Any CAD Guru's out there? We need your help!
Added 2022-12-08 17:31:29 +0000 UTCThis is the trusty genoa furler off Delos... Just before we left for Sweden I wanted to pull it off and inspect it because for the last few months it was making an interesting grinding noise. Well, good thing I did because a bunch of water and other crap poured out. The bearings on the electric motor are definitely shot and the culprit for the grinding noise.
So for the last few weeks I've been trying to hunt down the parts to rebuild it when we return to Mexico. Unfortunately this is the (paraphrased) message from the Amel Owners Group "The Amel Super Maramu furler unit was manufactured by a one-man machine shop in Switzerland. He has long since retired and spare parts are in short supply or no longer available. Please treat it your furler kindly! A new-style replacement furler will set you back $20,000 to $25,000 so don't mess it up."
I've been working with Amel Guru Bill Rouse on the group to try to utilize a commonly available electric motor and retrofit it to couple with the furler unit. I have some measurements and pictures supplied by the one man machine shop in Switzerland that created a conversion kit to adapt a modern motor. Unfortunately the kits are all gone and no plans to make more.
So here's where you could help.... If you are a CAD guru and would like to help me design an adapter plate I could then get it machined up at a machine shop like emachineshop.com or something similar. So if anyone out there has CAD skills and would like to give a hand comment below and I'll figure out a way to get you the measurements and pictures of the solution.
Fair winds and thanks so much! Brian
Comments
It would be good to see if I guessed correctly on the shoulder tolerancing. Please send to elists@cmorse.net
Christopher Morse
2022-12-18 16:49:09 +0000 UTCChristopher, I got the engineering drawing for both motors pictured. ISKRA says they have the same mechanical drawing. I'm wondering if that 3 lobe mount is an adapter?? Anyways, I hear the work is done. If anyone wants the official ISKRA drawing let me know.
HappyRock616
2022-12-18 16:44:40 +0000 UTCI hope you have a signal tracing kit, with one half clamping onto a wire or cable and injecting a signal, then the other half sensing the signal. These can be used while wires are powered since the injector and sensor make no hard electrical connection. This came to mind while you did troubleshooting on the solar panels. Also, mil-spec shielded connectors and sockets make sense for connection points that get any amount of salty air.
William Flower
2022-12-18 11:00:07 +0000 UTCAww boo, I would've loved to have helped. Oh well, no worries. Good luck!
Rick Mann
2022-12-15 01:12:26 +0000 UTCGlad you got it done. I'll be taking my 3D printer and laser engraver with us when we go cruising next year. BTW, I used the laser engraver to make the cutting board I gave to you guys in Annapolis. I'm an EE too and a registered professional engineer in several states. I hope to be of service when we visit new countries while we follow in your wake.
Brian Downing
2022-12-14 16:12:36 +0000 UTCGlad you got it all sorted out! Hope it turns out better than new!
John
2022-12-14 14:40:01 +0000 UTCHey thanks for that! We actually got a design done in CAD and it's at the machinist right now, also found a suitable replacement motor that will ship here to Sweden for the test fit so I think we are in good shape. The cool thing is I also submitted the design to Xoemetry, they were a good value but then I remembered we have a friend with a bad-ass CNC machine shop that offered to help us out if anything came up. So we took him up and it should be done soon :)
Sailing SV Delos
2022-12-14 12:24:48 +0000 UTCI know right, our Delos tribe is just sooo amazing! And alot of engineering talent out there :)
Sailing SV Delos
2022-12-14 12:21:29 +0000 UTCThanks for that Earl, I'll put up a post with the finished product but I think we are in good shape!
Sailing SV Delos
2022-12-14 12:21:11 +0000 UTCThanks for that Kresten, I'll put up a post with the finished product but I think we are in good shape!
