PROGRESS
REPORT
FOR A DIY MECHANICAL
CLOCK
PRESENTED TO: MOODY FARAG
PREPARED BY: GROUP PINK
RIDA FATHIMA
MOHAMMAD IMWAFI
RAJIB ALAM
AFNAN LAIBA
DATE: NOVEMBER 18, 2024
1
TABLE OF CONTENTS
1. INTRODUCTION ............................................................................................................ 3
2. PROGRESS SUMMARY ................................................................................................. 4
2.1 PLAN OF WORK .......................................................................................................... 4
2.1.1. Need Statement ....................................................................................................... 4
2.1.2. Concept Combination and Sketching for Assemblies and Parts...................................... 4
2.1.3. Final Design Selection ............................................................................................. 4
2.1.4. Made a Project Proposal Presentation ......................................................................... 4
2.1.5. Created Freehand Sketches of the Clock Design .......................................................... 4
2.1.6. Bill of Materials (BOM) ........................................................................................... 4
2.1.7. Completed AutoCAD Drawings for the Finalised Design ............................................. 5
2.1.8. Prototyped with Cardboard Cutouts ........................................................................... 6
2.2.1 ORIGINAL PROJECT SCHEDULE .............................................................................. 7
2.2.2 UPDATED PROJECT SCHEDULE .............................................................................. 7
2.3 TASK BREAKDOWN .................................................................................................... 8
2.3.1 TASK COMPLETED ............................................................................................... 8
2.3.2 TASK REMAINING ................................................................................................ 9
2.3.3 MAJOR MILESTONES ............................................................................................ 9
ACHIEVED MILESTONES.............................................................................................. 9
UPCOMING MILESTONES ........................................................................................... 10
3. PROBLEMS/CHANGES TO PROJECT ........................................................................... 10
4. CONCLUSION .............................................................................................................. 10
5. REFERENCES .............................................................................................................. 11
6. APPENDICES ............................................................................................................... 11
TABLE OF FIGURES
Figure 1: Bill Of Materials ...................................................................................................................... 5
Figure 2: AutoCAD Overall Clock Design and Side-view ..................................................................... 5
Figure 3: Cardboard cutouts made with our Trotec Speedy 400 laser-cutter......................................... 6
Figure 4: Original Gantt Chart ................................................................................................................ 7
Figure 5: Revised Gantt Chart ................................................................................................................ 7
Figure 6: Work Breakdown Structure ..................................................................................................... 8
Figure 7: Milestone Breakdown.............................................................................................................. 9
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1. INTRODUCTION
Our goal is to inspire interest in the scientific, technological, and historical aspects of
timekeeping and clock-making by designing a Do-It-Yourself Mechanical clock kit. By focusing on
hobbyists, educators, and students, this kit emphasises the educational significance of traditional
principles in mechanical timekeeping. Current educational tools lack a hands-on, mechanical-based
approach to demonstrate these principles without using electricity or batteries. Our project aims to fill
this gap by designing a DIY mechanical clock kit that is affordable, easy to assemble, portable,
accurate, and aesthetically pleasing, allowing users to appreciate the inner workings and historical
significance of mechanical timekeeping.
To achieve the project's success, we have defined several objectives, including reviewing
literature on the history and development of the mechanical clock designs, and comprehensive
engineering drawings. An extensive review of historical literature was taken to explore the evolution
of mechanical clock designs, focusing on advancements in pendulums, escapement mechanisms, and
related components that transformed timekeeping. This historical perspective lays a solid foundation
for understanding the traditional techniques that continue to influence modern horology. We
conducted comprehensive engineering and design work to create detailed drawings and assembly
details.
Assembling the clock by hand allows users to engage directly with the function of pendulums,
and the escapement mechanism, which releases energy and ensures a consistent time cycle. Through
this interactive approach, users gain a deeper appreciation for the mechanics between the gears, the
escapement, the pendulum and other clock components, showcasing the elegance of traditional
mechanical design.
