Misli Finalllllll

1
COURSE:
KKKM 3062 INTEGRATED PROJECT II
SEMESTER / SESSION:
SEMESTER 1 / 20202021
TOPIC:
MISLI BLOCK
LECTURES:
PROF. MADYA IR DR RIZAUDDIN BIN RAMLI
DR HAWA BINTI HISHAMUDDIN
DR NOR KAMALIANA BINTI KHAMIS
DR INTAN FADHLINA BINTI MOHAMED
DR ARMIN RAJABI NASIRABADI
GROUP 5
NAME / MATRIC NUMBER:
LAI YU HUNG A170342
NUR SYAMIMI BINTI ZAINAL ADELIN A169926
MUHAMMAD IZZ IRFAN BIN ZULKEFLY A169029
NURUL SAKINAH BT ABDUL BASIR A170367
MUHAMMAD ALIF IQRAK BIN SUHAIRUL AZMIE A170450
1
I
DECLARATION
I hereby declare that the work in this thesis is my own except for quotations and summaries
which have been duly acknowledged.
26 June 2021 LAI YU HUNG

A170342
NUR SYAMIMI BINTI

ZAINAL ADELIN
A169926
MUHAMMAD IZZ IRFAN

BIN ZULKEFLY
A169029
NURUL SAKINAH BT
ABDUL BASIR
A170367
MUHAMMAD ALIF
IQRAK BIN SUHAIRUL
AZMIE
A170450
I
II
ACKNOWLEDGEMENT
First and foremost praise to Almighty Allah for all his blessings for giving us patience and
good health throughout the duration of this project. We are very fortunate and we would like
to express our deep and sincere gratitude to our project supervisors Prof Madya Dr.
Rizauddin bin Ramli, Dr. Nor Kamaliana binti Khamis, Dr. Hawa binti Hishamuddin, Dr.
Mohd Faizal bin Mat Tahir, Dr. Intan Fadhlina binti Mohamed, Encik Zulkhairi bin Zainol
Abidin and Dr. Armin Rajabi Nasirabadi for giving us the opportunity to do this project and
providing invaluable guidance throughout this project. The dynamism, vision, sincerity and
motivation of the supervisor have deeply inspired us. They taught us the mechanism to carry
out the project and to present the works as clearly as possible. It was a great privilege and
honor to work and study under their guidance. We are extremely grateful for what they had
offered us. We should like to thank them for their friendship, empathy and great sense of
humor.
We are extremely grateful to our parents for their love, prayers, caring and sacrifices
for educating and preparing us for our future. We are also felt blessed for the love,
understanding, prayers and continuing of our supervisor to complete this project work. Also,
the cooperation and tolerance of each team member throughout this project work are so much
appreciated. Our special thanks goes to our friend for the keen and interest shown to complete
this project.
Finally, our thanks go to all the people who have supported us to complete the project
work directly or indirectly.
III
ABSTRACT
MISLI is a LEGO-compatible electronics kit with conductive blocks, screen, lights, motors
and sensors. MISLI building blocks bring the designs to life with electronic system and
connected apps. A body block adapted for releasable engagement to at least one other toy
building element body or to a corresponding baseplate, the body including at least one
conductive portion having at least one contact area adapted to generate pressure on a
conductive portion or contact area of an adjacent toy building element body, in such a way
that ensures electrical conduction between said toy building elements in a desired location
and direction. The aluminium-coated LEGO compatible blocks mean that can be added
controllable lights and motors to projects without needing wires. MISLI's electric blocks are
normal sized building blocks that are anything but normal. It's like Lego® on steroids, if
steroids also gave superpowers and taught the new languages. Basically, the blocks that
safely conduct electricity and connect to the phone to enable to do all sorts of cool things
with the designs. MISLI blocks include screen, LED lights, motor blocks and even sound,
light and sensors. MISLI aluminium-coated connector blocks conduct electricity. The unique
design enables adjacent bricks to conduct currents in any direction. MISLI’s smart internal
6V battery block powers of creations and constantly monitors the currents so that don’t have
to worry about short circuits. A built-in Bluetooth controller will let people change the
current’s direction and voltage levels via mobile application. MISLI trigger blocks are
designed to control the action without additional wiring. Connected along the current path,
the switch action blocks “on” and “off” using built-in light, sound and sensors. The trigger
blocks’ smart switching functionality operates the action blocks by controlling the current in
the circuit. MISLI block is not complete without its sensors. One of the major challenges so
far was finding a way to conduct electricity without using specially designated wires (or any
wires for that matter). The solution is simple trigger blocks, which sit along the circuit and
throttle the current flow through the block itself. Now, as the move from R&D to
manufacturing. Immediate challenge will be to convert to the working prototype models into
mass production molds of the highest quality, while maintaining reasonable pricing from the
e-waste recycle.
IV
TABLE OF CONTENTS
DECLARATION I
ACKNOWLEDGEMENT II
ABSTRACT III
TABLE OF CONTENTS IV
LIST OF TABLES VII
LIST OF ILLUSTRATIONS VIII
CHAPTER I INTRODUCTION
1.1 Background Of The Project 1
1.2 Problem Statement 2
1.3 Objective and Scope of Project 2
1.3.1 General Objective 2
1.3.2 Scope Of Project 2
CHAPTER II LITERATURE REVIEW

2.1 Review Based On Past Studies 4
2.2 Problem Statement based on past studies 4
2.3 Comparison with available product 5
2.4 Reason of developing 5
CHAPTER III METHODOLOGY

3.1 Project Work’s Flow 7
3.2 Gantt Chart 8
3.3 Brainstorming Activities 9
3.4 Data Analysis Description 9
3.4.1 Material Selection 9
3.4.2 Manufacturing Process 13
3.4.3 Block components 14
3.4.4 Component Testing For Each Block 18
3.5 Stress Analysis 19
3.5.1 Simple Circuit 19
3.5.2 Car Model 47
3.5.3 Discussion for Stress Analysis 74
V
CHAPTER IV DESIGN CONCEPT

4.1 Final Design 75
4.1.1 Car Model 75
4.1.2 Simple Circuit Model 78
4.2 Design Of Key Components 81
4.2.1 Motor Block 81
4.2.2 Lcd Screen Block 97
4.2.3 SINGLE BLOCK 109
4.2.4 Battery Block 114
4.2.5 Trigger Block 129
4.2.6 LED Block 138
4.2.7 Sound Block 146
4.3 Comparison of materials selection 152
4.3.1 Motor Selection 152
4.3.2 LCD Screen Selection 155
4.4 Design criteria and constraint 158
4.4.2 LCD Screen Block 159
4.4.3 Single Block 159
4.4.6 LED Block 161
4.5 Working principle, operation and mechanism 162
4.5.1 Whole MISLI Block System 162
4.5.3 LCD Screen Block 162
4.5.4 Single Block 163
4.5.7 LED Block 164
4.6 CALCULATION 164
4.6.1 Motor Block Theoretical Motor Calculation 164
4.6.3 LED Block 170
4.7 Cost/budget 174
CHAPTER V DISCUSSION
5.1 Safety 175
5.2 Reliability Factor 175
VI
5.2.1 Environment Community or Society 175

5.2.2 Contribution 175
5.2.3 Precaution 176
5.3 Ethical Issues 176
5.3.1 Safety Standards 176
5.3.2 Does Not Contribute Any Pollutions 176
CHAPTER VI CONCLUSION
REFERENCES 178
Appendix A Material Properties 179

VII
LIST OF TABLES
Table 3 Gantt Chart 7
Table 4 Result Analysis for Simple Circuit Stress Analysis 18
Table 5 Result Summary of Stress Analysis for Car Model 46
Table 6 Technical specification of Arduino Uno 106
Table 7 Device and Service Discovery 136
Table 8 DC Motor Specification 153
Table 9 Pros and cons to LCD panels 156
Table 10 Design Criteria and Constraint Motor Block 157
Table 11 Design Criteria and Constraint LCD Screen Block 158
Table 12 Design Criteria and Constraint Single Block 158
Table 13 Design Criteria and Constraint Battery Block 159
Table 14 Design Criteria and Constraint Trigger Block 159
Table 15 Design Criteria and Constraint LED Block 160
Table 16 Design Criteria and Constraint Sound Block 160
Table 17 Battery Specification 168
Table 18 Resistor specification 172
Table 19 Budget List For A Set Of MISLI Block 173

VIII
LIST OF ILLUSTRATIONS
Figure 3.1 Yield strength (elastic limit) (MPa) against density (kg/m^3) 10
Figure 3.2` Hardness – Vickers (HV) against Melting point 11
Figure 3.3 Recycle against Price (MYR/Kg) 12
Figure 3.4 Hardness-Vickers(HV) against Electrical Conductor / Insulator 12
Figure 3.5 Sketching for Arduino Uno and Bluetooth Module to LCD Screen
15
Figure 3.6 Application Layout 15
Figure 3.7 Example Arduino Coding to Connect the LCD Screen with
Smartphone 16
Figure 3.8 Example of Connecting 6V DC Motor to a Simple Circuit 17
Figure 3.9 Example of Arduino Coding for Controlling the 6V DC Motor by

Applications 18
Figure 3.10 Von Mises Stress 21
Figure 3.12 1st Principle Stress 22
Figure 3.14 3rd Principle Stress 24
Figure 3.16 Displacement 25
Figure 3.18 Safety Factor 26
Figure 3.20 Stress at XX-axis 27
Figure 3.22 Stress at XY-axis 28
Figure 3.23 Stress at XY-axis 29
Figure 3.24 Stress at XZ-axis 29

IX
Figure 3.26 Stress at YY-axis 31
Figure 3.28 Stress at YZ-axis 33
Figure 3.30 Stress at ZZ-axis 35
Figure 3.32 X Displacement 36
Figure 3.34 Y Displacement 37
Figure 3.36 Z Displacement 39
Figure 3.38 Equivalent Strain 40
Figure 3.40 1st Principle Strain 43
Figure 3.42 Strain XX 44
Figure 3.44 Strain XY 47
Figure 3.45 Strain XZ 49
Figure 3.46 Strain YY 49
Figure 3.48 Strain YZ 52
Figure 3.50 Contact Pressure 54

X
Figure 3.52 Contact Pressure X 56
Figure 3.53 Contact Pressure Y 58
Figure 3.54 Contact Pressure Z 58
Figure 3.75 1st Principle Strain 81
Figure 3.76 3rd Principle Strain 82
Figure 3.77 3rd Principle Strain 83

XI
Figure 3.79 Strain XY 86
Figure 3.83 Strain YZ 90
Figure 3.84 Strain ZZ 91
Figure 3.85 Strain ZZ 92
Figure 3.87 Contract Pressure X 95
Figure 4.1 Car Model 2D Drawing 100
Figure 4.2 Car Model 3D Drawing 101
Figure 4.3 Car Model Exploded View 102
Figure 4.4 Simple Circuit Model 2D Drawing 103
Figure 4.5 Simple Circuit Model 3D Drawing 104
Figure 4.6 Simple Circuit Model Exploded View 105
Figure 4.7 Motor Block 2D Drawing 106
Figure 4.8 Motor Block 3D Drawing 107
Figure 4.9 Motor Block Exploded View 108
Figure 4.10 6V DC Motor Drawing 109
Figure 4.11 Motor Block Main Body Drawing 110
Figure 4.12 Motor Block Side Body Drawing 111
Figure 4.13 Motor Block Front Circle Drawing 112
Figure 4.14 Motor Mechanical Operation 114
Figure 4.15 Characteristic curves of Motor 118

XII
Figure 4.16 LCD Screen Block 2D Drawing 122
Figure 4.17 LCD Screen Block 3D Drawing 123
Figure 4.18 LCD Screen Block Exploded View 124
Figure 4.19 LCD Screen Block Main Body Drawing 125
Figure 4.20 LCD Screen Block Bottom Cover Drawing 126
Figure 4.21 HC05 Bluetooth Module Drawing 127
Figure 4.22 Arduino Uno Drawing 128
Figure 4.23 IPHONE 5 Drawing 129
Figure 4.24 Circuit diagram of the LCD screen block 130
Figure 4.25 HC05 Bluetooth Module 131
Figure 4.26 Single Block 2D Drawing 134
Figure 4.27 Single Block 3D Drawing 135
Figure 4.28 Single Block Exploded View 136
Figure 4.29 Connector Main Body Drawing 137
Figure 4.30 Connector Bottom Cover Drawing 138
Figure 4.31 Battery Block 2D Drawing 139
Figure 4.32 Battery Block 3D Drawing 140
Figure 4.34 Battery Block Main Body 141
Figure 4.35 Battery Block Cover 142
Figure 4.36 Battery Drawing 143
Figure 4.37 Demand for Li‐ion batteries in two decades. Reproduced with
permission. 148
Figure 4.38 Comparison of energy densities and specific energy of different

rechargeable batteries. Reproduced with permission 6. 149
Figure 4.39 Illustration to show the basic components and operation principle
of a Li‐ion cell. Reproduced with permission. 150
Figure 4.40 Voltage versus capacity for positive‐ and negative electrode
materials presently used or under considerations for the next‐
generation of Li‐ion batteries. Reproduced with permission. 153
XIII
Figure 4.41 Trigger Block 2D Drawing 154
Figure 4.42 Trigger Block 3D Drawing 155
Figure 4.43 Trigger Block Exploded View 155
Figure 4.44 Trigger Block Main Body Drawing 156
Figure 4.45 Trigger Block Cover Drawing 157
Figure 4.46 HC05 Bluetooth Module 158
Figure 4.47 LED Block 2D Drawing 163
Figure 4.48 LED Block 3D Drawing 164
Figure 4.49 LED Block Exploded View 165
Figure 4.50 Main LED Body Drawing 166
Figure 4.51 Aluminium Plate Drawing 167
Figure 4.52 0.2W 2835 SMD LED Drawing 168
Figure 4.53 Resistor Drawing 169
Figure 4.54 Yellow Acrylic Round Plate Drawing 170
Figure 4.55 Sound Block 2D Drawing 171
Figure 4.56 Sound Block 3D Drawing 172
Figure 4.57 Sound Block Exploded View 173
Figure 4.58 Main Body Drawing 174
Figure 4.59 Aluminium Plate Drawing 175
Figure 4.60 HC05 Bluetooth Module Drawing 176
Figure 4.61 Speaker Drawing 177
Figure 4.62 6V DC Motor 3D Drawing 178
Figure 4.63 A basic diagram of a TFT LCD panel (TEAC,2000) 181
Figure 4.64 Comparison of display image of TPS and TN 182
Figure 4.65 Simple Circuit for LED Block 196
Figure 4.66 4 band resistor colour code 198
Figure 4.67 4 band resistor 199

