Slab Leveling Jig

Overview

Slab furniture has become a growing trend in the furniture industry recently. Although there are two main ways to create these large wooden slabs, they each have their own problems. Manual planers often require plenty of labor and tend to be inconsistent. On the other hand, CNC routers are very expensive and are too complicated for the average woodworking hobbyist to use. Our team’s objective is to create a slab leveling jig that will hold a handheld router and be controlled by a microcontroller that automates motion in two axes. This will lower the price of an autonomous router while also decreasing the amount of manual labor.

Objectives

-Create a microcontroller to automate motion in two axes
-Adjust the current frame to become expandable
-Replace the existing chain drive with a drive system that supports automation
-Keep the cost competitive with a manual planer
-Make the system simple enough for a hobby woodworker to use

Approach

-Met with sponsor weekly to present updates and receive advice
-Split into a mechanical and electrical team to focus our work
-Both groups met weekly to update on progress and share ideas when needed

Mechanical Team:
-Created original designs in Solidworks to confirm movements and sizing
-Purchased timing belt, fasteners, pulleys, and bearings based on the forces applied by the motors and handheld router
-Changed the existing chain drive to an open belt drive to support automation
-3D printed mounts, brackets, and belt tensioners to save money when possible

Electrical Team
-Chose stepper motors based on the required moving speed and force to move the router
-Calculated step rates and torque specifications required for automation
-Designed a state machine made of 3 states (idle, manual, and automatic)
-Assembled power circuit and soldered wires when needed
-Created an HMI system that would interface with the jig

Outcomes

-The team successfully created a slab leveling jig that automates movement in two axes
-The system will save about $300 compared to similar products
-The expandability of the frame allows for slabs of all different sizes
-Through the three different states, the jig is diverse in its uses
-In future applications, an electrical box and more safety features can be added