Mechanical 7‑Segment Counter

Report
Project Overview: Designed and fabricated a fully mechanical 7‑segment counter using gear trains and a ratchet‑and‑pawl mechanism. Counts up to 7 events or revolutions before resetting. Optimized gear ratios for smooth segment indexing. Modeled parts in SolidWorks and assembled a working prototype. Industry Applications: Industrial machinery (production cycle counting), conveyor systems, exercise equipment, vending machines, and analog meters in remote locations without power. Key Design Features: 7‑step indexing (51.4° per advance) Spring‑loaded ratchet‑and‑pawl for one‑way counting Automatic or manual reset Fully mechanical – no power required CAD Software: SolidWorks (3D modeling, assembly, motion study) Fabrication: 3D printed (PLA) / laser cut acrylic – assembled with fasteners and springs Real‑World Example: Attached to a conveyor shaft to count boxes per batch – workers see the count (0–7) instantly without batteries.
Published
in SolidWorks Design Services 3D Models of Machine Parts Mechanical CAD Design
solidworks fabrication prototyping rapid-prototyping mechanical-design cad-modeling assembly-design mechanism-design fabrication-drafting-services fabrication-design mecahnism mecanical design-for-manufacturing-dfm gear-train-design ratchet-mechanism
Rendering Images