Manufacturing Assembly Plan
P10007- Mechanical
Spine Test Platform
Base
• Vertical adjustment:
These are machined from 1"
SQR x .125" and 1.25" SQR x
.125" Tube Extruded Aluminum
Bare Square Tube 6063 T52.
Both rectangular tubes are cut to
length using a band saw. Then
the remaining material is milled
out of the outer tube using an
end mill. The holes are also
drilled out of the outer tube using
an end mill. To ensure a proper
fit the touching surfaces may
need to be filed down.
Base
• Base plug
The base plug is machined from
1" SQR 6061 Bar Extruded
Aluminum Bare Square 6061 T6.
First the base plug is cut to length
using the band saw. Then an end
mill is used to drill out the holes.
• Wooden base
The wooden base is made from a
3/4" AC Cabinet Grade Plywood.
Pieces are cut to length and then
glued. After our initial construction
the wood seemed to deform
slightly so a quick run over the
bottom surface with an end mill
ensures a flat bottom.
Base
• Mounting Pad
The mounting pad is machined
from 1" SQR 6061 Bar Extruded
Aluminum Bare Square 6061 T6.
First the mounting pad is cut to
length using the band saw. Then
an end mill is used to fillet the
edges and then drill the hole in the
center.
Ball Joint
• Upper Left / Right Joint
These are machined from 1" SQR
6061 Bar Extruded Aluminum
Bare Square 6061 T6. First the
ball joint is cut to length using a
band saw. Then an end mill is
used to mill out the remaining
material as well as drill the holes.
It is important to use the same bit
to mill both holes containing the
aluminum ball in the upper and
lower ball joint for consistency.
Ball Joint
• Lower Left / Right Joint
These are machined from 1" SQR
6061 Bar Extruded Aluminum
Bare Square 6061 T6. First the
ball joint is cut to length using a
band saw. Then an end mill is
used to mill out the remaining
material as well as drill the holes.
It is important to use the same bit
to mill both holes containing the
aluminum ball in the upper and
lower ball joint for consistency.
The pelvic ball joint is actually the
top part of the telescope section.
Ball Joint
• Ball Joint Stud
These are machined from 0.5" DIA
6061 T6 Extruded Aluminum Bare
Round 6061 T6.
.
First the stud is cut to length
using a band saw. Then a lathe
is used to reduce the diameters
to their set lengths and thread
one side. An end mill is then
used to drill the hole. When
threading it is crucial to be
careful as the part is small. It is
necessary to cut slightly into the
base of the end that is threaded
in order to ensure it can be
threaded all the way.
Member
• One Inch Segment
These are machined from 1" SQR
6061 Bar Extruded Aluminum
Bare Square 6061 T6.
First the vertical segment is cut
to length using a band saw.
Then an end mill is used to mill
out the remaining material as
well as drill the holes. Looking
back, it may have been better to
have had these parts made
using a CNC machine in order to
have tighter tolerances. There
were 8 made in all and some fit
better than others so they were
separated into two groups based
on fit. Then to make them fit
even better, each group was put
into an end mill together and
5/1000 of an inch were taken off
all sides to make them uniform.
Member/Ball Joint connection
• Joint Receptacle
This is machined from 1" SQR
6061 Bar Extruded Aluminum
Bare Square 6061 T6. First the
joint receptacle is cut to length
using a band saw. Then an end
mill is used to mill out the
remaining material as well as drill
the holes.
Horizontal Adjustment
• Collar
This is machined from 1.25" SQR
x .125" 6063 T52 Tube Extruded
Aluminum Bare Square Tube
6063 T52. First the collar is cut to
length using a band saw. Then an
end mill is used to mill out the
remaining material as well as drill
the hole. The inside of the collar
may need to be filed down to allow
smooth sliding over the members.
