Open Source Ecology - User contributions [en]

LifeTrac Prototype II

2011-04-24T09:44:02Z

Barowski: /* Performance Review */

{{Category=LifeTrac}}
See http://www.appropedia.org/LifeTrac_prototype_II

=Introduction=
last updated 1/10

We have already built [http://openfarmtech.org/weblog/?p=797 LifeTrac], the world's first, high performance, open source, multipurpose tractor. Our learnings from this project are:

*Design-for-disassembly via bolt-together xyz beam design is feasible for building heavy equipment
*Initial results indicate that complete, life-size Erector Set or Lego Set for real technology can be built using stock steel and components
*Lifetime design, modularity, simplicity, and ease of maintenance are key features
*Initial results indicate that DIY kits - reconfiguarable from small tractors to bulldozers just like Lego Blocks - with interchangeable motors and power units - are a viable route to widespread adoption of the technology
*Cost performance in the DIY scenario appears to be a factor of 10 improvement over the competition
**Machine combines functionality of an agricultural tractor and a skid loader
**Material costs for LifeTrac I were $4k ($500 engine, $2000 hydraulics, $1000 frame,$500 balance of system including used 16" wheels for $5 each)

We are aimng to complete LifeTrac Prototype II by end of February.

=Performance Review=

To date, LifeTrac I has undergone over 1 year of field testing. Bucket work, CEB press power, backhoeing, power generator work, bale spiking, tree hole augering, disking, rototilling, soil pulverizing, and other uses were performed. During initial testing, the articulated joint cracked in half and was redesigned completely. Since then, there have been no mechanical problems, such that down time never lasted more than a few minutes due to ready ability to repair.

While long-term performance only will determine whether LifeTrac is worthy of its implied lifetime-design name - the results after 1 year of operation are promising. No visible leaks are to be found on any of the hydraulic motors and cylinders.

*Hydraulic drive via a diesel engine reduces the mechanical complexity by eliminating the transmission-clutch-differential-drive train-steering-braking, and replacing it with hydraulic flow, valves, and hydraulic actuators that perform all of the above functions
**Thus, power transmission components are decoupled and made modular
*Hydraulic system is robust and flexible. It allows devices on and off the tractor to be powered using 3 sets of 12 gpm outlets.
*Articulated steering is an effective means of performing short-radius turns
*Articulated joint both rotates and moves side-to-side, keeping 4 wheels on the ground under all conditions
*Pressure can be varied everywhere with adjustable pressure reliefs
*Custom implements, such as soil pulverizer, and many others can be used with LifeTrac
*PowerCube can mount on the quick attach of LifeTrac I for auxiliary power in case of engine failure

We welcome third party testing organizations to get involved in the evaluation process we are currently building LifeTrac prototype II.

==Known Bugs==

There is a number of known issues on LifeTrac I:

*Too many valves - 6 different valves and flow regulators can be replaced with just 2, based on better flow strategy
*Loose hydraulic hoses rubbing against tractor body and other hoses
*Minor hydrauilic leaks from a number of loose or improper fittings
*Engine is presently located at the front, creating poor weight balance for front loads over 2000 lb even with a 2000 lb counterweight on the back.
*No roll-over protection and poor seat arrangement
*Pinch points due to articulation
*Shaky ride over rough terrain due the degrees of freedom of the articulating joint
*Even with a 50/50 flow divider between the front and back wheels, the tractor can lose traction by either front or back wheels spinning out in mud or snow (flow through different parallel segments of hydraulic circuits is inversely proportional to flow resistance)

All of these points will be addressed in the next prototype

=LifeTrac Prototype II=

The main difference in LifeTrac II will be a return to non-articulated design. While attractive from the perpective of low ground damage from turning and a constant traction of all 4 wheels on the ground, we decided that the added complexity, structural requirements, and danger associated with articulation are not worth the significant added effort. A non-articulated tractor is estimated to reduce the fabrication requirements by approximately a factor of 2 - allowing for an absolutely simple, robust design. This design still addresses gentle turning by wheel layout and and independent control of all 4 wheels. The design addresses traction by selectability between 2 or 4 wheel drive, as well as by the ability of LifeTrac II to use tracks instead of wheels.

