TEAM ALPHA PROGRESS REPORT

(FEB 24TH –MARCH 2ND)MAGGIE CLEGGCODY DONAGHESCOTT GARCIA

IVAN HERNANDEZJEHAN JAYAMAHA

ROBERT PECKHAM

OVERVIEW1. SUBSYSTEM 1

UPDATED BASE PLATE AND PRESS PLATESELECTED MOTOR, GEARBOX, AND BEARINGS FOR PURCHASE

2. SUBSYSTEM 2UPDATED STANDARD OFFSET SHAFT DESIGNDESIGNED HOUSING

3. SUBSYSTEM 3ACQUIRED MATERIALMINOR REDESIGN FOR MANUFACTURINGLABOR ESTIMATES

4. WHAT’S NEXT

1ST SUBSYSTEM

Press Plate Base Plate

Modified press plate and base plate. This design is better for manufacturing. Other parts of the first subsystem have been modified for laser cutting.

4-Speed Crank Axle Gearbox from Tamiya

Gearbox to be Used in the First Subsystem

Source:http://www.hobbyengineering.com/H2031.html

Assembled Gearbox Disassembled

Gearbox

Gearbox Specs: This 4-Speed Crank Axle Gear Box is small but has a lot of power. There are four gear ratios to choose from, including the slowest ratio that allows for two rotations per minute. Two crank arms are included for added flexibility in the design of projects. Gear Ratios: 126:1, 441:1, 1543.5:1, 5402:1. Motor: FA-130. This motor seems to be the best fit for our subsystem because of the flexibility it implements with the various gear ratios.

Sku: 2031Qty. Price1 to 4 $10.995 to 9 $9.89

10 to 19 $9.3420 or more $8.79

MOTOR TO BE USED IN THE FIRST SUBSYSTEM

Mabuchi FA-130 Motor 

Motor Specs: • Flat housing, metal brush motor. Operating voltage 1.5VDC to

3VDC. At 1.5VDC no load output is 9100RPM at 200mA, stall torque is 26g-cm (0.36oz-in) at 2.2A and maximum efficiency output is 6990RPM delivering 6g-cm (0.08oz-in) torque while drawing 660mA current.

• The motor has a 2mm (0.078") diameter shaft that extends 7.3mm (0.29") beyond the front bearing.

• The metal can dimensions are 15mm (0.59") over the flats and 20mm (0.79") over the curve. The length is 25mm (0.99") measured from the flat front of the can to the flat part of rear plastic cap. The body length is 29.1mm (1.15") measured to the bearing / alignment surfaces. The overall length is 38mm (1.5") measured tip-to-tip of the drive shaft.

Quick FactsSku: 2242Brand: Tinkering

SuppliesBrand's Part Number: FA-130

Qty. Price1 $2.99

2 to 9 $2.5410 to 19 $2.39

20 or more $2.24Source:http://www.hobbyengineering.com/H2031.html

FOR PURCHASE

The design requires 6 bearings. The selected bearing is from thebigbearingstore.com. The estimated total cost for 6 bearings with shipping is $17.39. The design has been modified for this specific bearing.

2ND SUBSYSTEM

Offset Shaft for Clamp Opener

Offset Shaft for Knife

The offset shafts for the second subsystem resemble the offset shaft used in the first subsystem. The offset shafts utilize the same parts in different configurations. Not pictured is the bearing which will be press fitted into the connecting shaft.

CHANGES TO BASE PLATE, PUSH PLATE, AND TURN DIAL

Before modifications After modifications

HOUSING• WILL HELP KEEP ROTATING COMPONENTS IN PLACE• WILL CONSTRAIN THE 2ND SUBSYSTEM IN PLACE

• MAX AMOUNT: 871 SQUARE INCHES, OR 6 SQUARE FEET OF 1/8’’ SHEET METAL

• THIS WILL GO TOWARD CONSTRUCTING HOUSING SIMILAR TO A BOX (EXCEPT FOR THE TOP AND ONE SIDE).

• A LOT CAN STILL BE CUT OFF, SO THE ACTUAL AMOUNT NEEDED WILL BE WAY SMALLER.

SUBSYSTEM 3 UPDATES• SHEET METAL ACQUIRED. PREVIOUSLY FOUND WILLING P.C. NOW WAITING FOR RESPONSE.• DUE TO NO FUND, REDESIGNED AS MANY COMPONENTS AS POSSIBLE TO BE CUT FROM

SHEET. INCLUDING• PAWL GEAR• CAM• PILLOW BLOCK BEARINGS (REPLACED BY LUBRICATED JOURNALS SUPPORTED BY SHEETING)

• NEW ESTIMATED BUILD TIME• LC PARTS (8HRS PROGRAMMING/CONVERTING FILES & SETUP MACHINE) (1HRS CUTTINGS)

• WELDING TOGETHER (10 HRS)• JOURNALS (6HRS)• BARREL (6HRS)• PISTON (3 HRS)• PISTON SPRING MOUNTS (3 HRS)• BARREL MOUNTS (4 HRS)• INNER SPRING PIN (10 HRS)• SPRING PIN SHEATH (3 HRS)• PAWL MOUNT (2 HRS)• RELEASE PIN (8 HRS)

SYSTEM 3 STILL REQUIRES

• CONFIRMATION THAT WE CAN STILL PURCHASE• COMPACT DC GEAR MOTOR FROM MCMASTER CARR ($53)

• 4RPM, 640 OZ-IN (94LB AT PISTON), 12VOLT, .7 AMP• 1 TORSIONAL SPRING (HOLD PAWL AGAINST GEAR)• AT LEAST ONE SET OF 4 TENSION SPRINGS IDEALLY MORE TO TEST BUT

DEPENDENT ON FUNDS• SS BALL BEARING BALLS ($6)

WHAT’S NEXT

• FINISH DESIGNING THE HOUSING• FIGURE OUT FUNDING• BUY/COLLECT MATERIALS• BEGIN MANUFACTURING• ASSEMBLE