XIV
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CHAPTER I
INTRODUCTION
1.I.1 BACKGROUND OF THE PROJECT
E-waste or electronic waste is all about unwanted electronic products such as television,
computer, camera, phone, and so many others. It has negative effects on air,
soil, water, and even humans too. Electronic waste contains toxic components that can bring
harm to human health. We need to recycle, refurbish, reuse the e-waste products properly to
avoid any toxic effects. Meanwhile, nature itself happens to have the same effects such as
acidification created in the water, soil contamination, and also air pollution due to releasing
dust particles into the air which can damage respiratory health.
E-waste also contains many materials that have a value such as plastic, aluminum, and
silver. For example, a computer has a lot of value contain only in one product itself. It gives
more benefits to humans to recycle, refurbish, and reuse e-waste materials. The good about
recycling is it helps us protect our environment and also reduce the cost of making new
products. It also brings benefits to the recycling industry to continue to grow and create jobs
for other people.
On top of that, not many toys or educational kits are being made from e-waste
material. As we look at some other toys in the market nowadays, a lot of them are quite
pricey. Educational kits or toys are really important for a child’s development. It is not
because of artificial intelligence, but because educational tools contribute to good intellectual,
social, and motor development. Scientific has proven that learning through play is very
important because playing helps to develop children.
For our project, we decided to create an educational kit that will bring good to the
children. Our idea was inspired by lego block and building block in the market. We do a lot
of research and take into account what will benefit the children and at the same time deliver
them the knowledge they need. We invented and improvised our product to fulfill the needs
of the consumer and parents.
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2
Children nowadays love to play with lego block no matter what gender they are.
Some adults also love to buy lego blocks for their collection. In today’s market, it’s quite
difficult to search for a toy that has educational purposes for children. By the mean of
educational purposes, it’s an advantage for the children to get early exposure to the electrical
and electronic concept. For example, kids love lego blocks and by combining lego block with
this advanced electrical knowledge, it can be a good educational kit for them. Children also
can learn more from our Misli block with the guidance of adults.
1.I.2 PROBLEM STATEMENT
Several problems occur in our studies regarding the lego block available in the market
nowadays. Many people complain the building blocks come with a wire that is hard for
children to use it. The wires themselves will easily be tangled towards each other. Other than
that, as we looking at the lego block in today’s market, most of the blocks already stated
manual on how to build the lego in and every each of the boxes. This manual instruction
makes the children think less and only depends on it . There is no imagination and also no
adaptability for them. It delivers no educational purposes. Some of lego design set contains
many odd shapes that only specific to a particular set. It also does not work with other’s
designs.
1.I.3 OBJECTIVE AND SCOPE OF PROJECT
1.I.3.1 General Objective
The objectives of this study is to create an educational kit for the children.
1. Early exposure for the childrens on how the building blocks related to the electrical &
electronic concept
2. The idea of bring in modern blocks into toys market for educational purposes
3. To help revive the imaginations of children of all ages everywhere.
1.I.3.2 Scope Of Project
This report the findings of a thorough study to create an educational kit using
electronic waste. A lot of things can be done using electronic waste materials. We come out
with the idea of MISLI BLOCK. The name itself represents each of the members of our
group. This MISLI BLOCK is inspired by lego block in the market nowadays but of course,
we do a lot of modification to it to make it more fun, unique, and easy for children to play. It
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is not an ordinary building block , but our Misli block provides a knowledge on how electric
and electronic works.
1.I.3.3 Targeted Respondent And Market Price
Since this product is function as an educational kit from electronic waste and recycle
material. We are targeted our respondent or user at 3 to 12 years old. This is mainly because
from our research found that the marketplace for educational kit for 3 to 12 years old have a
large potential to marketing. MISLI Block, our product will provide early exposure of basic
electronic and electrical concept when kids building the MISLI block with their imagination.
Imagination is a huge asset of kids. After undergo targeted respondent marketing survey and
research of related targeted respondent educational kit, we are agree to launched MISLI
Block at RM 95.00 for the selling price.
4
CHAPTER I
LITERATURE REVIEW
2.I.1 Review Based On Past Studies
Based on our past studies regarding this project, we have found few interesting issues
that give us some kind of eagerness to improve our idea. According to the article from
Madeline Walton-Hadlock, Children and Libraries, Chicago vol 6 (Winter, 2008), most
teenagers are often the only target for this technology programming. They ignored the
needs and the benefit for the children regarding this issue. Most of the children love
exploring technology. There are also few benefits for the children and their parents if this
technology programming being exposed to the children at such a young age.
An article was written by Julie Sarama and Douglas H.Clements with the title of
Building Blocks, playing to know the world mathematically. Based on the article, they
researched how children’s play can support the development of the foundations of
mathematic’s learning and how adults can support them as well. The building block is our
example of mathematical toys. Research about (Seo and Ginsburg 2004), they being
asked to form parallel lines from a building block and unfortunately when they arrive in
middle school, they may not understand this kind of parallel concept anymore. One
observational study confirmed that puzzle toys or lego blocks were related to the mental-
transformation ability by (McGuiness and Marley 1991). On the other hand, a study by
(Bruner 1985), children are more successful and more creative if they were asked to solve
a problem of it.
2.I.2 PROBLEM STATEMENT BASED ON PAST STUDIES
Based on the past studies, there are few problem statement that we want to
highlight. Research from (Sarama and Clements 2009) said there is a substantial and
widening gap in mathematical achievement between children from higher-income and
lower-income families starting as early as three years of age. Children that came from
low-income families may engage in mathematical play or any technology toys but they
are not being able to connect this mathematic in school because of the lack of
opportunities they have. Based on this acticle, one problem that we want to highlight here
is about lower-income families are unfortunate to own a technology toys for their children
due to their unstable financial. Toys in market nowadays are way too expensive especially
for the modern toys that build with technology with it. They might sell few cheaper toys
but the quality and the output are just not the same.
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There are a few drawbacks that we found based on Spilegaben's article. One of the
drawbacks is since lego blocks are famous and in high demand, the company always
creating new sets of them. Due to the high demand from the customer, the price as well
will be increasing every year for every new product. Other than that lego blocks are
fantastic toys for kids in terms of developing construction skills but not many of them
give educational benefits for the children. They are only toys without educational
purposes.
Furthermore, as we all know lego blocks are made from the plastic material. When
plastic material falls or break, they will shatter into small dangerous pieces that will harm
anyone who might step on it and children at age below 3 years old that might put it in
their mouth. The other drawback of these lego blocks is they can quite difficult to store.
Usually, they store the lego block in such a big container due to their tiny smaller pieces
and this will give the children difficulty finding matches pieces among the other small
pieces.
2.I.3 COMPARISON WITH AVAILABLE PRODUCT
The difference between toys in today’s market and our Misli Block are first lego
block in the market does not conduct electricity due to their plastic material meanwhile
our Misli block can conduct electricity because we using aluminum alloys as for the body
of the block. Secondly, for the lego block in the market, there are no components were
being installed to the lego block. Unlike our Misli block, each block were being installed
by some components and it be functional when the blocks connected into one simple
circuit. Other than that, our Misli block can produce sound, move and also produce light.
Lastly, we do provide a toy that has an apps feature with it. Children can easily attach the
blocks, watch educational videos on the LCD screen and it is easy to hold. Our Misli
Block is not just a simple plain toy but also an educational toy that will make children
think and wanted to explore more about it.
2.I.4 REASON OF DEVELOPING
After we go through all the past articles regarding toys and educational kit for
children, there is a lot of factors that gives us an idea to improve our project to the better.
The reason for us to develop more in educational kit for children is to help those that
aren’t fortunate to own one a toy that have so many benefits. Our Misli block are built
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with a reasonable price but higher in quality. We also safe our nature by using 90% of
recycle material including the body of the block.
Despite all the drawbacks of the lego blocks, we did think of a way to create an
educational kit that will give more advantages than disadvantages for the children. First of
all, we change the material from plastic material to aluminum alloys material due to the
properties of the aluminum alloys themselves. This will help to prevent the block itself
from shatter into small pieces and we consider it as one of the safety factors. The size of
our block is 20% bigger than the size of the lego block in the market. It is because we
want to avoid the children from putting the block into their mouths. In the matter of price,
we use almost 90% of the good quality recycled materials so sell our Misli block at a
reasonable and affordable price to the consumer. Our sell price is suitable for higher-
income families and also lower-income families.
The whole reason for developing this idea is to give an early exposure for the children
on how important for them to learn about educational technology at such a young age and
also will make their brain works better.
7
CHAPTER I
METHODOLOGY
3.I.1 PROJECT WORK’S FLOW
We are using Gantt chart to help us in making sure that our progression will always be
consistent an also to ensure that our project can be finished by week 14.
Firstly, we divide our team into 2 groups. The first group is responsible to conduct the
engineering drawing for each part of the components that our group will produced by using
Autodesk Inventor. While the other group were responsible in finding the best materials to be
used and also finding more information on the manufacturing process of our MISLI block
that we will produce. We also carry out some survey and make some discussion on how to
make sure that our product will fit the criteria needed.
Next we continued with the critical part which is the calculation for our electrical components
that we uses in manufacturing our MISLI block. We studied on the simulation data for each
components and from there we are able to analyze each of its components. From the data
outcome, we know that calculating the motor constant, motor speed under load, load current,
total load, power output, power input and the motor efficiency are the theoretical motor
calculation. So, from the data simulation we have obtain our theoretical motor calculation for
the motor that we use in our products. Then, we also studied on the theoretical battery
calculation by using the Ohm’s law to get the energy value that will produced by the battery
used in this project. Finally, we make a calculation fir LED block to gain the resistor
selection hat suitable to use for our SMD LED.
After finish the calculation part, we discover more information to improvise our product to
ensure that our product is more suitable and reliable. We conduct all the component’s
engineering drawing after completing the task for final evaluation. We also do some cost
budget for our product. Finally, we proceed to our final presentation and the report
submission week 14.
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3.I.2 GANTT CHART
Table 1 Gantt Chart
WEEKS
CASES 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Project briefing by
lecturer
Topic assigned by
lecturer
Problems identification
Brainstorming and
discussion
Design analysis
Proposal presentation
Finding information of
materials related to
product
Material selection for the

product
Simulation of the design
Calculation about
working mechanism of
the design after collecting
data from simulation
Revised design
Final evaluation
Engineering drawing
9
Budget of the final

product
Report
Final presentation
3.I.3 BRAINSTORMING ACTIVITIES
In our first meeting, our group plan for each members to came out with at least one idea that
is related to our project theme which is materials waste conservation for D.I.Y. educational
kit and also based on sub-theme that our lecturer has choose for us which is reuse for E-
waste. After sharing our opinions together we came out with two ideas. Our first idea was to
build an educational desk clock that will attach with a LCD screen that helps users to wake
up and the body of the clock were made from e-waste materials. Next idea was a MISLI
block that were made from electrical conductor materials and E-waste components were
installed into the block and users can build any kind of circuit or robot by themselves using
their own creativity.
Then, we arranged our first meeting with our supervisors and discuss our both ideas together.
During the meeting, our supervisors suggest us to choose our second idea since it have much
mechanism than our products and the second product seems to be interesting to build and use.
After that, we arranged our second meeting to share more ideas on how to improve our
products by adding more E-waste components that can be useful for the users so that they can
explore more about each block’s function. The ideas were accepted and we proceeded to our
proposal presentation. The figure below shows MISLI Block character is a robot which
shows our objective early exposure technology and educational knowledge to young
generation.
Figure 3.1 MISLI Block Character

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3.I.4 DATA ANALYSIS DESCRIPTION
3.I.4.1 Material Selection
The choice of materials is really important for our project to help to maintain the good
quality of the product and also bring good towards the consumer. Several types of material
properties have been taken into account to make sure the product should work properly and
safely used. Properties such as yield strength, density, hardness, melting point, electrical
conductor, and price has been taken into account to choose the best material for building up
this Misli Block.
By using CES Edupack 2019 software, we have shortlisted some materials based on
their general and mechanical properties. Firstly, we make a comparison based on yield
strength ( elastic limit ) (MPa ) and the density (kg/m^3). A graph of yield strength (elastic
limit) (MPa) against Density (kg/m^3) has been made by using CES Edupack software as
shown below.
Figure 3.2 Yield strength (elastic limit) (MPa) against density (kg/m^3)
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Based on the graph above, as we can see there are several materials at the
range of 1000 kg/m^3 for density and above 100 MPa for yield strength. The materials such
as aluminum alloys, magnesium alloys, titanium alloys, low alloy steel, nickel alloys, and
cast iron ductile (nodular).
For the second graph, we made a comparison between the Hardness – Vickers (HV)
against the melting point from the CES Edupack 2019 software.
Figure 3.3` Hardness – Vickers (HV) against Melting point
Based on the Hardness-Vickers(HV) against Melting point graph, at the range

between 500 degrees up until 2000 degree and the hardness is in between 10 up to 1000 HV,
we can see titanium alloys has the higher melting point compared to other materials that are
in the same range such as nickel alloys, aluminum alloys, and zinc alloys.
The price of material also has been taken into consideration to choose the materials
for the Misli Block and so does recyclability of the materials. A graph of Recycle against
Price (MYR/Kg) has been made using CES Edupack software 2019. The price range is
between RM10 to RM100.
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Figure 3.4 Recycle against Price (MYR/Kg)
Few recyclable materials are aluminum alloys, magnesium alloys, zinc alloys, copper
alloys, lead alloys, nickel alloys, tin, titanium alloys, and tungsten alloys. The price is shown
on an average of RM 10 to RM 100. Among all these materials aluminum alloys are the
cheapest and also a recyclable material.
Figure 3.5 Hardness-Vickers(HV) against Electrical Conductor / Insulator

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The graph above shows the Hardness-Vickers(HV) against Electrical

conductor/insulator. Based on the graph shown, several materials are proving as a good
conductor and few as a poor conductor. The good conductor materials are aluminum alloys,
medium carbon alloys, high carbon alloys, and low alloy steel. All of these materials are at
the range of 100 to 1000(HV) of hardness. Meanwhile, the poor conductors are stainless steel
and nickel alloys which shared the same hardness around 100 to 1000(HV) of hardness.
From all the graphs that we have studied, we choose aluminum alloys as our main
material due to the properties and characteristics. Among all other materials in the range list,
aluminum alloys are the best material for our Misli Block.
3.I.4.2 Manufacturing Process
The manufacturing process is really important in building our Misli Block. We have finalized
our decision to choose aluminum alloys to be our raw material for the body of the block. It
meets our standard due to its properties which are lightweight, corrosion to resistance, non-
toxic material, and recyclability.
Figure 3.6 Aluminium Alloy

