2016-11-01 (Tu) Clockwork Theremin

More holes were cut with the circle cutting saw. A second and third bearing holder were installed in the backing board. During installation, one holder broke in half, between the bearings, and had to be repaired with superglue. These parts were printed with a low infill percentage since they do not need a lot of strength.

Bearing holders installed

The process was to start with the final, largest, gear and work backward through the rest of the gears to make sure they all worked. While interlocking the teeth it seemed like it would be necessary to round the edges of the teeth which may be possible on a commercial belt sander, cylindrical sander or maybe the custom built belt sander.

After connecting the 300mm diameter gear next to the final gear, the project used a stack of gears where the bottom was a 100mm diameter gear and the top was the 500mm diameter gear. The 500mm gear was the heaviest of them all. The gears were connected with a fully threaded 5/16” (8mm) bolt and nuts with washers touching the plastic. It will be necessary to link these parts with a couple bolts to keep them from rotating against each other.

100mm diameter gear fastened to 500mm diameter gear

All three gears were installed on the board and tested. Clearance from the 600mm diameter gear was not easy since the half gear was not balanced. A bolt was installed with the nut exposed so the gear could have that level. The bolt and nut were installed on a line right between the two axles.

Exposed nut between axles of touching gears

Close-up of exposed nut

All the gears were installed and their teeth interlocked well. Rounding the corners may not be necessary but there’s a possibility it may still have to happen. To make it easier to handle and operate, the backboard was stood on its side. This way, the largest gear was prone to hanging down where it was still touching the next gear.

Gears all assembed and interlocking

A video clip was recorded to demonstrate how easily the gears moved together. The video showed the largest gear suspended at a steep angle then released so gravity carried it over the next gear, which spun the smallest gear under the 500mm diameter gear. There was a lot of inertia in the gears so it will be important to choose the best gear for powering. It may also be necessary to cut the gears to give them spokes. With spokes a lot of the mass would be removed from the system.

Video demonstration

Parts list:

The rest of the posts for this project have been arranged by date.

First time here?

Completed projects from year 1.

Completed projects from year 2.

Completed projects from year 3.

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2016-10-27 (Th)