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The Router Sled
MaslowCNC Wiki: Electronics | Firmware | Mechanics | Software| Community Garden
While the default instructions for the Router Sled as explained here are the most current suggested design, please note that the optimal configuration of the Router Sled is still in flux as of this writing (7/16/17).
Multiple paths of research are being undertaken by many MaslowCNC users and this page attempts to explain the issues at play, and possible solutions that may improve the MaslowCNC Router Sled part.
Chain Alignment | CoG | Friction | Torque | Weight
It is important that the chains remain in the same plane to each other, and parallel to the work surface. This is important to minimize friction on the gear/motor assembly and keep consistent pressure from the Router Sled on to the work surface.
If the chain is out of alignment there can be excessive torque exerted on the motors, their mounting points and the arm assembly. Similarly, if the chain is out of alignment, it's possible that the Router Sled will not maintain full contact with the work surface, jump or cut to inconsistent depths, or cause a recessed countersink to become snagged on the work surface.
Further, when different thickness of stock is used, it is necessary to move the chain attachment points to restore this alignment.
- When cutting thicker stock, the chain attachment points might need to be moved lower, towards the surface of the sled.
- When cutting thinner stock, they may need to be moved higher on the sled mounting brackets.
Accurately measuring and calculating the Router Sled's Center of Gravity (CoG) is important both to maintain the Router Sled flush with the work surface, and for accuracy of the motor control, and the machine overall. Errors cause by the CoG being wrong will show up as distortions in positioning in the bottom corners of the workspace.
It is important that this contact point be as friction free as possible, as well as a smooth surface, free of any interior pockets that could possibly snag a corner of newly cut, or outer edges of the work surface.
It is also important to keep any exposed counter sinks, or holes, free of sawdust and any other debris. This could further increase the friction between the Router Sled and work surface, or lift the Router Sled off of the work surface.
Multiple MaslowCNC builders and developers are currently (7/16/17) experimenting with different materials for the Router Sled's surface contact with the work surface, however the current design of simply rounding over the plywood Router Sled's outer edge and making sure that any counter sinks for mounting points keep hardware clear of the work surface is currently the recommended standard.
Once a compellingly more efficient design has been adopted this document should be updated.
It is important to minimize any torque that can occur at the chain attachment points to the Router Sled. Multiple MaslowCNC developers are working on mechanical solutions, as well as via software compensation, it is possible that the eventual solution to this problem will increase MaslowCNC's overall accuracy.
Router Sled weight is the primary means of maintaining a flush connection to the work surface and maintaining accuracy at the outer edges of the full 4'x8' work surface.
With regards to flushness to the work surface a great deal of weight isn't completely necessary.
With regards to accuracy, once one chain is fully extended (with the Router Sled in the opposite bottom corner of the work surface) sufficient weight in the router Router Sled currently is most important to maintain accuracy.
Unfortunately, when in the opposite situation near the top of the work surface, Router Sled weight creates torque on the chains that can have similar detrimental effects on accuracy.
Ideal sled weight currently is somewhere near 18lbs, as described in the Assembly instructions, but developers and builders have experimented with weights much lower, approaching only the weight of the Ridgid 22002 router and sled alone. (approx 8-9lbs)