To meet the diverse needs of our target audience, the kit is designed with affordability,
portability, accuracy, and aesthetic appeal in mind. We are committed to creating a cost-effective
product that is easily accessible to schools, hobbyists, and enthusiasts. The kit’s compact design
ensures it is suitable for workshops and classroom demonstrations, making it an effective educational
tool. Precision engineering in deciding the gear ratio is used to maintain accurate timekeeping, while
the clock’s aesthetic appeal showcases the beauty and craftsmanship inherent in mechanical
clockwork, creating a visually captivating product.
The invention of the mechanical clock, using a pendulum and an escapement, was a milestone
in science and technology. A DIY clock kit reveals how these key parts work together to keep
accurate time, offering a hands-on way to appreciate its mechanics, history, and engineering. Our
progress thus far includes detailed historical research and engineering planning, laying the
groundwork for a product that captivates and educates users, fostering a deep appreciation for the art
and science of clock-making.
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2. PROGRESS SUMMARY
2.1 PLAN OF WORK
Below is a detailed breakdown of the tasks we have completed so far:
2.1.1. Need Statement
We have gathered customer needs by conducting surveys among peers and identified six
primary customer needs, including affordability, portability, accuracy, ease of construction,
educational focus, and aesthetics.
2.1.2. Concept Combination and Sketching for Assemblies and Parts
We designed five concepts as potential candidates for our mechanical clock. We first listed all
the desirable combinations of the concepts in the form of a table. Furthermore, we sketched each
combined concept to have a clearer view of the design. There is a clear view of these concepts
available in Appendix A. The concept design focuses more on the aesthetics and the layouts of the
clock components and not on the details of the mechanical systems behind it. The mechanical gearing
systems of the clock were not explored in detail during this week.
2.1.3. Final Design Selection
We finalised the main and subassembly design sketches by means of a rubric that evaluated
the pros and cons of our two concepts. The rubric for design selection was designed to assess
compliance with the design brief and list of specifications. This included factors such as feasibility,
functionality, manufacturability, affordability, materials constraints, and user constraints such as ease
of assembly, reading time, and noise level. Our winning design was Concept E, which features a
pendulum, a Graham escapement, and a weight-based power source due to its simplicity and
effectiveness. Refer to Appendix A: Table 2 for more detailed information on this.
2.1.4. Made a Project Proposal Presentation
During this presentation, we outlined the goals, methods, and expected outcomes for our DIY
Mechanical Clock project. The feedback received led to the refinement of our design approach and
solidified the project timeline. This step marked the formal start of the project, allowing us to move
forward with detailed design and development.
2.1.5. Created Freehand Sketches of the Clock Design
Freehand sketches were created in the early stages to visualise and explore different design
configurations. These sketches facilitated team communication and served as a blueprint for
developing detailed CAD models.
2.1.6. Bill of Materials (BOM)
We prepared a list of required materials including plywood, bearings, screws, shafts, and
other components required to build the DIY mechanical clock. By preparing the BOM early, we
ensured that all necessary materials were identified, priced, and ordered within budget constraints.
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Figure 1: Bill Of Materials
2.1.7. Completed AutoCAD Drawings for the Finalised Design
We created precise 2D AutoCAD drawings for the finalised design, detailing part dimensions.
The completed drawings were submitted to ensure accuracy before proceeding with CNC laser
cutting.
Figure 2: AutoCAD Overall Clock Design and Side-view
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2.1.8. Prototyped with Cardboard Cutouts
As seen in Figure 3, we obtained cardboard cutouts of our parts to create a rough prototype of
our clock before making the final cutouts out of plywood. This allowed us to identify design flaws
and make changes accordingly. For instance, we realized that our escapement wheel was much too
small, the dimensions of the recesses for our ball-bearings were too large, and parts such as columns
and anchor-pallets need to be lengthened and thickened to make them more robust. This step was
indeed very useful in the design process.
Figure 3: Cardboard cutouts made with our Trotec Speedy 400 laser-cutter
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2.2.1 ORIGINAL PROJECT SCHEDULE
Figure 4: Original Gantt Chart
This chart represents the initial project timeline and planned tasks, outlining the sequence and
duration of each activity.
