LYMAN FILAMENT PELLET CUTTER Construction Manual

Transcription

1 LYMAN FILAMENT PELLET CUTTER Construction Manual Page 1 Read this whole Manual before starting to construct this Pellet Cutter.. User excepts all liability for the use of this Manual and the construction of this Pellet Cutter. Lyman is to be held harmless and Lyman excepts no liability. This is not a Toy. Copyright 2016 HUGH LYMAN INVENTOR All the parts and materials for this machine I had on hand. So the sizes and dimensions used were to accommodate these parts. Therefore you can modify or change to whatever you want. It took a lot of changing and redesigning this cutter, but mine now is running like a clock. The Pellet Cutter will cut 1500mm (5 feet) of filament into pellets 6mm long per minute at 18VDC.. Lyman 3mm Filament Cutter Thing: # This Filament Pellet Cutter was conceived from the thing: # published by 4ndreas in Thingiverse.com, which is a 1.75mm filament cutter. Using 4ndreas thing, my thing, # is a 3mm filament cutter requiring jaw handles to produce enough force to cut 3mm filament. As I extrude my own filament I end up with remnants of the filament which I now recycle into pellets and re-extrude. The Lyman Filament Pellet Cutter is an open source product licensed under: Creative Commons Attribution-Share Alike 4.0 International License.

2 CONSTRUCTION NOTES: Page 2 The Filament Pellet Cutter from now on referred to as Cutter which is produced with 5 sub assemblies plus a 24VDC Power Supply all mounted to a 3/4 wood panel: 1. Switch Assembly (drawing # 2) 2. Filament Cutter Assembly (drawing # 3) 3. Filament Feed Assembly (drawing # 4) 4. Cutting Motor Assembly (drawing # 5) 5. Pellet Hopper Assembly (drawing # 6) SWITCH ASSEMBLY See drawing # 2 (page 8) for the exploded view of the switch assembly. This picture shows both the switch assemble and the variable voltage controller. The switch turns on the 115VAC power to the power supply, wherein the power supply activates the 24VDC cutter gearmotor and the machine is running ready for a piece of filament to be inserted.. The variable voltage control regulates the speed of the puller motor feed assembly. The slower it goes the smaller the length of the pellet. So the length the pellets can be set with variable voltage controller. I am using 18V to the feeder motor and I am getting a pellet 6mm long x 2.6mm diameter. 2,6mm is what I extrude my filament to. The switch is rated for 125VAC. - The switch box is printed with 2 perimeters and 25% infill. VARIABLE VOLTAGE CONTROLLER SWITCH COVER (STL20)

3 See drawing # 3 (page 9) for exploded view of the cutter assembly As this assembly is fast moving care is needed to assemble. See drawing # 3 for the exploded view of this assembly. See 4ndreas thing: # for attaching the knife blade to the male base STL-4. I fit the blade in the slot to make sure it fits, then I remove the blade and apply carefully a bead of medium CA glue. Then set the blade in the slot and hold it perpendicular in the slot till the glue dries. The blade should have 6mm showing!!! FILAMENT CUTTER ASSEMBLY Page 3 The chute (STL-3 and the nozzle (STL-7) are attached centered to the female base hole with solvent cement Attach the clevis (STL-5) to the male knife assembly with the same solvent cement. The bearings in the push pull arm are 5mm ID and are press fit. The male base assembly plunges in and out 20mm. Where the knifes cutting stroke is 5mm, means that the blade is moving 15mm back from the cut, thus allowing the filament to advance freely. I tried less than 20mm and it didn t work, the filament jammed in the hole. Slide the knife blade assembly in the female base and by hand make sure it slides freely. I had to dress the part and I added a strip of plastic cut from a thin motel door key card to the bottom and one side of the assembly for a smooth fit. I printed STL-1,STL-2, STL-4, STL-5 and STL-6 with 90% infill, the others at 25% infill. The chute (STL-5) and the nozzle (STL-7) are attached center to the female base hole with solvent cement. CHUTE (STL-3) BACKSTOP (STL-1) NOZZLE (STL-7) FEMALE CUTTER BASE (STL-2) MALE CUTTER BASE (STL-4) PUSH PULL CLEVIS (STL-5) PUSH PULL ARM (STL-6)

