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KS3
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This project applies to all stages as it is simply here as a solution. Many times we need to drive a unit from a motor. The inability to line things up to the standards required in industry usuall means that a great deal of stress is placed on the motor shaft. This is where a mechanical error corrector would be helpful. It also reduces noise from the bearings that would normall have been pulled out of alignment.
Resources

 

The motor coupling was developed for the rock tumbler but as a neat solution bears repeating for any application that needs tha same sort of coupling.

The simplicity of manufacture comes from the use of an hexagonal bar for power transmission.

The hexagonal part engaging into the hexagonal hole in the laser cut acrylic.

The bar drops nicely into a three jaw chuck and a boss and a bore can easily be machined even on a manual lathe.

Then five disks of acrylic are cut, four with a hexagonal hole that fits the bar and one solid to sit in the middle and stop the coupling drifting out of position.

 

 

 

The coupling parts.

Coupling

Cut the acrylic and bolt all five together with 3mm / 25mm bolts with 3mm nyloc nuts. The solid disk must be in the centre.

The brass sections are turned from 19mm hexagonal bar, this gives the six sided drive without needing a milling process.

The centre holes are drilled to suit the motor shaft and the 7mm additions on the Style 2 shaft.

Coupling

The bosses will need drilling and tapping to allow a grub screw to grip the motor and drive shaft respectively.

Coupling

 

Boxford Lathe File for Bosses - Download

2D Draw files for lazer parts. - Download