This challenge is for designing the flat shear element for Open Source Ecology's Ironworker Prototype II. The rest of the prototype will be designed elsewhere. See our blog entry for more info on what we need to know.
This prototype will be the second version of the OSE's Ironworker. It will similar to Scotchman 120T. As well as having the 120T punch. This prototype will be able to shear 1”x12” flat and 6”x6”x1/2” angle steel. There will be a “tool cavity,” a space below the punching arm to which many accessory tools can attach. This will enable the machine to not only have the features above, but also attachments like brakes, notchers, and rod shears.
The shearing element must be designed first, as it will attach directly to the cylinder, and the rest of the machine will be designed around it. See above for a basic idea of the structure of it.
Basic Structure of Prototype:
1. It will have an upper and lower arm, both attached to the cylinder. The lower arm will be attached to the cylinder directly or via a linkage. The upper arm will be attached to the lower arm via a linkage.
2. The upper arm will have the punch permanently attached, and will have a table below it onto which you can put various accessories, including an angle shear.
3. The lower arm will only have a shear blade attached.
4. Accessory tools can be made as necessary. Possible tools include: brakes, tubing shear, notcher, rod shear and more.
The shear design should be as simple as possible.
The winning design will be the simplest design that uses the least material.
An angularly moving blade is preferred, as they seem much simpler to build, but vertically moving designs are welcome as well.
If you have good ideas for the rest of the prototype, please post them. These designs will also be eligible for winning.
Assembly must be able to shear 1"x10" steel
Assembly must use an ironworker blade that already exists. See American Punch Catalog for ideas: http://www.americanpunchco.com/AP_Catalog.pdf
The blade needs to cut a minimum of 12" wide material. Up to a 24" cutting surface is allowed
The force must be generated with a 5" bore hydraulic cylinder
There must be space to mount a linkage to the upper arm on the lower arm
There must be easy access to remove the blade if it dulls
The shear element should be designed for simplicity of fabrication
Winning design will be chosen based on the design and functionality
The competition is open to everyone
Team entries are welcome
You can submit several designs
Only models uploaded to GrabCAD library will participate in the competition
Tag your model with “Ironworker” to make it easier to find
Privately uploaded models will be made public after the competition deadline
Models can be done in any CAD software as long as a STEP or IGES files are also uploaded
Competition winner will be announced in GrabCAD’s blog
Only models uploaded through this challenge page will participate in the competition
The entire project is based on open source principles, encouraging people to participate for the good cause.
But there are some nice things we are giving away:
Limited Edition GrabCAD and Global Village Construction Set T-Shirt + Admission to a one-day Natural Building workshop at Factor e Farm. Includes hands-on experience: brick laying with CEBs and square bale insulation; assisting with lumber production with the Dimensional Sawmill, and square bale making with the Baler. See our Kickstarter campaign for more information on this package.
Most creative design will be chosen by Open Source Technology with a little help from GrabCAD.
Open Source Ecology is a network of farmers, engineers, and supporters that has been imagining and creating the Global Village Construction Set, an open source, low-cost, high performance technological platform. These DIY-fabricated industrial machines can be used to build a sustainable civilization with modern comforts. The GVCS lowers the barriers to entry into farming, building, and manufacturing. It is a life-size lego-like set of modular tools that can create entire economies.