4 See drawing # 4 (page 10) to see an exploded view of the feed assembly. The feed brackets A (14) and B 07 are separate to accommodate the installation of the rollers. FILAMENT FEED ASSEMBLY Press the bearing (02) into the feed bracket B. Press the roller assemblies into feed bracket A. Page 4 Now you can fit feed bracket B to feed bracket A. The bolt axle (16) (drive axle) needs a 1.5mm hole drilled for a lock pin (15) to secure the feed roller cog. Slip a washer (16) and a bearing (02) on to each bolt axle. A 1.5mm hole is drilled into on feed roller cog (04). This must align with the hole in the axle (16). Slip the cogs (04) onto the axles. Insert the lock pin through the drive cog and the axle (16). Work the latex tubes (05) onto the cogs. Slide the cog discs (06) onto the axles. These hold the latex tubes from creeping. Slide on a washer. Next slip a washer onto the drive axle and install the nut (18). Add another washer and slip on the couplers (08) with the flat faces together. Add a washer a nylock nut (09) and tighten securely. Next assembly the gear motor (13) to the bracket mount (11). Press on the coupler (12) to the motor shaft. Now place both assemblies on the base plate and align the motor coupler to the drive coupler. All the assemblies need to be placed on the base plate before attaching. When that is done wrap 6 of duct tape around the couplers. All the printed parts I printed with 90% infill. FEED COUPLER B (STL-11) MOTOR COUPLER A (STL-13) Duct tape makes a nice flexible coupler. FEED BRKT A (STL-14) Add duct tape around the idler roller as needed for added gripping. I added tape with motors running. GEAR MOTOR 24VDC IDLER ROLLER (STL-8) 2 REQ D FEED BRKT B (STL-10) MOTOR MOUNT (STL-12)

5 CUTTER MOTOR ASSEMBLY Page 5 See drawing 5 (page 11) for the exploded view of this assembly. The coupler STL-15 is press fit to the motor shaft with the key (02). The eccentric hole in the coupler is sized so a 5mm Bolt (07) can be installed making its on thread. The eccentric hole is offset 10mm. Assembling this should be easy. I printed the 3D parts with 90% infill. The mount bracket STL-16 is printed with PLA filament. All in white are printed with ABS filament. 24V POWER SUPPLY MOTOR MOUNT (STL-16 GEAR MOTOR 192 RPM MOTOR COUPLER STL-15 BASE PLATE

6 PELLET HOPPER ASSEMBLY Page 6 See drawing 6 (page 12) for the exploded view of this assembly. The hopper is place in position between the angles (05). It needs to be tilled to fit under the chute, wherein it stays in place. I printed this part with PLA filament with 25% infill. The hood (01) is attached to the base (02) with solvent cement.

7 Page 7 COMPOSITE BILL OF MATERIAL PART# DESCRITION QTY UNIT PRICE TOTAL NOTES 01 PELLET HOPPER ASSEMBLY 1 EA $1.45 $1.45 See Drawing # 6 02 CUTTER GEAR MOTOR ASSEMBLY 1 EA $68.51 $68.51 See Drawing # 5 03 POWER SUPPLY 24VDC 1 EA $25.00 $25.00 See Drawing # 8 04 SWITCH ASSEMBLY 1 EA $1.91 $1.91 See Drawing # 2 05 CUTTER ASSEMBLY 1 EA $7.37 $7.37 See Drawing # 3 06 PULLER FEED GEAR MOTOR ASSEMBLY 1 EA $25.98 $25.98 See Drawing # 4 07 VARIABLE DC VOLTAGE CONTROLLER 1 EA $10.00 $10.00 See Drawing # 8 08 WOOD BASE PLATE 400x400x19mm 1 EA $2.00 $2.00 See Drawing # 8 ESTIMATED TOTAL COST excluding shipping, wires & supplies $142.22