2.2.2 UPDATED PROJECT SCHEDULE
Figure 5: Revised Gantt Chart
This updated chart reflects adjustments made during project execution including completed tasks and
any scheduled shifts. Notably, it incorporates delays in CNC part cutouts and highlights the current
progress.
The revised Gantt chart highlights the adjustments made since the initial project schedule
outlined in the progress report. This updated version includes a light blue shaded box indicating tasks
that have already been completed. Currently, we are entering Week 11. Construction of the main body
and parts will commence upon the arrival of our plywood material at the beginning of Week 11.
There was a slight delay in the CNC parts cutout process, which began in Week 8 and
extended through Week 10. Despite this delay, the trials and testing phases of the components have
been successfully completed. This minor adjustment has not caused significant disruption to the
overall project timeline initially proposed. We are now prepared to proceed with the final stages,
including parts assembly and sub-assembly, ensuring the project remains on track.
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2.3 TASK BREAKDOWN
Figure 6: Work Breakdown Structure
The Work Breakdown Structure (WBS) shown above organises the DIY mechanical clock
project into four main phases: identifying customer needs, design and planning, component
fabrication and assembly, and testing/finishing. Each phase is broken down into specific tasks to
streamline the process from concept development to the final presentation of the completed product.
The production section focuses on the clock’s mechanical systems like power transmission and
control mechanisms, while the documentation section details necessary engineering processes and
required documents (e.g., design specifications, sketches, and project timing). The Work Breakdown
Structure served as a checklist and guided task allocation to ensure project success.
2.3.1 TASK COMPLETED
We have successfully completed over half of the essential work for this project. So far, we
have conducted comprehensive need assessments, developed design concepts, finalised detailed
sketches, designed gear-train, created a bill of materials, and prototyped with cardboard cutouts of our
parts. Additionally, we acquired proficiency in software necessary for generating project components
and translated our designs into AutoCAD for precise laser cutting of the clock parts. According to our
Work breakdown Structure (Figure 5), we are currently in the Component Fabrication and Assembly
phase, where the final CNC parts are being printed and raw materials like plywood, acrylic, and MDF
are awaited.
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2.3.2 TASK REMAINING
The remaining tasks involve the arrival of raw materials, including plywood, acrylic, and
MDF, followed by the final CNC parts printing. We will then proceed with constructing the main
assembly and sub-assemblies, integrating all components. This will be followed by testing and
debugging to ensure functionality, as well as preparing for advertising and the final display of the
completed product.
2.3.3 MAJOR MILESTONES
Figure 7: Milestone Breakdown
ACHIEVED MILESTONES
MILESTONE 1: Concept Selection
A big milestone in the project was finalising the design concept. A detailed evaluation process
was conducted to assess the feasibility, functionality, and overall effectiveness of each concept. This
rigorous selection process led to the identification of the most suitable concept, marking a critical
turning point in the project. This decision helped us create the full design and plan for building the
clock.
MILESTONE 2: Approval on the Selected Design
A key milestone was the success of our proposal presentation, where we presented our
research, findings, specifications, material selection, and gear-train mechanism. After thorough
evaluation, we received approval from our professor to proceed, confirming the project is ready to
progress to the prototype phase.
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UPCOMING MILESTONES
MILESTONE 3: Component Fabrication and Assembly
Assemble all clock components, including the housing, escapement, gear-train, and the
panels, to create a functional physical prototype that aligns with the approved design.
MILESTONE 4: Final Showcase and Presentation
Prepare for the final showcase and presentation by refining the clock’s features, testing for
reliability and rehearsing the project demonstration.
3. PROBLEMS/CHANGES TO PROJECT
The process thus far of creating the clock has been relatively smooth, with some challenges
that provided valuable learning experiences. One significant issue arose during the design of the gear
train. Our initial plan was to keep the shape of the clock and its internal mechanisms horizontal.
