Wonder Wyler Side Plate Prototype


Pictures and CAD Files

Coupling interface for side of Wonder Wyler unit.  Shows balls for coupling interface but no attachment mechanism is specified.
View showing assembled Wonder Wyler unit with magnet and balls.
Threaded magnet unit is used to apply preload between Wonder Wyler unit and the flange insert plate.  Prototype consists of an 8 lbf Samarium Cobalt magnet epoxied onto a turned steel piece.   Machining of this style of magnet is unsuccessful.  Distance between magnet and recess in flange insert can be changed by rotating the magnet.
Wonder Wyler unit showing threaded hole for magnet.  Three balls used for the prototype are 0.5 inch tooling balls available from McMaster-Carr.

Basic dimensions shown on Wonder Wyler side unit.

  Download Solid Works 2000 or IGES CAD Files (No assemblies for IGES)


Drawings of Parts

   Detailed drawings of Wonder Wyler Side unit  in Solid Works 2000 or PDF format
   Detailed drawings of threaded magnet unit in Solid Works 2000 or PDF format
   Detailed drawings of ball on post in Solid Works 2000 or PDF format


Description of Special Parts

Two special parts were required for this prototype.  The first was a Samarium Cobalt magnet, which is used to hold the Wonder Wyler unit to the robot.  The magnet was obtained from McMaster-Carr as part number 5716K67 at cost of US$22.86 each.  Dimensions for the magnet are 0.75 inch diameter and 0.285 inch thickness, which allows the magnet to hold a maximum force of 8 lbs.  The McMaster catalog page can be found here: mcmaster_magnet.pdf.

The second special parts were half inch diameter tooling balls, dimensioned as slip fit  These items consist of a sphere attached to a small shaft, which are hardened to approximately a Rockwell C value of 60.  Critical dimensions are shown in the Solid Works drawings above and on the McMaster catalog page.  The tooling balls are McMaster part number 8484A13 and cost US$10.77 each.  Three parts are needed per side plate.  The McMaster page can be found here: mcmaster_tooling_ball.pdf.


Manufacturing of Prototypes

Manufacturing of the side plate prototypes  is rather simple.  The following simplified steps were taken:

  1. Material cut to size along one direction (other direction already to size as stock)

  2. Material fixtured in milling machine and end surfaces are milled to meet dimensions and smoothed

  3. Material is refixtured and holes are located with center drill

  4. Outer holes are drilled through slightly undersized

  5. Outer holes are reamed

  6. Center hole is drilled out using 5/16 inch drill bit

  7. Center holed is tapped with 3/8-16 tap to provide threads

  8. Part is deburred and polished

  9. Tooling balls are pressed into corresponding holes using arbor press

Manufacturing the threaded magnet unit was slightly more complicated due to threading on lathe.  The following simplified steps were taken:

  1. Fixture bar stock into lathe

  2. Stock turned down to dimensions shown in drawings, including threaded area, stress relief area, and magnet area

  3. Add threads to part

  4. Cut off part

  5. Deburr part

  6. Epoxy applied to magnet area and magnet is glued in place