8 Page 8 BOM SWITCH ASSEMBLY PART# DESCRITION QTY UNIT PRICE TOTAL 01 SWITCH 120V 1 EA $1.50 $ SWITCH COVER FILAMENT STL 20 1 M $0.23 $ WASHER 4mm 2 EA $0.04 $ SCREW 4mm X 25mm 2 EA $0.05 $ SWITCH NUT (included with switch) 1 EA $0.00 $0.00 ESTIMATED SUB TOTAL COST excluding shipping, wires & supplies $1.91

9 Page 9 BOM CUTTER ASSEMBLY PART# DESCRITION QTY UNIT PRICE TOTAL 01 BOLT 6mm X 50mm 1 EA $0.25 $ SCREW 4mm X 25mm 8 EA $0.10 $ WASHER 4mm 8 EA $0.05 $ BACKSTOP BLOCK FILAMENT STL 1 1 M $0.23 $ NUT 6mm 1 EA $0.10 $ CUTTER BASE FEMALE PART A FILAMENT STL M $0.23 $ PELLET EXIT CHUTE FILAMENT STL M $0.23 $ CUTTER BASE MALE PART B FILAMENT STL M $0.23 $ PUSH PULL PART A FILAMENT STL M $0.23 $ NUT NYLOCK 5mm 1 EA $0.10 $ PUSH PULL PART B FILAMENT STL EA $0.23 $ WASHER 5mm 3 EA $0.04 $ INFEED NOZZLE FILAMENT STL EA $0.23 $ WOOD BLOCK 1 EA $0.50 $ SCREW FHSM 4mm X 40mm 4 EA $0.10 $ KNIFE BLADE 1 EA $0.10 $ BOLT 5mm X 25mm 2 EA $0.20 $ BEARING 5mm ID 2 EA $1.50 $3.00 ESTIMATED SUB TOTAL COST excluding shipping, wires & supplies $7.37

10 Page 10 BOM PULL ROLLER ASSEMBLY PART# DESCRITION QTY UNIT PRICE TOTAL 01 SCREW 4mm X 25mm 7 EA $0.10 $ BEARING 4mm ID 4 EA $1.50 $ BOLT 4mm x 70mm 1 EA $0.50 $ FEED PULLER COGS FILAMENT (2 REQ'D) STL M $0.23 $ LATEX RUBBER TUBING 39mm 2 EA $0.50 $ FEED PULLER COG DISC FILAMENT (2 REQ'D) STL M $0.23 $ PULLER FEED BRKT B FILAMENT STL 10 1 M $0.23 $ FEED COUPLER B FILAMENT (2 REA'D) STL M $0.23 $ NUT NYLOCK 4mm 4 EA $0.15 $ BOLT 4mm X 25mm 2 EA $0.25 $ PULLER MOTOR BRKT Filament STL m $0.23 $ PULLER MOTOR COUPLER FILAMENT STL M $0.23 $ PULLER GEAR MOTOR 1 EA $15.00 $ PUSH PULL PART A FILAMENT STL EA $0.23 $ PIN 1.5mm X 1 EA $0.10 $ WASHER 4mm 17 EA $0.04 $ NUT 4mm 1 EA $0.05 $0.05 ESTIMATED SUB TOTAL COST excluding shipping, wires & supplies $25.98

11 Page 11 BOM GEAR MOTOR CUTTER ASSEMBLY PART# DESCRITION QTY UNIT PRICE TOTAL 01 GEARMOTOR 192 RPM 1 EA $66.00 $ SHAFT KEY (INCLUDED) 1 EA $0.00 $ COUPLER MOTOR TO CUTTER FILAMENT STL M $0.23 $ SCREW 5mm X 25mm 4 EA $0.05 $ GEARMOTOR MOUNT BRKT FILAMENT STL M $0.23 $ WASHER 5mm 8 EA $0.04 $ BOLT 5mm X 20 4 EA $0.25 $1.00 ESTIMATED SUB TOTAL COST excluding shipping, wires & supplies $68.51