However, after consulting with our professor for feedback, we were advised to adopt a vertical design.
This change reduced the overall length of the clock and minimised wasted space, requiring us to also
modify the clock's outer housing.
Another challenge was the delayed arrival of raw materials, which were delivered a week
later than expected. It was difficult to find a vendor for the 3mm plywood that we will be using to
construct our clock. Though there are several vendors in the Greater Toronto Area who sell plywood,
most do not carry high-quality Baltic Birch plywood that is required for the purpose of laser-cutting
precision parts for our clock. We were eventually able to source the requisite plywood from Ply
Supply.
We also encountered design accuracy issues while creating the drawing model in AutoCAD.
This required redrawing and re-measuring parts, such as the escapement wheel and anchor. Despite
the challenges we faced, our team demonstrated adaptability, effective problem-solving, and a
commitment to excellence throughout the project. Each change we implemented contributed to a more
efficient and refined design, ultimately improving the overall functionality and aesthetics of the clock.
4. CONCLUSION
To conclude, our DIY Mechanical Clock project aims to inspire interest in the scientific,
technological, and historical aspects of timekeeping through an educational tool tailored for hobbyists,
educators, and students. By designing an affordable, accurate, portable, and aesthetically pleasing
mechanical clock kit, we strive to fill a gap in mechanical timekeeping education while celebrating
traditional principles of clock-making.
Our progress reflects a structured approach, with completed phases in design and planning,
including customer needs assessment, concept selection, and design approval. Despite challenges such
as gear-train adjustments, delayed materials, and AutoCAD accuracy issues, we adapted through
collaboration and problem-solving, resulting in a stronger final design. As we move into the final
assembly and testing phases, we aim to deliver a functional, accurate, and visually appealing product
that meets our objectives.
We welcome your feedback and kindly seek your continued support and approval as we
progress towards completing and showcasing the final product. Your insights will be invaluable in
refining our work and ensuring its impact as an engaging educational resource.
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5. REFERENCES
Proposal Report: Appendix A
6. APPENDICES
APPENDIX A: PROJECT PROPOSAL for a DIY MECHANICAL CLOCK
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PROJECT PROPOSAL
for a
DIY MECHANICAL CLOCK
Prepared for: Moody Farag
Prepared by: Group Pink
Rida Fathima
Mohammad Imwafi
Rajib Alam
Date: October 18, 2024
1
Table of Contents
Summary Of Problem and Project Description 3
Team Members 3
Research Findings of Customer Needs 4
Concepts 5
Selection Matrix 9
Winning Concept 9
Plan, Schedule and Work Structure 11
Deliverable (Final Design) 13
Budget (Bill Of Materials) 17
Resource Requirements 17
2
SUMMARY OF PROBLEM AND
PROJECT DESCRIPTION
Our goal is to spark curiosity in the scientific, technological and
historical aspects of timekeeping and clockmaking by designing a
Do-It-Yourself kit of a Mechanical Clock that will appeal to hobbyists,
educators and students.
Our DIY kit of a mechanical clock is powered mechanically without
the usage of electricity or batteries. Our research tells us that there is a niche
market for mechanical clocks that can be constructed from parts.
The invention of an accurate mechanical clock – operated with the aid
of a pendulum and an escapement – was a giant leap for humanity toward
scientific and technological progress. A DIY mechanical clock will illuminate
the simplicity and brilliance of the design principles which make it tick.
Furthermore, the hobby industry is booming both globally and in the
US and Canada. The DIY and Maker industry is thriving. The hobby
industry is worth about $50 billion dollars, and we would like to be a part of
it.
TEAM MEMBERS
We are a team of three Engineering students at Humber Polytechnic. Our group
comprises Rida Fathima, Mohammad Imwafi and Rajib Alam. We will share all
responsibilities equally in order to bring our DIY mechanical clock to fruition.
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RESEARCH FINDINGS OF
CUSTOMER NEEDS
In order to determine the needs of potential customers, we cast a wide
net and surveyed our peers, acquaintances, friends, family members and
relatives.
