Carolyn’s Status Report for 4/25/26

This week, I finished up the basic design, cutting, and assembly of the pill box. I designed the base attachment to the collection tray and printed it out.  Most of my time this week was focused on getting ready for the final presentation.  I collected testing data and synthesized the work we had done into slides and a script to share.

I think we are mostly on schedule, except for the integration of the software and electrical components.  We are planning to finalize that this weekend.  Then, do our remaining testing, which shouldn’t take too long.  In the next week, I hope to help finish the integration of the electrical and software.

Tests (both unit and overall) that have been/being accomplished: individual testing for motion sensor accuracy, weight sensor accuracy, timing accuracy when tracking which compartment to go to, web-app sending/storing the data that needs to be sent to the hardware end, the push-to-open accuracy/strength required, number of pills collected correctly, timing/day tracking on the software end being fully accurate, and overall run-through of the entire system working on a mock setup schedule. So far, the motion sensor + weight sensor accuracy isn’t very high (ranging from 40-70% depending on the number of servos in use, with an average of around 60%). The timing/tracking is still being tested as different power sources/pin arrangements are done during the debugging process. Push to open currently has around 7-8 on a scale of 10 for difficulty, something which needs to be adjusted down. The software end still needs to be fully tested with integration with the mechanical/hardware, which will be done in the coming days.

Carolyn’s Status Report 4/18/26

A lot of progress has been made.  I finished redesigning the trapazoidal pill compartments, including making the base and lid.  The lid design went through many iterations, and getting the hinges to fit and function properly was very difficult. I also had to make adjustments to the compartment sides, as I realized I forgot to make holes through which the strain gauge wires can come out.  Then I installed the push-to-open latches.  Getting them installed took many iterations as the acrylic was breaking easily.  I also made a second base for each compartment to hold the funnels.  Then I made the funnel for 3 compartments.  I also designed and made the sliding door attachments.  I am especially proud of myself for this, as I got the sizing of the holes so they fit on the servos exactly.

We are definitely behind on integration.  We are planning to spend a significant amount of time getting that sorted tomorrow.
• What deliverables do you hope to complete in the next week?
In the next week, I hope to have funnels for all the compartments, which shouldn’t take too long.  As well as maybe figuring out a better way to do the compartment hinges so they don’t break as often.
As you’ve designed, implemented, and debugged your project, what new tools or new knowledge did you find it necessary to learn to be able to accomplish these tasks? What learning strategies did you use to acquire this new knowledge?

My CAD skills have definitely improved while making the funnels, as well as my CorelDRAW skills.  For CorelDRAW, I bothered the TechSpark employees often about how to do certain things and use the tools.  For CAD, my meche friends, as well as YouTube videos, were a good source for figuring out how to make a trapazoidal funnel.

Carolyn’s Status Report 4/4/26

After making our prototype pill box, I realized that I had not sized the pill box compartments correctly.  So I had to redesign the compartments.  I now have them as trapezoids, which will allow the space to be used more effectively than squares.  Furthermore, I have been working on the push to open, so I can install them soon.

Our progress is a bit behind due to the parts we delayed.  Not having all the acrylic made it especially hard for me to finish the physical pill box.

In the next week, I should have the new compartments finished and added to the pill box.  As well as finish up the CAD designs of the funnels for each pill compartment.

For my portion of the project, there are two main things I will need to verify.  I will verify that the compartments do indeed hold up to a 30-day supply, 3 times a day, of any pill type.  I will verify this by ordering empty pill capsules online and filling them into the compartments.  I will use the largest pill size for the test to make sure the compartments will hold any pill size.  If the compartments can’t close with 90 pills of the largest pill size without damaging any of the pills, they will not pass the test.

Next, I will verify that all the user access doors can be accessed in 30 seconds or less.   I will have to install the push-to-open on each of the doors before I do this. This will ensure that all the access doors can be used by someone with dexterity issues easily.  I will have someone time me opening each door for 5 trials.  I will need to open each door within 30 seconds at least 4 out of the 5 trials.

Carolyn’s Status Report for 3/28/26

I have finalized the laser cutting files for our pill box.  The design went through many iterations as I had to balance several constraints, including pill size, number of pills, and width of the pill box.  Mapping out the dimensions was also time-consuming.  I have included a PDF version of one of the more complex pieces  COMPARTMENT_LAYER_cutouts.

Then I tested and laser cut all the parts in TechSpark.  Finally, I assembled the whole box.  I realized we do not have enough acrylic to print out the whole pill box, so I ordered more.

When meeting with Jieun, we realized we needed to adjust our pill box design because the servo sizing did not meet expectations.  So I had to adjust the laser cuts I made one more time.  I also realized we will need something to hold up the servos, so we ordered styrofoam.

I think I am a bit behind because I didn’t finish making the pill box since we ran out of acrylic.  I will have all the files ready, so when the acrylic comes, I can print it right away

Next week, I hope to have the CAD files for the funnels finalized.

