Project Code: VARGEL-LM-MOD
Duration: ~3 months
Role: Project Lead (Mechanical Design Manager, Toksel R&D Department)
Software: Autodesk Inventor
Project Overview
Development and reengineering of a modular linear motion system (VARGEL) intended to replace traditional screw-based actuators. The goal was to reduce production costs, improve reliability, and enable high-speed backlash-free operation without using threaded shafts.
Technical Description
VARGEL operates as a non-positive drive mechanism: it converts the rotation of a plain round shaft into axial motion using a precision roller-based mechanism. The system eliminates the need for lead screws or ball screws, achieving high-efficiency linear movement through mechanical rolling contact.
Key Contributions
- Redesigned the original cast iron housing into custom aluminum extrusions for weight reduction and simplified machining.
- Developed internal components with enhanced durability and optimized geometry based on manufacturability constraints.
- Led a small cross-functional team through prototyping, fit-testing, and redesign cycles, adapting tolerances to in-house CNC capabilities.
- Personally supervised mechanical testing of prototypes and verified design changes post-assembly.
Outcomes
- Weight reduced by nearly 70% for certain sizes.
- Production cost significantly lowered due to use of standard aluminum profiles.
- Performance and stability improved by eliminating backlash and reducing friction losses.
- Full documentation package prepared including BOMs, 2D/3D drawings, tolerance analysis, and assembly guidelines.
Reference Design Principles
- Backlash-free motion
- Release lever for manual reset
- Overload protection via slip
- Dust and humidity sealing for industrial environments
- Modular design for custom pitch and direction control
Note: Due to the proprietary nature of the internal mechanism, detailed geometry is not disclosed. However, the development was heavily inspired by modern threadless linear actuation principles and adapted for Toksel’s unique machine architecture.