Talk:Nickel-Iron Battery

2011-05-25T03:47:39Z

Colin:

2011-05-11T16:37:19Z

Colin: /* Preliminary Figures for a 12V, 1kWh pile */

Nickel-Iron Battery

2011-05-11T16:26:36Z

Colin:

{{under construction}}
http://en.wikipedia.org/wiki/Nickel_iron_battery

=Basic Concepts Behind Construction=
The electrochemistry of a Nickel iron battery is similar to a NiCd or NiMH battery in that nickel oxyhydroxide is used as an anode, but iron is used instead of the toxic metal complexes in NiCd and NiMH batteries. During discharge, both metals turn into their hydroxide forms: Ni(OH)2 and Fe(OH)2. (see the wikipedia article under electrochemistry). Given the resilience and rechargeability of the NiFe battery, it should be possible to build it in a discharged state, combining the appropriate hydroxides of Nickel and Iron. Alternatively, the battery could be constructed out of metallic nickel and iron, and the nickel should mostly convert to an NiOOH form after the first discharge-charge cycle.

=First test=
A sample concrete cell was tested, but no practical benefit is achieved using concrete as an electrolyte, as to be effective, the entire cell must be submerged, and the electrical conductivity of cement is far too high when submerged. A new design is in the works for a cell which would use raw glycerine (glycerol) as a byproduct of biodiesel production, thus improving the ecologies of both systems. The rationale is that the lye (KOH or NaOH) which 'contaminates' the glycerine should prove to be an effective electrolyte, and the glycerine itself should support a more stable cell. (Glycerine will evaporate much more slowly than water, and due to higher viscosity, should even further improve vibration-resistance of the cell. Ideally, this design could even be adapted to portable units.

=Preliminary Figures for a 12V, 1kWh pile=
NiFe cells produce a working potential of 1.2V, and charge at 1.4V. A 12V battery would then consist of 10 cells. To achieve 1kWh capacity, we will need 1000W/12V = ~85Ah. This means that each cell will need to provide 85Ah capacity. This corresponds to 306,000C, which is approximately 3.17 moles of electrons. Sheet steel will form a base material for the electrodes, so iron is not a limiting factor. Nickel's electrochemistry in an NiFe battery indicates a 1:1 molar ratio, so 3.17 moles of nickel will be required. This is about 185g of Ni at a molar mass of 58.69g/mole. For a 'safety' margin, we will round up to 200g. At 200g Ni per cell, a total of 2kg of nickel will be needed for a 1kWh unit. The actual capacity of this cell based on the rounded values above would be 1095.8kWh.

Nickel-Iron Battery

2011-04-26T01:30:05Z

Colin:

This page is very much a work in progress-improvements are forthcoming.

There are several methods to cut an involute gear, but I will focus on hobbing techniques, as a simple hob can be made with the most basic lathe. (see [[Hob]])

The tools necessary for this process include: 
1. A vertical milling machine (horizontal will probably work as well, but I will focus on vertical here) 
2. The appropriate gear-cutting [[Hob]] for the dimensions of the gear desired 
3. An indexing head attachment for the milling machine [http://en.wikipedia.org/wiki/Indexing_Head] 
4. A mandrel matching the inside diameter of the gear (where the shaft will be mounted when finished)
5. Appropriately sized round stock of a material no harder than the material of the hob 
6. An engine or benchtop lathe and appropriate attachments

First, the gear blank needs to be cut. In the case of making a set of identical gears for a hydraulic [[gear pump]], a single double-wide gear can be made and cut in half when finished. If the thickness of the gear is very important, then the swarf of the blade that will be used to cut the gear in half must be considered when cutting the length of stock needed.

Before mounting in the lathe, a length of roundstock should be cut. This step does not require precision, so a hacksaw will do in a pinch. (A chop saw is preferable) The piece should then be mounted in a 3-jaw chuck on the lathe if possible (that is, if the piece will fit in the 3-jaw chuck) A four jaw chuck may be used, but extra care must be taken to ensure that the part is centered. now the end of the piece should be machined to a smooth finish and center-drilled to roughly 3/16" after removing the piece from the chuck, turn it around and repeat the process used on the first end. (If the stock is short enough, it can be cut down to the outer diameter of the gear desired while still mounted in the chuck the first time, but it is advisable to center-drill the piece to mark the center of the hole where the shaft will be mounted.)

When ready to trim down to diameter, ensure that the lathe RPM and feed rate are set properly for the diameter you are cutting from (before the cut) and the material being used. The rough formula for RPM is (CS x 4)/D where CS is the cutting speed which is specified for the work material and D is the diameter of the workpiece. The feed rate used will depend on the material being used, shop practice, and the desired finish of the cut. Typical lathe feedrates used for carbon steel are .002-.005"/revolution.