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Figure 3.7 Uniaxial Tension Properties
The first thing we do is collect the aluminum alloys from our e-waste supplier.
Examples of electronic waste that contain aluminum are kitchen tools, the body of the
bicycle, and aluminum tread plate. It is an e-waste material so the price is not too high
compare to non-e-waste material.
After we collect the aluminum alloys, it will then go through a process called the die
casting process. The die casting process is a process that suitable for material like aluminum
alloys due to the properties and characteristics of the material. This process will be made at
the casting factory in Shah Alam and once the die casting process is done, they will send to
us the final shape of the body of the Misli block.
Figure 3.8 High Pressure Die Casting Manufacturing Process

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Figure 3.9 Mechanism of Die Casting
Once we have the body of the block, every electrical component such as 6V DC
motor wire, Arduino UNO, HC-05 Bluetooth module, connector, 0.2W 2835 SMD LED, and
Arduino nano 33 BLE then will be inserted into each of the body of the Misli block. All the
components are also from waste material.
After we did insert all the components inside of the body of the Misli block, it then
will go through several inspections and tests which include stress analysis and having
discussion with manufacturing engineer. As a result, MISLI block shows great performance
in analysis report, then it safe to use and sell to the consumer.
3.I.4.3 Block components
a. Arduino Uno simulation for LCD block and applications
The LCD screen that was attached to the LCD block is to display the educational kits from
the applications that we build. Liquid Crystal Display or known as LCD is a type of flat panel
displays that use liquid crystal as the primary form of operations. In this simulation, LCD
screen from old smartphone that can be categorised as E-waste will be used in order to follow
the project criteria that have been selected by the lecturers to our group.
The LCD screen will be installed with Arduino Nano and HC-05 Bluetooth module so that an
Arduino coding can be built to connect the LCD screen with any smartphone through
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Bluetooth. An educational kits application also will be built by our group by using software
and the application helps to attract kids towards educations as it can be used to do activities
such as play educational videos, learning alphabets and numbers, reading, playing
educational games and also control the movement of MISLI block.
The applications in LCD screen can be controlled by any smartphone through Bluetooth.
Install the applications in the LCD screen and smartphone then paired it together with
Bluetooth and smartphone users can control the LCD screen by choosing any educational
activities that available in the applications to be display in LCD screen. If smartphone user
does not want to control the LCD screen they can disconnect their smartphone with the LCD
screen by turning off their smartphone Bluetooth. The applications also can be control
directly through the LCD screen too. Since our MISLI block is suitable for kids with an
average age around 3 to 12 years old, their parents can still monitor their child's activities by
controlling the LCD screen.
Figure 3.10 Sketching for Arduino Uno and Bluetooth Module to LCD Screen
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Figure 3.11 Application Layout
Figure 3.12 Example Arduino Coding to Connect the LCD Screen with Smartphone
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In this study, we can make 2 test analysis for each components that were being installed in
the LCD screen. Firstly, if the application created can work well on LCD screens and
smartphones, it means that the coding used can be run properly by using the suitable software
in creating the applications. Next test analysis is if the LCD screen and smartphone can be
connect together through Bluetooth, it shows that the installations of the Arduino Uno and
Bluetooth module is correct. In addition, the Arduino coding for the Arduino Uno also are
correct and can be run properly.
b. Simulation for 6V DC Motor
The 6V DC motor in our product used to make our building blocks to move around so that it
will make our MISLI will be more interesting to play and kids can go creatively while
building the block. Many types of moving building models can be make such as car models
and can be work just like Remote Control car as it also can be control through the
applications that we build.
In our MISLI block set, there will be some blocks that will be installed with 6V DC motor in
it and the block were called as motor blocks. There are 2 ways that can be used to make the
DC motor to move. First, by connect each part of the blocks including the motor blocks into
one simple circuit or any type of circuit that users like. Make sure that the battery block also
were connected together to the circuit as the power supply so that the current can flows to
each of the blocks. The motor block will instantly moves once we turn on the battery block
and if users does not want to use the motor block or to stop the motor movement they can just
easily take out the motor block and replace it with any single block. By replacing the motor
block with the single block, other components in the circuit such as LED block and sound
block can be still functioning as the current will still flow through the circuit.
Figure 3.13 Example of Connecting 6V DC Motor to a Simple Circuit
The second ways to make the 6V DC motor to move is by turning on or off the motor by
using the applications. A trigger block were made by installing it with an Arduino Nano BLE
33 that were attached with a Bluetooth sensors. An Arduino coding will be create to connect
the Arduino module with any smartphone or LCD screen on LCD block through same
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applications that were being use for the educational activities. In the applications there were
on and off button to control the motor block to move and stop. To use the applications to
control the motor, users need to connect the trigger block and motor block with other block
and user must also connect the battery block together so that the battery can supply energy for
the motor to move. The users need to make sure that the Bluetooth on their smartphone or the
LCD screen itself is on and use the motor block button in the application to control the motor.
Users do not need to take out or replace the motor block and trigger block with a single if
they do not want to use it, they can just turn off the motor block in the applications and the
other components will be still functioning as the current will still flow through the blocks
because the body of our all blocks were made from material that can conduct electricity.
Users can build any moving models based on their own creativity and imaginations.
Figure 3.14 Example of Arduino Coding for Controlling the 6V DC Motor by

Applications
From here we can see that there are 2 test analysis that we can do which first is the test
analysis for installing the 6V DC motor and Arduino Nano BLE 33 to motor block and
trigger block. The other test is creating an Arduino coding for Arduino Nano BLE 33 in the
trigger block so that the motor can be control through the application. If both test is success
that is mean our installations of the components use and Arduino coding can be used to make
our motor to move so that the motor block can work well.
3.I.4.4 Component Testing For Each Block
In our MISLI block group, we will also provide other blocks that will be installed with some
electrical components that will help the block to be functioning properly and make the block
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become more interesting to explore. Other components that will be installed are LED lights,
speakers and battery. Each component has their own functions according to user’s usage and
each of the block’s body were made from a material that can conduct electricity in it.
First, the LED block is installed with LED and resistors so that the block model can be light
up and various types of LED block colours will also be provided in the MISLI block set.
Users only need to connect the LED block with the circuit or block model to turn on the LED
block and also can just remove it from the circuit or block model to turn off the LED block.
However, they need to ensure that the circuit or block model is connected together with the
battery block that will supply current to each block and the LED block can be functioning as
well.
Next for our sound block, a HC-05 Bluetooth module and wireless speaker will be installed in
the block. Users can just paired their smartphone or the LCD screen with the speaker that
were installed in the sound block by turning on the Bluetooth. Then they can choose any
videos or music to be played and the sound will be produced by the speaker at the sound
block that were attached to the circuit or block models. To disconnect the connection of the
smartphone or LCD screen with the sound block, turn off the Bluetooth and the sound block
can be take out from the circuit or the block models. Make sure there are power supply which
is the battery block connect together in the circuit or block models to ensure the current to
flow in it so that the sound block can be functioning just like the other blocks.
The most important part in our MISLI block is our power supply as it is the source to provide
the current to each components so that they can be functioning. Battery block were installed
with a rechargeable 9V battery and the purpose of using a rechargeable battery is to avoid
wastage. If the battery is weak, they do not need to buy a new battery as they can just only
charge the battery and reuse it back for a long term. If the other electrical components does
not working it means that there are no current flows through the circuit or block models due
to low power supply from the battery and also maybe the installations of the battery block
might be wrong.
Lastly, for the single block, there were no components will be install in the single block as it
works to connect the circuit or block models together so that the current can still be flow in it.
If users want to take out the LED blocks, LCD blocks, motor blocks, trigger block, sound
block or LCD block when they do not want to use it in the circuit or block models they can
just replace it with a single blocks. The circuit or block models cannot have an empty space
that was not connected with any components as it will stop the current flows into the whole
circuit or block models.
3.I.5 STRESS ANALYSIS
3.I.5.1 Simple Circuit
Table 2 Result Analysis for Simple Circuit Stress Analysis

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Figure 3.15 Von Mises Stress

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Figure 3.17 1st Principle Stress

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Figure 3.19 3rd Principle Stress

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Figure 3.21 Displacement

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Figure 3.23 Safety Factor

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Figure 3.25 Stress at XX-axis

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Figure 3.27 Stress at XY-axis

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Figure 3.28 Stress at XY-axis

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Figure 3.29 Stress at XZ-axis

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Figure 3.31 Stress at YY-axis

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Figure 3.33 Stress at YZ-axis

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Figure 3.35 Stress at ZZ-axis

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Figure 3.37 X Displacement

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Figure 3.39 Y Displacement

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Figure 3.41 Z Displacement

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Figure 3.43 Equivalent Strain

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Figure 3.45 1st Principle Strain

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Figure 3.47 Strain XX

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Figure 3.49 Strain XY

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Figure 3.50 Strain XZ

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Figure 3.51 Strain YY

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Figure 3.53 Strain YZ

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Figure 3.55 Contact Pressure

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Figure 3.57 Contact Pressure X

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Figure 3.58 Contact Pressure Y

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Figure 3.59 Contact Pressure Z

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3.I.5.2 Car Model
Table 3 Result Summary of Stress Analysis for Car Model

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Figure 3.80 1st Principle Strain

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Figure 3.81 3rd Principle Strain
Figure 3.82 3rd Principle Strain

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Figure 3.84 Strain XY

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Figure 3.88 Strain YZ

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Figure 3.89 Strain ZZ
Figure 3.90 Strain ZZ

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Figure 3.92 Contract Pressure X

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3.I.5.3 Discussion for Stress Analysis
The stress analysis report that has been generate from the Autodesk Inventor software is
important as it is helps our group to understand how our design will performs under certain
conditions. Based on the result summary for our simple circuit and car model design, the
simple circuit if 100Mpa Von Mises stress were applied on the simple circuit the minimum
stress will be around 0.00000341567 MPa and the maximum stress will be around 4.70734
MPa. For the car model, if 100MPa of Von Mises stress were applied, the minimum stress
will be 0.0000000010087MPa and the maximum stress will be 0.0853689 MPa. The Von
Mises stress value is to estimate the yield failure criteria for both materials used to find the
fatigue strength calculations.
From this report we also can see the stress and strain of our design at every 3D axis if load
were applied on it. For our simple circuit and car models, the have their own stress limit
depends to the material that we used in making the MISLI blocks, which are presented as the
material yield or ultimate tensile strength. The factors safety that shows in the stress analysis
report shows out the areas of potential yield. Equivalent stress results shows in red is the
highest area of stress. If maximum expected load applied repeatedly at the red areas there are
possibility that our design will perform failure.
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CHAPTER I
DESIGN CONCEPT
4.I.1 Final Design
4.I.1.1 Car Model
a. 2D DRAWING
Figure 4.96 Car Model 2D Drawing

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b. 3D DRAWING
Figure 4.97 Car Model 3D Drawing

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c. EXPLODED VIEW
Figure 4.98 Car Model Exploded View

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4.I.1.2 Simple Circuit Model
a. 2D DRAWING
Figure 4.99 Simple Circuit Model 2D Drawing

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b. 3D DRAWING
Figure 4.100 Simple Circuit Model 3D Drawing

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c. EXPLODED DRAWING
Figure 4.101 Simple Circuit Model Exploded View

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4.I.2 DESIGN OF KEY COMPONENTS
4.I.2.1 Motor Block
a. 2D DRAWING
Figure 4.102 Motor Block 2D Drawing

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b. 3D DRAWING
Figure 4.103 Motor Block 3D Drawing

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c. EXPLODED VIEW
Figure 4.104 Motor Block Exploded View

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d. MOTOR BLOCK COMPONENTS
i. 6V DC MOTOR
Figure 4.105 6V DC Motor Drawing

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ii. MOTOR BLOCK MAIN BODY
Figure 4.106 Motor Block Main Body Drawing

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iii. MOTOR BLOCK SIDE BODY
Figure 4.107 Motor Block Side Body Drawing

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iv. MOTOR BLOCK FRONT CIRCLE
Figure 4.108 Motor Block Front Circle Drawing
e. Components of Design
i. Calculating Initial Power Requirements
DC motors are transducers because they convert electrical power (P in) into mechanical power
(Pout). The quotient of both terms equates to the efficiency of the motor. The frictional losses
and copper losses result in total power loss (P loss) in Joules/sec (Iron losses in coreless DC
motors are negligible). There are additional losses due to heat rise, but we will discuss those
below:
In physics, power is defined as the rate of doing work. The standard metric unit of power is
the “Watt” W. How is power calculated? For linear motion, power is the product of force and
distance per unit time P = F · (d/t). Since speed is distance over time, the equation becomes P
= F · s. In the case of rotational motion, the analogous calculation for power is the product of
torque and angular distance per unit time or simply the product of torque and angular speed.
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Where:
P = Power in W
M = Torque in Nm
F = Force in N
d = Distance in m
t = Time in s
ω rad = Angular Velocity in rad/s
The symbol used for torque is normally the lowercase Greek letter “τ”(tau) or sometimes just
the letter “T”. However, when it is called Moment of Force, it is commonly denoted by the
letter “M”.
European nomenclature often employs the lowercase letter “n” to represent speed about an
axis. Usually “n” is in units of revolutions per minute or rpm.
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Figure 4.109 Motor Mechanical Operation
It is important to consider units when calculating mechanical power. In calculating power, if

