Hidden Staircase

Digital Design - 5.2m x 2.2m x 3.4m (L x W x H)

SKILLS USED: SolidWorks CAD, SolidWorks Simulation

I was given a concept of a staircase with a section that would drop away to reveal a hidden passage. When I started on the project the set was already under construction and a proof of concept maquette was finished. In brief the effect would be accomplished by a ramp built under the stairs. When lowered each step would follow, guided by an angled track into their new bottom position. My role on the project was to create a complete design for the full size mechanical rig to be retrofitted.

I started by surveying the underside of the staircase and surrounding area making note of critical dimensions required for the mechanism and its installation. From that information I created a 3D model of the steps and worked out the basic geometry and dimensions.

Under each step in my design was a pair of wheels to smoothly roll along the ramp as it changed angles. There were also guide slots to keep the steps level as they moved and dictated the spacing between them in transition. A critical point of this design was when the ramp was horizontal, that each step had enough clearance as they passed each other. The amount of clearance was dictated by the angle of the guide rails for each step. There was fine adjustment built in for the height of each step from the ramp along with adjustment for the width of the step assembly between the channel guides. The goal was to have the steps seamlessly blend in at the top position and then effortlessly glide down to the bottom position.

This was my project when the pandemic hit and lockdowns started. By the time we got back to work the scrip had changed and this gag was out. I never got to see the ramifications of my design choices in the workshop, troubleshoot through those problems, or ask detailed follow up questions to more senior crew members. Above are some of the simulations I ran on the mounts for the hydraulic cylinder. I'm very conscious that plugging in garbage constraints and values into a simulation will result in garbage out. When I stopped on the project I had the FOS just under where I wanted it (4). I'm keen to gain more real world experience in this area in the future.