mechanical design attaching to handle with tie rod

[sgbaird]

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Based on these specifications, it says that the mounting holes will allow for m4 screws to fit. ...

LINK: https://actuonix-com.3dcartstores.com/assets/images/datasheets/ActuonixL16Datasheet.pdf

Originally posted by @pranshu-ui in #132

To provide a bit of context for where I'm leaning towards: https://chatgpt.com/share/68d44598-5d98-8007-ae93-c43bec132dc5

A connecting rod ("tie rod") set to a fixed distance with a jam nut, a clevis rod end that screws into/onto the connecting rod and attaches to the clevis of the actuator. On the other end is a rod end bolt. The trickier part is attaching that rod end bolt to the handle, as was found above. Ideally, this would be clamped at the same spot where one would normally open from by hand, i.e., right in the middle of the handle to keep the force parallel with the opening direction and not put strain on the door (noting that it's not circular like it is on the edge).

One option is to use a (square) U-bolt that clamps around the handle, secured via a matching U-bolt plate, and drilling holes into a "tab" or a corner bracket to then fasten it to the rod end bolt.

However, I think the far simpler near-term solution is to use a reusable cable or zip tie between the handle and the rod end bolt.

Originally posted by @sgbaird in #132

Dimensions:

• Handle Diameter (left to right): 24mm
• Handle Diameter (top to bottom): 20mm
  (Handle is elipsoid)
• Right side to first handle length: 120mm (the 3d printed piece itself is 150mm across)
• Distance form front of SEM face to face of clevis on the actuator: ~15mm
• Will update full handle length & width here:

I will lay out all the disassembled pieces there.
It does actually come with a threaded rod end piece.

Originally posted by @pranshu-ui in #132

• [] fetch and read the transcript from ChatGPT to get additional context
• [] extract the data from the datasheet to get the size of the clevis
• [] identify a combination of tie rod + jam nut, etc. that can be used with this design

Include direct (validated) links to parts directly in your comment reply so I can easily check and review them. Also include brief descriptions of the parts directly in your comment reply, and justification for why these will work together in tandem with each other. Describe any tools that would be necessary

[pranshu-ui]

I was thinking of using a snug fit cushion clamp connected with a 3d printed rod to then the actuator end.

https://www.mcmaster.com/products/cushioned-loop-clamps/?utm_source=chatgpt.com

I believe this would eliminate binding at either joint, be adjustable, ensure that the rigid arm clears the SEM face, and that the handle opens smoothly with force along its natural direction.

[sgbaird]

Main concern on my end is the strength of the 3D printed rod. Do you have a specific part number for a snug fit cushion clamp?

[pranshu-ui]

I beleive that the strength of the rod isn't too much of a concern as the actuator isn't jerky or too powerful. Even so, its strength could easily be increased by increasing the print infill.

The beauty of using a cushion clamp is that it's fairly adjustable, so if the fit isnt exact, it can still be tightened to fit snug.

Based on our measurements:
https://www.mcmaster.com/3177T57/ (321 stainless steel)
https://www.mcmaster.com/3177T17/ (aluminum)

It's important to note that the mounting holes for these is constrained to 13/64'' universally.

[sgbaird]

I ordered the following:

Delivers Friday

Connecting Rod

18-8 Stainless Steel, 9" Overall Length, 10-32 Thread

6516K385

1 each

$10.56 each

$10.56
1

Steel Narrow-Profile Hex Nuts

Zinc-Plated, 10-32 Thread Size, 1/4" Wide

90760A150

1 pack of 100

6.73 per pack of 100

6.73
2

Ball Joint Rod End

10-32 Thread, Right Hand

60645K31

1 each

3.77 each

3.77
3

Reusable Nylon Cable Tie

Squeeze Release, Standard, 6" Long, Black

7134K152

1 pack of 20

7.11 per pack of 20

7.11
4

Total

28.17

$28.17

Could you give this combination a try? If above is too problematic after trying, happy to put in another order designed with the snug fit clamps in mind.

