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Frame top 23/4" Frame top 1" x 1/2" Corner angle iron
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Frame bottom FIGURE 26.1 Cutting and assembly for the polar arm base risers. a. Riser placement; b. Hardware assembly detail.
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SHOULDER ROTATION MECHANISM
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Top view FIGURE 26.2 Cutting and assembly detail for crosspiece and turntable.
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TABLE 26-1
PARTS LIST FOR POLAR COORDINATE ARM.
Frame/BASE
4 4 4 4 4 8 Misc 1 1 12-inch lengths 41/64-inch-by-1/2-inch-by-1/16-inch aluminum channel stock 10-inch lengths 41/64-inch-by-1/2-inch-by-1/16-inch aluminum channel stock 2 1/2-inch lengths 41/64-inch-by-1/2-inch-by-1/16-inch aluminum channel stock 2-inch-by-1/2-inch flat mending iron 1-inch-by-1/2-inch corner angle iron 1 1/2-inch-by-3/8-inch flat corner angle iron 8/32 stove bolts, nuts, tooth lock washers
Shoulder Base
10 5/8-inch length 57/64-inch-by-9/16-inch-by-1/16-inch aluminum channel stock 9-inch length 57/64-inch-by-9/16-inch-by-1/16-inch aluminum channel stock
392 BUILD A POLAR COORDINATE ARM
TABLE 26.1
PARTS LIST FOR POLAR COORDINATE ARM. (Continued)
Shoulder Base
2 2 2 1 1 2 2 1 1 1 1 1 7-inch length 57/64-inch-by-9/16-inch-by-1/16-inch aluminum channel stock 2 1/2-inch mending plate T 1 1/4-inch-by-5/8-inch corner angle iron 3-inch-diameter ball-bearing turntable 3-inch-by-10/24 stove bolt, nuts, flat washers, tooth lock washers Plastic closet pole holders 1/2-inch bearings 1/2-inch aluminum spacer 3-inch-diameter 35-tooth chain sprocket (#25 chain) Stepper motor 1 3/4-inch-diameter 20-tooth chain sprocket (#25 chain) 17-inch-long (nominal) #25 roller chain
Misc 1/2-inch-by-8/32 stove bolts, nuts, tooth lock washers
Elbow
2 2 1 1 2 1 1 6-inch lengths 57/64-inch-by-9/16-inch-by-1/16-inch aluminum channel stock 3 1/2-inch lengths 1-inch-by-1-inch-by-1/16-inch aluminum angle stock 2 1/2-inch length 1-inch-by-1-inch-by-1/16-inch aluminum angle stock 7 1/2-inch length 1/4-inch 20 all-thread rod, nuts, locking nuts, flat washers, tooth lock washers 1 3/4-inch-diameter 20-tooth chain sprocket (#25 chain) 17-inch-long #25 roller chain Stepper motor
Misc 1/2-inch-by-8/32 stove bolts, nuts, tooth lock washers
Forearm
1 2 1 1 2 1 16-inch-long (nominal) drawer rail 1-inch-to-1 1/2-inch-diameter spur gears, with setscrew recessed in hub 3 1/2-inch length 1-inch-by-1-inch-by-1/16-inch aluminum angle stock 18-inch length (approx.) 1/16-inch diameter steel aircraft cable 14 16 gauge wire lug Stepper motor
Misc 8/32 stove bolts, nuts, tooth lock washers
SHOULDER ROTATION MECHANISM
Nut Tooth lockwasher Arm column base Nut
Spacer Flat washer Tooth lockwasher Nut Nut Flat washer Tooth lockwasher Chain sprocket Tooth lockwasher Flat washer
Spacer
Flat washer Nut
1/ " aluminum 2
Bearing Turntable
Cross piece Bearing 3" x 10/24 bolt
FIGURE 26.3 Hardware assembly detail for central shoulder shaft. a. Assembled shaft; b. Exploded view.
plop them onto the shaft. The drive sprocket should be approximately one inch above the cross brace. Use a 10/24 bolt and tooth lock washer and a flat washer to clamp the drive mechanism into place. Attach a 20-tooth 1 3/4-inch diameter #25 chain sprocket to the shaft of the motor, as shown in Fig. 26.4. The prototype arm used a medium-duty stepper motor with a 1/4-inch shaft. The 1/2-inch I.D. hub of the sprocket was reduced to 1/4-inch with reducing bushings. If you use a similar motor (they are common on the new and surplus market) and the same-size sprockets, the roller chain length should be a nominal 17 inches. You can use a
394 BUILD A POLAR COORDINATE ARM
FIGURE 26.4 The mounted shoulder motor, with chain sprocket and roller chain.
slightly longer or shorter length of roller chain because you can position the motor anywhere along the length of the frame to compensate. Choose a mounting location with the roller chain in place. Move the motor along the edge of the frame until the chain is taut (but not overly tight), and mark the mounting location. At the mark, attach the motor to the frame using two 1 1/2-inch-by-3/8-inch flat corner braces. Elevate the braces using 1/2-inch spacers. Use 6/32 by 1/2-inch bolts and nuts to secure the motor to the braces and 8/32 by 1/2-inch bolts and nuts to secure the braces to the frame. Construct the arm column using two 7-inch lengths of 57/64-inch-by-9/16-inch-by-1/16inch aluminum channel stock and one 9-inch length of the same. Mount a 7-inch length flush to one end of the 9-inch member. Use 1 1/4-inch-by-5/8-inch corner angle brackets and 8/32 by 1/2-inch bolts and nuts to secure the pieces in place. Mount the other 7-inch length 3 inches from the opposite end of the 9-inch member (see Fig. 26.5 for details). Likewise, secure it using an angle bracket. Drill a 1/4-inch hole in the center of the 9-inch piece, and mount the assembly on the shoulder rotation shaft, as shown in the figure.
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