Sailing SV Delos
2022-12-14 12:20:53 +0000 UTCAhoy Rick- Awesome thanks for your response. Sorry for the delay but I think we have this all sorted. The CAD drawings are at the machinist right now and he says it's pretty straightforward. I'll let you know if anything comes up but should be all sorted now! Brian
Sailing SV Delos
2022-12-14 12:20:25 +0000 UTCAhoy Tody- Awesome that's such a cool skill set! Sorry for the delay in response but I think we have this all sorted. The CAD drawings are at the machinist right now and he says it's pretty straightforward. I'll let you know if anything comes up but should be all sorted now! Brian
Sailing SV Delos
2022-12-14 12:19:55 +0000 UTCHey thanks Scott, I actually found one here in Sweden to do a fitting that was a good deal but great to have that link for the future. Cheers! Brian
Sailing SV Delos
2022-12-14 12:18:48 +0000 UTCHey Kelly- awesome and thanks for that! Sorry for the delay in response but I think we have this all sorted. The CAD drawings are at the machinist right now and he says it's pretty straightforward. I'll let you know if anything comes up but should be all sorted now! Brian
Sailing SV Delos
2022-12-14 12:17:50 +0000 UTCHey Brian, right on and thanks for that! We actually got the design whipped up in CAD and it's at the machinist right now. 3D printing really is cool, need to get one of those onboard! Brian
Sailing SV Delos
2022-12-14 12:17:10 +0000 UTCHey John- Thanks for your response and sorry for the delay in but I think we have this all sorted. The CAD drawings are at the machinist right now and he says it's pretty straightforward. I'll let you know if anything comes up but should be all sorted now! We did run a few calculations on the force of the motor and the reduced key length. The motor is only 7nm and with the design we think there is more than enough meat to handle this. It's based on a retro-fit design the original machinist did years ago and there are a number of units out there working. But like anything we will just need to see how it performs in the wild :). Cheers- Brian
Sailing SV Delos
2022-12-14 12:16:05 +0000 UTCHey Tim- awesome and thanks for that! Sorry for the delay in response but I think we have this all sorted. The CAD drawings are at the machinist right now and he says it's pretty straightforward. I'll let you know if anything comes up but should be all sorted now! Sounds like your 2 sons are well on their way to an awesome career though! Brian
Sailing SV Delos
2022-12-14 12:13:15 +0000 UTCHey Todd- awesome and thanks for that! Sorry for the delay in response but I think we have this all sorted. The CAD drawings are at the machinist right now and he says it's pretty straightforward. I'll let you know if anything comes up but should be all sorted now!
Sailing SV Delos
2022-12-14 12:12:10 +0000 UTCHey Craig- we did indeed find a good solution! I ended up sourcing an AMJ4725 2KW 24V motor and then we designed an adapter plate to mate the motor to the furler. Total cost for parts should be around 500 Euros, I'll let you know how it works out in the video!
Sailing SV Delos
2022-12-14 12:11:04 +0000 UTCBrian, you appear to be fairly along in this project, but you might find Western Motors helpful. They can find/supply pretty much any DC motor that's ever been manufactured: https://www.wms1.com
Scott St. Clair
2022-12-11 01:40:15 +0000 UTCSending you a message of someone who can help.
Carol and Greg Gegner
2022-12-09 16:59:34 +0000 UTCSo wild, my dad used to work at LoveJoy. If he were around, I would ask him to help me figure something out!
David Hagler
2022-12-09 16:02:24 +0000 UTCI have a message out to the vendor for ISKRA trying to get engineering drawings of the mounts. The online drawings are missing dimensions. Brian, you may want to look at Misumi for a new shaft coupler. You can customize the length and mating diameters (buy a spare). A simple love joy style rubber isolator coupling would be best. For a small order try Xoemetry.com, they are basically a brokerage for CNC work. Need to verify furler shaft diameter and length but this is a good option: (https://us.misumi-ec.com/vona2/detail/221302477750/?CategorySpec=00000043641%3a%3ad%0900000043674%3a%3ad%2ce%0900000043626%3a%3amig00000001422110%0900000043665%3a%3amig00000001422045%0900000043740%3a%3amig00000001427988&list=PageCategory)
HappyRock616
2022-12-09 13:58:46 +0000 UTCHey Brian fellow super maramu owner and former machinist. Iβve read that post a few times on the owners group and unfortunately that is the one gearbox that we donβt have a spare of so would love to work on getting a replacement ready for both of our benitits lost me know how I can help
Ryan Driver
2022-12-09 11:23:02 +0000 UTCNothing to add other than it's great to see so much help being offered and the Karma that Brian and Kazza have been gathering over the years coming back :-)!
Thomas Riley
2022-12-09 10:15:22 +0000 UTCWas guna offer my help as well but looks like I'm late to the party!
earl dahl
2022-12-09 04:24:24 +0000 UTCLooks like you are in good hands. I donβt have my own machine shop but I can help with cad if you need it another time. Based in Copenhagen, Denmark π©π°
Kresten Dinesen
2022-12-09 03:57:10 +0000 UTCYes, I know Fusion 360, and I have a machine shop. I'm in Los Angeles.
Rick Mann
2022-12-09 00:33:01 +0000 UTCsent a rough draft see what you think...
Kelly Bruce
2022-12-08 21:53:44 +0000 UTCHey Brian, I work as a mechanical engineer and use CAD (Creo Parametric/Pro Engineer). It looks like the motor is driving a worm shaft and worm gear set with the worm gear driving the furler unit. Having the pictures and measurements will be a good way to start the design process. Look forward to hearing from you.
Tody Mihov
2022-12-08 21:14:37 +0000 UTCBrian, I have a associates in machining and own a makerspace. I would love to help with this just send me the details and I will do a rough draft...
Kelly Bruce
2022-12-08 21:03:53 +0000 UTCBrian, if you still need help with the CAD let me know. I use Fusion360 to design parts that I print on my 3D printer. I could make a mockup part in ABS that you can test. If it fits your machine shop should be able to make a metal one Brian Downing
Brian Downing
2022-12-08 20:08:29 +0000 UTCHey Brian, I have access to CAD and could also help with this. All the items Todd listed would be needed along with how thick this adapter plate could be. From the photos you have I am most concerned about how the motor shaft interfaces with the furler unit and if the added thickness of the spacer would cause an issue.
