I Over-Engineered this Machine, cause Manufacturers Didn't
Marius Hornberger・66 minutes read
The oscillating Edge sander features a height preset for sanding, a dust collection part, and a meticulously designed oscillation mechanism for smooth operation. Various parts were carefully machined and assembled for optimal performance, with adjustments made to ensure accurate fit and smooth operation during assembly.
Insights
- The oscillating Edge sander is meticulously crafted with a height preset, dust collection part, and a cycloidal drive concept for smooth operation.
- Precision machining and assembly of components like the gearbox, pulley, and oscillation mechanism ensure optimal performance, while unique features like the tilting belt and sanding backing plate enhance functionality.
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Recent questions
What are the key features of the oscillating Edge sander?
The oscillating Edge sander can accommodate different size drums and belts for sanding inner and outer contours. It includes a height preset for using the upper part of the belt, easy belt changing with a lever, and a dust collection part for efficient cleaning. The sander's oscillation mechanism is meticulously designed for smooth operation, featuring a cycloidal drive concept and a ramp shape for oscillating motion without bevel gears. Precision-ground shafts, bearings, pins, and screws ensure optimal performance, with parts like the gearbox and pulley machined and assembled for efficiency.
How is the oscillation mechanism of the sander designed?
The oscillation mechanism inside the sander was meticulously crafted to ensure smooth operation. It involves a cycloidal drive concept for a high gear reduction of 9 to 1, eliminating the need for bevel gears. The mechanism includes precision-ground shafts, bearings, pins, and screws, meticulously assembled for optimal performance. This design choice allows for efficient sanding and precise oscillating motion without compromising on durability or functionality.
What materials are used in the construction of the oscillating Edge sander?
The oscillating Edge sander is constructed with precision and durability in mind. Parts like the gearbox, pulley, and upper bearing block are meticulously machined and assembled for optimal performance. The main drum is made from plastic sheets, while rollers are crafted from aluminum tubing with bearings for smooth operation. Metal plates, aluminum plates, and shafts are used in the belt tensioning mechanism for adjustment. These materials are chosen for their strength, longevity, and ability to withstand the rigors of sanding operations.
How is the table of the oscillating Edge sander mounted?
The table of the oscillating Edge sander is mounted securely for stability during sanding operations. Steel brackets with bushings and washers are used for swiveling parts, with slots to prevent flex. The table is mounted with bolts and blocks, with holes drilled for rail mounting. Aluminum table plates from JLC 3DP arrive with precise cuts and threads already in place, ensuring a secure and stable mounting surface. This mounting method provides the necessary support and rigidity for accurate and efficient sanding tasks.
What improvements were made to the tensioning drum of the oscillating Edge sander?
To address belt tracking issues, modifications were made to the tensioning drum of the oscillating Edge sander. A new crown was designed for the tensioning drum to improve tracking adjustment, ensuring the belt stays in place during sanding operations. The drive block was also modified to enhance tracking adjustment, providing a smoother and more precise sanding experience. These improvements enhance the overall functionality and performance of the sander, making it more efficient and effective for woodworking tasks.
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Summary
00:00
Efficient Oscillating Edge Sander with Height Preset
- The oscillating Edge sander can accommodate different size drums and belts for sanding inner and outer Contours.
- A key feature of the sander is a height preset that allows the use of the upper part of the belt for sanding.
- Changing belts on the sander is easy by flipping a lever to remove the whole belt attachment.
- The sander does not include a tilting table, as the tilting belt is deemed more useful and effortless to adjust.
- The sander features a dust collection part at the back for efficient cleaning.
- The oscillation mechanism inside the sander was meticulously designed to ensure smooth operation.
- The oscillation mechanism involves a cycloidal drive concept for a high gear reduction of 9 to 1.
- The mechanism also includes a ramp shape for creating oscillating motion without the need for bevel gears.
- The oscillation mechanism was carefully assembled with precision-ground shafts, bearings, pins, and screws.
- Parts for the sander, including the gearbox, pulley, and upper bearing block, were meticulously machined and assembled for optimal performance.
16:51
Precision Machining Techniques for Machine Assembly
- Two bolts are used to secure the machine, allowing it to operate smoothly.
- The CNC machine's accuracy affects the fit of the bearing, requiring adjustments.
- Round off cuts from a laser are used to create threads for holding the part on a lathe.
- Material is faced and turned to achieve a precise fit with aluminum for centering.
- Holes are drilled and tapped to specific sizes for screws and bearings.
- A layer of Sharpie is used to adjust the bearing's fit, resolving the issue.
- Components like the drive block are faced, turned, and cut to fit the template.
- Single flute bits are used to prepare birch plywood for machining in a CNC router.
- Parts are precisely positioned for second-side operations to ensure accuracy.
- Assembly involves screw joints, dowels, and precise alignment for a finished sled frame.
34:39
Creating Weather-Resistant CNC Router Parts
- Sand the material to fit the cutout in the carriage for the slot.
- Used a step drill to remove the middle, jigsaw for cutting, and filed the rest.
- Demonstrated the concept with a part from the CNC router made of HPL, a mixture of wood fibers and resin.
- HPL is weather-resistant, durable, and easily machinable with woodworking tools.
- Used polyethylene sheets for guides due to low friction and stability.
- Checked and adjusted the thickness of the step to match the slider.
- Created smaller guides with manual work and encountered a misalignment issue.
- Used an acrylic glide bushing for the pin, secured with a lock nut.
- Installed gas shocks for smooth operation with a 10 kg sled.
- Assembled the trunnion assembly with polyethylene sheets, gear teeth, and gear mounts for precise angle adjustments.
52:59
"Swiveling Table with CNC Insert Plates"
- The table has pockets underneath to hold various insert plates, some of which can swivel.
- The insert plates are CNC parts and are assembled without screws on the top for a clean look.
- Steel brackets with bushings and washers are used for swiveling parts, with slots to prevent flex.
- The table is mounted with bolts and blocks, with holes drilled for rail mounting.
- Aluminum table plates from JLC 3DP arrive, with precise cuts and threads already in place.
- Insert plates are made to fit different tools, with leveling screws and brackets for support.
- A belt tension assembly is created with three rollers, two for sanding and one for tensioning.
- The main drum is made from plastic sheets, with precise turning and drilling for assembly.
- Rollers are made from aluminum tubing with bearings, ensuring smooth operation.
- A belt tensioning mechanism is assembled with metal plates, aluminum plates, and shafts for tension adjustment.
01:09:25
Enhanced Sanding Machine with Innovative Features
- Three Holts and threaded inserts are used to allow movement in the frame while keeping the drive block stationary.
- Adjusting bolts are used to ensure the table remains level and straight when tightened down.
- A cam lever with a threaded rod and teut is used for quick and easy tightening.
- A new crown for the tensioning drum is made to address belt tracking issues caused by the previous design.
- Modifications are made to the drive block and tensioning drum to improve tracking adjustment.
- A sanding backing plate is added using a steel plate with chamfered edges.
- A 3D printed dust collection system is created and installed for improved cleanliness.
- Sanding spindles are designed with a unique clamping mechanism using rubber sleeves and a knob for changing sanding sleeves.
