Slab Flattening - Router Sled Jig - Design and Construction

the force pulling both down and to both lower corners will be constant with a counter weight system. While the opposite counter weight will pull away from the corner, it is balanced by the close counter weight, and the applied force from that close counter weight will be specifically in the intended direction. Locating the pulleys below the bottom of the work area will also aid in positioning the sled. The main advantage here is in adding an x-axis vector of force to the sled in addition to the y-axis vector, whereas the brick method only provides a y-axis vector and relies on that force to pull the sled in the x-axis by virtue of the sled acting as a pendulum on the nearly vertical chain. If it ends up being a concern, then the bricks and the counter weight could be used in tandem with less weight (one brick?) being on the sled.

I agree, which I why I suggest using an eye nut (rather than an eyelet or eye screw) on counter sunk (on the bottom of the sled) through bolts.

2 liter bottles filled with water? there are options galore. It’s not to say that getting bricks is hard, but some have expressed difficulty. Bricks are also fairly large and a little unwwieldy. I am currently using some lead ingots that I had lying around from another project, which allows me to keep the weight within the outline of the sled, which could be a bonus for some who need to limit the vertical height of the whole set up as bricks seem to extend the bottom of the sled a couple inches. I know it’s not a lot, but there are certainly people who have already expressed an interest in minimizing any additional height.

I haven’t thought the connection all the way through, but a couple of ideas spring to mind including a single attachment point to the sled (which would allow the counter weights to balance themselves when removed), or having a cleat at each bottom pulley to secure them on removal. It would have to be worked out for sure, but this is just an initial run at it, so certainly time to collaborate with those interested to find a good solution.

That would be pretty cool. I’d be interested in that solution, though their is certainly an added complexity and cost associated with that as well.

That is fair, but it still seems like something to explore. There’s always the chance that there’s no benefit in it, but aside from speculation at this point, there’s no way to know without further study and/or experimentation. And it may not be for everyone (after all, there are a lot of different frame designs out there), but for some it might be ideal for one reason or another.

also, apologies to @Jacob, I did not mean to hijack your thread. When I have a little more time I will pull this conversation out to a new thread. I’d also appreciate a tag in your follow-up

(perhaps that is where this discussion should go? thoughts?)**

the force pulling both down and to both lower corners will be constant with a
counter weight system. While the opposite counter weight will pull away from
the corner, it is balanced by the close counter weight, and the applied force
from that close counter weight will be specifically in the intended direction.
Locating the pulleys below the bottom of the work area will also aid in
positioning the sled. The main advantage here is in adding an x-axis vector
of force to the sled in addition to the y-axis vector, whereas the brick
method only provides a y-axis vector and relies on that force to pull the sled
in the x-axis by virtue of the sled acting as a pendulum on the nearly
vertical chain. If it ends up being a concern, then the bricks and the
counter weight could be used in tandem with less weight (one brick?) being on
the sled.

the close line will be at a fairly steep angle, so only part of it’s force will
be in the X direction while the far line will be at a shallow angle so that most
of it’s force will be in the (wrong) X direction.

so the net effect of the two lower lines will always be to pull the sled towards
the middle.

I agree, which I why I suggest using an eye nut (rather than an eyelet or eye screw) on counter sunk (on the bottom of the sled) through bolts.

which doesn’t eliminate the need for countersinking on the bottom :slight_smile:

2 liter bottles filled with water? there are options galore. It’s not to say
that getting bricks is hard, but some have expressed difficulty. Bricks are
also fairly large and a little unwwieldy. I am currently using some lead
ingots that I had lying around from another project, which allows me to keep
the weight within the outline of the sled, which could be a bonus for some who
need to limit the vertical height of the whole set up as bricks seem to extend
the bottom of the sled a couple inches. I know it’s not a lot, but there are
certainly people who have already expressed an interest in minimizing any
additional height.

you can mount the bricks at any angle, nothing says they need to be at the 45
degree angle that they are by default, make them sit at 90 degrees and they
won’t extend past the bottom of the sled.

I haven’t thought the connection all the way through, but a couple of ideas
spring to mind including a single attachment point to the sled (which would
allow the counter weights to balance themselves when removed), or having a
cleat at each bottom pulley to secure them on removal. It would have to be
worked out for sure, but this is just an initial run at it, so certainly time
to collaborate with those interested to find a good solution.

you also want to check how this will rotate the sled.

That is fair, but it still seems like something to explore. There’s always
the chance that there’s no benefit in it, but aside from speculation at this
point, there’s no way to know without further study and/or experimentation.
And it may not be for everyone (after all, there are a lot of different frame
designs out there), but for some it might be ideal for one reason or another.

I’m all for throwing out ideas and working through the implications, that’s why
I asked for more details on the tensioners.

I’ve made lots of suggestions for changes, many of which have ended up being
improvements and made it into the standard design, some of which seemed like
good ideas at the time, but later on they ended up not being as good due to
factors that none of us were thinking of at the time.

David Lang

Here’s a variation of your idea, using a unistrut trolley to direct the force down all across the workarea.
IMG_0352

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That has a better chance of working, the question is how well the trolly will
follow the sled.

