Optimizing a universal joint design

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SUMMARY

The discussion focuses on optimizing a universal joint design for a wireframe project, specifically a tesseract structure. The user seeks a compact joint that allows for at least 45 degrees of deflection in any direction while minimizing bulk and play. Traditional universal joints are deemed unsuitable due to their size and rotational design. Suggestions include using cup magnets and steel bearing balls to create a more efficient and robust joint mechanism.

PREREQUISITES
  • Understanding of mechanical joint designs, specifically universal joints and ball-and-socket joints.
  • Familiarity with materials such as brass tubing and 3D printing techniques.
  • Knowledge of magnet strength and applications, particularly neodymium magnets.
  • Basic principles of structural integrity and joint mechanics.
NEXT STEPS
  • Research compact joint designs for mechanical applications.
  • Explore the properties and applications of neodymium magnets in engineering.
  • Investigate alternative joint mechanisms that allow for multi-directional deflection.
  • Learn about 3D printing techniques for creating custom joint components.
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Mechanical engineers, product designers, hobbyists working on complex structures, and anyone interested in innovative joint mechanisms for multi-directional movement.

DaveC426913
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TL;DR
Looking for a hinge-joint that has the required freedom of movement in a compact and practical design.
First, a caveat: this is one component of a project, which is difficult to describe without quite a but of digression. If my descriptions seem illogical, it may be because I haven't described the function of the component in its proper context. I assume it will take a little bit of back-and-forth before I'm understood. For those of you who have known me online, this is a revisitation of my tesseract project.I'm designing a wireframe of a ... "cube-like thing" from hollow tubing (may be brass hobby tubing, may be 3D printed). It needs to have joints - actually vertices - that can deflect by at least 45 degrees in any direction.

I have been using universal joints, like they use in automobile drivetrains, but they are not ideal. U-joints are meant to undergo rotation, and mine does not need to. MY problem with the u-joint is that it's bulky. The actual length of the joint mechanism (vertex) takes up more of the cube's edge that I can afford.

What I want is a compact design. By that I mean I'm not concerned about the width, just the length that the parts of the joints take up (independent of scale).

Every vertex is a sphere with 4 (four) of these universal joints merging from it equally. (only one shown here).
1615755222483.png


I am looking for a joint design that:
- provides a deflection of at least 45 degrees in any direction
- is as compact as possible (i.e. short along its primary axis)
- provides minimum play (eg. a piece of string provides unlimited deflection but can just as easily collapse)
- is robust (string for example, will break over time)
- can be practically constructed

I've tried several designs - everything from ball-and-socket joints** to string to springs.

**interestingly, a ball-and-socket joint can't deflect by 45 degrees at all.

Looking for suggestions.
 
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Cup magnets in the ends of the tubes. One steel bearing ball as the vertex.
Maybe glue ball to one tube to prevent loss/injestion.
 
Baluncore said:
Cup magnets in the ends of the tubes. One steel bearing ball as the vertex.
Maybe glue ball to one tube to prevent loss/injestion.
Yeah. Good idea. Those neodymium magnets are pretty strong, but I'm not sure they're strong enough. Might be worth an experiment.
 
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