Automata Design Project: The Perpetual Flapper

This project involved the systematic design and construction of an automata mechanism—a mechanical device that produces animated motion through a rotating crank. The project required developing a structured design process using objective trees, morphological charts, and weighted objective analysis to evaluate multiple design concepts before selecting and building a final prototype. The chosen design, "The Perpetual Flapper," is based on the Flappy Bird theme and demonstrates smooth mechanical performance through coordinated cam-driven motion.

Problem

To design and construct a functional automata mechanism that demonstrates clear, coordinated motion through mechanical means. The project required systematic design documentation including: a three-level objective tree breaking down primary, secondary, and tertiary design goals; a morphological chart presenting at least four sub-functions with four solutions each (including both words and hand-drawn sketches); a weighted objective analysis comparing three different design directions; and a final physical prototype demonstrating smooth mechanical performance.

Approach

The design process followed a structured engineering methodology, beginning with an objective tree that organized design goals into primary, secondary, and tertiary levels. This hierarchical structure ensured that functional requirements, performance criteria, and aesthetic considerations were systematically addressed.

A morphological chart was developed to explore design alternatives systematically. The chart identified key sub-functions (drive system, motion mechanism, aesthetic theme, and presentation format) and presented multiple solution options for each, enabling comprehensive exploration of the design space.

Three distinct design directions were evaluated using weighted objective analysis: Flappy Bird Automaton, Boat & Fish Automaton, and Desert Racer Automaton. The analysis weighted six criteria: Smooth Mechanical Performance (25%), Ease of Construction (20%), Distinctness & Clarity of Motions (20%), Aesthetic/Theme Quality (15%), Reliability/Usability (10%), and Ease of Presentation (10%). The Flappy Bird design emerged as the superior choice with a score of 4.55/5, selected for its smooth mechanical performance, clarity of motion, ease of construction, and clean integration of theme with mechanical behavior.

The final automaton, "The Perpetual Flapper," features a cam-driven mechanism that produces two distinct motions: vertical flapping of the bird's wings and horizontal movement through obstacles. The mechanism uses gears, cams, and linkages to coordinate these motions from a single rotating input.

Methods & Tools

• Structured design methodology (objective trees, morphological charts)
• Weighted objective analysis for design evaluation
• Cam design and fabrication
• Gear design and gear cutting
• Linkage mechanism design
• 3D modeling for component design (3D-printed joints, cam supports, rollers)
• Mechanical assembly and tuning
• Design documentation and technical reporting
• Public naming survey (Instagram polls) for thematic development

Outcome

The final automaton, "The Perpetual Flapper," successfully demonstrates smooth, coordinated mechanical motion with clear visual appeal. The design process documentation, including the objective tree, morphological chart, and weighted objective analysis, provides a comprehensive record of the systematic approach to design decision-making. The project demonstrates proficiency in mechanical design, systematic problem-solving, and the application of structured design methodologies to create functional, aesthetically integrated mechanisms.

Key Leverage

This project highlighted the value of structured design methodologies in making informed engineering decisions. By systematically breaking down objectives, exploring alternatives through morphological charts, and quantitatively evaluating options using weighted criteria, the design process moved from uncertainty to a well-justified solution. The final automaton's smooth performance and clear thematic integration demonstrate how disciplined design methodology leads to superior outcomes compared to ad-hoc design approaches.