Kinetic Sculpture

Inspiration

For shop tech secret santa this year I wanted to make something visual. I stumbled across the work of Anthony Howe, who builds massive mesmerizing kinetic sculptures out of stainless steel. I decided to make a scaled down version for my secret santa gift, using a small motor rather than wind power.

Motion Simulation

The concept behind the sculpture is fairly simple. Each set of petals is attached to a roller, and each roller pushes on the next to synchronize the motion. The secret is the slight offset between each roller, such that each is out of phase. This prevents the petals from colliding as they pass through the center. It also generates the spiraling motion. Depending on the phase shift, the pattern changes significantly.

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6° Phase Shift

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12° Phase Shift

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20° Phase Shift

Design

I chose 19 rollers since it fit nicely on an 8in circular hoop. I settled on a 7° phase shift between rollers, which gave a nice spiral pattern without too much overlap. The first roller is driven through a set of bevel gears attached to a small motor. Each roller is 3D printed, and contains 4 stems. Each stem is a piece of 3/32in stainless welding wire. On the end of each stem is a 3D printed petal, which on both dies is covered in holographic vinyl.

The base of the sculpture features a ring of LEDs with a diffuser on top. An arduino nano runs the LEDs, and switches a relay to drive the motor. The whole system is driven off of 5V USB power.

The design totals 76 individual petals and stems, and 152 vinyl stickers.

Build

The most important part of the sculpture is the motion, so it was critical to test the rollers as early as possible. Each roller was printed out of Markforged Onyx, and then the forks and rollers were superglued in to their designated holes.

My setup for cutting all 57 drive rods and 76 petal stems

Glueing drive rods

Drive rods drying while suspended to help prevent the rods becoming misaligned

Test fit on an 8in diameter hoop of 1/8in mild steel filler rod

Applying vinyl holographic stickers to each petal

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Gear train test run

Friction and Stiction

The small 5V motors I had struggled to overcome the friction of the rollers and drive rods in one specific spot: As the drive rods turned towards the center of the hoop, the friction greatly increased, and the motion slows down.

I tried a miniature stepper motor as well, thinking that maybe this could give me more uniform motion. However, the stepper also did not have enough torque to drive the motion.

Eventually I determined that the friction was due to the drive rod binding between the forks. By removing one side of the fork, I could greatly reduce the friction. This constrains the motion to now only work in one direction, which is not a problem for the motor driven sculpture as opposed to a wind driven sculpture. Additionally, I alternated the side on which the drive rods push, which means that only half of them will be pointed towards the center at any given time. This also helps even out the friction across the motion.

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High friction and binding results in irregular motion

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Alternating drive rods help average out the friction over the whole motion

Roller and petal assembly

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Friction greatly reduced!

The base contains LEDs, a relay for running the motor, and a power switch. The arduino nano sits inside the mast underneath the motor.

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