12 Page 12 BOM PELLET HOPPER PART# DESCRITION QTY UNIT PRICE TOTAL 01 HOPPER HOOD FILAMENT SLT M $0.23 $ HOPPER BASE FILAMENT STL 18 1 M $0.23 $ SCREW 4mm X 25mm 2 EA $0.10 $ WASHER 4mm 2 EA $0.04 $ HOPPER BRACKET FILAMENT STL 19 1 M $0.23 $0.23 ESTIMATED SUB TOTAL COST excluding shipping, wires & supplies $1.45

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14 BOM COMPILED & SORTED # DESCRITION QTY UNIT PRICE TOTAL 1 BOLT 6mm X 50mm 1 EA $0.25 $ BACKSTOP BLOCK FILAMENT STL 1 1 M $0.23 $ BEARING 4mm ID 4 EA $1.50 $ BEARING 5mm ID 2 EA $1.50 $ BOLT 4mm X 25mm 2 EA $0.25 $ BOLT 4mm x 70mm 1 EA $0.50 $ BOLT 5mm X 20 4 EA $0.25 $ BOLT 5mm X 25mm 2 EA $0.20 $ COUPLER MOTOR TO CUTTER FILAMENT STL M $0.23 $ CUTTER BASE FEMALE PART A FILAMENT STL M $0.23 $ CUTTER BASE MALE PART B FILAMENT STL M $0.23 $ FEED COUPLER B FILAMENT (2 REA'D) STL M $0.23 $ FEED PULLER COG DISC FILAMENT (2 REQ'D) STL M $0.23 $ FEED PULLER COGS FILAMENT (2 REQ'D) STL M $0.23 $ GEARMOTOR 192 RPM 1 EA $66.00 $ GEARMOTOR MOUNT BRKT FILAMENT STL M $0.23 $ HOPPER BASE FILAMENT STL 18 1 M $0.23 $ HOPPER BRACKET FILAMENT (2 REQ'D) STL 19 1 M $0.23 $ HOPPER HOOD FILAMENT SLT M $0.23 $ INFEED NOZZLE FILAMENT STL M $0.23 $ KNIFE BLADE 1 EA $0.10 $ LATEX RUBBER TUBING 39mm 2 EA $0.50 $ NUT 4mm 1 EA $0.05 $ NUT 6mm 1 EA $0.10 $ NUT NYLOCK 4mm 4 EA $0.15 $ NUT NYLOCK 5mm 1 EA $0.10 $ PELLET EXIT CHUTE FILAMENT STL M $0.23 $ PIN 1.5mm X 1 EA $0.10 $ POWER SUPPLY 24VDC 1 EA $25.00 $ PULLER FEED BRKT B FILAMENT STL 10 1 M $0.23 $ PULLER GEAR MOTOR 1 EA $15.00 $ PULLER MOTOR BRKT Filament STL M $0.23 $ PULLER MOTOR COUPLER FILAMENT STL M $0.23 $ PUSH PULL PART A FILAMENT STL M $0.23 $ PUSH PULL PART A FILAMENT STL M $0.23 $ PUSH PULL PART B FILAMENT STL M $0.23 $ SCREW 5mm X 25mm 4 EA $0.05 $ SCREW 4mm X 25mm 2 EA $0.05 $ SCREW 4mm X 25mm 29 EA $0.10 $ SCREW FHSM 4mm X 40mm 4 EA $0.10 $ SHAFT KEY (INCLUDED) 1 EA $0.00 $ SWITCH 120V 1 EA $1.50 $ SWITCH COVER FILAMENT STL 20 1 M $0.23 $ SWITCH NUT (included with switch) 1 EA $0.00 $ VARIABLE DC VOLTAGE CONTROLLER 1 EA $10.00 $ WASHER 4mm 29 EA $0.04 $ WASHER 5mm 11 EA $0.04 $ WOOD BASE PLATE 400x400x19mm 1 EA $2.00 $ WOOD BLOCK 1 EA $0.50 $0.50 ESTIMATED TOTAL COST excluding shipping, wires & supplies $ Page 14

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