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Thursday 10th heavy overcast with fine drizzle. Another miserable day. With absolutely no excuse to do nothing at all.
So I made an asymmetric angle profile with one leg shorter than the other. From a handy bit of aluminium scrap. Which had once served as a fence post. You may well imagine how much cleaning up was required once it was reduced to size. No point in cleaning the whole length unless it is to be used shortly.
This angle profile will be bolted to the top of the motor housing. To provide lateral support for the channel section, worm housing in the foreground. The separation pressure of the worm teeth on its wheel pushes from the direction of the camera.
The image shows the basic idea. The three, odd screws were just dropped into the fixing holes to hold the alignment of the parts in the photograph. I haven't managed a full "trough" housing but it will be better than nothing.
The [newly shiny] angle profile sits behind the channel section. Note now that worm housing has been moved to the front edge of the motor housing box. Note that I have simply drawn in the 5mm thick motor attachment plate on the right. I may partially plate over the front of the box to close the weakening of the slot for the motor's power socket. There is plenty of scrap, box section aluminium left if I do decide to change the design.
The motor can be reversed, end for end, but this still requires a slot for its power socket. [Arrowed] Because the motor isn't the full length of the box, the socket always ends up in the middle. So regardless of motor orientation access is still has to be required. The large slot cannot be made any smaller nor any shorter. I prefer the motor orientation where the socket can be easily reached by its plug.
Now I am just waiting for some countersunk, machine screws to be delivered. So that I can fix it all together. Then I can mark out the new motor plate. It is too fiddly trying to mark anything out properly when the whole assembly is sliding about. The motor itself will need to be shimmed before I know its final position. This will affect the [large] pulley hub clearance holes in the motor plate.
I have found some nice, clean, flat strips of aluminium for shimming the motor. These will slide perfectly between the stepper motor and its box section housing on two sides. The sturdy stepper motor will then help to solidify its surrounding box section. Helping to avoid the motor/worm assembly distorting under load. Which it was doing quite visibly in the earlier videos.
Six new holes will need to be countersunk on the inside of the motor box for these new screws. I have made a start but will leave the final depthing for the actuals screw heads. There is no clearance for any other but countersunk screw heads on the inside. With the screw threads facing outwards. It took some ingenuity to develop a means of countersinking inside a 70mm square box.
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