Instructions

1. Watch the video above.

2. This is a team project. Talk with your team-mate about how to divide responsibility for the work.

3. Download the SolidWorks design as Pascaline-v5.zip.

4. Lay out your parts as drawing files to make the most efficient use of your plastic. For example, the FrontPanel and BackPanel can be combined into a single drawing and cut from a single 12x12 inch sheet of clear acrylic. All the green parts can fit on one sheet; the same for the red parts, and the yellow parts. The blue parts will require two sheets.

5. Turn your drawings to DXF files, colored appropriately.

6. Cut your parts on the Rabbit Laser.

7. Follow these assembly instructions to build and test your Pascaline.

Construction Tips

1. Use the right screw for the job so you don't have excess metal sticking out past the nut. Here's how to calculate the correct length. Each plastic part is 1/8 inch thick. The nut or standoff requires 1/8 inch of thread. So if you're screwing two plastic pieces together using a nut, you need 1+1+1 = 3/8 inches of thread: use a 3/8 inch screw. Similarly, if you're attaching a standoff to a piece of plastic, you'll need also need a 3/8 inch screw.

2. Don't rip open your screw and nut packs. Cut a tiny opening in one corner, and squeeze out the parts as you need them. This protects you from having all your parts spill on the floor if you drop a pack.

3. Don't coat the entire screw with thread locker. Just squeeze one tiny drop onto the screw at the point where the nut will rest. Wipe up any spillage so it doesn't discolor your parts.

4. Use pliers, not your fingers, to hold the nut as you tighten the screw down. You'll get a tighter fit that way.

What to Hand In

• Hand in your SolidWorks parts and drawing files, and two rendering images, via Autolab.
• Bring your Pascaline to class to show off.
• Files and assembled Pascalines due by Monday, Nov. 24. No extensions.

Grading

• 7 points for customization and properly laid out drawing files
• 3 points for properly colored DXF files
• 3 points for cutting the plastic
• 7 points for correct assembly and demonstrating a fully working replica

Complete Parts List

Aluminum Standoffs
Size	Type	Length	Quantity	Use
1/4 in.	Hex	4 in.	3	Accumulator shaft
1/4 in.	Hex	2.5 in.	3	Readout gear shaft
1/4 in.	Hex	2 in.	3	Input gear shaft
1/4 in.	Hex	1.5 in.	2	Sautoir shaft
1/4 in.	Hex	1 in.	2	Input brace
1/4 in.	Hex	3/4 in.	3	Backstop pawl
1/4 in.	Round	3/4 in.	6	Accumulator carry tubes
1/4 in.	Round	1/4 in.	2	Sautoir arm rest

Zinc-Plated Steel Machine Screws and Nuts
Size	Length	Quantity	Use
4-40	1.5 in.	9	Readout assembly
4-40	1 in.	90	Accumulator gear teeth
4-40	3/4 in.	1 pk	miscellaneous
4-40	5/8 in.	1 pk	miscellaneous
4-40	1/2 in.	1 pk	Output gear teeth
4-40	3/8 in.	2 pk	miscellaneous
4-40	1/4 in.	1 pk	miscellaneous
4-40	nuts	2 pk	miscellaneous
4-40	nylon locknuts	4	Output cover; sautoir
3/8-16	5/8 in.	2	Carry lever weight
3/8-16	nuts	5	Carry level and backstop pawl weights

Miscellaneous Parts
Description	Quantity	Use
#4 washers, OD 3/8 in.	24	Shaft endcaps; backstops
#4 nylon spacers, 1/4 in.	21	Readout wheels, sautoirs, finger stops
Loctite 222, 0.34 oz	1 bottle	Thread locker
Springs: 0.875 in,    0.125 OD, 0.014 wire	2	Sautoir
Stickers	30	Output digit labels

Last modified: Mon Nov 17 18:16:05 EST 2014