John
2022-12-08 19:52:14 +0000 UTCAs always, I love your project. Congrats again on the circumnavigation.
FRANCIS DEL VECCHIO
2022-12-08 19:19:56 +0000 UTCHey Brian, I not that much of a genius but my 2 sons are. My eldest is a mechanical engineer and CAD guru and my youngest is going into the Navy to work on Nuclear Reactors and the manufacturing lead for his Robotics team. The good news is that my youngest (18) is studying precision machining right now and has access to CAD and a HAAS 4-axis CNC Mill. Right now he is making parts that look significantly more complex than what you've shown in the images. He's looking for a project and may be able to prototype parts for you. If you are interested let me know.
Tim Cone
2022-12-08 19:00:54 +0000 UTCRegretfully, I have no special skills to be able to help you. I have felt for a long time that these parts that you were discussing and actually entire motorized units should be kept in sealed containers in reserve, lest you should have a malfunction on a long passage. I know this adds tremendously to your expenses, but I believe it is necessary. I have seen numerous videos of repairs that were exceedingly difficult, while at anchor, that would have been completely impossible underway.
FRANCIS DEL VECCHIO
2022-12-08 18:58:42 +0000 UTCI'm happy to help as well Brian. I also can't see the HEIC vids. I just need the measurements, the pics of the interfaces and if there are any stay out zones for the adapter plate/fitting periphery. With that, using Unigraphics NX, I can create a 3 view drawing for fabrication. Shouldn't take but a few hours...to a day. Mech engineer at JPL. I would love to help you fix the problem.
Todd
2022-12-08 18:24:45 +0000 UTCI also have a milling machine if that helps.
Richard S Florence
2022-12-08 18:22:18 +0000 UTC20-25K!?!? Wow. The previous owner installed ZERT fittings on all the furlers on our Amel so that we are able to pump grease into them to force out any water but this still scares the heck out of me lol. I will be following closely and if you end up finding a solution hopefully you can share with the Amel community.
Craig Maggio
2022-12-08 18:19:33 +0000 UTCMaybe there's a machine shop close to you in Sweden that could accept the files via email and you could get it sooner? You could also then have that person bring up the files and verify the dimensions. I had an issue sending a part to be cut out and when the guy brought up my files, the dimensions were wrong.
don clay
2022-12-08 18:17:53 +0000 UTCHi Brian! Based on the other comments it looks like you're in good hands, but I more specialize in 3d scanning so if you need something that may be difficult to model from scratch with limited measurements I can scan it relatively easy.
Mac Kolb
2022-12-08 17:52:27 +0000 UTCHave you considered reaching out to any of the YouTube gurus like "Stuff Made Here". I'm willing to bet one of them might do it just for the challenge.
Sammy the Ditch Doctor
2022-12-08 17:47:45 +0000 UTCAlso have I hand crank milling machine
Richard S Florence
2022-12-08 17:46:28 +0000 UTCIt would be an honor to help
Christopher Morse
2022-12-08 17:45:51 +0000 UTCHey Richard- thanks so much! I think I have Christopher from messages here to help but if for any reason that falls through will let you know. Sounds like you defenitely have the experience!
Sailing SV Delos
2022-12-08 17:45:23 +0000 UTCAwesome Christopher, thanks so much I'll send you an email right now! Brian
Sailing SV Delos
2022-12-08 17:44:41 +0000 UTCI took a look at the photos. Looks really straightforward. I can work on it a bit today. Maybe email me at elists@cmorse.net and we can get a WhatsApp to talk over some questions.
Christopher Morse
2022-12-08 17:40:57 +0000 UTCThanks Robrt, ha ha yes I should have converted them before uploading.
Sailing SV Delos
2022-12-08 17:39:12 +0000 UTCHi Brian. Just a note about the files you uploaded. The three .HEIC images are the likely result of an iPhone with Live images turned on. They're very cool, but difficult to open outside of Apple devices. If you can export them to .jpg or some other standard image format, that may help people view these images. Either that or if you can re-take them with the Live option turned off, you should get a native .jpg image that way too. Fair winds and good luck!
Robert Faulkner
2022-12-08 17:38:10 +0000 UTCI was hoping to get it done within the next week if possible, so that I have time to get machined and make sure it fits before we fly back to Mexico.
Sailing SV Delos
2022-12-08 17:38:01 +0000 UTCHi Brian. I have 20 years of experience in Cad we use autodesk inventor 3D let me know what I can do
Richard S Florence
2022-12-08 17:37:03 +0000 UTCHi Brian - I'm a mechanical engineer / roboticist with my own CAD license and lots of prototyping experience. I can probably help. What sort of timeframe do you need?
Christopher Morse
2022-12-08 17:34:30 +0000 UTC