“n” (speed) is in min-1, then it must convert it to angular velocity in units of rad/s. This is
accomplished by multiplying the speed by a unit conversion factor of 2π/60. In addition, if
“M” (torque) is in mNm, then we must multiply it by 10-3 (divide by 1 000) to convert the
units to Nm for calculation purposes.
Where:
n = Speed in min-1
M = Torque in mNm
Given that it is necessary to determine the power of which a 6V DC motor in this project, it is
expected to deliver at cold operation with a torque load of 20gcm or 1.96 mNm at a speed of
10900 rpm. The product of the torque, speed, and the appropriate conversion factor is shown
below.
2π
Pmech =1.96 mNm∙ 10900 rpm∙ ( 60000 )=2.24 W
Calculation of initial power requirements is often used as a preliminary step in motor or gear
motor selection. If the mechanical output power required for a given application is known,
then the maximum or continuous power ratings for various motors can be examined to
determine which motors are possible candidates for use in the application.
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ii. Finding Motor Parameters Empirically
One commonly used method of plotting motor characteristics graphically is the use of torque-
speed curves. While the use of torque-speed curves is much more common in technical
literature for larger DC machines than it is for small, ironless core devices, the technique is
applicable in either case.
Normally, torque-speed curves are generated by plotting motor speed, motor current,
mechanical output power, and efficiency as functions of the motor torque. The following
discussion will describe the construction of a set of torque-speed curves for a typical DC
motor from a series of raw data measurements.
The 6V DC motor has a nominal voltage of 6 V. If we can have a few fundamental pieces of
laboratory equipment, we can measure the torque-speed curves for a dc motor at a specified
operating point.
Step 1: Measure Basic Parameters
Many parameters can be obtained directly by using a motion controller. Most controller
manufacturers offer software, which includes a trace recording function that plots voltage,
current, position, speed, etc. They can also provide an accurate snapshot of motor operation
in great details. This is probably the quickest method for obtaining the data to plot a torque-
speed curve, but it is not the only method.
If a controller with trace recording capability is not available, then we can also use some
basic lab equipment to characterize a motor under stall, nominal and no load conditions.
Using a voltage supply set to 6 V, run the motor unloaded and measure the rotational speed
using a non-contacting tachometer (a strobe, for instance). Also, measure the motor current
under this no-load condition. A current probe is ideal for this measurement since it does not
add resistance in series with the operating motor. Using an adjustable torque load such as a
small particle brake or an adjustable hysteresis dynamometer, a load can be coupled to the
motor shaft.
Now increase the torque to the motor just to the point where stall occurs. At stall, measure the
torque from the brake and the motor current. For the sake of this discussion, assume that the
coupling adds no load to the motor and that the load from the brake does not include
unknown frictional components. It is also useful at this point to measure the terminal
resistance of the motor. Measure the resistance by contacting the motor terminals with an
ohmmeter. Then spin the motor shaft and take another measurement. The measurements
should be very close in value. Continue to spin the shaft and take at least three measurements.
This will ensure that the measurements were not taken at a point of minimum contact on the
commutator.
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Now we have measured the:
n0 = No-Load speed
I0 = No-Load current
MH = Stall Torque
R = Terminal Resistance
Step 2: Plot Current vs. Torque and Speed vs. Torque
By prepare a graph with motor torque on the abscissa (horizontal axis), speed on the left-side
ordinate (vertical axis), and current on the right-side ordinate. Scale the axes based on the
measurements we took in step one. Draw a straight line from the left origin of the graph (zero
torque and zero current) to the stall current on the right-side ordinate (stall torque and stall
current). This line represents a plot of the motor current as a function of the motor torque.
The slope of this line is the current constant kI which is the proportionality constant for the
relationship between motor current and motor torque (in units of current per unit torque or
A/mNm). The reciprocal of this slope is the torque constant kM (in units of torque per unit
current or mNm/A).
Where:
kI = Current constant
kM= Torque constant
For the purpose of this discussion, it will be assumed that the motor has no internal friction.
In practice, the motor friction torque MR is determined multiplying the torque constant kM of
the motor and the measured no-load current I0. The torque vs. speed line and the torque vs.
current line are then started not at the left vertical axis, but at an offset on the horizontal axis
equal to the calculated friction torque.
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Where:
MR = Friction Torque
Step 3: Plot Power vs. Torque and Efficiency vs. Torque
In most cases, two additional vertical axes can be added for plotting power and efficiency as
functions of torque. A second vertical axis is usually used for efficiency and a third vertical
axis can be used for power. For the sake of simplifying this discussion, efficiency vs. torque
and power vs. torque will be plotted on the same graph as the speed vs. torque and current vs.
torque plots (example shown below).
Construct a table of the motor mechanical power at various points from no-load to stall
torque. Since mechanical power output is simply the product of torque and speed with a
correction factor for units (see section on calculating initial power requirements), power can
be calculated using the previously plotted line for speed vs. torque.
A sample table of calculations for motor 2668W024CR is shown in Table 1. Each calculated
point for power is then plotted. The resulting function is a parabolic curve as shown below in
Graph 1. The maximum mechanical power occurs at approximately one-half of the stall
torque. The speed at this point is approximately onehalf of the no-load speed.
Construct a table on a spreadsheet of the motor efficiency at various points from no-load
speed to the stall torque. The voltage applied to the motor is given, and the current at various
levels of torque has been plotted. The product of the motor current and the applied voltage is
the power input to the motor. At each point selected for calculation, the efficiency η of the
motor is the mechanical power output divided by the electrical power input. Maximum
efficiency occurs at about 10% of the motor stall torque.
Plot definitions
Blue = Speed vs. Torque (n vs. M)
Red = Current vs. Torque (I vs. M)
Green = Efficiency vs. Torque (η vs. M)

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Brown = Power vs. Torque (P vs. M)
Figure 4.110 Characteristic curves of Motor
Note: Dotted lines represent values that might be plotted from a cold motor (no temperature
rise), however the solid lines account for the effects of magnet and coil heating on a warm
motor (more on this later). Note how all four solid plots change as a result of increased
resistance in the copper windings and weakened torque output, due to heat rise. So the results
may differ slightly depending on whether the motor is cold or warm when we plot our graphs.
iii. Calculating Motor Parameters Theoretically
Another useful parameter in motor sizing is the motor constant. Utilizing this figure of merit
properly will substantially reduce the iterative process in selecting a DC motor. It simply
measures a transducer’s intrinsic ability to transform electrical power to mechanical.
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Maximum efficiency occurs at about 10% of the motor stall torque. The denominator is
known as the resistive power loss. With some algebraic manipulation, the equation can be
simplified to:
Please keep in mind that km (motor constant), shouldn’t be confused with kM (torque

constant). Note that the motor constant subscript is a lowercase “m” while the torque constant
subscript utilizes an uppercase “M”.
For a brush or brushless DC motor of relatively small size, the relationships that govern the
behavior of the motor in various circumstances can be derived from the laws of physics and
the characteristics of the motors themselves. Kirchoff’s voltage rule states, “The sum of the
potential increases in a circuit loop must equal the sum of the potential decreases.” When
applied to a DC motor connected in series with a DC power source, Kirchoff’s voltage rule
can be expressed as “The nominal supply voltage from the power source must be equal in
magnitude to the sum of the voltage drop across the resistance of the windings and the Back-
EMF generated by the motor.”
Where:
U = Power supply in V
I = Current in A
R = Terminal resistance in Ω
UE= Back-EMF in V
The Back-EMF generated by the motor is directly proportional to the angular velocity of the
motor. The proportionality constant is the Back-EMF constant of the motor.
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Where:
ω = Angular velocity of the motor
kE = Back-EMF constant of the motor
Therefore, by substitution:
The Back-EMF constant of the motor is usually specified by the motor manufacturer in
V/rpm or mV/rpm. In order to arrive at a meaningful value for the Back-EMF, it is necessary
to specify the motor velocity in units compatible with the specified Back-EMF constant.
“The sum of the potential increases in a circuit loop must equal the sum of the potential
decreases.”
(Kirchoff’s voltage rule)
The motor constant is a function of the coil design and the strength and direction of the flux
lines in the air gap. Although it can be shown that the three motor constants normally
specified (back EMF constant, torque constant, and speed constant) are equal if the proper
units are used, calculation is facilitated by the specification of three constants in the
commonly accepted units.
The torque produced by the rotor is directly proportional to the current in the armature
windings. The proportionality constant is the torque constant of the motor.
Where:
Mm= Torque developed at motor
kM = Motor torque constant
Substituting this ratio for current yields:

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The torque developed at the rotor is equal to the friction torque of the motor plus the load
torque ( due to external mechanical loading):
Where:
MR= Motor friction torque
ML = Load torque
Assuming that a constant voltage is applied to the motor terminals, the motor velocity will be
directly proportional to sum of the friction torque and the load torque. The constant of
proportionality is the slope of the torque-speed curve. Motor performance is better when this
slope is a smaller number. The steeper the drop in slope, the poorer the performance one can
expect from a given coreless motor. This ratio can be calculated by:
Where:
Δn = Change in speed
ΔM = Change in torque
MH= Stall torque
n0 = No-Load speed
An alternative approach to deriving this value is to solve for speed, n:
Using Calculus, we differentiate both sides with respect to M, which yields:
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or
Although we are not showing a negative sign here, it is implied that the result will yield a
declining (negative) slope.
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4.I.2.2 Lcd Screen Block
a. 2D DRAWING
Figure 4.111 LCD Screen Block 2D Drawing

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b. 3D DRAWING
Figure 4.112 LCD Screen Block 3D Drawing

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c. EXPLODED VIEW
Figure 4.113 LCD Screen Block Exploded View

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d. LCD SCREEN BLOCK COMPONENTS
i. LCD SCREEN BLOCK MAIN BODY
Figure 4.114 LCD Screen Block Main Body Drawing

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ii. LCD SCREEN BLOCK BOTTOM COVER
Figure 4.115 LCD Screen Block Bottom Cover Drawing

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iii. HC05 BLUETOOTH MODULE
Figure 4.116 HC05 Bluetooth Module Drawing

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iv. ARDUINO UNO
Figure 4.117 Arduino Uno Drawing

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v. IPHONE 5
Figure 4.118 IPHONE 5 Drawing

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i. Circuit Diagram And Connection
The circuit diagram of the LCD screen block using bluetooth and Arduino uno is given
below.
Figure 4.119 Circuit diagram of the LCD screen block
It is built around arduino uno board, iphone 5 lcd display & hc-05 bluetooth module.
The circuit can be operated using a battery block by MISLI block. HC 05 works on serial
communication. The Android app is designed to send serial data to the Arduino Bluetooth
module when a button is pressed on the app. The Arduino Bluetooth module at the other end
receives the data and sends it to the Arduino through the TX pin of the Bluetooth module
(connected to RX pin of Arduino). The code uploaded to the Arduino checks the received
data and compares it.
ii. HC05 Bluetooth Module
The HC-05 is a very cool module which can add two-way (full-duplex) wireless functionality
to the projects. By using this module to communicate between two microcontrollers like
Arduino or communicate with any device with Bluetooth functionality like a Phone or
Laptop. There are many android applications that are already available which makes this
process a lot easier. The module communicates with the help of USART at 9600 baud rate
hence it is easy to interface with any microcontroller that supports USART. We can also
configure the default values of the module by using the command mode. So if look for a
Wireless module that could transfer data from computer or mobile phone to microcontroller
or vice versa then this module might be the right choice.
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The HC-05 has two operating modes, one is the Data mode in which it can send and receive
data from other Bluetooth devices and the other is the AT Command mode where the default
device settings can be changed. We can operate the device in either of these two modes by
using the key pin as explained in the pin description.
It is very easy to pair the HC-05 module with microcontrollers because it operates using the
Serial Port Protocol (SPP). Simply power the module with +5V and connect the Rx pin of the
module to the Tx of MCU and Tx pin of module to Rx of MCU as shown in the figure below
Figure 4.120 HC05 Bluetooth Module
During power up the key pin can be grounded to enter into Command mode, if left free it will
by default enter into the data mode. As soon as the module is powered we should be able to
discover the Bluetooth device as “HC-05” then connect with it using the default password
1234 and start communicating with it. The name password and other default parameters can
be changed by entering into the AT command mode.
f. Arduino uno
Arduino Uno is a microcontroller board based on the ATmega328P (datasheet ).

(Arduino,2021) It has 14 digital input/output pins (of which 6 can be used as PWM
outputs), 6 analog inputs, a 16 MHz ceramic resonator (CSTCE16M0V53-R0), a
USB connection, a power jack, an ICSP header and a reset button. It contains
everything needed to support the microcontroller; simply connect it to a computer
with a USB cable or power it with a AC-to-DC adapter or battery to get started. We
can tinker with our Uno without worrying too much about doing something wrong,
worst case scenario you can replace the chip for a few dollars and start over again.

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"Uno" means one in Italian and was chosen to mark the release of Arduino Software
(IDE) 1.0. The Uno board and version 1.0 of Arduino Software (IDE) were the
reference versions of Arduino, now evolved to newer releases. The Uno board is the
first in a series of USB Arduino boards, and the reference model for the Arduino
platform; for an extensive list of current, past or outdated boards see the Arduino
index of boards.
Table 4 Technical specification of Arduino Uno
Microcontroller ATmega328P
Operating Voltage 5V
Input Voltage (recommended) 7-12V
Input Voltage (limit) 6-20V
Digital I/O Pins 14 (of which 6 provide PWM output)
PWM Digital I/O Pins 6
Analog Input Pins 6
DC Current per I/O Pin 20 mA
DC Current for 3.3V Pin 50 mA
32 KB (ATmega328P) of which 0.5 KB used by

Flash Memory
bootloader
SRAM 2 KB (ATmega328P)
EEPROM 1 KB (ATmega328P)
Clock Speed 16 MHz
LED_BUILTIN 13
Length 68.6 mm
Width 53.4 mm
Weight 25 g
120
The Arduino Uno can be programmed with the (Arduino Software (IDE)). Select "Arduino
Uno from the Tools > Board menu (according to the microcontroller on your board).
The ATmega328 on the Arduino Uno comes preprogrammed with a bootloader that allows
us to upload new code to it without the use of an external hardware programmer. It
communicates using the original STK500 protocol (reference , C header files ).
We can also bypass the bootloader and program the microcontroller through the ICSP (In-
Circuit Serial Programming) header using Arduino ISP or similar.
The ATmega16U2 (or 8U2 in the rev1 and rev2 boards) firmware source code is available in
the Arduino repository. The ATmega16U2/8U2 is loaded with a DFU bootloader, which can
be activated by: (Arduino,2021)
 On Rev1 boards: connecting the solder jumper on the back of the board (near
the map of Italy) and then rese ing the 8U2.
 On Rev2 or later boards: there is a resistor that pulling the 8U2/16U2 HWB
line to ground, making it easier to put into DFU mode.

We can then use Atmel's FLIP software (Windows) or the DFU programmer (Mac

OS X and Linux) to load a new firmware. Or use the ISP header with an external
programmer (overwriting the DFU bootloader).

