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Rack-and-Pinion Opposed-Dasher Churn: Two Rows of Hanging Dashers Move Opposite Ways Through Slots in the Lid
Nelson Gabel of Gratis, Ohio, received US 33,080, dated 20 August 1861, for a box churn worked by racks and a pinion. Two slides lie on the lid over two slots, each carrying three dashers that hang down into the cream. A rack on each slide meshes a pinion between them, so when a lever on a standard pushes one slide to and fro, the other moves the opposite way. The currents meet and break against each other and the box's ends.
The patent gives no sizes; every size here is ours.
Intermediate
About 3 days
Instructions
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Two rows passing each other
Two rows passing each other
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A frame slid to and fro on the lid, a year and a half before
A frame slid to and fro on the lid, a year and a half before
Morgan's sliding frame spins beaters by a cord. Gabel's two slides carry the dashers themselves, and a pinion makes them move against each other.
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Read US 33,080
Read US 33,080
"Thus it will be observed that when milk is put into the box and the lever (a) worked to and fro the agitation of the milk will be very great. As the currents each way will be broken and dashed in opposite directions the globules will thus be crushed both by sudden concussion against the side of the box and the violent reverse action of the currents."
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Box A on legs, top B with two slots
Box A on legs, top B with two slots
Glue up a hardwood box A 600 x 300 mm inside and 300 deep from 20 mm boards, the joints sealed with silicone sealant, and screw four hardwood legs 40 x 60 mm, 220 long below it. Cut a 20 mm HDPE or hardwood top B to fit over the mouth, with two slots 30 mm wide and 500 long, 33 mm either side of the centre line, and a 12.6 mm hole at the centre for the shaft C.
Materials for this step:
Hardwood Board4 pieces
Wood Glue1 piece
Silicone Sealant1 piece
Wood Screws30 pieces
HDPE Sheet1 pieceTools needed:
Table Saw
Router
Jigsaw
Cordless Drill
Drill Bit Set
Bar Clamp
Screwdriver Set
Tape Measure5
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Print the racks b (two)
Print the racks b (two)
A rack: 416 mm long, module 2.5, 20 mm thick. Print two, in halves if the bed is short. PETG, 0.2 mm layers, 30 % infill, 4 walls.
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Print the pinion a
Print the pinion a
The pinion: 16 teeth, module 2.5, 20 mm thick, 12.2 mm bore. PETG, 0.2 mm layers, 30 % infill, 4 walls.
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Slides h, racks b, dashers k
Slides h, racks b, dashers k
Cut two hardwood slides h 560 x 50 x 25 mm and screw a rack b along the inner edge of each, teeth inward. Cut six 12 mm HDPE dashers 115 mm wide and 210 long; drill four 25 mm holes in four of them, the end ones. Screw each to a hardwood stem 20 x 20 mm, 90 long, and fix three stems under each slide, at its middle and 180 mm either side, to hang through the slot with the dashers 40 mm off the floor. Lay the slides on the top over the slots, racks facing.
Materials for this step:
Hardwood Board1 piece
PETG Filament1 pieceHDPE Sheet1 pieceWood Screws20 piecesWood Glue1 pieceTools needed:
FDM 3D PrinterTable SawJigsaw
Spade Bit SetCordless DrillDrill Bit SetScrewdriver Set8
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Shaft C, pinion a and strap D
Shaft C, pinion a and strap D
Cut a 12 mm stainless shaft C 90 mm long, stand it in the top's centre hole and pin the pinion a on it meshing both racks. Bend a mild steel flat bar strap D over the pinion and the slides, bore it 12.6 mm over the shaft's top, and screw its feet to the top beyond the slides.
Materials for this step:
Stainless Steel Rod1 piecePETG Filament1 piece
Mild Steel Flat Bar1 pieceWood Screws4 pieces
Split Pin1 pieceTools needed:
Hacksaw
Files (Hand File)
Bench ViseCordless DrillDrill Bit SetScrewdriver Set9
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Lever d, standard m and lever f
Lever d, standard m and lever f
Bolt a mild steel flat bar lever d, 470 mm long, to the outer slide with a spacer block, reaching past the box's end. Make a standard m of two hardwood posts 30 x 20 mm joined at the foot, standing beside the box's end and reaching 260 mm above the top, with a 10 mm bolt across their tops. Hang a flat bar lever f between them on the bolt, its lower end slotted over a bolt through the end of d and its upper end a handle.
Materials for this step:
Mild Steel Flat Bar2 piecesHardwood Board1 piece
Hex Bolt Assortment3 pieces
Nylon Insert Lock Nut3 pieces
Flat Washer6 piecesWood Glue1 pieceWood Screws6 piecesTools needed:
HacksawFiles (Hand File)Bench ViseCordless DrillDrill Bit Set
Adjustable SpannerTable Saw10
10
The build in 3D
The build in 3D
FreeCAD model of this build, the box's front wall cut away: the two rows of hanging dashers (the end ones holed), the slides on the top with their racks and the pinion under its strap, and the levers d and f on the standard.
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Churn
Churn
Lift the top off with the slides and dashers, pour about 20 litres of heavy cream at about 15 °C, checked with the thermometer, into the box, and set the top back. Work the lever f to and fro through its full swing, timing it. When the butter comes, lift the top and dashers out, take out the butter, pour the buttermilk into a bowl, wash the butter in cold water until it runs clear, salt and weigh it.
Materials for this step:
Heavy Cream20 l
Coarse Sea Salt1 piece
Water1 pieceTools needed:
Leave-In Probe Thermometer
Stopwatch
Digital Kitchen Scale
Stainless Steel Mixing Bowl (Large)12
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Troubleshooting
Troubleshooting
Rack-and-pinion churn troubleshooting.
Flow
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History and honest limits
History and honest limits
**Nelson Gabel** of Gratis, Preble County, Ohio, US 33,080, 20 August 1861, "Churn". He claimed "the employment and arrangement of fixed pinion (a), double reciprocating racks (b b) and slides (h h)". His text calls the hand lever both (a) and (f). He gives the dashers only as drawn, three to a slide with holes in the end ones; ours are plain boards. The patent gives no sizes; every size here is ours.
Materials
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Tools Required
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Design Files
3This blueprint makes
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