New product: Ultimate Servo Bracket
08-06-2014, 02:56 PM
#1
Thread Starter
New product: Ultimate Servo Bracket
The Ultimate Servo Bracket is a new product from Ultimate Jets. It is CAD designed and CAM produced. The entire digital production chain enables very high levels of precision and low manufacturing tolerance.
This set is produced from PYCABS. This is a new generation material 3D printed from a mix of ballistic grade PolYCarbonate ans ABS. The result is an amazingly strong material that is very easy to glue.
The inside of the bracket is printed from a honeycomb structure. The bottom of the bracket features an open honeycomb structure with the first two layer being offset from the next ones. This provides a bullet proof epoxy adhesion from inside the part when gluing the brackets in the model.
On the picture above, one can see the first two layers ( in blue ) being offset from the next ones ( in red ).
Here is another view of the bottom with a JR8711 fitted:
Each bracket is custom designed for a specific type of servo and fits within 0.2 mm. This ensures an amazing level of rigidity of the assembly.
Furthermore, the bracket is designed with the maximum side area in contact of the servo for a very large clamping effect. The clamping surface is up to 300% larger than competitor brackets.
The servo is fastened by sliding flat in the brackets and is secured with 4 ultra large #6 sheet metal socket head screws. The socket head enables very strong screwing torque with an Allen key. Note on the picture above how the lower prong bend on the servo tab when squeezed by the lower socket head screws.
This is the first time in the industry that this type of fasteners is used for high torque servo application. The large diameter of the #6 screws ensure a minimum clearance in the servo tabs holes. The resulting fastening effect is phenomenal.
Finally the brackets feature two wrap-around prongs clamping the servo longitudinally. One set at the front of the servo ( when seen laying on its side as on the picture above ), and one set at the back. These ensure additional rotational securing around the vertical axis.
An additional bolt-through tab will be available as an option soon. It is a carbon fiber tab fastened vertically on top of the brackets for additional clamping on servo hatch assemblies. On the picture above you can see the two vertical holes designed for this purpose.
The USB are available initially in standard size ( JR 8711 type ) and mini size ( JR 3421 type ). One bracket kit comprises of two PYCABS clamps, 4 sheet metal screws in #6 size and two washers for the upper screws.
Available here.
This set is produced from PYCABS. This is a new generation material 3D printed from a mix of ballistic grade PolYCarbonate ans ABS. The result is an amazingly strong material that is very easy to glue.
The inside of the bracket is printed from a honeycomb structure. The bottom of the bracket features an open honeycomb structure with the first two layer being offset from the next ones. This provides a bullet proof epoxy adhesion from inside the part when gluing the brackets in the model.
On the picture above, one can see the first two layers ( in blue ) being offset from the next ones ( in red ).
Here is another view of the bottom with a JR8711 fitted:
Each bracket is custom designed for a specific type of servo and fits within 0.2 mm. This ensures an amazing level of rigidity of the assembly.
Furthermore, the bracket is designed with the maximum side area in contact of the servo for a very large clamping effect. The clamping surface is up to 300% larger than competitor brackets.
The servo is fastened by sliding flat in the brackets and is secured with 4 ultra large #6 sheet metal socket head screws. The socket head enables very strong screwing torque with an Allen key. Note on the picture above how the lower prong bend on the servo tab when squeezed by the lower socket head screws.
This is the first time in the industry that this type of fasteners is used for high torque servo application. The large diameter of the #6 screws ensure a minimum clearance in the servo tabs holes. The resulting fastening effect is phenomenal.
Finally the brackets feature two wrap-around prongs clamping the servo longitudinally. One set at the front of the servo ( when seen laying on its side as on the picture above ), and one set at the back. These ensure additional rotational securing around the vertical axis.
An additional bolt-through tab will be available as an option soon. It is a carbon fiber tab fastened vertically on top of the brackets for additional clamping on servo hatch assemblies. On the picture above you can see the two vertical holes designed for this purpose.
The USB are available initially in standard size ( JR 8711 type ) and mini size ( JR 3421 type ). One bracket kit comprises of two PYCABS clamps, 4 sheet metal screws in #6 size and two washers for the upper screws.
Available here.
Last edited by olnico; 08-06-2014 at 11:49 PM.
08-06-2014, 11:44 PM
#5
Thread Starter
08-08-2014, 12:30 AM
#6
Thread Starter
Here is a screen shot of the bracket designed for "standard size" Futaba servos.