121
4.I.2.3 SINGLE BLOCK
a. 2D DRAWING
Figure 4.121 Single Block 2D Drawing

122
b. 3D DRAWING
Figure 4.122 Single Block 3D Drawing

123
c. EXPLODED VIEW
Figure 4.123 Single Block Exploded View

124
d. SINGLE BLOCK COMPONENTS
i. CONNECTOR MAIN BODY
Figure 4.124 Connector Main Body Drawing

125
ii. CONNECTOR BOTTOM COVER
Figure 4.125 Connector Bottom Cover Drawing

126
4.I.2.4 Battery Block
a. 2D Drawing
Figure 4.126 Battery Block 2D Drawing

127
b. 3D Drawing
Figure 4.127 Battery Block 3D Drawing
c. Exploded View
8 7 6 5 4 3 2 1
D D
PARTS LIST
ITEM QTY PART NUMBER
1 1 Battery Body Block
2 1 6V Battery Cell
C 3 1 Battery Close Block C
3
B B
DRAWN
MUHAMMAD ALIF IQRA1K6/1/2021
CH E CK ED
A QA
TITLE
A
MFG
EXPLODED BATTERY BLOCK
EXPLODED VIEW APPROVED
SIZE DWG NO REV
SCALE 3 : 1 D BATTERY ASSEMBLY. LABEL

SCALE
3 : 1 SHEET 1 OF 1
8 7 6 5 4 3 2 1
128
d. Battery Block Components
i. Battery Block Main Body
2 1
38.00
Ø 4 .8 0
Ø 6.50
B B
9 4 .0 0
9 3 .5 0
4 0 .0 0
2 .5 0
1 5 .0 0
3 5 .0 0 8.00
A A
2 .0 0
.5 0
2 .5 0 1 .5 0
9 5 .0 0
2 1
Figure 4.128 Battery Block Main Body

129
ii. Battery Block Cover
2 1
2 .5 0
B B
7 .0 0
35.00
2 .5 0
3 .0 0
A A
1 5 .0 0
4 .0 0
2 1
Figure 4.129 Battery Block Cover

130
iii. Battery
2 1
B B
8 8 .0 0
2 8 .3 0
A A
3 .7 0
3 2 .0 0
88.00
2 1
Figure 4.130 Battery Drawing
e. Components of design
i. Energy Calculations
Energy is the amount of work done. SI Units of energy are Joules repre- sented
by ’J’. Since the Power Monitor is very sensitive and it generates 5000 samples
per second, the log files of huge size are dealt with using a code written in Perl.
File name, start time and end time are applied as input parameters to the Perl
code during execution. The cummulative value of energy consumption of a
specific test case is measured by
131
n Σ
Te
E= P
i
n
i=1
Pi = P1 + P2 + · · · + Pn
Pn = Power consumed during ’n’th sample.
Te = Time over which the energy needs to be calculated.
= Tend − Tstart
n = Number of samples generated over the time period.
The average value and standard deviations of energy and time are calculated
using the formulae
1 Σk
= E
E avg k
i
i= 1
1 Σk
T avg = T e,i
k i= 1
‚
k
. 1 Σ
E std = , (E i − E avg )2
k − 1
i= 1
‚
T std = ., 1
k Σ
(T − T )2
e ,i avg
k − 1 i= 1
132
ii. Formulas and Definitions
Single Battery
The following formula shows the relationship between the current drawn from the battery, its
capacity, and C-rate:
or
where
Ibat is the current in amperes drawn from the battery,
Cbat is the rated capacity of the battery in amperes-hours (means amperes times hours), which
is usually marked on the battery, and
Crate is the battery C-rate, which is defined as the discharge current divided by the theoretical
current draw at which the battery would deliver its rated capacity in one hour.
The run time t and C-rate are inversely proportional:
or
Note that it is a theoretical run time. Because of various external factors, the real run time
will be about 30% less than calculated using this formula. It should also be noted that the
allowed depth of discharge (DOD) of the battery further limits its operating time.
The rated energy in watt-hours stored in a battery is calculated using the following formula:
where
Ebat is the rated energy stored in the battery in watt-hours,
Vbat is the rated voltage of the battery in volts, and
Cbat is the rated capacity of the battery in Ah.

133
The energy in joules, which are watts-seconds, is calculated as follows:
We know that one ampere flowing in a wire for one second will use 1 coulomb of charge.
Therefore, the charge in the battery is defined from Q = I · t from the known capacity in Ah,
which is the current a battery can provide for 3600 seconds:
where
Qbat is the charge in a battery in coulombs (C) and
Cbat is the rated capacity of the battery in amperes-hours.
Battery Bank
The rated voltage in volts of the battery bank is determined as
where
Vbat is the rated voltage of the battery in volts,
Vbank is the rated voltage of the battery bank, and
Ns is the number of batteries in one or several series sets.
The capacity in ampere-hours of the battery bank, Cbank is determined as
The rated energy in watt-hours stored in the bank Ebank is determined as
where
Ebat is the rated energy stored in one battery,
Ns is the number of batteries in a series set, and
Np is the number of batteries connected in series in a parallel set.
The energy in joules is calculated as follows:
where Ebank, Wh is the rated energy in Wh stored in the bank.

134
The charge in coulombs in the bank, Qbank is determined the sum of charges of all batteries in
the bank:
The discharge current of the bank, Ibank is calculated as
The run time of the bank tbank is determined as
Li‐ion batteries, as one of the most advanced rechargeable batteries, are attracting much
attention in the past few decades. They are currently the dominant mobile power sources for
portable electronic devices, exclusively used in cell phones and laptop computers. Li‐ion
batteries are considered the powerhouse for the personal digital electronic revolution starting
from about two decades ago, roughly at the same time when Li‐ion batteries were
commercialized. As one may has already noticed from his/her daily life, the increasing
functionality of mobile electronics always demand for better Li‐ion batteries. For example, to
charge the cell phone with increasing functionalities less frequently as the current phone will
improve quality of one's life. Another important expanding market for Li‐ion batteries is
electric and hybrid vehicles, which require next‐generation Li‐ion batteries with not only high
power, high capacity, high charging rate, long life, but also dramatically improved safety
performance and low cost. In the USA, Obama administration has set a very ambitious goal
to have one million plug‐in hybrid vehicles on the road by 2015. There are similar plans
around the word in promotion of electric and hybrid vehicles as well. The Foreign Policy
magazine even published an article entitled “The great battery race” to highlight the
worldwide interest in Li‐ion batteries.
The demand for Li‐ion batteries increases rapidly, especially with the demand from electric‐
powered vehicles. It is expected that nearly 100 GW hours of Li‐ion batteries are required to
meet the needs from consumer use and electric‐powered vehicles with the later takes about
50% of Li‐ion battery sale by 2018. Furthermore, Li‐ion batteries will also be employed to
buffer the intermittent and fluctuating green energy supply from renewable resources, such as
solar and wind, to smooth the difference between energy supply and demand. For example,
extra solar energy generated during the day time can be stored in Li‐ion batteries that will
supply energy at night when sun light is not available. Large‐scale Li‐ion batteries for grid
application will require next‐generation batteries to be produced at low cost. Another
important aspect of Li‐ion batteries is related to battery safety. The recent fire on two Boeing
787 Dreamliner associated with Li‐ion batteries once again highlights the critical importance
of battery safety. This will trigger another wave of extensive research and development to
enhance safety of Li‐ion batteries, beyond pursuing high‐energy density. In this tutorial
review, I will try not to have a comprehensive coverage due to the limited scope, but instead I
will highlight the basics, progress, and challenges regarding Li‐ion batteries.
135
Figure 4.131 Demand for Li‐ion batteries in two decades. Reproduced with permission.
Li‐ion batteries are highly advanced as compared to other commercial rechargeable batteries, in terms of
gravimetric and volumetric energy. Figure compares the energy densities of different commercial rechargeable
batteries, which clearly shows the superiority of the Li‐ion batteries as compared to other batteries. Although
lithium metal batteries have even higher theoretical energy densities than that of Li ‐ion batteries, their poor
rechargeability and susceptibility to misuses leading to fire even explosion are known disadvantages. I anticipate
that lithium metal batteries based on solid‐state electrolytes with enhanced safety will be commercialized in the
next decade. Recently, lithium‐air and lithium‐sulfur batteries regain wide interest, although the concepts have
been proposed for a while. Promising progress has been achieved regarding Li‐air and Li‐sulfur batteries, but it
may take another two decades to fully develop those technologies to achieve reliable performances that will be
comparable to Li‐ion batteries. It is expected that Li‐ion batteries will still be dominant in rechargeable battery
market, at least for the next decade, for advantages they offer. Li‐ion batteries are design flexible. They can be
formed into a wide variety of shapes and sizes, so as to efficiently fit the available space in the devices they
power. Li‐ion batteries do not suffer from the problem of memory effect, in contrast to Ni‐Cd batteries. Li‐ion
batteries have voltages nearly three times the values of typical Ni‐based batteries. The high single‐cell voltage
would reduce the number of cells required in a battery module or pack with a set output voltage and reduce the
need for associated hardware, which can enhance reliability and weight savings of the battery module or pack
due to parts reduction. The self‐discharge rate is very low in Li‐ion batteries – a typical figure is <5% per month
136
which compares very favorably to 20–30% of Ni‐based batteries.
Figure 4.132 Comparison of energy densities and specific energy of different rechargeable
batteries. Reproduced with permission 6.
Basics of Li‐Ion Batteries
A Li‐ion battery is constructed by connected basic Li‐ion cells in parallel (to increase
current), in series (to increase voltage) or combined configurations. Multiple battery cells can
be integrated into a module. Multiple modules can be intergrade into a battery pack. For
example, the 85 kWh battery pack in a typical Tesla car contains 7104 cells. Typically, a
basic Li‐ion cell consists of a cathode (positive electrode) and an anode (negative electrode)
which are contacted by an electrolyte containing lithium ions. The electrodes are isolated
from each other by a separator, typically microporous polymer membrane, which allows the
exchange of lithium ions between the two electrodes but not electrons. In addition to liquid
electrolyte, polymer, gel, and ceramic electrolyte have also been explored for applications in
Li‐ion batteries. Figure illustrates the basic operating principle of a typical Li‐ion battery cell.
The basic design of Li‐ion cells today is still the same as those cells Sony commercialized
two decades age, although various kinds of electrode materials, electrolyte, and separators
have been explored.
137
Figure 4.133 Illustration to show the basic components and operation principle of a Li‐ion
cell. Reproduced with permission.
The commercial cells are typically assembled in discharged state. The discharged cathode
materials (e.g., LiCoO2, LiFePO4) and anode materials (e.g., carbon) are stable in atmosphere
and can be easily handled in industrial practices. Yohsino made a significant contribution to
the commercial production of Li‐ion batteries by using discharged electrode materials in full
cells for the first time. During charging process, the two electrodes are connected externally
to an external electrical supply. The electrons are forced to be released at the cathode and
move externally to the anode. Simultaneously the lithium ions move in the same direction,
but internally, from cathode to anode via the electrolyte. In this way the external energy are
electrochemically stored in the battery in the form of chemical energy in the anode and
cathode materials with different chemical potentials. The opposite occurs during discharging
process: electrons move from anode to the cathode through the external load to do the work
and Li ions move from anode to the cathode in the electrolyte. This is also known as “shuttle
chair” mechanism, where the Li ions shuttle between the anode and cathodes during charge
and discharge cycles.
Electrochemical reactions at the two electrodes released the stored chemical energy. The total
Gibbs free energy change due to the electrochemical reactions on the two electrodes is
138
determined by the electrode materials selected. Given the overall electrochemical reaction
and charges transferred, one can estimate the theoretical cell voltage (∆E = −∆G/nF). The
performance of Li‐ion batteries can be evaluated by a number of parameters, such as specific
energy, volumetric energy, specific capacity, cyclability, safety, abuse tolerance, and the
dis/charging rate. Specific energy (Wh/kg) measures the amount of energy that can be stored
and released per unit mass of the battery. It can be obtained by multiplying the specific
capacity (Ah/kg) with operating battery voltage (V). Specific capacity measures the amount
of charge that can be reversibly stored per unit mass. It is closely related to number of
electrons released from electrochemical reactions and the atomic weight of the host.
Cyclability measures the reversibility of the Li‐ion insertion and extraction processes, in
terms of the number of charge and discharge cycles before the battery loses energy
significantly or can no longer sustain function of the device it powers. Practically, the cycle
life of Li‐ion batteries is affected by depth of discharge (DOD) and state of charge (SOC), as
well as operating temperature, in addition to the battery chemistry. Cycle life is enhanced
with shallow DOD cycles and less SOC swing, and avoiding elevated temperature. Li
dendrite formation on graphite anode can occur at low‐temperature charge which should be
avoided. Safety requirement is very high for Li‐ion batteries with multiple cells. Battery
management systems (BMS) are typically employed in battery cells/packs/modules to prevent
any possible thermal runaway. For example, in the case of battery cell failure inside a battery
pack, the BMS could detect and isolate the particular cell.
Abuse tolerance is a critical requirement for practical application of Li‐ion batteries,

especially in electric vehicles. Typically, mechanical, thermal, and electrical abuse
evaluations are carried out on prototypes to evaluate abuse tolerance of the batteries. The
mechanical abuse evaluation includes mechanical shock and drop, roll‐over, nail penetration,
and immersion in water tests. The thermal abuse evaluation includes radiant heat, thermal
stability, overheat, and extreme cold tests. The electrical abuse evaluation includes short
circuit, overcharge, over‐discharge, and alternative current exposure tests. Those abuse
tolerance tests are extremely important for their applications in electric vehicles, as electric
vehicles are expected to compete with existing internal combustion engineer‐powered
vehicles that run well in rough conditions. The rate of charge or discharge measures how fast
the battery can be charged and discharged, typically called C‐rate. At 1 C, the battery is fully
discharged releasing maximum capacity in 1 h. Common Li‐ion batteries with carbonaceous
anodes used in personal mobile devices take 1–4 h to return to the fully charged state. Li‐ion
batteries used in electric vehicles may take even longer, for example, overnight, to get fully
charged, although it could be quickly charged to certain low SOC at high current with special
charging devices. One of the active research directions in Li‐ion battery community is to
increase the rate performance so that the time consumed for charging a battery can be
dramatically reduced, which is particularly crucial to the market acceptance of electric
vehicles.
Theoretical capacity of active electrode materials can be estimated based on electrochemical

reactions involved. For example, electrochemical reaction for the anode of graphite that can
intercalate reversibly with lithium to form LiC6, the reaction is
(1)
139
The theoretical specific capacity (mAh/g) of anode graphite can be estimated as the
following:
where x is number of electrons transferred in reaction (1), F = 96485 C/mol is Faraday's