The above considerations result in LifeTrac with the highest degree of simplicity and highest degree of flexibility - even compared to LifeTrac I. Based on our learnings, we believe that we can deliver the world's first, completely life-size Lego Set for heavy equipment. This will allow amateurs and professionals alike to tame machinery into useful service. In particular, the design specifications are:

*Bolted, xyz construction with 4x4 inch square tubing as the stock steel of choice
*All metal used is stock steel, and requires minor amounts of welding in lieu of bolted, xyz construction
*Skid-steer design
*2 or 4 wheel drive
*Modular design allows components to be interchanged and added
*Additional PowerCube engine units can be added for scaling power
*Additional wheels can be added for increasing drawbar power
*Frames can be interchanged while retaining same power units and wheels
*Adaptability/convertibility between MicroTrac and LifeTrac configurations
*Attachability of extra wheels on demand - such as 6 or 8 wheel drive for higher torque
*Ready adaptability to tracked drive by putting on metal tracks for added traction
*Stackability of 2 small tractors into a bigger one
*Two loader units - one larger for the front and a smaller loader for the back, for doing 2 different tasks simultaneously
*Front loader is extra heavy duty to accommodate bulldozer and grader functions
*All loaders have quick attach plates for ready interchangeability of implements
*Ready accommodation of tractor weigths
*Engine mounted on back
*Driver sits inside a driver's cage, just like in standard skid steers

=Deliverables=

This project aims to realize the full potential of a life-size Lego Set for constructing real technology - and in particular - for a wide range of heavy equipment from small, 2-wheeled garden tractors to 20,000 pound bulldozers, and everything in between. By using simple building blocks in the form of stock steel tubing with bolt-together xyz corners - this is possible - provided you have access to designs and plans that break through the confusion of advanced technology and reduce it to simple, understandable implementations. We have proven that this is possible with LifeTrac I. We aim to tame the power of mechanical technology - by putting it in the hands of average people to use and modify according to their needs. Moreover, we will be developing PowerCubes running on steam power in addition to standard fuels, using pelletized biomass - so you can make your own fuel as well. This is aimed to be a breakthrough contribution to humanity, with applications ranging from sustainable agriculture, natural building, third-world development, to resilient communities and many other applications. With the addition of readily-retrofittable, open source controllers such as the [http://arduino.cc/ Arduino], this entire package becomes the link between basic needs of everybody and bold steps into a prosperous future.

=Support=

This project is 100% open source and supported totally by crowd donations. If you want to see the above results come to life sooner rather than later, please consider supporting our work financially:

**[http://openfarmtech.org/index.php?title=Open_Source_Ecology:Site_support Donate to the project]
**[[Image:donate button.jpg]]
**[http://openfarmtech.org/index.php?title=Open_Source_Ecology:Site_support Subscribe] to this work:
**[[Image:subscribe button.jpg]]

Open Source Steam Power Generator

2011-04-24T09:34:10Z

Barowski: /* March 2011 */ units!

=Introduction=

This begins work on Prototype 1 of a turnkey, 1 kW, stationary electrical power generator. This is the more general product ecology:

[[Image:DistributedPower.png|403px]]

The goal is the introduction of a modern, open source steam engine into the marketplace. Goals are both stationary and mobile power, scalable in units of 1, 10, and 100 hp.

=Concept Specifications=
*Electrical power generator
*Open source product development
*Turnkey operation
*1kW max electrical power
*Solid pellet fuel
*Water-based system
*Easy maintenance
*Lifetime design
*Modular design
*Simplicity (KISS)
*Open source plans
*Open source business model

Other
*Retrofittable into existing stoves - this would be another version beyond scope of Prototype I

=Project Plan=
Define 1kW Genset specs
*Set engine specs – Stan Jakuba
*Define burner specs – Karl
*Prelim burner sketch – Karl
*Define generator specs and control – Randy Burmeister
*Burner review – Larry Dobson

Concept development
*Sketch engine
*Sketch burner
*Sketch steam generator
*List control elements and methods

Concept review

Project timeline, cost review

Prototype design
*Engine
*Generator
*Burner
*Steam generator

Proto Build
*Engine
*Generator
*Burner
*Steam Generator
*Controls
*Packaging

Test

Review

Product Design
*Engine
*Generator
*Burner
*Steam Generator
*Controls
*Packaging

=Concept Technical Details=
*2 cylinder opposed
*[http://www.fisherpaykel.com/ Fischer & Paykel] generator - very efficient $500-1000 - replacement or factory second
**Radial field generator - to be opensourced via digital fabrication at 10 time cost reduction.
**Nylon bobbin with copper wire around
*High performance burner expertise - [http://www.fundamentalform.com/html/energy_from_waste.htm]
*Gasifier with secondary flame burn for radiant heat - luminous flame
**"Pile of burning coals' is not good enough
[[Image:fpgen1.jpg|thumb]]
[[Image:fpgen2.jpg|thumb]]
[[Image:fpgen3.jpg|thumb]]
[[Image:fpgen4.jpg|thumb]]
[[Image:fpgen5.jpg|thumb]]

=Implementation Options=
*Reciprocating engine
*Uniflow bash valve for long life
*Design for fabrication
*Design for disassembly (Steam Engine Construction Set)
*Scalability
*Modularity
*[[OSE Specifications]]
*Monotube
*Fully automatic
*Efficient (temperature, pressure, regeneration)
*Low cost (max $500 materials, max $500 fabrication)

=Team=

==Developers==
*[[Karl Petersen]]
*[[Marcin Jakubowski]]
See [Steam Engine Construction Set corresponding blog post].