Carolyn’s Status report for 3/21/26

This week I have been making the laser cutting file for the pill box.  I focused on refining the mechanical design of the pill dispensing system.

Progress is on schedule. Current work aligns with planned milestones, and design decisions are now converging toward final selections.

I will also continue refining the CAD design and contribute to the next report deliverables.

Carolyn’s Status Report 3/14/26

I finalized our parts list based on our design and put in most the the parts orders.  I also reviewed our feedback from design presentation and worked on filling the gaps that were addresses.  This primarily consisted of doing research to justify some of our design choices, or deciding they were unjustified and removing them.  I have also been working on the laser cutting file for our design.  This has been going through much iteration, But I believe the work is worth it as it is the whole structure of our project and without a proper structure the mechanical components will not function correctly.  Part of this process has also been maping out the exact measurements needed to satisfy all out use cases.

We are generally on schedule but we need to be making significant progress leading up to the demo.

If the acrylic comes in time I hope to print out the pill box design and assemble it.

 

Team Status Report for 3/7/26

The most significant risk to our project currently is the possible mechanical errors of the retractable door.  This is the most mechanically complex portion of our project.  We need a sliding door on each compartment that will let only one pill fall down at a time.  The timing and force need to be accurate to be implemented properly.  To make sure our design will be functional, we are going to make two prototypes of sliding doors before implementing it in our pillbox.  The two designs we will look at are the lead screw + nut design and the timing belt design.  We will see which one works most reliably and then look at which is easiest to implement.  Based on the results, we will choose one design for all the sliding compartment doors in our pillbox.  Our contingency plan in the case we are not able to get the sliding doors to allow only one pill to drop at a time is to have the user place all the pills for one day/time together in one compartment, so when the day/time comes, all the pills in a particular compartment can be dropped into the collecting tray.

One change we have made to the design of the system is that we are no longer basing on average pill sizes and are instead using pulsing to ensure that only a singular pill drops at a time.   Originally we were going to base it on average pill sizes so a specific sliding door knew how much to retract based on the pill size contained in the compartment.  We realized this adds too much complexity in the setup of the pills for the user.  Additionally, we no longer believe this will aid in ensuring only one pill is dropped at a time since there will still be variation within each group of pill sizes.  We believe pulsing is a more robust solution for all the varying pill sizes.

Originally the size of the pillbox was made to accommodate the largest average pill size we were looking at.  Now, the size of the pillbox has been updated to accommodate a 90-pill supply of the largest pill size.  The width of the pillbox was also limited in the amount of tabletop space that the pillbox takes up to be comparable to unautomated pillboxes on the market.  The cost of this change is that the pillbox will now take up more vertical space.  The more vertical our design, the higher the risk of tipping over; to mitigate this, we will have a weighted base and anti-slip base, which will be a high-friction rubber or silicone pad.  Additionally, we will have keyhole slots on the back of the pillbox so it can mount to the wall (still “on a shelf” but optionally fixed.)

Another change is we will use Wi-Fi + MQTT via a broker instead of Bluetooth, as our design study showed it to be more reliable for its remote caregiver access and clean sync model.  The cost of this change is that it creates an additional requirement for the user to have Wi-Fi, as well as requiring more infrastructure like brokers and authentication. However, we would assume that if a user were to want to be a user of our product, which requires electricity (we do not plan for a battery design), they would also have access to WiFi.

Below is our updated schedule.  Primary tasks of each person have reminded fixed, but individual tasks have been adjusted according to design changes.

Part A: Global Factors, written by Carolyn

Our pillbox is for older adults who have trouble managing multiple prescriptions.  A challenge faced worldwide as we face aging populations.  By operating in both online and offline modes by storing schedules locally and providing alerts on the pillbox itself we are ensuring our product can still be used in locations with unreliable internet connection.  Which is a common global concern.  Additionally, we are designing the physical interface and guided workflow to be as simple and intuitive as possible for the user to make the devices accessible for those who are not technologically experienced.  Furthermore, prescription pill access can vary based on locations.  Certain users may have to travel far to access their nearest pharmacist.  We do our best to accommodate this by supporting high-capacity storage.  Which should limit pharmacy visits to once per month ideally.  This allows the device to remain useful in areas with limited healthcare infrastructure.

Part B: Cultural Factors, by Jahnvi

Medication routines are often heavily shaped by cultural beliefs, specifically norms regarding elder care.  In many cultures older adults rely heavily on family members for there medication needs.  Which is why Magic Pillbox supports and allows for caregiver involvement, specifically through the app where issues and taken status are logged.  Furthermore, many elders show distrust of advanced technology.  Respecting this preference, we ensure that our pillbox is fully operational offline, except for setup steps, which should have to be carried out no more than once a month typically so they can be carried out by a caretaker if needed, instead of the primary elderly user. This allows the primary user to have minimal interaction with the app if desired.  We use audible and visual reminders on the box itself for this.