We were able to boil down our customers’ needs to six primary factors.
Our research indicates that we must design a clock which is (ranked by
importance):
● AFFORDABLE
○ The bill of materials for our clock is $40. We intend to sell our
clock for $75.
● LIGHT/PORTABLE
○ This is a priority for both us and our customers in order to
maximize ease of handling, and minimize shipping costs.
● ACCURATE – INFREQUENT ADJUSTMENT
○ Customers desire a clock which does not require frequent
adjustment. We intend to make our clocks with an error-margin
of less than a minute a day, which is certainly attainable since
pendulum clocks of the twentieth century had an error-margin
of less than a minute per week.
● EASY TO CONSTRUCT – NOT EXCESSIVELY
COMPLEX
○ We think that the level of complexity of our DIY clocks will
appeal to most adolescents and adults.
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○ A mechanical clock constructed with a pendulum and an
escapement is a remarkably simple apparatus despite its enormous
utility and accuracy.
● COMPONENTS ARE EASILY OBSERVED AND
STUDIED
○ Hobbyists and enthusiasts wish to watch and appreciate the
internal mechanisms of a clock, which is a major selling point of
our DIY clock. This is why we will be constructing our clock
with transparent acrylic.
● AESTHETICALLY PLEASING
○ A majority of our customers will want to hang their clocks on a
wall where they and others can observe and admire its intricacies.
Thus, aesthetics is a major priority as well.
CONCEPTS
Essentially, a mechanical clock is composed of an oscillator,an
escapement mechanism, and a power-source.
An oscillator can either be a pendulum or a coiled spring, also known
as a balance-spring. We have chosen a pendulum for our clock.
There are many types of escapements, but most accurate pendulum
clocks contain a Graham escapement, which also happens to be the type of
escapement that we will be implementing in our clock.
A mechanical clock can be powered by a weight or a coiled spring, also
known as a mainspring. We have chosen a weight to power our clock.
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We designed five concepts as potential candidates for our mechanical
clock.
Our concept combination chart consisted of the following.
Oscillator Escapement Power-source
Pendulum Recoil Anchor Weight (Gravity)
Balance-Spring (with Deadbeat Mainspring (Elastic)
Balance-Wheel)
Lever
Verge
As an example, Figure 1 shows our concept, Concept C, of a
mechanical clock with a balance-spring, a Swiss-lever escapement and a
weight.
And Figure 2 shows our concept, Concept E, of a mechanical clock
with a pendulum, a Graham escapement (also known as a deadbeat
escapement), and a weight.
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Figure 1: Concept C
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Figure 2: Concept E
Concept A was designed with a recoil anchor, a pendulum and a
weight, Concept B was designed with a recoil anchor, a pendulum and a
mainspring, and Concept D was designed with a balance-spring, a lever and a
mainspring.
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SELECTION MATRIX
Selection Criteria Concept
A B C D E
Cost of Materials + 0 0 - +
Total Mass 0 + 0 + 0
Accuracy of Oscillator - - 0 0 0
Complexity of Internal + 0 0 - +
Mechanisms
Ease of Manufacture + 0 0 - +
Noise 0 0 0 0 +
Tools Required for DIY + - 0 - +
Portability - 0 0 + -
Sum +’s 4 1 0 2 5
Sum 0’s 2 5 8 2 2
Sum –’s 2 2 0 4 1
Net Score 2 -1 0 -2 4
Rank 2 4 3 4 1
Continue? No No Yes No Yes
Table 1: Selection Matrix
Our selection matrix in Table1 indicated to us that Concept C and
Concept E are our highest ranked design concepts.
WINNING CONCEPT
After scrutinizing and scoring our five concepts, we arrived at our
weighted concept scores.
Portability, cost of materials, ease of construction, total mass, accuracy
and degree of complexity were all weighted heavily in our analysis.
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Our runner-up is Concept C, the aforementioned mechanical clock
equipped with a hairspring, a Swiss-lever escapement and a weight. Though
we would very much like to build and sell this concept, a balance-spring and
a Swiss-lever escapement are both much more complex than a pendulum and
a Graham escapement.
