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Design challenge: rope-to-rope transfer in a small cylindrical coupling

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Hi, working now on a small-scale linear actuator project and need a compact coupling between two coaxial cylinders. Both are 44 mm in diameter, with the upper one hollow (22 mm inner Ø). The idea is to transfer a pulling force (~80 N) from a Dyneema rope running outside the lower cylinder to a rope that runs inside the upper one. I’ve already built a clutch with a rotatable ring and radial sliders that lock an adapter in place at ±60° from neutral. That part works fine, but I’m struggling with the mechanism that should selectively connect the internal rope either to string A or string B, depending on the ring position. Ideally, the mechanism should tolerate any angular orientation when the adapter is inserted, and I’d like to keep it 3D-printable. Has anyone tackled a similar bidirectional rope-to-rope coupling problem in a compact form factor?

    • V

      Hi, working now on a small-scale linear actuator project and need a compact coupling between two coaxial cylinders. Both are 44 mm in diameter, with the upper one hollow (22 mm inner Ø). The idea is to transfer a pulling force (~80 N) from a Dyneema rope running outside the lower cylinder to a rope that runs inside the upper one. I’ve already built a clutch with a rotatable ring and radial sliders that lock an adapter in place at ±60° from neutral. That part works fine, but I’m struggling with the mechanism that should selectively connect the internal rope either to string A or string B, depending on the ring position. Ideally, the mechanism should tolerate any angular orientation when the adapter is inserted, and I’d like to keep it 3D-printable. Has anyone tackled a similar bidirectional rope-to-rope coupling problem in a compact form factor?

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    • E

      Hey Victor, for 3D-printing specifically, the cleanest route might be a sliding shuttle inside the hollow cylinder. The shuttle has two sockets, one for rope A and one for rope B. A keyed track linked to your clutch ring decides which socket lines up with the incoming rope. The advantage of this is that you avoid small cams or springs, which are tricky to print at that size. But a downside is you’ll need precise tolerances to keep friction low.

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Design challenge: rope-to-rope transfer in a small cylindrical coupling
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