Horizontal Adjustment
• Left and Right Horizontal
The horizontal bars are made from
.75" x .25" 6061 T6 Extruded
Aluminum Bare Rectangle 6061
T6. First the horizontal bars are
cut to length using a band saw.
Then they are cut to shape and
the hash marks indicating
measurement are made in a CNC
machine.
Pelvis
• Left and Right Pelvis
The left and right pelvises are
machined from 1.25" x .125" 6061
T6 Extruded Aluminum Bare
Rectangle 6061 T6 , 12". First the
pelvises are cut to length using a
bandsaw. Then an end mill is
used to mill out the remaining
material as well as drill out the
hole. The hash marks indicating
measurement are made in a CNC
machine.
Sensor Mounting
• Mounting Arm
This is machined from 0.5" DIA
6061 T6 Extruded Aluminum Bare
Round 6061 T6. First the
mounting arm is cut to length
using a band saw. Then an end
mill is used to mill out the
remaining material.
• Sensor mount
This is machined from 1.25" x
.125" 6061 T6 Extruded Aluminum
Bare Rectangle 6061 T6. First the
sensor mount is cut to length
using a band saw. Then an end
mill is used to mill out the
remaining material as well as drill
out the holes.
Assembly
First set the wooden base down with the uniformly
flat side on top. Then Place the base plug in the
square notch that was milled out of the top surface
of the base. Place the bolt through the bottom of the
base and screw it into the base plug until tight.
The next step is to weld the mounting pad to the
side of the bottom of the stand (female part), to
enable a more secure grip for the knob. Once this is
done place the bottom part of the stand over the
base plug and bolt it in securely. Next, place the top
part of the stand into the bottom part and adjust to
the desired height before tightening the knob.
After this the ball joint needs to be constructed.
Screw the ball joint stud into the aluminum ball until
flush. Next, secure the ball clamp of the lower ball
joint to the pelvic ball joint (top part of the stand)
with the aluminum ball in between, using two set
screws to hold it in place. Screw in bolt until both
sides fit tightly together. Then epoxy the ball joint
stud into the joint receptacle.
The next step is to construct the collar. Weld the
horizontal bars to the side surfaces of the collar.
Then construct the mount for the 3DM sensors.
Weld the mounting arm to the sensor mount and
then weld this to the back surface of the lower joint
receptacle with the face of the sensor mount laying
parallel to the ground.
The next step is to then weld the left and right
pelvises onto the sides of the upper part of the
stand. To adjust the height of the member (lower
lumbar) add or remove the one inch vertical
segments on top of each other and secure them in
place with thumb screws.
After the sensor mount is successfully attached,
place the collar over the joint receptacle. As the
height is adjusted slide the collar up to the top
vertical segment and secure it tightly using the
same thumb screw as the top segment.
The next step is to then weld the left and right
pelvises onto the sides of the upper part of the
stand. To adjust the height of the member (lower
lumbar) add or remove the one inch vertical
segments on top of each other and secure them in
place with thumb screws.
The next steps are the repeated from the
construction of the lower lumber. Construct the
upper ball joint using two set screws with the
aluminum ball in between the left and right halves.
Screw the ball joint stud into the aluminum ball
until flush. Then place the ball joint inside the top
vertical segment from the lower lumbar and tighten
with a screw. Epoxy the ball joint stud into the joint
receptacle. Then weld the horizontal bars to the
side surfaces of the upper collar. Construct the
mount for the 3DM sensor by welding the
mounting arm to the sensor mount. Then weld this
to the back surface of the joint receptacle with the
face of the sensor mount laying parallel to the
ground. Once complete place the collar over the
joint receptacle. As in the lower lumber, adjust the
height of the member (upper lumbar) by adding
one inch vertical segments and securing them in
place with thumb screws.
As the height is adjusted slide the collar up to the
top vertical segment of the upper lumbar and secure
it tightly using the same thumb screw as the top
segment. Finally place 3DM sensors onto their
corresponding sensor mounts and screw in until
tight.