Concept C Concept E
Selection Weight (%) Rating Weighted Score Rating Weighted Score
Criteria
Cost of 20 3 .6 4 .8
Materials
Total Mass 10 3 .3 3 .3
Accuracy of 15 3 .45 3 .45
Oscillator
Complexity of 15 3 .45 4 .6
Internal
Mechanisms
Ease of 20 3 .6 4 .8
Construction
Noise 5 3 .15 3 .15
Tools Required 5 3 .15 4 .2
for DIY
Portability 10 3 .3 5 .5
Total Score 3.0 3.8
Rank 2 1
Continue No Yes
Table 2: Weighted Concept Scores
As our weighted concept scores in Table 2 indicate, Concept E — our
concept with a pendulum, a Graham escapement, and a weight — was the
clear winner among our five concepts. In fact, the Graham escapement is a
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simple yet highly accurate escapement that is used in nearly all high-quality
pendulum clocks.
PLAN, SCHEDULE AND WORK
STRUCTURE
Schedule
Early Late
Activity ES EF LS LF
Activity Description Duration in Slack
Weeks
1 Construct Needs Statement 2 0 2 0 2 0
2 Determine Specs/Metrics 1 2 3 2 3 0
3 Design and Sketch Concepts 1 3 4 3 4 0
4 Select a Concept 1 4 5 4 5 0
5 Make Detailed Sketches 1 5 6 5 6 0
6 Finalize Design (Main Assembly, 1 6 7 6 7 0
Subassembly and Parts)
7 Create Bill of Materials (BOM) 1 7 8 7 8 0
8 Order Materials (Bearings, Bushings, Pins) 2 8 10 8 10 0
9 Gather Raw Materials (Acrylic, MDF) 1 5 6 7 8 2
10 CNC Parts 2 8 10 8 10 0
11 Construct Parts and Subassembly 1 10 11 10 11 0
12 Construct Main Assembly 1 11 12 11 12 0
13 Test and Debug 2 12 14 12 14 0
14 Construct End-Product 2 14 16 14 16 0
15 Final Display
Table 3: Schedule
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As seen here, we have mapped out a tight timeline for the development
of our DIY clock; there is only a slack-time of two weeks for gathering raw
materials such as acrylic and MDF.
We just completed the final design of our clock, which is stage 6 of our
product-development schedule. That leaves us with another seven weeks to
complete our project. We are currently drawing up our bill of materials, and
will be ordering materials, such as bearings, bushings and pins next week.
Our GANT chart further lays out our path ahead, for those who prefer
a visual representation of our schedule.
Weeks From Start
Activity 0 2 4 6 8 10 12 14
Construct Needs
Statement
Determine
Specs/Metrics
Design and Sketch
Concepts
Select a Concept
Make Detailed
Sketches
Finalize Design
(Main Assembly,
Subassembly and
Parts)
12
Create Bill of
Materials (BOM)
Order Materials
(Bearings,
Bushings, Pins)
Gather Raw
Materials (Acrylic,
MDF)
CNC Parts
Construct Parts
and Subassembly
Construct Main
Assembly
Test and Debug
Construct
End-Product
Display
End-Product
Table 4: GANT Chart
Slack
DELIVERABLE (FINAL DESIGN)
To reiterate, the final design of our clock consists of a pendulum, a Graham
escapement, and a weight to drive it. We are excited to present our design
sketches here!
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Figure 3: Sketch of DIY Mechanical Clock
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Figure 4: Escapement Wheel, Anchor and Pallet
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Figure 5: Side-view of Escapement and Pendulum.
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BUDGET (BILL OF MATERIALS)
We have yet to determine our bill of materials, though we expect it to be less
than $75.
RESOURCE REQUIREMENTS
We will be using the labs and equipment, such as CNC machines, laser
cutters, available at Humber Polytechnic. Furthermore, we will be mentored
by Mr. Ali Taha for this project.
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