constant, n is number of moles of a chosen electroactive component that take place in the
reaction, and M is the molecular weight of the same electroactive component.
The cathode reaction for LiCoO2, with 0.5 as the practical number of electrons transferred, is
(2)
The theoretical specific capacity can be estimated similarly
In practice, to evaluate specific capacity of a Li‐ion battery cell, one not only has to take into
consideration of the integration of cathode and anode materials but also other essential
components, such as binders, conductive enhancers, separators, electrolyte, current collectors,
case, tabs, as well as battery management systems (BMS). Therefore, the practical energy
density is always less than that estimated based the battery chemistry.
Progress in Li‐Ion Batteries
Since the commercialization of Li‐ion batteries by Sony, Li‐ion batteries have been attracting
much attention world widely. The global production of Li‐ion batteries continuously increase
in the past two decades, especially with popularity of personal mobile electronics devices,
such as mobile phones and personal computers, and electric vehicles. Although Li‐ion
batteries are highly successful commercially, there are still noticeable disadvantages. The
cost of Li‐ion batteries based on per unit of energy stored ($/kWh) is still very high, although
the price was decreasing over the past two decades. The Li‐ion battery packs for electric
vehicles could cost about $600/kWh, and it is anticipated that the cost could be reduced to
about $200/kWh by 2020. In contrast, the average retail price of electricity to customers is
about 0.1 $/kWh in 2014 according to the U.S. Energy Information Administration. The
performances of Li‐ion batteries degrade at high temperature. At the same time, it may not be
safe if rapidly charged at low temperature. Therefore, protective circuits are typically used
avoid overcharge and thermal runaway. However, the protective circuits could add weight
burdens and decrease energy density of the whole batteries. Another disadvantage is the
possible venting and fire when crushed, which requires critical safety enhancement. The
recent accidents of fires in Li‐ion battery packs upon crushed by metal objects in the
promising Tesla Model S cars highlights the importance of battery safety. Therefore, active
140
research is continuing in all aspects of batteries, from anode, cathode, separator, electrolyte,
safety, thermal control, packaging, to cell construction and battery management. The
electrode materials selected are critical to the performances of Li‐ion batteries, as they
generally determine cell voltage, capacity, and cyclability. There are a number of potential
alternative electrode materials to replace carbon‐based anodes and LiCoO2‐based cathodes.
Composite alloys, Si, Sn‐based materials and 3d‐metal oxides materials have relatively
higher specific capacities than graphite. However, they suffer from severe volume expansion
during the process of lithiation, which causes the fracture of original structure upon lithium
extraction, leading to bad electrical contact between particles and current collectors and poor
cycling performance. Li metal has the issue of dendrite formation and is not safe as anode,
which explained the failed commercialization of the Exxon's lithium ion batteries in the 70s.
Given the high capacity of Li metal as anode, it should still be worthy for further exploration
and research should focus on depressing the dendrite formation issues. In terms of cathode
materials, a number of Co, Mn, Ni‐based layered and spinel materials have been explored
(mainly concentrated in the left upper corner of Fig). Recently, much effort is shifted to
polyanionic components, such as LiFePO4 and LiMnPO4. The main requirements for cathode
materials are high free energy of reaction with lithium, incorporating large quantities of
lithium and insoluble in electrolytes. Although various promising electrode materials have
been proposed, the slow lithium ion diffusivity, poor electronic conductivity and high cost are
limiting their practical applications.
Figure 4.134 Voltage versus capacity for positive‐ and negative electrode materials
presently used or under considerations for the next‐generation of Li‐ion batteries. Reproduced
with permission.
To address those issues associated with alternative electrode materials, recent efforts are to
employ nanostructured materials for Li‐ion batteries. It is generally believed that size and
shape tunable properties of those lithium‐active materials at nanoscale can offer additional
parameters for further optimization of their electrochemical performances. The fascinating
size‐shape‐related properties of nanomaterials bring new opportunities for a potential
breakthrough in the development of next‐generation Li‐ion materials. Nanostructured
141
electrode materials can offer various advantages not available in conventional bulk materials,
and are believed to be the material‐of‐choice for the next‐generation Li‐ion batteries.
However, nanomaterials bring along with new problems as will be discussed. In this tutorial
review, I will try to provide an introduction on four aspects of Li ‐ion batteries, including
cathode materials, anode materials, electrolyte, and separators, with emphasized on the
progress achieved and challenges faced in those areas. Battery management and monitoring
and optimization and cell integration are out of the scope of this review.
4.I.2.5 Trigger Block
a. 2D Drawing
Figure 4.135 Trigger Block 2D Drawing

142
b. 3D Drawing
Figure 4.136 Trigger Block 3D Drawing
c. Exploded View
Figure 4.137 Trigger Block Exploded View

143
d. Trigger Block Components
i. Trigger Block Main Body
Figure 4.138 Trigger Block Main Body Drawing

144
ii. Trigger Block Cover
Figure 4.139 Trigger Block Cover Drawing

145
iii. HC05 Bluetooth Module
Figure 4.140 HC05 Bluetooth Module
e. Components of design
i. Research
According to research done, Nick Day (Nick Day, 2010) proposed a system for users to vote
using their mobile phones. The system architecture consisted of:
 Mobile client application

 Server application
 Database back-end and web-based administration tool
 Graphical front-end
Based on this proposed architecture and recommendations given, the interactive Bluetooth
student voting system was modeled. Modeling of the system required several design
considerations in term of:
146
 Performance: Mobile phones have limited resources such as memory,

processing power and screen size. The mobile client would therefore be
a light-weight application
 Access Points: The University covers a very large area and it was
important to make use of access points where students can connect to
the server and download the questions. Bluetooth-enabled devices
(laptops) were chosen to act as access points which were all connected
to a LAN.
 Throughput: Bluetooth-enabled devices can only accept seven
 connections at a time, adequate number of access points have to be

provided to accommodate for a maximum number of students.
 Security: Wireless signal could be intercepted and therefore, encryption

mechanisms were considered for the Bluetooth communication
ii. Wireless Communication Technologies
Therefore, Bluetooth was chosen as the communication medium. Bluetooth is an open

wireless technology standard for exchanging data over short distances. It uses client server
architecture and operates within a range of 10 meters. Bluetooth can be implemented as a
multipoint communication medium, to allow multiple clients to simultaneously connect to a
single server device (Hopkins, B. and Antony, R. 2003).
Mobile Client Application
RhoMobile, MoSync, Java Me and .NET Compact Framework are different platforms for
developing the client application.
Table 2: Mobile Platforms
RhoMobil MoSync Java ME .NET

e
Framework
Language Ruby C/C++ Java Visual Basic
.Net and C#
Market Enterprise Consume Consumer Enterprise

Focus r and
Enterprise
147
and
Enterpris
e
Installer APK - JAD/JAR OTA

packagin
g options packaging packaging deployment
,
CAB files,
Active
Sync
RhoMobile make use of Rhodes which is an open source Ruby-based framework to rapidly
build native apps for all major Smartphone operating systems (iPhone, Windows Mobile,
RIM, Symbian and Android). Applications can be built quickly in HTML and Ruby. MoSync
makes it easy and cost efficient to develop mobile application for all the major platforms.
Using C++ and a set of powerful APIs, you can harness the full power of modern Smartphone
platforms while still supporting Java ME devices using a single codebase (Mosync, 2011).
Java ME is a java platform designed especially for the development of resource limited
devices such as mobile phones. Most mobiles and PDA’s are java enabled and run
applications developed on J2ME platform. Developers already familiar with any of the
languages supported by Microsoft Visual Studio such as Visual Basic
.Net and C# can easily migrate to a .NET Compact Framework mobile environment (Tometa
software, 2011). It offers greater processing speed than Java ME but implementation
processes are very much distinct in Java ME. The system was developed as 3-tier
architecture.
iii. Implementation And Testing
The mobile phone application was developed on Java ME platform which allowed the
application to run on all java enabled phones. For the development of the web administration
site EasyPHP was used which include the scripting language PHP, the web server Apache,
and the SQL server MySQL. The server application was developed using Java SE platform. It
will be run on different Bluetooth enabled laptops connected to a LAN which will act as
access points to retrieve the votes of student. The Graphical Front End has been developed
using PHP and will display dynamic information in the form of a bar chart. The system was
implemented as four different modules:
1. The web administration site: The web administration site will be used
to manage groups and questions.
2. The server application: The server application will only be seen by the
main user and system administrators. It outputs a log of all the events
happening with the date and time stamp to each activity.
148
3. The client application: To perform the voting.
4. The graphical front end: To display the results.
The Universal Unique Identifier (UUID) was used to uniquely identify a service which is
provided by the server. The url begins with btspp://localhost: , which is required if a
Bluetooth serial port profile is used (Oracle–Base, 2011). Encryption is set to true in order to
send data securely. The local device class will provide access to and control of the local
Bluetooth device. The discovery agent class provides method to set the local device into a
discoverable mode. The GIAC mode was used which stands for General/Unlimited Inquiry
Access Code (GIAC).
Since the Java SE does not have any JSR 82 (Java Api for Bluetooth), it is important to
import a JSR 82 library in order to develop the Bluetooth server. Bluecove which is an open
source java library for Bluetooth has been used to develop the server application (Bluecove,
2011). Since the system will be running on different PCs, Easyphp need to be configured to
allow remote access to the central server. Steps in discovering the device and search service
are detailed in the table below:
Table 5 Device and Service Discovery
Server Client
1. The server access the local 1. The client access the local device
device
2. The client then runs the
2. Local device is set into discovery agent that searches the
discoverable mode Bluetooth UUID
3. When set to discoverable mode 3. The agent reports the url that
GIAC (General Inquiry Access provide the service and the client
Code) is used, it means that connect to the url
everyone having the
application can access the 4. When the device is discovered
server the server then obtains that
remote device instance
4. The server passes the url as
parameter in Connector. Open 5. The client will search the
method which advertises the services which the server
Bluetooth UUID provides
5. Then the server wait for a
connection to occur
149
4.I.2.6 LED Block
a. 2D Drawing
Figure 4.141 LED Block 2D Drawing

150
b. 3D Drawing
Figure 4.142 LED Block 3D Drawing

151
c. Exploded Drawing
Figure 4.143 LED Block Exploded View

152
d. LED Block Components
i. Main LED Body
Figure 4.144 Main LED Body Drawing

153
ii. Aluminium Plate
Figure 4.145 Aluminium Plate Drawing

154
iii. 0.2W 2835 SMD LED
Figure 4.146 0.2W 2835 SMD LED Drawing

155
iv. Resistor
Figure 4.147 Resistor Drawing

156
v. Yellow Acrylic Round Plate
Figure 4.148 Yellow Acrylic Round Plate Drawing

157
4.I.2.7 Sound Block
a. 2D Drawing
Figure 4.149 Sound Block 2D Drawing

158
b. 3D Drawing
Figure 4.150 Sound Block 3D Drawing

159
c. Exploded Drawing
Figure 4.151 Sound Block Exploded View

160
d. Sound Block Components
i. Main Body
Figure 4.152 Main Body Drawing

161
ii. Aluminiuim Plate
Figure 4.153 Aluminium Plate Drawing

162
iii. HC05 Bluetooth Module
Figure 4.154 HC05 Bluetooth Module Drawing

163
iv. Speaker
Figure 4.155 Speaker Drawing
4.I.3 COMPARISON OF MATERIALS SELECTION
4.I.3.1 Motor Selection
When selecting a DC Motor for an application, or when developing a powered prototype,

there are several basic motor physics principles which must be considered to produce a safe,
well-functioning, sufficiently-powered precision drive system. In this project, we have
provided some important methods, formulas and calculation details to determine the power
output of a dc motor, the speed-torque curve of the motor, the current and efficiency plots,
and the theoretical cold calculations that estimate motor performance. DC motors come with
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a variety of specifcations, including RPM, no-load speed, maximum current load, and stall
torque. We decide to choose using 6V DC motor from old toys as our component for motor
blocks. This is because tons of toys dc motor is being disposed which cause pollution to our
environment. As United Nation sustainable development goals 12, responsible consumption
and production, we have to reduce the production by using e waste to invention a educational
kits that help introduce a better learning ways to young generations. We have doing motor
selection through DC motor specification, RPM, no-load speed, stall torque and maximum
current.
Figure 4.156 6V DC Motor 3D Drawing
RPM (Revolutions per minute)
RPM is one of the most important specifications of a DC motor. RPM, which stands for
revolutions per minute, is the amount of times the shaft of a DC motor completes a full spin
cycle per minute. A full spin cycle is when the shaft turns a full 360°. The amount of 360°
turns, or revolutions, a motor does in a minute is its RPM value. So a motor with an RPM of
9000 is much more high speed than a motor which has 9000RPM. RPM is important when
we need the motor to spin a certain number of times in a given time period. When speed is
important, RPM is a crucial factor to look over when choosing a motor. In certain high-speed
applications, it is imperative that motors that have high RPM are chosen. This may include
applications such as washing machines with high-speed rinse cycles, treadmills that reach
high speeds, and any such applications. Usually when the RPM value for a motor is specified,
it normally is given with the voltage that will make it make that amount of turns per minute,
such as 9000RPM @ 6V. Thus, the motor will spin 9000 times per minute when fed 6 volts
DC into it.
No-load Speed
The no-load speed of a DC motor is the speed that the DC motor will turn when nothing is
attached to its shaft. This is why it is called no load. The DC motor isn't loaded with an
object. When a DC motor has nothing attached to its shaft, it is able to operate at its highest
maximum speed. When it is then loaded with an object on its shaft, its speed will decrease.
This is because it now has to bear with the weight of an object on it. The no-load speed serves
as a reference to how fast the shaft of a motor will turn before weight is added to it. Thus, a
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circuit designer can have a frame of reference. The RPM value of a motor that will be
specified will normally be the no-load speed.
Stall Torque
Stall torque is the torque produced on a motor when the output rotational speed is zero. This
is why it is called the stall torque. It stalls the shaft of the motor, so that it longer spins and
has rotational motion. This occurs when the torque load is either equal to or greater than the
motor shaft torque. In this condition, the motor draws maximum current but does not rotate.
Electric motors are devices which continue to provide torque when stalled. It's the same as a
situation where a machinery is trying to lift up an object that is too heavy to lift. Though the
object can't be lifted because it's too heavy, the machinery is still exerting force on it (to try to
get it to lift up). This is the same with motors. If too much weight is applied to the shaft, more
load than it can handle, the motor will not be able to sufficiently rotate. So stall torque has to
do with the amount of weight a motor shaft can handle before it stalls. For this reason, stall
torque is specified as g∙cm. This is the amount of grams of weight that a motor shaft can
withstand per centimeter (cm) of its length. An example of a stall torque of a motor is 36
g∙cm. So the motor shaft has more than 36 g∙cm on its shaft, it will stall. Below this weight, it
will have more torque than the load and, thus, will be able to rotate. Stall torque is a very
important specification of a motor when weight on a shaft is important. If a circuit designer is
only going to put a lightweight object on the motor's shaft, it isn't such a concern. If the
designer is going to place a heavy item on the shaft, then it plays a huge role. The designer
must be able to know whether that motor can handle that type of weight and still rotate. For
motors spinning heavy objects, much more powerful motors must be used.
Maximum Current
The maximum current specification of a motor is the maximum amount of current that a
motor can withstand passing through it without being damaged or destroyed. So the
maximum current is a power restraint that circuit designer must make sure is not exceeded.
An example of a maximum current specification of a 6V DC motor is 70mA. This means the
motor cannot be fed more than 70mA.
As a conclusion, we choose the best DC motor which RPM, no-load speed, stall torque and
maximum current fits our selection. The specification is showed below and details calculation
in calculation section.
Table 6 DC Motor Specification

Technical Characteristic Details
Operating Temperature -10°C ~ +60°C
Rated Voltage 6.0V
Rated Load 10 g*cm
No-load Current 70 mA max