There are actually two standard sizes in the Futaba range of servos. One in 21 mm by 40 mm and one in 21.5 mm by 40.5 mm ( Standard + ).
So I have designed two sets of brackets for these.
It is important to choose the appropriate set as the 0.5 mm difference is significant on these very precisely printed products.
In general the Standard + size ( 21.5 by 40.5 ) is for newer servos:
S9075SB, S 9353HV, all BLS series, all Sbus series
The Standard size is for older servos:
S 9452, S9156, S3152 and so on...
I find it quite interesting to see a deviation in the standard size within the same brand.
Note that Standard + is my own naming. Nothing official from Futaba.
There are actually two standard sizes in the Futaba range of servos. One in 21 mm by 40 mm and one in 21.5 mm by 40.5 mm ( Standard + ).
So I have designed two sets of brackets for these.
It is important to choose the appropriate set as the 0.5 mm difference is significant on these very precisely printed products.
In general the Standard + size ( 21.5 by 40.5 ) is for newer servos:
S9075SB, S 9353HV, all BLS series, all Sbus series
The Standard size is for older servos:
S 9452, S9156, S3152 and so on...
I find it quite interesting to see a deviation in the standard size within the same brand.
Note that Standard + is my own naming. Nothing official from Futaba.
08-08-2014, 02:46 AM
#8
Oli
Very nice product, I have previously machined mine from fibreglass but would certainly swap to your version!
Hoping to be released from hospital this weekend, week in hospital is enough I want to get back to my workshop :-)
Alan
Very nice product, I have previously machined mine from fibreglass but would certainly swap to your version!
Hoping to be released from hospital this weekend, week in hospital is enough I want to get back to my workshop :-)
Alan
08-08-2014, 03:07 AM
#9
Thread Starter
08-08-2014, 03:09 AM
#10
Thread Starter
Let me know when you need some. Will send them from Dubai by Fedex. Fast and cheap...
I will need some more leads probably in September.
08-12-2014, 12:33 PM
#11
Thread Starter
Could someone send me a detailed schematic of a Hitec HS-7950TH with all the dimensions?
Or if someone happens to have a damaged servo to send me, I would send back a pair of brackets as a gift.
Or if someone happens to have a damaged servo to send me, I would send back a pair of brackets as a gift.
08-20-2014, 11:57 AM
#12
Thread Starter
08-20-2014, 12:17 PM
#13
Oli
That looks a very strong structure and I would think stronger than solid and obviously lighter!
I have actually managed to make some leads this week that were ordered before I decided to throw myself at the floor so nice to get back to doing something, only another 3 weeks in resin cast :-(
Did you get the sizes for the 7950? The only large Hitec I own is in my Extreme Flight Yak which is the 7955 don't know if that is the same as 7950
Alan
That looks a very strong structure and I would think stronger than solid and obviously lighter!
I have actually managed to make some leads this week that were ordered before I decided to throw myself at the floor so nice to get back to doing something, only another 3 weeks in resin cast :-(
Did you get the sizes for the 7950? The only large Hitec I own is in my Extreme Flight Yak which is the 7955 don't know if that is the same as 7950
Alan
08-21-2014, 01:42 AM
#14
Thread Starter
Oli
That looks a very strong structure and I would think stronger than solid and obviously lighter!
I have actually managed to make some leads this week that were ordered before I decided to throw myself at the floor so nice to get back to doing something, only another 3 weeks in resin cast :-(
Did you get the sizes for the 7950? The only large Hitec I own is in my Extreme Flight Yak which is the 7955 don't know if that is the same as 7950
Alan
That looks a very strong structure and I would think stronger than solid and obviously lighter!
I have actually managed to make some leads this week that were ordered before I decided to throw myself at the floor so nice to get back to doing something, only another 3 weeks in resin cast :-(
Did you get the sizes for the 7950? The only large Hitec I own is in my Extreme Flight Yak which is the 7955 don't know if that is the same as 7950
Alan
I am not sure about the Hitec dimensions. I am not a Hitec user and their documentation is extremely poor on that matter.
08-21-2014, 04:48 AM
#15
Oli
Manage to find this drawing of the 7955 perhaps any one with a 7950 can measure and compare?
I cannot find a 7950 drawing but will keep looking
Ok found pic of 7950, I would have thought that mounting tabs are the same size as the 7955 etc
Alan
Manage to find this drawing of the 7955 perhaps any one with a 7950 can measure and compare?
