1. ME 549 Project: Router Surfacing Jig Lyndsey Hylbert Jason Lichtman Mike Miller Suzy Pursell Stephen Strombeck

2. Agenda  Design Objective  Design Specifications  Designs Considered  Solution  Analysis of Solution  Summary Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

3. Design Objective  To develop and analyze a concept for a router accessory that allows a router to accurately surface and plane “rough sawn” lumber Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

4. Target Market  Age: 18+  Gender: Male/Female  Cognition: High School Level  Probable Use:  Non-professional/Hobbyist Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

5. Product Design Specifications (1)  Board Sizes:  Length: 6in  8 feet  Width: 1in  2 feet  Thickness: ¼in  4in  Router:  Porter Cable 694VK or 893PK plunge routers Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

6. Product Design Specifications (2)  Environment  Temperature: -40 to +100 F  Location: Indoors or outside weather permitting  Hazards: Sawdust and humidity  Corrosive Agents: Humidity and wood sap Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

7. Product Design Specifications (2)  Performance  Speed: Max bit speed determined from router adjustability  Transport/Setup: 1 person to setup/move  Storage: Must be stored; not a permanent floor tool  Feed: Manual or automatic Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

8. Product Design Specifications (3)  Quality and Reliability  Life: At least that of the router without major component replacement  Ergonomics  Controls: Built into router or in safe location  Adjustments: Easy to adjust without the use of tools  Weight: Moving components of low weight Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

9. Product Design Specifications (4)  Safety Issues  Lateral Stability: Very stable  Restraint: Over-travel stops  OSHA Standards: Hazards from end grain, kick back, flying chips  Overall: No sharp edges to cut or snag  Controls: Easy to reach without nearing the bit Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

10. Designs Considered (1)  Sliding Workpiece - Basics Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

11. Designs Considered (2) Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary  Sliding Workpiece - Tabled Designs

12. Designs Considered (3)  Sliding Workpiece - Radial Arm Saw Approach Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

13. Designs Considered (4)  Stationary Board  Use of worktable Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

14. Designs Considered (5)  Variable Height Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

15. Solution Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

16. Analysis of Solution slides along x-direction slides along y-direction Locks router position in x-direction Locks router position in y-direction Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

17. 4” Thick Board ¼” Thick Board Router bit height can be adjusted using plunge feature Router bit height can also be adjusted using multiple carriage tracks Analysis of Solution Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

18. Router Bit Deflection Bit Length (in) Vertical Deflection ( δ2) (mil) 0.00 0.250.03 0.500.11 0.750.25 1.000.45 1.250.70 1.501.01 1.751.38 2.001.80 2.252.28 2.502.81 2.753.40 3.004.05 3.254.75 3.505.51 3.756.32 4.007.19 4.258.12 4.509.10 4.7510.14 5.0011.24 Vertical Deflection δ2 (mil) Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

19. The number of strap clamps used will vary based on size and quality of workpiece Strap clamps can be repositioned in an infinite number of configurations. This, in turn, allows clamps to be moved so that the router can pass over the area. Analysis of Solution Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

20. Rotate to lock carriage rail at current position Lever (2x) Lever Support (4x) Analysis of Solution Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

21. Carriage Rails (2x) Carriage Base (2x) Main Rails (2x) 1.5”x4.5” Aluminum Extrusion (2x) Work-piece C-Clamp (4x) Strap Clamp (6+) Porter Cable Router Analysis of Solution Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

22.  Allows travel in x-direction  Allows travels in y-direction  Router can be locked in either direction  Height of carriage track can be adjusted  Depth of cut is adjustable  Adjusts to accommodate size of workpiece  Can be disassembled and stored in a small space  Can be used on a workbench of minimal size Agenda Design Objective Design Specifications Designs Considered Solution Analysis Summary

23. Questions?