After working with Marcel, proto 9 is underway. The design is starting to get refined
New arm will be 3/8 aluminum screwed to 1/4 steel
Cut the profile
I'm making two sets of parts, one for me, one for Marcel's studio
Pressed in bronze bearings and shoulder screws will increase smoothness
More fixturing
And more
Small parts can be a bit tricky
But, all is well
Ready for the next step
Steel is a bit harder to deal with
But, steel is necessary for the magnetic lock
Weld magnet plate to shaft. It will be turned flat on the lathe
Test fit, all is well
I love CAD, but sometimes when designing hand controls, a flexible, physical test bed is useful..even if it's crude
The hand control is a complex part, hogged out of 1.25 stock
Finish the profile
Make the cap
Encoder and buttons fit nicely
With end cap in place
Make a Padouk handle on the lathe. I like Padouk
This is one of the most complex pieces in the design
Fits the handle nicely
Encoder and buttons fit nicely
I think I like the black buttons better
Not much space for wiring, but I prefer good ergonomics over ease of assembly
End cap fits nicely
First test of all axis locking. Mostly works well. Main axle locking feels weak
In testing, it was observed that aluminum was being deposited on the glass and that the aluminum shaft collars were galling the rollers. The new design uses delrin rollers with larger aluminum end plates to shield the plastic from heat
In testing, the tube clamp on proto 8 proved inadequate when used with tubes larger than 25mm. The clamp rotated about an axle, causing the contact point to vary with tube diameter. The new design will have linear clamping, and 3 rollers, to work better with large diameter tube. Initial design spec was 38mm. I have increased this to 50mm
First attempt at a linear lock almost works. Time to pop a beer, take a toke and think...
Ahh.. the life of an inventor
Sometimes, I wish I was smart enough to get it right on the first proto
Most other times, I just enjoy the journey
Flat bar works better as a clamp, but narrow slots are hard to mill, so, try a round rod. It works, but it's right on the edge of not working..hmmm..
Wasted too much time on round rods. Figured out how to make the slot easily
This version feels good
Proto 9, all parts complete, time for wiring and software
Everything works, but the 40mm magnets are way too weak. Time to switch to 50mm magnets. Lots of parts need to be rebuilt. In order to get the maximum magnet force, the mating surfaces need to be precisely aligned. In this photo, I applied lapping compound and put the joint into the lathe, at low speed, to try to get a closer fit
Proto 9, with precisely lapped 50mm magnets, on the glass bench
Marcel Braun testing Proto 9
Proto 9, being shown at CHAMPS by Marcel Braun