I cannot find a 7950 drawing but will keep looking
Ok found pic of 7950, I would have thought that mounting tabs are the same size as the 7955 etc
Alan
Last edited by fireblade5437; 08-22-2014 at 06:19 AM.
08-22-2014, 05:35 AM
#17
Thread Starter
08-22-2014, 05:46 AM
#18
Thread Starter
Oli
Manage to find this drawing of the 7955 perhaps any one with a 7950 can measure and compare?
I cannot find a 7950 drawing but will keep looking
Ok found pic of 7950, I would have thought that mounting tabs are the same size as the 7955?
Rest if dimensions you Cavan see the slight difference..
Alan
Manage to find this drawing of the 7955 perhaps any one with a 7950 can measure and compare?
I cannot find a 7950 drawing but will keep looking
Ok found pic of 7950, I would have thought that mounting tabs are the same size as the 7955?
Rest if dimensions you Cavan see the slight difference..
Alan
Would you happen to know the thickness of the servo tabs as well as the tab ridge?
08-22-2014, 06:18 AM
#19
Oli
Not without taking a servo out of the Yak and as presently as on crutches I cannot get to the Yak
I am sure someone must have a 7955/7950 servo out that they could accurately measure the tabs for you?
Just noticed all the jiberish at end of my post to you, really have to check better as iPad spell/grammer not the best, it ends up re-arranging what you have written and if you don't notice.......
Alan
Not without taking a servo out of the Yak and as presently as on crutches I cannot get to the Yak
I am sure someone must have a 7955/7950 servo out that they could accurately measure the tabs for you?
Just noticed all the jiberish at end of my post to you, really have to check better as iPad spell/grammer not the best, it ends up re-arranging what you have written and if you don't notice.......
Alan
Last edited by fireblade5437; 08-22-2014 at 06:23 AM.
08-30-2014, 12:02 AM
#21
Oli I saw on another thread GRC has tank fittings that are much larger than the standard fittings to allow for larger fuel clunks, I really like the design since it looks like the inner ring screws onto the outer ring which is glued to the fuel cell. Makes for much easier maintenance, when will these be added to vendors for purchase?
08-30-2014, 04:49 AM
#22
Thread Starter
09-04-2014, 07:36 AM
#23
Thread Starter
Following my glue joint strength test, I am happy to rate the USB at 95 kgs/ cm of shear torque or 1319 oz.in on E-20HP glue.
The maximum rated torque for the bracket on E-20HP is 67 kgs/ cm or 930 oz.in, limited by the glue joint strength on hard wood.
Maximum rated torque with the top screw inserted in unknown yet and will most probably be limited by the PYCABS shear resistance.
This test will be done as well at a later stage.
Already, this test shows that the bracket exceed all commercial servos specifications by a large margin and would also offer a nice protection against flutter. At these levels of resistance, the structure would most certainly be the weak point.
The maximum rated torque for the bracket on E-20HP is 67 kgs/ cm or 930 oz.in, limited by the glue joint strength on hard wood.
Maximum rated torque with the top screw inserted in unknown yet and will most probably be limited by the PYCABS shear resistance.
This test will be done as well at a later stage.
Already, this test shows that the bracket exceed all commercial servos specifications by a large margin and would also offer a nice protection against flutter. At these levels of resistance, the structure would most certainly be the weak point.
09-04-2014, 09:47 AM
#25
Hi Oli,
Now that you have tun this test, how do you feel about the practice of adhering a bracket like this to a servo cover and then bolting the cover to the structure? How does the tensile strength of the screw mounting compare to the strength of this bracket/adhesive/cover?
Also if you don't mind me asking, what kind of 3D extruder are you using? Looks customized.
This honey comb technique looks like it would be ideal to make engineered bulkheads as well, with any servo mounts, air cylinders, gear mounts etc already built in. Very exciting.
Now that you have tun this test, how do you feel about the practice of adhering a bracket like this to a servo cover and then bolting the cover to the structure? How does the tensile strength of the screw mounting compare to the strength of this bracket/adhesive/cover?
Also if you don't mind me asking, what kind of 3D extruder are you using? Looks customized.
This honey comb technique looks like it would be ideal to make engineered bulkheads as well, with any servo mounts, air cylinders, gear mounts etc already built in. Very exciting.