Planning and initial fabrication of the beta prototype was able to begin while the 2 test coils were being made. The beta prototype reflected the SolidWorks model that the team has been working with throughout the course of the project. This frame was designed with adjustability in mind. There are a number of parameters in the design that may potentially need to be altered to optimize the device’s functionality. T-slot framing was favored for its simplistic assembly and for how easily it can be modified if needed be. There are a number of t-slot accessories that can be used to make the process even simpler. The frame construction was relatively straightforward. It involved cutting the extrusion down to the correct size and then tapping threads into the channels of the t-slot. This would later be used to secure the cut sections of extrusion together via three way corner brackets.

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Figure 7: Tapping T-slot in Machine Shop 

 

The drivers were constructed using PVC pipe. The calculated optimized length of 0.5m for the drivers was deemed to be too long by the team. Making them this length would start to compromise the required ‘portability’ of the prototype. In order to attach the drivers to the supports, linear bearings designed specifically to be used with t-slot extrusion were placed on either side of each driver. The linear bearings also have a small piece of t-slot extrusion that is used to hold the two sides of the bearing together. They also double as a convenient location to mount the pushrods used to connect the magnets to the drivers as they are threaded straight through. The pushrods were made with ¼” diameter cylindrical aluminum extrusion. One end of the extrusion was threaded using the machine shop’s lathe. The lathe was ideal in order to create perfectly concentric threads which are difficult to achieve via hand threading a rod with a die.

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Figure 8: Driver Housing Assembly 

Further developments of the mechanical system beta prototype will occur in the coming weeks with addition of a finalized version of the alpha prototype subsystem. Following the CAD model, an aluminum electrical box will be built above the driver housing. The coils will be mounted in line with the magnets fixed to push rods as seen in Figure 8. Additional components must be added to the driver system as well including the spring mechanisms which will help ensure the drivers maintain their proper range of motion. The springs will be mounted concentrically around the pushrods for the sake of packaging and to aid in stopping the springs from binding.