Ironworker 3

Hint: This was a milestone in which we built an ironworker machine in 2 days - with only 2 people - by radical simplification of design, which still allowed for shearing 1x10 inch steel like butter. The former build took 6 months. Caveats: we took version 3 to destructive testing, where upper arm bent cutting 1x12 steel slabs. The older version continues to be used as part of our infrastructure. Minor redesign on v3 can yield lifetime design as well: the concept was sound, but means of fixing the beams together (such as welding) would need to be implemented for the arms.

The is the main page for version 3 of the Ironworker. See that page for general info and how it fits into the GVCS.

Development Template

Ironworker 3 Short description Specifications Product Ecology What other GVCS tools does this use? License OSHWA and OSI compliant. CC-BY-SA-4.0 International, GPLv3, DIN SPEC 3105. Module 1 Describe features of Module 1 Module 2 Describe features of Module 2 Key Specification Key spec data point Construction Describe basic construction technique and materials Productivity Describe how this relates to industrial productivity on a small scale Completion Status Describe whether built, prototyped, etc. Link to relevant Genealogy and Status of Completion. Do you want more of this? Get Involved

Development Template

	Description	Link to Work Product	%
	DESIGN
1	Requirements + Value Proposition	Ironworker 3 Requirements + Value Proposition	0
2	Industry_Standards	Ironworker 3 Industry Standards	0
3	Conceptual Design	Ironworker 3 Conceptual Design	0
4	Module Breakdown	Ironworker 3 Module Breakdown	0
5	Design Guide	Ironworker 3 Design Guide	0
	TECHNICAL DESIGN
6	3D CAD	Ironworker 3 3D CAD	0
7	Calculations	Ironworker 3 Calculations	0
8	Electronics Design	Ironworker 3 Electronics Design	0
9	Wiring and Plumbing	Ironworker 3 Wiring and Plumbing	0
10	Software	Ironworker 3 Software	0
	BILL OF MATERIALS
11	BOM	Ironworker 3 BOM	0
12	vBOM	Ironworker 3 vBOM	0
13	CAM Files	Ironworker 3 CAM Files	0
14	Cut List	Ironworker 3 Cut List	0
	BUILD
15	Build Instructions	Ironworker 3 Build Instructions	0
16	Fabrication Drawings	Ironworker 3 Fabrication Drawings	0
17	Exploded Part Diagram	Ironworker 3 Exploded Part Diagram	0
18	Production Engineering	Ironworker 3 Production Engineering	0
	LIFECYCLE DESIGN
19	Build Pictures and Video	Ironworker 3 Build Pictures and Video	0
20	Data Collection	Ironworker 3 Data Collection	0
21	Future Work	Ironworker 3 Future Work	0
22	Troubleshooting and Repair	Ironworker 3 Troubleshooting and Repair	0

Status

As of Oct 2013, we're finishing version 3. See the Research and development link above.

As of Feb 2020 - this is the existing documentation - https://www.youtube.com/user/marcinose/search?view_as=subscriber&query=ironworker

Build - 2013

Getting the Blade Gap Correct

Blade gap problem statement:

5 Hour Assembly Time Total 'From Kit'

2.5 hours to assemble, up to the midway point of operating machine.

Blade Gap Not Right

When the blade gap is not right, the machine does not cut and just stalls -

Cut Samples of 1/2"x12" Steel and 1"x4" Steel

Showing 1/2"x12" cut - good results. Some excessive blade gap visible with the 1/2"x8" cut. Showing 1"x4" cut - nice. Next moving to 1"x6".

Bending

Bending of the frame is visible at 1"x6" steel cutting- but that is using 4" square tubing with 1/4" wall. So we decided to go to 1/2" wall tubing to cut 1"x6" steel and higher. The results with 1"x8" above are actually after the frame was redone from 1/4" to 1/2".

At the end of the day, we went up to 1"x8" (caught in above videos), and then we continued. I can't remember if we got up to 1" by 10" or 12"- but at the end, the upper arm bent so we ended up taking the machine up to destructive testing. We did not use the Prototype 3 machine after that, because our Prototype 2 machine works better with a streamlined workpiece holder clampdown. We have succeeded in a proof of concept that a radically simplified design can be effective.

The remarkable part is that the machine is nominally a 2 part count design: tubing and bolts! Which shows the limit of simplicity for a powerful machine which still maintains a proper blade gap. You can see our playlist here - https://www.youtube.com/playlist?list=PL6Jpysxw3Ty9MoPMozOaTrMGGbiNo0HZO

Links

• Ironworker Genealogy
• Realtime Documentation