Testing the new Brake

We’ve been busy working on a few various projects and we’ve finally had time to do some testing the new brake.  Here’s a project we just worked on and recently completed, this blog post describes the process that it took to build it.  The part was designed in Solidworks and then a flat pattern was created and then cut on the CNC table.

The engraved marks indicate the bend line locations.  And the two barely noticeable centermarked locations are for two #4-40 countersunk screws to pass through to allow for an Arduino to be mounted inside.  The holes allow for 12v power and USB access for programming.

The box is not a typical 90 degree box, it is tapered from the front to back so when it sits on the base it will tilt the sign slightly back.  So the first four bends are bent to 100.6°.

Removing some teeth in the brake to allow for the secondary bends.

These next four bends will be formed to 79.4°. which will close up the box.

Here it is finished forming.  You can see the four #4 holes for mounting the Arduino Uno.

Next the box goes through an acid bath to remove the mill scale and then bead blasting to give it a nice finish to work with during testing.  Also the front panel is cut out of 16ga steel sheet.  Here you can see the Arduino mounted with a prototype shield installed.  This allows for quick wiring and testing of code.  In this photo the LED strip is a 12v white LED, however the final version will most likely have a RGB LED strip.  This is an overkill application for the use of an Arduino, however the cost of the electronics is a very small percentage of the project.

Here is the preliminary testing to get an idea of how bright things will look and allowing some experimentation with the code.

Before final assembly the front panel is drilled in all the center marked location (center marking was done by the CNC table prior to any plasma cutting).  The corners of the box are TIG welded and ground down smooth.  Then the box is then powder coated with wrinkle black powder.  Here’s my daughter making sure all the rivets are accounted for prior to final assembly.

 

All the pieces ready for assembly (sans Arduino Uno).

Here the Arduino Uno installed, wired and ready to go.  The Type B USB port is left open to allow for reprogramming of the Arduino, to the right of it is the power entry port.  That allows an AC-to-DC adapter (wall-wart) 12v power supply to run the Arduino as well as power the LED’s.

This is just a prototype light box, once the design is solidified dozens of these will be made and sent out to retail shops carrying Möbius Threads line of scarves, headbands and breast feeding covers.