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Showing posts from June, 2009

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Why I Wrote The Sheet Mechanic (And Why Calculations Aren’t Enough)

For engineers who already know the math—but still lose projects. For the last few years, I’ve been sharing technical guides here on Mechanical Design Handbook —how to size a motor, how to calculate fits, and (as you recently read) how to choose between timing belts and ball screws. But after 25 years in industrial automation, I realized something uncomfortable: Projects rarely fail because the math was wrong. They fail because: The client changed the scope three times in one week. A critical vendor lied about a shipping date (and no one verified it). The installation technician couldn’t fit a wrench into the gap we designed. University taught us the physics. It didn’t teach us the reality. That gap is why I wrote my new book, The Sheet Mechanic . This is not a textbook. It is a field manual for the messy, political, and chaotic space between the CAD model and the factory floor. It captures the systems I’ve used to survive industrial projec...
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The Machine Designer's Guide to CE Marking & UKCA Compliance

When designing a machine for customers in the European Economic Area (EEA), mechanical designers must ensure the equipment has full CE compliance . It is not optional; it is a legal requirement. However, the landscape has changed significantly in recent years. With updated directives, the introduction of the UKCA mark post-Brexit, and the upcoming transition to the new Machinery Regulation , staying compliant is more complex than ever. Advertisement What is CE Marking? The CE marking stands for " Conformité Européenne " (European Conformity). By affixing this mark, the manufacturer asserts that the product meets all essential "Health and Safety" requirements of the relevant European legislation. Figure 1: The CE mark acts as a passport for the EU market, while the UKCA mark is now required for Great Britain. It acts as a "passport" for your product, allowing it to be sold freely within the EU Single Market...

Sankyo AD Alpha Series: The Ultimate Dial Indexer for Automation

If you are looking for a robust indexing box for your dial application, the Sankyo AD Alpha Series is a top contender. Apart from its product specifications, we have expanded this guide to include useful technical context on why these drives are chosen over other technologies. Advertisement Design and Core Technology Figure 1: The low-profile AD Alpha Series unit features a ground pilot flange for precise mounting. Sankyo's AD/Alpha Series features a low-profile cast iron housing with a ground pilot flange for mounting dial plates, hubless gears, or weldment fixtures. The heart of the system is the Globoidal Cam mechanism. Unlike barrel cams, a globoidal cam is tapered to match the radius of the needle-bearing cam followers. This optimizes the contact area, maximizing torque transfer and significantly extending service life. Above the indexing dial, a stationary hollow center allows engineers to route air lines...

High-Speed Automation: The Mechanics of Sankyo SANDEX Indexing

In my design work for high-speed automation, I've frequently relied on indexing boxes from the Japanese manufacturer Sankyo Seisakusho . The SANDEX series is a generic name for their cam units that utilize the superior Roller Gear Cam mechanism . Sankyo's core technology combines a precision-machined globoidal cam with a follower turret fitted with high-capacity needle bearings. To visualize how this robust mechanism works, consider the conceptual model below. Figure 1: A conceptual model illustrating the interaction between the input roller gear cam (bottom) and the output follower turret (top). Advertisement The Superior Mechanics of the Roller Gear Cam As depicted conceptually in Figure 1 , the SANDEX unit uses a continuous rib on the input shaft to drive the output turret. This is a significant upgrade over traditional Geneva mechanisms . Geneva drives suffer from high impact shock at the start and stop of motion due to inhere...
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