Wave Blaster

thingiverse

UPDATE 12/5/2015 I thoroughly redesigned the gear train, kindly print the gear files ending in "_UPDATED". The original gear train used a 3:1 ratio, which proved to be too high and excessively demanded torque to turn the handle. The newly engineered gears operate on a 2:1 ratio and perform flawlessly. Unfortunately, to replicate the speed displayed in my proof of concept video, the higher gear ratio would need to be applied. My revised gear ratio operates as follows. I deployed bevel gears at a 1:1 ratio, intermediate gears at a 2:1 ratio, and a second intermediate gear at another 2:1 ratio. This leads to an 18:16 final gear ratio. Calculations yield a gear ratio of 4.5:1. This means the last design generates much less noise compared to the previous model. The videos below demonstrate the last design in action. Due to my phone's mic noise cancellation features, I feel the gear sound may not be as pronounced. The drive pin requires some caution during installation as it needs to be seated between the rotor’s vertical fins, making sure it aligns with its position markers. To facilitate easier disassembly, the crankshaft is placed horizontally along the case sides rather than on top. If there are any tight clearances during reassembly or removal of parts, use sandpaper for precise adjustments. For improved build quality and reduced risk of deformation due to gravity-induced stress on thin areas or small overhangs: Ensure all prints, especially key features that benefit from optimal lateral strength such as crank handles and gears, maintain adequate resolution. Configure the settings according to the device and project needs so moving components fit within a tolerable play for operational effectiveness. Care should be exercised while attaching parts since several assemblies demand minimal clearances for proper alignment during operation. The solution would either entail configuring your printer or employing light sanding with grit papers based on needed results for your desired design, print parameters, and quality. Post-print assembly follows: Insert the Drive Pin through its mounting area at a perpendicular angle to ensure accurate placement in the main assembly hole's surface markers. Seat the rotor within this setup properly before applying gentle but firm force while turning the entire system with slight pressure to check that each movement point performs optimally. Repeat for necessary readjustment steps based on performance inspection data collected. In order to assemble accurately, follow precise sequences outlined for individual parts such as Front Case, Back case and handle positioning which will provide better mechanical interlocking between mating components once placed within its respective grooves without applying pressure too quickly