<html>
<object width="400" height="233"><param name="allowfullscreen" value="true" /><param name="allowscriptaccess" value="always" /><param name="movie" value="http://vimeo.com/moogaloop.swf?clip_id=15167957&server=vimeo.com&show_title=1&show_byline=1&show_portrait=1&color=00ADEF&fullscreen=1&autoplay=0&loop=0" /><embed src="http://vimeo.com/moogaloop.swf?clip_id=15167957&server=vimeo.com&show_title=1&show_byline=1&show_portrait=1&color=00ADEF&fullscreen=1&autoplay=0&loop=0" type="application/x-shockwave-flash" allowfullscreen="true" allowscriptaccess="always" width="400" height="233"></embed></object><p><a href="http://vimeo.com/15167957">1 kW Steam Engine Electric Generator Prototype</a> from <a href="http://vimeo.com/user2016419">Marcin Jakubowski</a> on <a href="http://vimeo.com">Vimeo</a>.</p>
</html>

==Consulting Subject Matter Experts==
*Stan Jakuba - [http://www.steamcar.net/jakuba-1.html SES steam car project]
[[Category:Steam Engine]]

=Communications=

==March 2011==
Last October I got together the 1 kW concept with the engine configuration, the generator for direct connection to 12VDC system and self regulating steam generator with gravity hopper feed. These things can be published and crowd-funded and the process can be begun at any time. The initial design is next, then the prototype of the engine/generator, then the prototype burner/steam generator, and the system integration. Then development and production prototype can be built. There is material on hand for a thousand units. With that kind of momentum, further materials will not need to be recycled materials but can be economically sustained by normal manufacture.

==Generators in November 2010==
The basic components selection of the steam genset are being nailed down.
The F&P based generator is the key engineering component and all else will
be sized to this element. Therefore I am at the point where the technical
details are needed so the system can be designed. I believe it would be best
to design around the newer technology since it is likely to remain available
longer, but of course if the units are more available with the older
technology, the design should accommodate them.

We have said that this is a 1kW basic design, and so I would be interested in
what the speeds, voltage and current are likely to produce 1kW, and also
what would the number be if driven at your estimated max of 3kW. We have
been talking about charging 12VDC batteries, and it is possible to simply
protect against reverse current but not regulate the output except by the
shaft power going in. Incremental design advances extending to speed control
for 120VAC 60Hz are not in the initial concept, and I have said that it is
much better to synthesize the AC from a battery bank anyway. Our burner,
steam generator, controls and funding plan have been accepted, so we are
anxious to begin filling in the details.

The next phase is to show the conceptual design with some technical detail
and credibility to be able to fund the engineering and prototype stage.

