CAD Models and Fabrication Instructions

Assembly and Fabrication Instructions:

Test Bed:

1. Cut 1” T-slotted aluminum to length.

2. Add the tee bracket to the length of aluminum that goes in the middle of the base connected to the vertical linear rail. 

3. Connect the lengths of aluminum together to form the base of the test bed using the L brackets

4. Add the vertical upright aluminum bars using the tee brackets and tighten in place. 

5. Attach the vertical linear rail to the front of the center upright.

6. Slide in 8 fasteners on either side of the central upright for the stop blocks to attach to. 

7. Using two L brackets on the sides and one tee bracket in the middle attach the upper horizontal bar of aluminum to the three uprights.

8. Attach the test bed plate to the front of the platform using four M5 bolts

9. Use 2 L brackets to attach the 7” length of aluminum to the left side of the test bed. 

10. Thread the 3 springs into the spring attachment bracket, and using the 1: l brackets attach it to the left side of the 7” aluminum bar.

11. Using 3 screws attach the ends of the springs to the left side of the test bed platform 

Linear Actuator:

1. 3D Print Motor Mounts, brake, bushing holder, stepper motor clamp, coupling nut holder from CAD files. 

2. Press fit M3 lock nuts into the bushing holder, both parts of the motor clamp. 

3. Screw in M3 bolts to all necessary 3D prints. 

4. Press fit bushing into 3D print holder. 

5. Clamp stepper motor into 3D print using M3 bolt on the side. 

6. Press fit coupling nut into 3D print holder. 

7. Heat sink insert into shaft coupler print. 

8. Screw in threaded rod to:

   1. Coupling nut

   2. Shaft coupler

9. Attach rubber onto the brake. 

10. Screw in brake and motor mounts to linear rail and carriage, respectively.

11. Attach carriage to rail utilizing 3D printed mount converter.

12. Slide carriage onto T-slot aluminum vertical bracket.

Linkages:

13. Lasercut the linkages using the CAD files. 

14. Countersink the holes according to the CAD.

15. Pressfit the bearings and bushings into the linkages.

16. Using M4 bolts stack and bolt the linkages together

17. Using the shoulder bolts connect the linkages at the joints placing a washer in between them.

Planetary Gearbox

1. 3D print the ring casing, sun gear, 4 planetary gears, carrier, and lid.

2. Add heat inserts to the ring casing.

3. Sand the carrier face.

4. Screw sun gear on to the motor.

5. Attach the ring gear to the linear bearing-motor mount.

6. Place the planetary gears in the gear box.

7. Put the carrier in the 4 planetary gears.

8. Add grease in between the gears.

9. Screw on the lid