue to the rim of the fabulous 3D-printed Headpiece then place the fabulous 3D-printed Headpiece on the base as indicated in the images.

Apply Plastic Glue on the inner surface of the bearings inside the 3D-printed wheels then place the 3D-printed wheels on the cart by fixing an axe to the inside of each bearing.

Tie your String around the gap between the 2 holes at the front of the base of your brand-new functional vintage toy cart with Battery-Powered lights!

Take your new creation out on a walk where ever you like! :D

Problem Statement:

Our FRC team desires the design of a toy cart.

Constraint List:

• Must use power from a battery.
• Must be viable to build.
• Must be teachable through an Instructable using Pictures, Verbiage, and 3D Models.
• Cannot violate the rules of the contest.
• Must incorporate an Autodesk product.

Problem Research:

• The first thing I researched ways to create a 3D model of someone's head based on images of it and I found a helpful article.
• Then because I am most proficient with Blender I used ctr-f to scan the article for the keyword “Blender” and located a section of the article allocated to the use of Blender for creating a 3D model of someone's head based on images, with the help of the KeenTools Face Builder Add-on
• I also researched the designs for toy carts which aided me in designing the frame of my toy cart.

Brainstorming Ideas(Highlighted ideas are the ones I used in my final design): 

• Modern Theme
• Steampunk Theme
• Vintage Theme
• Futuristic Theme
• Retro Theme
• Spooky Theme
• Flintstones Theme
• Holiday Theme
• Classic/Themeless
• Primitive Theme
• Minimalist Theme
• Lowpoly Theme
• Make it Mr. Nortons Head
• Stretched out to be more shaped like  a cart
• Left be(More likely to fall over)
• Normal Eyes
• Hollow eyes with battery-powered lightbulbs behind them
• Make the toy cart remote controlled

-Play Music

-Use Arduino

-Tank Treads

-Wired Control

-Wireless Control

-Ultrasound

-Infrared

-Radio Waves

-Mecanum Drive

-Omni-Directional Drive

-Spider Legs

-Traditional Tank Drive

-Weels

-Brissel Drive

• Make the toy cart draggable with a string on the ground(Borderline remote-controlled):

-Sled on the bottom

-Skees on the bottom

-Carriage wheels on the bottom

-Traditional wheels on the bottom

-Twine

The engineering design process often includes failed designs, I experienced this in my utilization of the engineering design process:

-My first approach was to make an infrared RC car, but this failed

-I was luckily able to utilize much of my previous wiring designs to try a wired RC circuit, this did work, however, I came to the realization that the sheer amount of wires present in the design made the actual application of this design in my given time constraint impossible.

-I then resorted to one of the other ideas I came up with while brainstorming wich is an RC car driven with a string, this was much more feasible in my given time constraint so that was the design I ended up going with.

Designing a Solution(The solution that was feasible in my given time constraint):

After researching I proceeded to design a solution:

• I first gathered the following images of My robotics mentor's face.
• I then used Keen Tools Blender Add-on to generate a 3d model of Mr. Norton's head given those images.
• I then stretched a place in the middle of the 3d model of Mr. Norton's head, subdivided, smoothed, repeated, etc. I then extruded all of the faces along their normals to generate a rough shell of the 3d models and carved an even rim around the bottom of the 3d model of Mr. Norton's head and then corrected any issues such as loose vertices, holes, etc.
• After finishing the stretched 3d model of a shell of Mr. Norton's head I exported it to Onshape.
• In  Onshape I used the bottom rim of the stretched 3d model of Mr. Norton's head to create a rough base for the toy cart.
• I then made a frame and wheels for it using a tweaked version of the old frame and wheels I had made when I was working on the second failed design attempt.
• Then found some viable bearings, a rocking switch, twine, lightbulb sockets, lightbulbs, a AA Battery holder, plastic glue, and electrical tape to assist with my design.
• I created 3d models of the components that would be purchased online(using data tables and dimensions) to aid in using 3d models to help with developing visuals in my instructable.
• I then used Tinker cad(An Autodesk Product) to develop a wiring diagram for my design and created a guide on how to make it on Instructables and entered it into the competition.

Instructables:

https://www.instructables.com/Functional-Vintage-Toy-Cart-With-Battery-powered-L/

OnShape:

https://cad.onshape.com/documents/81bcd664281a632c3a7bc56c/w/c036d38c886af1fa835b6a7d/e/ea8ee46dd64841a650a3fa41?renderMode=1&uiState=6468775d1cb7e56fc89d26b3