SAWSTOP

ENSURING SAFETY
1. Design Specifications Overview
2. Major subsystems
2.1. Detection and trigger system
2.2. Braking
2.2.1. Energy absorber
2.2.1.1. Design
2.2.1.2. Analysis
2.3. Spring Damper System for safety mechanism
2.3.1. Design
2.3.2. Analysis
3. Bill of Materials
Frozen Design Specifications Bosch’s GTS 10J
RPM - 3865
Feed speed - 20 mm/sec
Moment of Inertia - 6.1853*10−3 kg*m*m
Torque (0.1s stopping time)- 1437.9 N*m
Saw Blade diameter – 254 mm
Base blade thickness – 1.86 mm
Hole diameter- 25.4 mm
Trigger distance - 3 cm
Motor weight – 7 kg
Magnet lifting capacity – 40 kg
Major subsystems

1. Detection and trigger system

2. Braking subsystem
2.1. Energy absorber
2.2. Disc brake
3. Spring Damper System for safety mechanism
 Detection and trigger system

1. Contact detection system

2. Using IR proximity sensor
Contact detection system

The contact based detection system has 3 units:

•Oscillator: The oscillator circuit takes a DC voltage as
input and outputs an AC waveform. For our application
we want a square wave output with an oscillating
frequency of 200 - 500 kHz. Oscillators can be made in
many ways, using a timer ic, using a binary counter or
using an opamp and some passive elements. The output
of the oscillator is passed through a shielded cable to
protect from energy losses and outside interference and
fedded into the capacitive plates coupled to the cutting
blade.
•Capacitive coupling: Two plates of appropriate
dimensions and orientation are placed on either side of
the cutting blade and capacitively coupled to the blade.
This makes a capacitor which is the total capacitance of
the two plates and the cutting blade
Using IR proximity sensor
Braking 1 - Energy absorber
DESIGN

Blade and energy absorber

assembly
 ANALYSIS

Function
Absorber should be able to stop the inertial motion of blade

Variable quantities
Braking time Depth of cut Absorber material

Approach (A) :
ANSYS: Explicit Dynamics
Goal :
For Aluminium checking for what value of depth of
cut does the blade stop within desired time
Outcome:
Did not get results. Some error.
Approach (B) :
t Torque (J*dw/dt) Force on each(3) teeth check whether teeth fails?
(Using ANSYS: Static Structural)

On absorber side –
1. (Analytically) Assuming orthogonal cutting, find the required depth of cut for above calculated force values
2. (Using ANSYS) Iteratively, finding for what depth of cut values we are getting above forces

Problem Setup
Input parameters :
RPM (velocity)
Friction coefficient
Forces’ values
Fixed parameters : Absorber material – Aluminium
Braking time – 0.1s
Output parameters :
Depth of cut
Blade Stress Analysis for del(t) = 0.1s
With calculated force(input here) =
3.774 kN per teeth
 Safety mechanism - 2

Function
Drop with rapid acceleration and then decelerate with certain distance

Constraints
Length of guides and screw, Less load on motor

Variable quantities
Damping coefficient, Spring constant, Magnet strength
 Disassembled Table saw to arrive at the given design
Glimpses…..
DESIGN
 Acceleration (time)
A(0.1)=0.5 m/s2
A(0.01)=5 m/s2
A(0.001)=50 m/s2

For 5 cm drop without

Magnet lifting capacity – 40 kg
Total drop distance - 8 cm(max)
ADAMS simulation
damping(MATLAB),
K = 2500 N/m
C = 75 N-s/m
Velocity = 1.5 m/s
Stop distance = 3.5 cm
Max force on system = 450 N
Bill of
materials
THANK YOU !