Wonder Wyler Flange Insert Plate Prototype

Pictures and CAD Files

ball_groove_assembly_v1.jpg	This view shows the initial concept for the ball and groove coupling inside the flange.
plate_groove.jpg	Coupling interface on flange are individual grooves press fit into hole in the flange.
ball_groove_assembly.jpg	Current version of flange design. Shows insert plate (red) with grooves in center of flange (light gray). Wonder Wyler unit (dark gray) is shown in position, although balls and magnet cannot be seen.
ball_groove_assembly_2.jpg	Cut-away view of coupling showing only coupling elements. Magnet (green) is attached to a post and is mounted in the center of the coupling. The balls (blue) are grouped on a 20mm radius circle with 120 degrees separating them.
groove_insert_in_flange.jpg	View showing the grooved insert plate in the flange. This insert could feasibly be added to the structure of the flange, removing the extra piece. The insert could be press fit or bolted into place with some geometric features to align the grooves to the control pin hole.
ww_side_with_grooved_insert.jpg	Prototype of side of Wonder Wyler with three balls and magnet and prototype of grooved insert for flange. Dimensions of prototypes conform to dimensions required by ABB.
assembled_ww_unit.jpg	Wonder Wyler unit engaged with grooved insert. The magnet used for the prototype's preload keeps the two pieces together under a considerable force.
ww_unit_in_flange.jpg	Wonder Wyler unit and grooved insert plate shown in flange. Using a press fit, the insert plate can be secured to the flange. Insert plate has not been secured in this picture, which causes the insert plate to stick out of the flange. The top surface of the insert plate will sit slightly below the flange surface after a press fit.
grooved_flange_insert.jpg	Basic dimensions shown on grooved flange insert.
	Download Solid Works 2000 or IGES CAD Files (No assemblies for IGES)

Drawings of Parts

Detailed drawings of insert plate unit in Solid Works 2000 or PDF format

Description of Special Parts

The only special part required for this prototype is a 90 deg. Drill/Mill used to machine the grooves. The mill is a 7/8 inch diameter, 90 degree high speed steel mill. This tool is available from McMaster-Carr as part number 2957A56, at a cost of US$50.51. A copy of the McMaster catalog page for this tool is available here: mcmaster_tool.pdf.

Manufacturing of Prototype

Manufacturing of the insert plate prototype required a CNC machine to machine grooves. Solid Works CAD files were exported into Master CAM CNC machining software for setup. The following simplified steps were taken:

Material fixtured in CNC lathe
Material turned to proper diameter and thickness
Part fixtured into CNC milling machine
Center recess is milled out using end mill tool
Grooves are machined using 90 deg. drill/mill tool
Deburr edges and chamfer outer edges