[pranshu-ui]

https://youtube.com/shorts/SqlDBy5RrQY?feature=share

The SEM setup with the McMaster parts kind of worked. When the actuator extended, it opened it without a hitch, but when it retracted, the SEM didn't fully close to seal. I believe it has to do with the fact that the zipties aren't able to stay flush with the actuator. I think next time, I'll try a similar setup where the bar is parallel to the handle, and the actuator juts out a bit more from the side just to ensure even force application. If that doesn't work, I highly recommend ordering the cushion clamp.

[sgbaird]

Thanks! I'll order the cushion clamp, but for this design - the rod end should be on the other side with a single cable tie cinched through the rod end hole, and the actuator should be removed and rotated by 90 degrees so that the clevis opening is horizontal instead of vertical. Then, the other end of the connecting rod shaft can feed through the clevis directly. Use the hex nuts to secure the position of the connecting rod shaft up against the clevis on both sides.

The speed of the actuator should be reduced by ~4x. Also ensure the amount of actuation isn't enough to push the door past its max opening distance.

[pranshu-ui]

Apologies for the jank setup but the rod itself won't fit through the clevis hole so I thought of this temporary setup. It opens consistently, closes till seal, and is pretty secure. But, I would like to see it have a more sturdy setup so either I can 3D-print a mount for it really quickly so that they can connect or we can order another rod. Nonetheless, the cushion clamp will help distribute the force along the handle so I'd still recommend that. And what is the ball-joint like connecting part for? I was having a hard time integrating that.

[sgbaird]

Ah, that's unfortunate.. I guess it really needed to be M4 to fit through the clevis. I will get back to you on this one.

Attach the rod end bolt (ball joint) as follows

Remove the two zip ties, and then have one zip tie go through the eye of the rod end bolt and around the handle.

[pranshu-ui]

Like this?

[sgbaird]

I think so. Figured it would have been threaded directly through the middle (looks like it's threaded through bottom somehow at first glance). As long as it's relatively secure. Cinch tightly

Main issue is just the size mismatch on the right, unfortunate that the red diameter below was too large to fit through blue diameter

EDIT: such a simple check (4.25 mm vs. 4.8 mm, that was my bad - had been going off of an assumption from another thread)

It also looks like I may have misinterpreted something related to the length of the rod.

I was expecting the lengths to match up such that it would still be the threaded section when going through the clevis, not the unthreaded section, that way the jam nuts could be used to keep it from sliding.

[sgbaird]

Ordered following:

Est delivery on Th

Some redundancy with nuts. We can just use two lock nuts on either side of the clevis. The other two types gives us flexibility to use as a jam nut configuration.

Zip tie should be able to fit through rod end bolt.

Clamp is for testing to see how it conforms, doesn't have additional required hardware yet. Please include a video/picture when you test.

Rod will stick out somewhat far. That's fine. We can cut later - let's focus on proof of concept.

Delivers Thursday

Ball Joint Rod End

M4 x 0.7mm Internal Thread, Right Hand

59935K14

1 each

$7.50 each

$7.50
1

Reusable Nylon Cable Tie

Squeeze Release, Narrow, 6" Long, Black

7134K174

1 pack of 100

18.88 per pack of 100

18.88
2

18-8 Stainless Steel Threaded Rod

M4 x 0.7 mm Thread Size, 300 mm Long

90024A221

1 pack of 1

5.41 per pack of 1

5.41
3

Thin-Profile Nylon-Insert Locknuts

Zinc-Plated Low Strength Steel, M4 x 0.7 mm Thread Size

90453A112

1 pack of 25

7.14 per pack of 25

7.14
4

Snug-Fit Vibration-Damping Loop Clamp

321 Stainless Steel with Neoprene Cushion, 1-1/4" ID

3177T57

1 pack of 5

9.94 per pack of 5

9.94
5

18-8 Stainless Steel Thin-Profile Hex Nut

M4 x 0.7 mm Thread, DIN 439B, ISO 4035

90710A035

1 pack of 100

7.53 per pack of 100

7.53
6

18-8 Stainless Steel Hex Nut

M4 x 0.7 mm Thread

91828A231

1 pack of 100

6.59 per pack of 100

6.59