@blurfl I remember a thread long ago that pertained to this very topic. Cant find it :thinking: please correct me if Im wrong but I think the key was to have the bungie pulling in line with the bit (same as the chains)
I remember something about possibly having a full ring with 2 additional rollers at the bottom (router/dust would prob get in way) with the end of th left and right chain attacched to bungee cords routed in similar fashion as @Jacob ‘s, connected to the added bottom rollers. The reason bungees would be used was due to the precision there would need to be if going with all chain.
Whew!! With all that said, I like your idea because it does seem like the force would vary at X on each side

1 Like

Using a ring linkage, if the bungees both attach to the same point on the vertical midline of the sled, the geometry will be correct.
I think we’d get an even better outcome if we could arrange to have the bungees (hot pink) pull in line with the midpoint of the angle between the chains (green).
bisect-thge-angle. That would take some additional steering of the trolley/traveller, though. An improvement beyond that would put more force on the bungee when the sled is close to the bottom of the workarea, less when near the top (more force when the angle between the chains reduced, less when the angle increased). Not asking for much, am I? :grin:

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Yep, man I feell like that tail is being chased… all in trying to tighten up the bottom corners.

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I set this up quick just to see what would happen. It did not work the way I had hoped. @dlang was spot on.

@Jacob so sorry to steal any of your thunder on the flattening jig!! Awesome idea and design!!! The pic of your setup just sparked that whole tightening up the bottom corners dilemma. The way I deal with them now is to manually apply force (think shaper origin)

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that is a good question. It seems like the cord would want to always be the shortest distance possible, which would be straight down. This setup could be done with a single weight on the right (to choose a side) with the left side of the cord fixed. Then cord would then run through a left hand pulley on the trolley, up to a pulley on the sled, then back down to a right hand trolley pulley, over to the right hand side to go up to the weight. That might encourage the trolley to follow the sled better as any lag would be counteracted by the weight wanting to keep the cord between the trolley and the sled as short as possible. Starting to get into a lot of pulleys, though. Still an interesting idea.

Bummer, but thanks for verifying.

Hi all, in response to all of the discussion sparked by the tensioners in my post (@blurfl, @clintloggins, @dlang, @Keith, @ScrumdyBum, @bar), I figured I should shed some light on how they work.

Firstly, I want to establish the core relationships of certain parts of the maslow in relation to one another during normal operation, from which I derived the system.

At its core, the system relies on this:

  • When a chain is at it’s greatest extension, the maslow (gravity acting on sled) can provide the least amount of force in the opposite direction that the extended chain is pulling.

  • When a chain is at its greatest extension, the slack in the chain is at its minimum length.

From those two observations, I arrived at my current design:

The “Block and Tackle” setup uses the relatively small movements of the chain slack to greatly increase and decrease the length of the elastic cord depending on the sled’s position on the work area. One block (top one in diagram) is attached to the frame – the other to the blue paracord, and when the chain is fully extended, and the slack is pulled up, the pulleys pull apart, tightening the elastic cord on the opposing side.

If you mirror the mechanisms, you get this:

I understand this is all a bit confusing, but essentially you’re just using pulleys to magnify the chain slack’s movements on the opposing side of the frame to increase tension in the desired direction when it is in the corners.

As an added benefit, the tensioners also relax when the sled it towards the top of the work area where they are not needed, since the slack in the chains is longer when in the raised position.

I did some more testing this evening, and was pretty pleased with the results when running the calibration test code. I’ll post a video later this week to show the system in action in the comments here if anyone is interested.

@clintloggins No worries! I’m glad to add my drop to the magnificent bucket of effort here in the forums.

Thanks guys!
-J

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Here’s a few more photos for clarity:

Uploading…

-J

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I thought about just one weight, but that will pull the sled to the side towards
the weight

Awesome. I was going to make a single attachment point at the bottom that would be moved left and right by another motor and chain to give pull in the appropriate direction (down, or down/towards a corner). I was starting to think of making it not need a third motor and was starting to think about how to do it with block and tackle but looks like you worked it out already. I like the design and look forward to experimenting with it once I finally get to build my maslow! Nice work! I had all the same thoughts as dlang until I saw how you cross-linked them so the force grew greater towards the corner.

How many wheels are on your blocks to make it work out?

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I still think I’ll also play with what I had in mind (have the parts). More control will be possible with the motorized bottom as the amount of pull to either side in the corners will be able to be changed to find optimal much easier than a system like this, but this is a pretty slick setup for not needing more electronics and motors.

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The other concern that I have about this sort of thing is that you are replacing
predictable chain sag with a much more unpredicatable force on the sled.

We need to have measurements with and without the lower tensioners (on the same
machine to make sure they are apples-to-apples comparisons) to see which is
actually better.

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Absolutely agree with you there.

Yep, I also agree. It will need a lot of testing to adjust/verify. Just an observation: the chain sag doesn’t appear to be much different, other than it goes in the intended direction down in the problem areas.

My main concern is the force on the motors. While the rotational force is actually reduced, the sideways loading on the shaft is probably about double what a standard tensioner would be. That could cause bearing failure if it’s too high.

-J

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I have considered the same arrangement… one fly in the ointment is that the top pulley on each side would need to be at least 10’ high to cover the full motion of the sled, top to bottom on both sides. Also, the design needs to create more pull towards the outside the closer the sled gets to the bottom corners… it seems like there will be no change in performance with this layout, as the weights just cancel each other out. Maybe using the slack chain with pulleys and bungees could create what we want, but the added complexity would likely create other problems. Perhaps the best answer is to make the top beam wider to increase the motor spacing by maybe a foot on each side? More chain, of course.

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Block and tackle setup took care of the 10ft. But I agree, I think a 12 ft top bar may be the best chance.

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