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No-load Speed 9100 ±1800 rpm
Loaded Current 250 mA max
Loaded Speed 4500 ±1500 rpm
Starting Torque 20 g*cm
Starting Voltage 2.0
Stall Current 500mA max
Body Size 27.5mm x 20mm x 15mm
Shaft Size 8mm x 2mm diameter
Weight 17.5 grams
Source: Digi-Key Electronics (2020)
4.I.3.2 LCD Screen Selection
Liquid Crystal Display (LCD)
When it comes to smartphone displays, there are two main types that are utilized; the first of
which is LCD and the another is AMELOD. LCD stands for Liquid Crystal Display. There
are four main layers to an LCD panel: there's the outer protective layer, the polarizing layer
(or layers), the liquid crystal layer and the backlight. The outer protective layer is basically
there to protect the other components from getting damaged, and it's usually made of clear
plastic or glass. The polarizing layers help the crystal layer deliver the correct light, or no
light when off or black, to our eyes.
The most important part is the liquid crystal layer, which is what controls the colors passed
through and ultimately the picture displayed. When an electrical current is passed through the
crystalline layer, liquid crystal cells coupled with filters of red, blue and green, corresponding
to the subpixels in the display, "twist" to let backlight through at different intensities. The
crystals filter the neutral back light into certain color intensities, and combined with
neighboring crystals of different colors, the full range of millions of colors is created.
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Figure 4.157 A basic diagram of a TFT LCD panel (TEAC,2000)
The backlighting layer is almost always LED backlight, and while there are different types of
LED backlighting the one used almost always is white LED backlighting. This is where thin
and solid white light-emitting diodes (LEDs) are placed behind the liquid crystal layer to
provide a base light for the crystals to modify. RGB LED backlighting also exists which
allows for better color reproduction, but this is more expensive and seldom used in
smartphones. This is a simplified explanation of how LCD panels work. LCDs that are used
in smartphones are all active matrix, which refers to the way the pixels are addressed, and
they are all also used TFT technology. TFT basically means thin-film transistor and its these
components that help with more accurate color reproduction, contrast and responsiveness.
Underneath the TFT banner there are a two different types we can get.
Twisted Nematic (TN) LCD
Twisted Nematic is a term that is rarely used by smartphone manufacturers, instead preferring
to call their displays simply "TFT LCD". It refers to the method in which crystal cells are
twisted in the display to reproduce the colors, and is most commonly used in cheaper
smartphone displays due to their ease of production. Compared to the other type of LCD, In-
Plane Switching (IPS), TN LCD panels have more limited viewing angles, contrast and color
reproduction, hence why they are generally used in cheaper devices. That said, your computer
monitor or (older) LCD TV is most likely going to be using a TN panel, so they are not
always bad, just there is better technology out there.
The best type of TN LCD panel available is the Sony/Samsung-made Super LCD, or S-LCD,
which has considerably better contrast levels and color reproduction compared to standard
TN panels. These types of displays started appearing in the HTC Desire as a replacement for
AMOLEDs when supply was short, and has since been superseded by Super LCD 2 displays.
In-Plane Switching (IPS) LCD

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IPS LCD panels use a more organized method of crystal cell twisting, which allows for a
better quality picture and so it's the preferred type of display for higher end smartphones. The
main advantages over TN panels is significantly better viewing angles and truer color
reproduction because the way the panel works reduces off-angle color shift. Modern
generation IPS panels also feature much better contrast ratios than TN panels, which makes
them (in some instances) comparable with AMOLED technology.
Most IPS panels used in smartphones are technically either Super IPS (S-IPS) or Advanced
Super IPS (AS-IPS), and in some cases proprietary technology that improves on different
aspects of IPS panels. Occasionally smartphone manufacturers will designate their panels as
"IPS LCD" or "TFT IPS LCD", but in other cases they will use a brand name such as those
listed below.
Retina , the term used for Apple's LG-manufactured IPS LCD panels with high pixel
densities, used since the iPhone 4 and 3rd-gen iPad. NOVA, LG's marketing term for their
IPS LCD panels that produce a brightness of 700 nits, which is brighter than many other
displays. Super LCD 2 , the second-generation of S-LCD panels made by Sony that switch
from using TN to IPS technology. They have phenomenal color reproduction, great contrast,
brightness and viewing angles due to reducing the size and spacing of the component layers,
and are arguably the best displays available.
Figure 4.158 Comparison of display image of TPS and TN
Pros and cons to LCD panels
As one of the major two display types, we summarise the pros and cons in table below.
Table 7 Pros and cons to LCD panels
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PROS CONS
Cheap to produce Due to the need for a backlight,

huge contrast ratios and solid black
levels are hard to achieve
IPS panels have accurate color TN panels have bad viewing

reproduction angles
Low chance of color tinting or In some cases they are power

color shift consuming and physically thick
Can be bright and clearly

readable outside
As a conclusion, we choose the best phone screen that fits our selection. After consider the
type of phone screen, type of LCD screen, display image, cost and durability, we have chosen
used iphone 5 IPS LCD screen as our screen component for LCD screen block. Details
costing is in the price list section.
When selecting a battery for the Misli block circuit, or when developing a powered battery,
there are several basic motor physics principles which must be considered to produce a safe,
well- functioning, sufficiently powered precision battery system. In this project, we have
provided some important methods, formulas and calculation details to determine the power
output of the battery, the current and efficiency of battery, and the theoretical calculations
that estimate battery performance.
4.I.4 DESIGN CRITERIA AND CONSTRAINT
4.I.4.1 Motor Block
Table 8 Design Criteria and Constraint Motor Block
Function  To function as a outcome of the block circuit.

 To provide spin move to the MISLI block.
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 To provide early exposure electrical knowledge to

kids.
Constraints  Using e-waste (Toy motor)
 Size and torque of the motor should be efficient to
perform the action.
 Safe to play by kids.
 Using sustainable recycle material.
 Low cost
 Educational kits
Objectives  Can efficiently to perform spin action outcome.
 Durable, convenient and potable.
 Can connect into a electrical block circuit without any
wiring needed during playtime.
Free variables  Variation of current supply.
 Variation of load.
4.I.4.2 LCD Screen Block
Table 9 Design Criteria and Constraint LCD Screen Block

 To provide interactive figure to the user.
 To function as a display images and play video.
 To function as a display clock.
Constraints  Using e-waste (Iphone 5 LCD screen)
 Bluetooth sensor to allow on off of the LCD screen
block.
 Low cost
Objectives  Can efficiently to display images or video.
Free variables  Variation of images and video.
 Variation of playtime and standby time.
4.I.4.3 Single Block
Table 10 Design Criteria and Constraint Single Block
Function  To function as a connector of the block circuit.

 To provide diversity of the buildings.
Constraints  Using recycled-waste (aluminium waste)

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 Low cost
Objectives  Can efficiently to conduct electricity.

Free variables  Variation of current.
Table 11 Design Criteria and Constraint Battery Block

 To provide energy move to the MISLI block.
 To provide early exposure electrical knowledge to
kids.
Constraints  Using e-waste (Phone battery)

 Voltage of the battery should be efficient to perform
the action.
 Low cost
Objectives  Can efficiently perform power.


 Variation of load.
Table 12 Design Criteria and Constraint Trigger Block

 To provide signal Bluetooth and wifi.
 To function as a sensor block.
Constraints
 Bluetooth and wifi sensor to allow on off controller

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block.
 Low cost
Objectives  Can efficiently receive signal.


 Variation of accepting device connection.
4.I.4.6 LED Block
Table 13 Design Criteria and Constraint LED Block
Function  To provide colourful light to the MISLI block.
Constraints  Using e-waste.

 The power from the led light should be efficient to
perform the action.
 Resistor is used to provide a suitable current supply
to the led components.
 Low cost.
Objectives  Can connect into an electrical block circuit without

any wiring needed.
 Can efficiently perform a light up.

 Variation of playtime.
4.I.4.7 Sound Block
Table 14 Design Criteria and Constraint Sound Block
Function  To provide sound for MISLI block.
Constraints  Using e-waste.

 Bluetooth sensor to allow speaker to connect to any
devices.
 Low maintenance cost.
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Objectives  Can connect into an electrical block circuit without

any wiring needed.
 Can efficiently perform a play audio.
Free variables  Variation of sounds can be produced.

 Variation of devices can be connected via
bluetooth.
4.I.5 WORKING PRINCIPLE, OPERATION AND MECHANISM
4.I.5.1 Whole MISLI Block System
a. Working principle
User can connect the choice of blocks in a complete circuit to perform attractive action,
including spin, light up, sound and visually.
b. Operation and mechanism
The MISLI block can operate accordingly when it in complete circuit.
4.I.5.2 Motor Block
By connect it in a complete MISLI block circuit, it can perform spin action. Can work as a
wheel or source for moving.
Convert energy from adjacent block to perform spin action from motor
4.I.5.3 LCD Screen Block
1. Connect it in a complete MISLI block circuit

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2. Connect it to phone application
3. It can display output visually and it work awesome with speaker block.
By pairing smartphone bluetooth with LCD Screen Block, user can control the visual output
on the LCD Screen Block.
4.I.5.4 Single Block
User can connect the single block adjacent to others MISLI blocks as their preference in a
complete circuit so that current can flow through it. Kids can having unlimited of
combination from our MISLI blocks.
By connect adjacent to other MISLI block, it can conduct electricity to adjacent blocks and
acts as a connector so that the buildings can be more complex.
Main power supply. By connect it with other component MISLI block, it can complete the
circuit.
Supply energy to component MISLI block.

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1. Connect it in a complete MISLI block circuit
2. Connect it to phone application
By pairing smartphone bluetooth with Trigger Block, user can control by switching on and
off the motor Block.
4.I.5.7 LED Block
LED which embedded in the led block will emit light when all the the blocks connecting to
each other. (current flow through it)
LED block works as an output to the MISLI block which the LED itself will emit the light in
a various of colours.
4.I.5.8 Sound Block
The speaker in the sound block provides sound that should be connected to any devices via
bluetooth.
Once the sound block has been connected to the MISLI block, it has to be connected to any
devices via bluetooth to perform.
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4.I.6 CALCULATION
4.I.6.1 Motor Block Theoretical Motor Calculation
Let’s delve a bit into the theoretical calculations. The 6V DC motor is to be operated with 6
V applied to the motor terminals and a torque load of 0.98 mNm. Find the resulting motor
constant, motor speed, motor current, motor efficiency, and power output. From the motor
datasheet, it can be seen that the no-load speed of the motor at 6 V is 9100 min -1. If a torque
load is not coupled to the motor shaft, the motor would run at this speed.
First, let’s get a general idea of motor performance by calculating the motor constant km. In
this case, we arrive at a constant of 0.0891 mNm/sqrt(W).
3.9
k m= =0.0891mNm / √ (W )
√1916
The motor speed under load is simply the no-load speed less the reduction in speed due to the
load. The proportionality constant for the relationship between motor speed and motor torque
is the slope of the torque vs. speed curve, given by the motor no-load speed divided by the
stall torque. In this example, we’ll calculate the speed reduction (neglecting temperature
effects) caused by the 0.98 mNm torque load by cancelling out the mNm units:
1916
¿ =4693 min−1 /mNm
3.9 mNm 2 π
A
∙ ( )
60
Now through substitution:

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min−1
(
n L =0.98 mNm∙ 4693
mNm )=4600 min−1
The motor speed under load must then be approximately:
n=9100 min−1−4600 min−1=4500 min−1
The motor current under load is the sum of the no-load current and the current resulting from
the load.
The proportionality constant relating current to torque load is the torque constant (kM). That
value is 3.9 mNm/mA. By taking the reciprocal, we end up with the current constant kI which
can help us calculate the current at load. In this case, the load is 0.98 mNm and the current
resulting from that load (neglecting heat rise) equates to approximately:
mA
I load =0.98 mNm∙ 255 =250 mA
mNm
The total motor current can be approximated by summing this value with the motor no-load
current. The datasheet lists the motor no-load current as 70 mA. After rounding, the total
current is roughly:
I =250 mA+70 mA =320 mA
The mechanical power output of the motor is simply the product of the motor speed and the
torque load with a correction factor for units (if required). Therefore, the output power of the
motor would be approximately:
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Pout =0.98 mNm∙ 6000 rpm∙ ( 260π )=615 W

The mechanical power input to the motor is the product of the applied voltage and the total
motor current in Amps. In this application:
P¿ =6 VDC ∙ 121.33 A=728
Since the efficiency η is simply power out divided by power in, let’s calculate it at our
operating point:
615 W
η= =0.8448=84 %
728 W
Power vs. Energy
While 9 V sounds impressive, voltage is not the only consideration when it comes to the
“power.” Or, more correctly, the energy in a battery. To start, let’s make sure we understand
the difference between energy and power.
Power
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While the term “power” does tend to get misused, it has a very scientific definition. Power is
“the rate at which energy is delivered to a circuit.” Power’s SI unit is “Watt.” A watt is
defined as one joule per second.
Properties of a battery, like its internal resistance and how that resistance changes with
temperature, determines the battery’s maximum deliverable power. Now, let’s compare that
to the term Energy.
Energy
The lesson I remember from high school physics is that energy can not be created or
destroyed. You can, however, transfer or transform it. In the case of a battery’s cells, energy
is stored chemically and delivered electrically. This distinction is important: cells convert
energy between chemical and electrical forms.
You can waste, consume, or store energy. But you cannot create or destroy it. (Apparently,
you can also buy small cans of it marked as Red Bull.)
The SI unit joule (J) expresses the unit used to measure energy.
Energy is the ability to do work. Power is getting work done.
Energy Stored
The energy capacity of a battery is how much energy it can store in its chemical structure. We
can calculate a battery’s stored energy with a simple formula.
Calculating Energy in a 9V Battery
The formula calculates the energy stored in a battery:
In this formula “V” is the (nominal) voltage of the battery, “I” is the current capability in
amps, and “t” is the time in seconds.
We know that a typical alkaline battery stores 600mAh, at best. That is part of our current
capability. However, that rating is in milliamp-Hours, which is a funny unit of measure. To
convert to amps per second, just multiply the number by 3600.
With these three pieces of data, our equation becomes:
19,400 joules sounds like a bunch, right? Next, let’s compare to the amount of energy in a
single AA battery.
Calculating Energy in an AA Battery
A single Energizer AA, or E91, is rated for just under 3000 mAh at 25 mA drain. For this
calculation, I picked 25mA because that is the nominal current draw for a 9 V. As a
conservative value, let’s use 2750 mAh.
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Using the same energy formula before, we can calculate the amount of energy in a single 1.5
V AA battery.
Wow, that is almost the same number, yet, the battery’s rating is only 1.5 volts! That is pretty
amazing when you think about it! Of course, We need six more cells to get to 9 V. Which
gives the total energy of:
Obviously, that calculates as 6X a single AA and just slightly more than 4X a 9V battery.
Next, let’s take volume into account.
Energy Density
Using the volume and the weight of the battery, we can calculate the energy density of both
the 9V and AA.
We can get those values from Energizer’s data sheets for Zinc / Manganese-Dioxide (MnO2),
aka Alkaline, batteries. Combine that and we can get the energy densities.
Table 15 Battery Specification
Energy / Volume Energy /