<pre>
> Karl,
> Yes, I have a written contract with the local F&P manufacturing facility
> in Clyde, Ohio which is about an hour and a half drive for me. I had to
> promise that I would not allow my parts to be used as replacement parts
> for their washing machines. The use as a generator is excellent.
> Currently they have over eight hundred "seconds" stored for me. I would
> love to sell them to you. You could not afford to reverse engineer them
> or even manufacture them at this price. With a five horse motor driving
> one you can get about 3,000 Watts output, but I believe that would be
> the maximum. Of course you can scavenge them out of the junk yards, but
> the washing machines that use these models are very reliable and we
> won't see many for several more years. Let me know how many you want and
> I'll figure how much discount I can give you.
>
> Here is the standard verbage that I usually send in reply to a F&P
> inquiry.
>
> Great News! I have been able to get a shipment of Smart Drive motors
> directly from the Fisher & Paykel Appliance Motor plant, and yes, I have
> plenty left. This motor is comprised of a hub, stator, and main shaft.
> The Stator is stationary and comprised of 36 wound coils. Each coil is
> wound with 195 turns of 0.053” diameter copper wire, so without
> re-wiring it can produce some high voltage. The ends of the windings are
> easily accessible for re-wiring. Since this doesn't have brushes, when
> the hub is spun it actually becomes an alternator producing AC current.
> The new type 4 magnet hub has 48 magnetic poles. I am in love with this
> new motor. I put one together with a couple of bearings (6005) and
> bearing holder and spun it by hand and felt almost NO cogg. Price for
> this raw Smart Drive bundle is $105.00. To make the motor complete, you
> will need two bearings, (6005 or USF205-25 4-bolt flange bearing), two
> 12 x 30 mm Bolts, four ¼-20 x ¾” bolts and a bearing holder or pivot
> weldment. (I now have a new HAWT design available). The Stator normally
> is piloted off the bearing to align it with the main shaft for the
> magnetic hub. That bearing (6005) should stick out from .100” to .125”
> to allow this alignment. I was in the process of developing a “kit” for
> these motors, but that has yet to materialize. I am willing to “talk”
> you thru any problems or questions. If you have any questions, please
> email. More windmill pictures are posted on my web page you can follow
> this link to www.randysworkshop.com. Shipping weight is approx. 16# from
> zip code 45306 and can ship Priority Mail for $18.00 to your US zip
> code. (Over seas estimate is $58.00)
>
>
> I have seen the price of Ametek motors go from $15.00 six years
> ago to over $150.00. And for that you get what? A maximum of 100
> to 150 watts? With a SmartDrive windmill and the correct amount
> of wind and a good blade you should see upwards of 600 watts.
> Yes, this is the way to go!
>
> Randy B.
</pre>

==November 2010==
The plan would be to prepare a blog post for next week, say Wednesday or Friday, where we put this project up for crowd funding to pay you for initial design. Then we can discuss the implementation. With a clear plan, we can promise the crowds specific results, and we could get this funded.

At this time, we can move forward on design work, according to specifications we discussed initially.

The general specifications are here:

http://openfarmtech.org/index.php?title=Open_Source_Steam_Power_Generator

Can you prepare a simple concept 3D drawing for the entire system? I was thinking a vertical hopper next to a vertical chimney heat exchanger stack next to a vertical pellet container. That could be a unit plugged into a regenerator.

Perhaps make Prototype I a bulky stationary system with 100% passive fluid motion, and Prototype II with a much more compact form factor - literally like a mobile generator with forced air and forced cooling for a radiator - literally comparable to regular generators.

Let's work on the technical details at this time. Could we come up with a budget and timeline for the project? Tell me what you need to guarantee your attention on this, and we can put up a funding basket.

Proposed timeline:

1. Blog post - Wed. Oct 27, 2001
*Concept fleshed out with more details
*Bill of Materials
*Realistic time schedule
*[[Stan Jakuba]] feasibility
*[[Larry Dobson]] - on heat generator
*[[Randy Burmeister]] on Fischer Paykel motors

2. Design funding period - Oct 13-Nov. 13

3. Design complete by Dec. 13

4. Fabrication funding period - Dec. 13 - Jan. 13.

5. Build complete by Feb. 13.

Basically, initial proposal with full budget by next week:

1. Design cost

2. Materials cost

3. Fabrication cost

After funding is complete, then we do one month to complete the design, followed by one month of build. Does that sound feasible? First build by Feb. 13.

[[Category:Bidding]][[Category:Proposal Briefs]]

The Only Production Steam Engine in the World

2011-04-24T09:32:43Z

Barowski: /* Plans */ update link

The only company producing practical, small scale steam engines in the world that we know of is http://www.tinytechindia.com -

<html>
<object width="640" height="385"><param name="movie" value="http://www.youtube.com/v/54s4vg3IgYg&hl=en_US&fs=1&"></param><param name="allowFullScreen" value="true"></param><param name="allowscriptaccess" value="always"></param><embed src="http://www.youtube.com/v/54s4vg3IgYg&hl=en_US&fs=1&" type="application/x-shockwave-flash" allowscriptaccess="always" allowfullscreen="true" width="640" height="385"></embed></object>
</html>

[[Category:Steam Engine]]

Also http://www.strathsteam.com/
A South Australian steam manufacturing company

[http://www.pearlengine.com/ PEARL ENGINE COMPANY]

=== Kit Manufacturers ===

[http://www.tinypower.com/ Tiny Power Steam Engines]

[http://www.bjorklundsteam.com/ B-Steam Steamengines]

[http://www.mikebrownsolutions.com/mbsteam.htm Mike Brown Solutions]

[http://www.steamlaunch.com/ Elliott Bay Steam Launch Company]

[http://www.pearlengine.com/ PEARL ENGINE COMPANY]

=== Plans ===

[http://www.reliablesteam.com/ Reliable Steam Engine Co.]