Spacecraft Abort Handle

A 3D-printed abort handle based on the CST-100 cockpit and suitable for KSP

Tobias

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Description

One of my ongoing projects is to build a set of immersive controls for Kerbal Space Program (on hackaday.io here: https://hackaday.io/project/183090-ksp-controller-hardware). This included an abort control, but just as a simple push button, which was pretty dull compared to the real-life versions.

This version is a rotate-to-activate switch that uses a spring-loaded cam that gives a satisfying feel, as well as a microswitch for a tactile click.

I've set this up as a seperate project as it has a very different set of parts and assembly process

Files

abrt_base.stl Standard Tesselated Geometry - 957.02 kB - 07/28/2023 at 07:05		Download
abrt_handle.stl Standard Tesselated Geometry - 464.54 kB - 07/28/2023 at 07:05		Download
abrt_lid.stl Standard Tesselated Geometry - 537.58 kB - 07/28/2023 at 07:05		Download
abrt_base_test.stl Standard Tesselated Geometry - 355.16 kB - 07/28/2023 at 07:05		Download
abrt_inner_lid.stl Standard Tesselated Geometry - 262.48 kB - 07/28/2023 at 07:05		Download

View all 7 files

Components

4 × Axial Ball Thrust Bearing F8-19M 8x19x7mm https://www.ebay.com/itm/120896819964
2 × 10PCS 604ZZ Miniature Bearings (4mm*12mm*4mm) https://www.ebay.com/itm/141258883919
1 × M4x20mm Ultra Thin Flat Wafer Head Screw https://www.ebay.com/itm/153550101060
1 × M4x45mm Hex Socket Cap Head Screw https://www.ebay.com/itm/153352081727
9 × M4x25mm Hex Socket Cap Head Screw https://www.ebay.com/itm/153352081727

View all 12 components

Project Logs

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Prototype and Cam Mechanism
Tobias • 08/08/2023 at 06:40 • 0 comments

Here's a gif showing how the mechanism operates - essentially as the handle is turned the bearings run along a cam surface. The bearings are on a lever tensioned by the extension spring. The cam surface is designed so that the deflection of the lever is linear with the rotation of the handle - and so the resistance is linear. This also means that the handle rotates in both directions, and snaps back smoothly to the centre

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Build Instructions

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1
Before Assembly
Most of the assembly is covered in the video below, but there are a few things that need to be done first:
1. Solder leads onto the microswitch
2. Insert threaded inserts either with a soldering iron or with a press
2

Assembly

This video covers all of the main steps of assembly:
You might notice that I haven't installed all of the screws... turns out I ran out of threaded inserts
3

Complete!

You'll now have a complete abort handle that acts as a simple switch. From here you can wire it up to an Arduino, Raspberry Pi, computer or really anything

View all 3 instructions

Spacecraft Abort Handle

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Description

Files

abrt_base.stl

abrt_handle.stl

abrt_lid.stl

abrt_base_test.stl

abrt_inner_lid.stl

Components

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Prototype and Cam Mechanism

Build Instructions Collapse

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