Introduction: Giant Functioning Emergency Stop Button

Emergency Stop (E-stop) buttons are a very important safety measure utilized to prevent catastrophic events from escalating. While these buttons are featured everywhere, a person is rarely put in an unfortunate position that requires the activation of one. Needless to say, these shiny buttons look very tempting and fun to use. For years we have been told to not push the red button... until now. This Instructables will outline how to assemble your very own GIANT e-stop button that actually works.

The end result of this project will yield a button that looks and performs like a traditional emergency stop button. While this is great for harmless projects, it should never be used to replace certified shutoffs.

Please be sure to watch the gifs that are included with most steps for assembly clarification.

Step 1: Parts

4 - Metal Badge Clips - Link

1 - Micro Limit Switch - Link

1 - 15x21x4mm Precision Ball Bearing - Link

1 - PCB Screw Terminal Block Connectors - Link

- M2 x 3 mm Brass Cylinder Knurled Insert Nuts - Link

- 2mm x 0.4mm x 6mm Phillips flat head screws

Step 2: 3D Printing

Everything was modeled, rendered, and animated using Fusion 360.

All parts were printed on the Creality Ender 3 pro using PLA with a 0.2mm layer height.

Due to the complex nature of the parts, enabling supports will yield the best result.

Step 3: Getting Started

First, start with the clip frame.

This 3d printed part mounts the clips in the designated slots to allow one direction travel. These clips will hold the button in the shutoff position when pressed.

The piece has 16 holes that are designated for the m2 threaded inserts. Half can be found on the sides of the and the rest on the bottom. Position the part with the tabs found inside the cylinder at the top. Using two screws per side, fashion the clips with the teeth facing upwards.

Step 4: Suspension

Next, it is time to assemble the spring suspension system. This will allow the button to return to its primed position.

The spring base has four holes on the bottom designated for heated inserts.

Insert one spring into each cylinder found on the part. Once the springs are in position, the spring lid can be lowered on top. This should allow for linear movement between the two parts with minimal friction.

When the assembly is deemed functional, press-fit a bearing into the center hole found on the spring lid.

Currently, this system is not securely attached together. With some movement, it is bound to fall apart. Once this frame is included in the final assembly, the pieces will be properly held in the correct position.

Step 5: Main Body Assembly

Using four screws, the tabs of the clip body can be attached to the bottom of the spring assembly.

When the two features are firmly secured, the camshaft can be press-fitted into the pre-installed bearing from below.

The bottom of the camshaft is egg-shaped by design. The lobe of the cam will toggle a limit switch on and off depending on the state of the button.

This assembly makes up the internal frame.

Step 6: Outer Shell

The next step in the process is to assemble the outer shell. While it is cosmetically enhanced, these parts are crucial to the success of the internal mechanism.

The button top had slots for 12 heated inserts to be installed. This number is twice the amount required for assembly. The holes will be intermittently used for both the inner and outer rings. In case of damage or aggravated strain, the other slots can be utilized to prolong the life of the part.

The outer cylinder can then be attached to the top using the four tabs found on the inner surface of the cylinder.

Step 7: Putting It All Together

Once the internal frame and outer shell are each assembled, it is time to combine the features. The frame can be slotted into the shell with the bearings and camshaft aligning with the cylindrical extrusion located on the base of the button top. The shaft can then be fastened into the top using two screws. This attachment will cause all pieces to be secured in their designated place.

Step 8: Electronics

As previously mentioned, a limit switch will be used to make the button functional. The switch will be positioned in alignment with the asymmetrical camshaft. When the camshaft is arranged at both the right height and angle it will be able to toggle the connected circuits.

The NO and NC circuits (found on the limit switch) are each wired to a block connector, creating an easy connection point to any circuit.

The electronics frame is designed to house both the limit switch and block terminals in acceptable locations. This frame is designed to be easily swapped or modified to suit project needs.

Step 9: Base

Once all of the components are assembled inside of the housing, the button can be attached to the base. First, attach the electronics frame using the designated holes found on the base. When the electronics are secure, the base itself can be attached using the screw holes aligned with the clip frame. This should allow the button enough travel to properly use the latching mechanism.

Step 10:

Attached are the STL files required for the project.

Everything was designed using the metric system.

It is important to note that there are two different versions for the base model.

Step 11: Cad Download

While I am hesitant to release the cad files for this project I understand that every printer is different and some file modifications are necessary. Please understand that my design process is somewhat chaotic and unorganized. I did my best to go through the parts and make everything as clear as possible. The file uploaded is for Fusion 360. Please reach out if you have any questions. I will try to be more responsive.

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