Part C: Environmental Factors, written by Jieun

In consideration of environmental factors, our pillbox is extremely careful in trying to minimize the material used, as we do aim to build our main body with plastic, which has already been flagged as a potential environmental harm in terms of disposal should the product be defective, etc. By carefully discussing and simulating the design as much as possible before creating the main prototype, we can minimize the plastic material used in total. This applies even after initial prototyping; should our product or a similar design ever make it into the real market, minimizing the overall size also minimizes plastic and electronic waste. We will also be avoiding including designs that can create choking hazards should there ever be an improper disposing of items (which we will, of course, try our best to never let happen in the first place by including instructions and also being careful on our own end). The one cup holding that can be separated from the main device is designed and will continue to be looked at so that it’s large enough to not be a potential choking hazard but not too large as to incur greater waste.

Carolyn’s Status Report 3/7/26

This week, I focused on refining the mechanical dispensing system and updating several core design elements.  I fleshed out our sliding door feature on the pill box.  I came to two possible solutions that will be most reliable lead screw + nut design and timing belt design.  After reevaluating our sliding door feature I wanted to pivot away from casing on average pill size.  Originally we did this so a specific sliding door knew how much to retract based on the pill size contained in the compartment.  Yet it would not account for all the possible pill sizes negating our use case, as well as I believe not being much more accurate as there is still variation in the pill sizes in each size group.  Instead I proposed pulsing would be better fit for handling all the different pill sizes accurately.

Since we had gotten rid of the average pill size casing we now needed to accommodate all possible pill sizes, so the pill box size needed to be adjusted accordingly.  An additional constraint that I added based on the feedback of the professors was to limit the size of the pill box based on the size of pill boxed currently on the market.  The most valuable space that our pill box would take up is table top space, so I specifically limited the width of the box on the table based on market research.

Another piece of feedback we received was to account for humidity causing pills to stick together, to counteract this I added airtight compartments and silica gel packets in each compartment to the design.

Based on the design updates we made I updated the individual tasks in our schedule.

I also made our parts list along with specific vendor links.

Using the constraints on pill box size identified above I conducted a design trade study to identify the ideal height of the pill box.  Illustrated in the graph below.

Finally for our design report I was responsible for writing the quantitative design requirements, design trade studies and project management sections.  I reviewed and edited my partners sections before the final submission.

We are on schedule for everything except ordering parts.  Now that I have accumulated the parts list I will start putting in the orders soon.

In the upcoming week I hope to make prototypes of each of the sliding door designs to identify the best solution to implement in our pill box.

Carolyn’s Status Report for 2/21/26

I have been working to update our design based on the feedback we have received from our design presentation.  We need to figure out how the user will reset the device when there is a misdropping of a dose.  I will continue working through this with our TA and prof during our upcoming meeting.  For now, we will set an alarm in the app if a dosage was dropped incorectly which will instruct the user to take the dose out of the tray for it to be readministered.  I also made a diagram of our proposed pill box design.

We are mostly on schedule.  Yet we are a bit behind schedule for ordering the parts our project will need.  I didn’t realize how much we would tweak our plan after every meeting and presentation, so the exact parts we need have been continuously changing.

Next week, I plan to make updates to the laser-cutting file design for the box and print it out.  So we can have the physical pieces as soon as possible.  As well as finalize parts lists and put in orders.

Team Status Report for 2/21/26

What are the most significant risks that could jeopardize the success of the
project? How are these risks being managed? What contingency plans are ready?

At our Design presentation, we received helpful feedback from the audience that exposed additional risks in our product.  The first was what will the pill box do when the wrong pill is dispensed?  We had already established that we would use the weight and motion sensors to make sure the correct pills are dispensed.  So when we know the wrong pill/number of pills were dropped, we send a warning to the user through the app that that dosage is incorrect.  Yet we still need to think about the next steps.  What will the user do with the pills? How will the box be reset? We plan on having it so that an alarm will be set up on the app within a set amount of time (for now, we aim to have the user set the time in the app as medications vary in terms of within how much time it should be taken in), warning the user or their caregiver to take the pills and reset/re-allocate the pills as necessary.  Another question we received was how we will test if our pill box works, since our target audience is elderly people with dexterity issues.  We plan to contact some elder care facilities to see if any volunteers would be willing to test our product.  Or if the staff at the facilities can give us feedback on our project as well.

• Were any changes made to the existing design of the system (requirements,
block diagram, system spec, etc)? Why was this change necessary? What costs does the change incur, and how will these costs be mitigated going forward?

We have made the change of going from using a FPGA and ESP32 microcontroller to using two ESP32 microcontrollers for two main reasons: firstly, we did not want to overcomplicate the process as the communication between two microcontrollers would be a challenge in itself to have an almost perfect accuracy rate, and secondly, for bluetooth, there is a more reliable ESP-NOW protocol available for communication between two ESP32s, which would allow for cleaner and less error-prone connections. This would actually lower the technical cost of our project as a FPGA is much more costly than an ESP32 Arduino Nano (which is the specific microcontroller we wish to use for this project for both size and price).

• Provide an updated schedule if changes have occurred.

Our schedule remains the same as a whole.