pic: Floating Zip Tie Chain Tensioner

[dtengineering]

Originally Posted by rc_cola1323

Here is my final design of it:

I can see why you would want two different sized grooves for the chain to accommodate both #25 and #35 chain, but do you need the different sized grooves for the zip ties, too?

I ask only because it would seem to save a few manufacturing steps to put only a single groove in for each zip tie.

In a similar vein, would it, perhaps, be easier to drill the holes ALL the way through the tensioner? That way you would only need to do two drilling operations rather than four.

You may have a different production path in mind than I envision (as I've mentioned, I see this being an ideal shape to cut on a table saw). For instance with a CNC router, putting in extra grooves would require little in the way of additional manufacturing time. But if you are going to be kicking these out by the hundred using some manual production method, you probably want to include optimizing the production path as part of your design process.

Just a few thoughts that occurred to me without having "seen inside your head" to know why you made these design choices... perhaps I have overlooked something perfectly obvious to you. If so, my apologies.

Jason

[NickE]

Originally Posted by dtengineering

I can see why you would want two different sized grooves for the chain to accommodate both #25 and #35 chain, but do you need the different sized grooves for the zip ties, too?

I ask only because it would seem to save a few manufacturing steps to put only a single groove in for each zip tie.

In a similar vein, would it, perhaps, be easier to drill the holes ALL the way through the tensioner? That way you would only need to do two drilling operations rather than four.

I agree that the 2 grooves for zipties seems unneccesary, and that the holes could go all the way through.

Another thing to consider:
If you were to make 2 different models for two different sizes of chain, it would simplify your design immensely.
I doubt many teams will be switching their tensioners between different sizes of chain very often.
Just because there is demand for more than one chain size, doesn't mean you need to incorporate all sizes into one product

Honestly, I liked your original design better. I think the most recent one you posted looks too complicated and time-consuming to machine.

[R.C.]

Guys, the reason for one tensioner is that we used the #25 Tensioner for both 25 and 35 chain and it worked perfectly. There will be no machining, i am probably going to have a mold for this made. I will probably end up changing the final design after all the comments and after more test runs of this tensioner.

Thanks Cd

[dtengineering]

Originally Posted by rc_cola1323

Guys, the reason for one tensioner is that we used the #25 Tensioner for both 25 and 35 chain and it worked perfectly. There will be no machining, i am probably going to have a mold for this made. I will probably end up changing the final design after all the comments and after more test runs of this tensioner.

Thanks Cd

If you are molding it then I would suggest rounding the exterior edges and corners. You might also want to think about putting some draft in to your design, and possibly stamping a product name, website or trademark in to the side as part of the molding process.

I hope that the sales volume is sufficient to cover the up-front cost of the tooling.

Jason

[Cory]

Originally Posted by dtengineering

If you are molding it then I would suggest rounding the exterior edges and corners. You might also want to think about putting some draft in to your design, and possibly stamping a product name, website or trademark in to the side as part of the molding process.

I hope that the sales volume is sufficient to cover the up-front cost of the tooling.

Jason

Unless he's got someone to make him a mold for free, there's just no way he can make a profit off these. The cost of getting a mold made is going to be extremely extremely high if it's being paid for.

[R.C.]

Originally Posted by Cory

Unless he's got someone to make him a mold for free, there's just no way he can make a profit off these. The cost of getting a mold made is going to be extremely extremely high if it's being paid for.

I have a company in mind

[Gary.C]

Really cool invention, so this year we can replace the mcmaster carr tensioners. Will buy

[R.C.]

This product is finally going to be released. Andymark is going to mold and sell this. So thank you everyone that replied and helped me. The final design is not shown.

Thanks CD

[Elgin Clock]

Looks like AndyMark is stocking these now!

http://andymark.biz/am-0286.html

[Taylor]

1529 will be sporting these fancy accessories on our 2009 robot. They just came in today and they look awesome.

[MikeDubreuil]

I bought a pair for my control system practice bot. They come in a great package with 2 rubber bands and 3 zip ties.

The robot was originally built for a college capstone project. The bot worked great except the chains would fall off. I haven't had a chance to try the tensioners yet.