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Hello, I have looked high and low for something that meets these requirements and I cannot find a single component that matches them, am I crazy or should this exist? - Male-Female mating pair - Both panel mount - Mating but not locking (this seems to be the hardest requirement to meet) -...

@drawoh Thank you for the response! 5052-H32 really does seem to be the bread and butter of most sheet metal shops I've dealt with, I've even had some quote flats specced as 6061-T6 in 5052 without even asking if it was acceptable [upsidedown] However, if there really is no cracking (and that...

Hi all, I inherited a sheet metal part design that has some tabs bent on it that allow tensioned stabilizing lines (basically guy wires, but for a dock) to loop through as a tie-off point. I've gathered that the previous designer was very weight-conscious so specced the part as .188" 6061-T6...

@desertfox Thank you for the response! I did find that the overhung load was over mfg specs and have already implemented a better tensioning procedure. Unfortunately, some failed units were below the overhung load spec and there are also a lot of these in the field already. I inherited this...

@rb1957 Definitely makes sense, I'm almost entirely certain that the belt tension is the culprit but not entirely sure in what way it causes failure besides excessive stress concentration at the flat to shaft transition. Motor design and some other parameters are fixed unfortunately. This is...

@Jboggs Thanks for your response, I have since updated the tensioning procedure for exactly the reasons you laid out [hourglass] I think I may end up flipping the pulley around because otherwise it has to rest right at that flat transition due to other assembly constraints.

@MintJulep It's partially my own interest to see if I can make theoretical converge with the field results and also to fulfill a requirement for the report haha!

@TugboatEng Thank you for the input and resource, I think the manufacturer could do something to help out with the undercut; I'll reach out to them about it!

@dvd Thanks for the response! My spec for the tension is now below the mfg allowable overhung load [dazed] unfortunately there are a lot in the field that already got delivered apparently. I think you may be onto something with the motor use-case; the literature seems to reflect that at least...

@Tmoose I actually think I may go with the flipped pulley suggestion you had, it would allow the flat transition to be within the pulley instead. I already developed a tensioning procedure that prevents over-tensioning (ostensibly) but there are hundreds in the field already... I'm...

@3DDave Thank you for the response! That's what I feared...definitely makes sense about just avoiding the situation altogether but unfortunately I'm a bit backed into a corner in that I have a relatively narrow scope of allowable action on this. I could definitely see if the supplier could...

Hello, I'm having trouble determining how to account for stress concentrations at the root of the flat on a motor shaft due to overhung radial loading. I inherited a motor/pulley assembly that has an propensity for the shaft to snap off right at where it transitions from a D-shape to circular...

@moon161 sounds good, will do!

Hi, As a project I'm making a robot that travels inside of a PVC pipe track (kind of a reverse train track). It has rubber wheels and weighs approximately 10 kg. I want to look into the long-term wear of the rubber wheels on the PVC pipe but in school we didn't learn much about wear beyond...

I am trying to get a custom optical part made and need to model the threads in SolidWorks for the machinist. The threads have to be M77 x .75 but I cannot find it in any of the typical resources I consult; either the charts stop around M50 or only do coarse threads in the M77 range. I need to...

drawoh, I hate set screws as well, they always seem to be a worse way of doing something that has already been correctly solved. It's on a stepper motor indeed and it's supposed to move back and forth relatively rapidly (5Hz or so), so I really don't like the idea of using a set screw in...

A stepper motor with a 5mm shaft was specced and passed along to me to affix a 14-tooth pulley to. The motor has a flat machined on the shaft and is clearly set up for a setscrew-style attachment. Additionally, the pulleys in the correct sizing also use setscrews. This is a problem because...

@IRstuff Thank you for the input! When you say angle error are you referring to an error in the wheel angle itself or the encoder angle output? I apologize if this is relatively fundamental I am just having trouble visualizing how such a small displacement could cause such a large error. Best, -Shea

@3DDave thank you for the response! I had assumed it meant displacement along the axis of rotation, but based on what you're saying it's referring to the distance between the shaft axis and "ideal" axis location? With some bench-top tests I've noticed that the encoder sometimes misses a few...

I am using an Avago AEDM-5810-Z06 Optical Encoder and the data sheet (Link) lists a "Shaft Perpendicularity Plus Axial Displacement" value of 15 mm (.006") under the "Recommended Operating Conditions" (Pg.3). This is a tiny tolerance compared to some of the others on the sheet so I was wondering...