Ballpoint Fixture - Version 1

During a meeting midway in the project the client suggested to use simple ball points, that the operator would rest the panels on while working on them. From this point on, using ball points has been the only focus when designing fixtures. Therefore, the modelling has revolved around creating a prototype that gives the operator a flexible fixture that can be used for various parts.

In total, 6 versions of the Ballpoint Fixtures has been made - the first version was created to show the capabilities of the idea itself, and versions 2 to 6 (as shown in Fig.

61) were created with improvements to simplify the production and making a more complete final product.

Figure 61: Fixture evolution - top left: V1 - bottom right: V6

The first version was fairly simple but as a consumer product it would be too compli-cated and expensive to produce in mass numbers. Regardless, this was created with the mindset of portraying the fixtures functionality for the client.

The system was made with a rotational joint that could be locked in certain orientations by rotating the wheel and entering a locking pin through the alternative holes near its perimeter.

The aluminium profiles was chosen for the sole purpose of creating a telescopic function where the outer aluminium profile is locked in the pole mount and the inner aluminium profile has a outer diameter smaller than the outer profiles inner diameter which lets it

6.4.4.1 Rotation Joint - Version 1

The schematic for theRotation Joint can be found in Appendix I.

Figure 62: Prototype V1.0 - Rotation Joint

The rotation joint shown in Fig. 62 was made this way to simply be able to showcase the planned functionality of the systems’ rotational capabilities. It lets the rotation pin enter and hold in the exact position so the rotation bracket can be placed in the center plane of the rotation joint, which gives the fixture symmetry. It also has two holes underneath with nuts printed into so that machine screws can mount it to the bottom plate.

6.4.4.2 Wheel - Version 1

The schematic for theWheel can be found in Appendix I.

Figure 63: Fixture prototype V1.0 - Wheel

The wheel shown in Fig. 63 was created to be able to stop the rotation at set intervals by using a locking pin. The pin holds it in position by locking the movement with the wheel joint part described later in the sub chapter. The wheel is connected with the rotation pin using a M5 machine screw.

6.4.4.3 Wheel Joint - Version 1

The schematic for theWheel Joint can be found in Appendix I.

Figure 64: Fixture prototype V1.0 - Wheel Joint

TheWheel Joint shown in Fig. 64 was created to have a fixed placement for the wheel.

The inside surface was created with circular ”bumps” to give smaller surface area and less friction when rotating wheel.

6.4.4.4 Rotation Pin - Version 1

The schematic for theRotation Pin can be found in Appendix I.

Figure 65: Fixture prototype V1.0 - Rotation Pin

The Rotation Pin shown in Fig. 65 was created to connect the Rotation Joint, the Rotation Bracket and the Wheel. It was created with a ”slot” for the pole mount to be fixed in the center position. This solution was a very temporary solution as it was a very complex and difficult way of solving a relatively easy problem.

6.4.4.5 Rotation Bracket - Version 1

The schematic for theRotation Bracket can be found in Appendix I.

Figure 66: Fixture prototype V1.0 - Rotation Bracket

The Rotation Bracket shown in Fig. 66 was created to connect the Rotation Pin and the Pole Mount. The mounting solution was a complex and difficult alternative which evolved in later versions.

6.4.4.6 Pole Mount - Version 1

The schematic for thePole Mount can be found in Appendix I.

The Pole Mount shown in Fig. 67 was created to connect the Outer Aluminium Pole to the system. The mount has a tight fit Ø30 dimension to hold the pole in place.

The connection to theRotation Bracket was a solution which would be complicated to manufacture, and therefore it needed to be changed in later revisions.

(a) (b)

Figure 67: Fixture prototype V1.0 - Pole Mount

6.4.4.7 Bottom Plate - Version 1

The bottom plate shown in Fig. 68 was created as an anchor for each individual fixture

”mount”. Ideally this would have legs to stand on rather than the the machine screws.

Figure 68: Fixture prototype V1.0 - Bottom Plate

6.4.4.8 Outer Aluminium Pole - Version 1

The schematic for theOuter Aluminium Pole can be found in Appendix I.

Figure 69: Fixture prototype V1.0 - Outer Aluminium Pole

The Outer Aluminium Pole aluminium pole shown in Fig. 69 was designed with a length of 300mm and has a tight fit to the Pole Mount, which it is also locked to using a set screw. It also has a thight fit thePole Clamp which is tightened even harder when rotating thePole Clamp Ring - Large.

6.4.4.9 Inner Aluminium Pole - Version 1

The schematic for theInner Aluminium Pole can be found in Appendix I.

Figure 70: Fixture prototype V1.0 - Inner Aluminium Pole

TheInner Aluminium Pole shown in Fig. 70 was designed with a length of 300mm but had an outer diameter 1 mm smaller than theOuter Aluminium Poles’ inner diameter,

6.4.4.10 Steel Ball Plug - V1.0

The schematic for theSteel Ball Plug can be found in Appendix I.

Figure 71: Fixture prototype V1.0 - Steel Ball Plug

The Steel Ball Plug shown in Fig. 71 was designed so the operator could easily place the composite parts on top of multiple of them. It has a M22 fine pitch thread which matches the Inner Aluminium Pole which enables the operator to adjust the height of the fixture more precise.