Battery Energy (J) Weight (g) Gram (cm3) cm3
9V 19,440 45.6 426.3 21.1 921.3
Single AA 14,850 23.0 645.7 8.1 1833.3
Qty 6 AA 89,100 138.0 Same 48.6 Same
So for three times the weight, you get 4.6 times the available energy, while only taking up
about 2x the space required.
Using Ohm's law with a 1 Ω load, this should give us:
V = I/R
I=9V*1Ω
Current = 9 A
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9 V battery, 550 mAh battery life
550 mA for 1 hour
550 mA/h * 3600 secs = 1980 A for 1 sec
Energy
E = V x I t
E = 9V x 550ma x 3600s
E = 17820J
4.I.6.3 LED Block
1. Select the resistor’s ohm
At first, in order to get the efficient of lights produced by the led, a suitable resistance should
be applied.
Figure 4.159 Simple Circuit for LED Block
Now, we will go by selection the best resistance for the resistor.
The formulas will be used for the entire calculation:
1. Ohm’s Law: V =IR

2. P=VI
Let assume:
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V S =voltage supply
V L=voltage led
V R=voltage resitor
I L =led forward current
Here are the value for the voltage supply and the formula on how to calculate voltage drop.
V S =9 V
V L=3.33 V
V R=V S−V L
Here are the specification for the smd led.
Smd led: 0.2W, I L =0.06 A
Now, the calculation to get the value for led voltage.
P=V L I L
0.2=V L ( 0.06 )
V L=3.33 V
After the led voltage has been calculate, next is to find the voltage drop or the voltage for the
resistor.
V R=V S−V L
V R=9−3.33
V R=5.67 V
Next is the final part to select the suitable resistance for led, ohm’s law is applied.
V =IR
V
R=
I
183
5.67 V
R=
0.12 A
R=47.25 Ω
Resistance for 0.2W 2835 SMD LED ≈ 47.25 Ω

184
2. Choosing type of the resistor
Figure 4.160 4 band resistor colour code
For 47 ohms resistor,
1st band value = 4(yellow)
2nd band value = 7(violet)
Multiplier = x1(black)
Tolerance = +-5%(gold)
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For a 4 band resistor color code, we can begin by first finding the tolerance band as it is
usually gold or silver. The tolerance band is also easily identified due to the increased gap
between the tolerance band and the multiplier band. In this project, it is gold and thus gives a
tolerance of ±5% when we look up the resistor color code chart.
Starting from the other end, the first band is thus identified to be yellow which has a 1st
significant digit of 4. The second band is violet and has a second significant digit of 7. The
3rd band is black which means that the multiplier is 1. Using the formula. The resistance
obtained is 47 × 1 = 47Ω. Lastly, the tolerance band which we identified to be gold gives a
tolerance value of ±5%.
Table 16 Resistor specification

Value 47 Ω
Type 4 Band Colour Code System
Colour Code Yellow, Violet, Black, Gold
Multiplier Black, 1
Tolerance Gold Band ±5%
Figure 4.161 4 band resistor
Resistance = 47.00 ohms
Tolerance = ± 5%
Minimum = 44.650000 ohms
Maximum = 49.350000 ohms

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4.I.7 COST/BUDGET
Table 17 Budget List For A Set Of MISLI Block
ITEM PRICE
6V DC MOTOR WIRE RM 1.80
ARDUINO UNO RM 15.00
HC-05 BLUETOOTH MODULE RM 6.90
CONNECTOR RM 0.80
PERSPEX ACRYLIC RM 2.50
0.2W 2835 SMD LED RM 4.95
ALUMINUM ALLOY RM 26.90
ARDUINO NANO 33 BLE RM 22.65
TOTAL RM 81.50
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CHAPTER I
DISCUSSION
5.I.1 SAFETY
Based on the Scientific Committee on Health, Environmental and Emerging Risks

(SCHEER), Europe published a final opinion to set the tolerable daily intake for aluminium
at 0.3 kg/mg bodyweight/day. The tolerable opinion in tolerable intake of aluminium is to
adapting the migration limits for aluminium in products.
In our project we will set a limit for the aluminium intake in producing our MISLI block and
we will choose aluminium that is not harmful to be use by the users. Some aluminium are
toxic and can cause harm to people. In order to control the safety of our product for users, we
will do many research about the material used for the body block which is aluminium so that
we can found the best and suitable type of aluminium to be used in this project.
5.I.2 RELIABILITY FACTOR
5.I.2.1 Environment Community or Society
This project will meets sustainable development goals which 90% of our material used is
from e-waste and we recycle it by using it as the components in our block. This will help to
reduce the pollution that can be caused by waste. By purchasing our product, our society are
exposed to recycling practices and also helps in reducing the pollution caused by high amount
of waste.
Society also can understand that not all e-waste are cannot be used anymore, some of them
are still functioning well but society have the thought that every old electrical components
that were not being used nowadays or outdated and not useful. Instead, society need to know
and understand that some electrical components can be recycled and reused to suit their
functions. This steps will also help to reduce the amount of waste in our environment.
5.I.2.2 Contribution
For contribution, we can reduce the amount of aluminium waste and e-waste production by
making the MISLI block using these waste. We can collect every aluminium waste and e-
waste production from recycling centre and recycle them by processing the materials into a
new product that can be functioning just like others new product in the market.
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By using the e-waste materials, we can help consumer to gain a basic knowledge about the
mechanical and electrical. Consumer can see from our MISLI block how does the electrical
components works with its function and also know about their mechanical works too.
5.I.2.3 Precaution
In our productions of our MISLI block, we must ensure that precautions are one of the
important aspects because the users of our product mostly is for kids that have an average age
among 3-12 years old. We need to make sure that the kids do not harm themselves during
playing with the MISLI block such as separating the block pieces with their teeth. Hence, we
will give them some brick separator tools and also a manual on how to use the brick separator
tools.
5.I.3 ETHICAL ISSUES
5.I.3.1 Safety Standards
For safety standards during this project, our team leader are responsible for the safety of each
team members. Team leaders need to exposed each members with the safety standards that
have been set to and to ensure that each members comply the safety standards to avoid any
unwanted incidence to happens while conducting the project
5.I.3.2 Does Not Contribute Any Pollutions
This project must need to make sure that their project does not contribute any pollutions to
the environment. For example, during the manufacturing process of aluminium, we must
ensure that the process is not contribute to pollution or at least less pollution occurs. We also
will try our best to increase the usage of a recyclable E-waste in processing our MISLI
blocks.
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CHAPTER I
CONCLUSION
First of all, the cooperation from each team members throughout the completion of this
project work is so much appreciated. We learned a lot throughout this project work from the
design process until the ways to do an actual report. Throughout this project work, we tend to
make discussion with members in order to obtain a better design. Overall our team feels that
the project is pretty successful although we did face few problems to create our product
because we need to think of concept design or project for educational kits from the e-waste
which is the main theme in order to design this project. It is also supported with other
materials that come from a sustainable recyclable waste which is not harmful for kids and this
project are for people to enjoy playing with the toys while at the same time they are gaining
some knowledge about mechanical and electrical. In conclusion, our team create ‘MISLI
Block’, a combination of lego blocks with electronic sensors, motors and connected apps.
From our point of view, the invention of the MISLI Block is a new break through
from the traditional lego blocks. It helps people especially kids to gain knowledge while
enjoy playing their toys (MISLI Block). We had lots of refer and arguments throughout the
completion of this project work to obtain a better mechanism that can conduct electricity to
the whole blocks as well as safe to be played by the user.
From the selection of chrome as our main body to the aluminium alloy, we had
changed the design of our project work many times. Thanks to the cooperation given by each
team member, we tend to come up with a new design that help to solve the problem that we
encountered, which is the aluminium alloy materials as our main lego body. We spent a lot of
time trying to figure out how to connect all the lego blocks to each other. At last, we finally
got a finalised design which from our opinion is safe and well-functioning.
Throughout this project work, we have learned to do a simple thesis by referring some
example online. This skill is actually helpful in our future for example the final year project.
From this project work, we learned how to design using CAD software which is Autodesk
Inventor to obtain the finalised 3D design. We also learned how to calculate stress, rpm,
voltage, current and resistance to make sure that our design is safe and secure. In order to
determine the material to be selected for each part of our design, we are using the CES
program. Furthermore, we learned on how to calculated the product fees from the overhead
fees until the raw material fees. From this project work, we learned to select the market
demand and also our product target market from the perspective of an entrepreneur.
190
In conlusion, we hope that with our design, the MISLI Block, we are managed to help
people to gain a basic knowledge about mechanical and electrical while enjoying playing our
product and also give a good impact to the environment which reduce the e-waste material.
Hence, our objective is achieved from creating our product.
191
REFERENCES
Augustyn, A. (2019). LEGO toy. Journal of Encyclopædia Britannica, 11-20.
Boysen, E. (2012). Complete Electronics Self-Teaching Guide with Projects-Honest.

Chicago: Adventure Electronics.
Clements, J. S. (2016). Playing to Know the World Mathematically. Journal of Building

Blocks and Cognitive Building Blocks, 45-65.
Commission, E. (2016). Final Opinion On Alloy Toys. European: European Commission.
Dahl, Ø. N. (2016). Electronic for Kids: Play with Simple Circuits and Experiment with
Electricity! India: Øyvind Nydal Dahl.
Geier, M. J. (2016). How to Diagnose and Fix Everything Electronic, Second Edition.
Washington: McGraw-Hill Education.
Group, F. (13 December, 2016). Motor Calculations. Retrieved from pages:

https://pages.mtu.edu/~wjendres/ProductRealization1Course/DC_Motor_Calculations
.pdf
Herman, S. (2014). Building a History: The Lego Group. Canada: Grub Street.
Hewes, J. (23 July, 2021). LEDs. Retrieved from electronic.info:

https://electronicsclub.info/leds.htm
Industries, A. (21 November, 2011). DC Toy / Hobby Motor - 130 Size. Retrieved from
components101:
https://components101.com/sites/default/files/component_datasheet/Toy%20DC
%20motor%20Datasheet.pdf
Sachin Kumar, P. T. (2019). Internet of Things is a revolutionary approach for future

technology enhancement: a review. Journal of Big Data, 111.
Spielgaben. (8 August, 2015). Comparison between Lego and Spielgaben. Retrieved from
Spielgaben: https://spielgaben.com/lego-vs-spielgaben/
Walton-Hadlock, M. (23 January, 2008). Tots to Tweens: Age-Appropriate Technology

Programming for Kids. Age-Appropriate Technology Programming for Kids, pp. 52-
55.
192
Wilcher, D. (2017). Build an IoT Notification Device with an Arduino UNO. All About
Circuit, 10.
193
APPENDIX A
MATERIAL PROPERTIES
Figure 6.162 General Properties of Nickel Alloys

194
Figure 6.163 Specific Properties of Nickel Alloys

195
Figure 6.164 General Properties of Low Alloy Steel

196
Figure 6.165 Specific Properties of Low Alloy Steel

197
Figure 6.166 General Properties of Magnesium Alloys

198
Figure 6.167 Specific Properties of Magnesium Alloys

199
Figure 6.168 General Properties of Titanium Alloys

200
Figure 6.169 Specific Properties of Titanium Alloys

201
Figure 6.170 General Properties of Zinc Alloys

202
Figure 6.171 Specific Properties of Titanium Alloys

203
Figure 6.172 General Properties of Lead Alloys

204
Figure 6.173 Specific Properties of Lead Alloys

205
Figure 6.174 General Properties of Copper Alloys

206
Figure 6.175 Specific Properties of Copper Alloys

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1

NUR SYAMIMI BINTI ZAINAL ADELIN A169926

MUHAMMAD IZZ IRFAN BIN ZULKEFLY A169029

NURUL SAKINAH BT ABDUL BASIR A170367

MUHAMMAD ALIF IQRAK BIN SUHAIRUL AZMIE A170450

26 June 2021 LAI YU HUNG

NUR SYAMIMI BINTI

MUHAMMAD IZZ IRFAN

CHAPTER II LITERATURE REVIEW

CHAPTER III METHODOLOGY

CHAPTER IV DESIGN CONCEPT

5.2.1 Environment Community or Society 175

Appendix A Material Properties 179

Table 3 Gantt Chart 7

Table 4 Result Analysis for Simple Circuit Stress Analysis 18

Table 5 Result Summary of Stress Analysis for Car Model 46

Table 6 Technical specification of Arduino Uno 106

Table 7 Device and Service Discovery 136

Table 8 DC Motor Specification 153

Table 9 Pros and cons to LCD panels 156

Table 10 Design Criteria and Constraint Motor Block 157

Table 11 Design Criteria and Constraint LCD Screen Block 158

Table 12 Design Criteria and Constraint Single Block 158

Table 13 Design Criteria and Constraint Battery Block 159

Table 14 Design Criteria and Constraint Trigger Block 159

Table 15 Design Criteria and Constraint LED Block 160

Table 16 Design Criteria and Constraint Sound Block 160

Table 17 Battery Specification 168

Table 18 Resistor specification 172

Table 19 Budget List For A Set Of MISLI Block 173

Figure 3.2` Hardness – Vickers (HV) against Melting point 11

Figure 3.3 Recycle against Price (MYR/Kg) 12

Figure 3.4 Hardness-Vickers(HV) against Electrical Conductor / Insulator 12

Figure 3.6 Application Layout 15

Figure 3.8 Example of Connecting 6V DC Motor to a Simple Circuit 17

Figure 3.9 Example of Arduino Coding for Controlling the 6V DC Motor by

Figure 3.10 Von Mises Stress 21

Figure 3.11 Von Mises Stress 21

Figure 3.12 1st Principle Stress 22

Figure 3.13 1st Principle Stress 23

Figure 3.14 3rd Principle Stress 24

Figure 3.15 3rd Principle Stress 25

Figure 3.16 Displacement 25

Figure 3.17 Displacement 26

Figure 3.18 Safety Factor 26

Figure 3.19 Safety Factor 27

Figure 3.20 Stress at XX-axis 27

Figure 3.21 Stress at XX-axis 28

Figure 3.22 Stress at XY-axis 28

Figure 3.23 Stress at XY-axis 29

Figure 3.24 Stress at XZ-axis 29

Figure 3.25 Stress at XZ-axis 30

Figure 3.26 Stress at YY-axis 31

Figure 3.27 Stress at YY-axis 32

Figure 3.28 Stress at YZ-axis 33

Figure 3.29 Stress at YZ-axis 34

Figure 3.30 Stress at ZZ-axis 35

Figure 3.31 Stress at ZZ-axis 36

Figure 3.32 X Displacement 36

Figure 3.33 X Displacement 37

Figure 3.34 Y Displacement 37

Figure 3.35 Y Displacement 38

Figure 3.36 Z Displacement 39

Figure 3.37 Z Displacement 40