Pin Router Duplicator

The initial design was based on the following:

The analysis of the project will be designed around the requirements and ensuring that they meet the requirements. Making assumptions about the weight of the wood carving duplicator as a system, and estimated dimensions of the two plates, linkage arms, linkage mounts, stylus, and the mount for the stylus, allows for an analysis to be performed. One of design requirements is that the 4 bar linkage system weighs less than 125lbs, which in this case, it doesn't exceed 125lbs. The first design didn't work because it was too heavy and deflected more than .005inches, so a new design is optimized for weight reduction and deflection. The new design was optimized by using lighter material i.e. aluminum 6061 T6. Assuming the weight of the 4 bar linkage system is 25lbs, there will be a spring that will be used as a counterbalance, which will allow the 4 bar linkage system to move back into a neutral position for repeatability. With the goal of 6 inches of travel in the Z-Axis, a model will be developed in SolidWorks. Bending moment and shear force calculations are calculated to ensure that, under failure, the router head will remain intact with the base frame.

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i) Design Issue:

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A potential design issue is that the spring won’t be able to counterbalance the weight of the router head. The dimensions of the router head will need to fit within the main frame to ensure no interference. However, changes may be made. A second potential design issue is the material of the router head. The material could potentially not support the weight of the router head, which could lead to parts breaking.  

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ii) Calculated Parameters:

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Included below are sample figures that are calculated:

Bending Moment for Base Plate:                                                                                            90lb-in

Bending Moment for Stylus Mount:                                                                                      45lb-in

Shear Force for Base Plate:                                                                                                      15lbs

Shear Force for Stylus Mount:                                                                                                 7.5lbs  

Moment of Inertia for Base Plate:                                                                                      .0399in^3

Moment of Inertia for Stylus Mount:                                                                                  .0045in^3

 

iii) Best Practices:

 

As the pin router duplicator is designed for the class Lean Manufacturing (MET 345) offered at Central Washington University, it is of the utmost importance that the safety of students is ensured. When designing the duplicator, a safety factor of 3 will be used. Additionally, sources of components that are commercially available, will lead to easy maintenance and repair, if needed. By keeping up with maintenance, anticipated failures can be minimized.

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