Now the hole by which the gear will be mounted should be machined. This step will involve first drilling then reaming the hole to produce a smooth, precision finish on the inside of the gear. First, the appropriate drill bit for the reamer to be used will be mounted in the chuck on the tailstock. Now the hole will be drilled past the width of the gear, leaving deadspace so that the reamer can ream the entire width of the gear. Next, the drill bit will be replaced with the reamer, and the hole will be reamed to size.

Now the width of the gear to be cut will be cut from the end of the workpiece (twice that plus swarf for two identical gears). This should be done while still on the lathe to maintain precision thickness.

Now the gear blank should be mounted on the mandrel and the mandrel in a chuck. The blank on the mandrel in the chuck should be checked for concentricity using a dial-gauge mounted on the tool-post on the lathe, hand turning the spindle. Once properly centered on the mandrel and in the chuck, the entire chuck should be transferred to the milling machine and mounted in the rotary table or indexing head. At this time, make sure that the rotary table or indexing head is at a 90 degree angle to the spindle (so that the piece is parallel to the mill table)

In this article, I will focus on using the so-called 'parallel hob' mentioned in [[hob]].

The hob should be mounted in a collet and then on the mill spindle. The quill should then be lowered so that one of the inner teeth of the hob is roughly centered on the horizontal diameter. Lock the quill feed. the table should now be raised or lowered in .001" increments until centered within .001". Lock the table z-axis. This can be checked by placing a machinist rule against the work and moving the table to push the work against the hob. The rule should be perpendicular to the table if the hob is at the proper height. The actual process of cutting the gear may now proceed. The final depth of cut into the blank should be equal to the tooth depth which is determined by the formula 2.157/Dp where Dp is the diametral pitch, or number of teeth per inch of pitch diameter. Diametral pitch is determined by the ratio of the number of teeth to the pitch diameter. These three factors also determine the dimensions of the [[hob]] you'll require.

Now the head (again, rotary table or indexing head) should be locked in a known position, and proceed to cut .005" into the blank. Now rotate the work before cutting again by 1/N rotations or 360/N degrees where N is the number of teeth on the gear. Cut .005" from this location. Repeat this process of cutting and turning until the first cut is reached again. You'll continue this process .005" at a pass until reaching the depth of cut (which is the tooth depth) which is determined by the formula above (2.157/Dp).

After finishing the gear form, it is advisable to return it to the lathe and file away any burrs left behind from the process. After this, the gear form should be complete, and all that is required for service is to cut a keyway and provide a shaft on which to mount the gear.

http://en.wikipedia.org/wiki/Involute_gear

[[Category:Hydraulic Motors]]

Involute Gear

2011-04-26T00:42:22Z

Colin:

Involute Gear

2011-04-25T15:07:28Z

Colin:

Hob

2011-04-25T15:06:06Z

Colin:

http://en.wikipedia.org/wiki/Hobbing

This article is intended to go with [[Involute Gear]]

The process of cutting a gear calls for either an involute cutter or a gear hob. The advantage of a hob is that it can easily be cut from carbon steel on a lathe and milling machine. Once cut, the hob is then heat treated (even mildly will suffice) so that it can more easily cut the gear material. There are a few types of hobs, namely helical and what I will, for lack of machining experience, call a parallel hob. Out of simplicity, this article will focus on the so-called 'parallel hob' as it can be used on a standard vertical mill and doesn't require a hobbing mill.

(This page is a work in progress, improvements should be forthcoming)

Colin Dodson

2011-04-25T14:25:36Z

Colin:

=Team Culturing Information=

last updated: 22. April, 2011

==='''WHO''' are you?===
*''Name/Nationality/Ethnicity'' - Colin Dodson, United States

*''Location'' – Urbana, IL

*''Contact Information'' –
colin.dodson (at) gmail (dot) com 
+1(618)841-8849

*''Introductory Video'' -

*''Resume/CV'' –
2005-2008: Attended the Illinois Math and Science Academy (IMSA) in Aurora, IL. worked most summers with village workers in my hometown of Marissa, IL 
2008: Graduated from IMSA; Began study at University of Illinois at Urbana-Champaign (UIUC) 
2009: Left University due to family medical circumstances 
Summer 2010: began study at College of Dupage (COD) in Glen Ellyn, IL. Also began working as a student aide in Computer Support and Printing Services (CSPS) at the Library at COD. 
Fall 2010-Spring 2011: Continued courses relevant to engineering major at COD, adding Welding and Machine Shop for personal interest. Continued work with CSPS. 
 
[future] 
2011: Return to UIUC in the summer-intended major of Industrial Engineering. Will continue each semester until finished.

*''Hobbies and Pastimes'' - Computers, technology, appropriate technology, occasional political debate/discussion, thoughtful reading, wishful inventing. (Lots of neat inventive ideas, not all of them realistic)

==='''WHY''' are you motivated to support/develop this work?===
*''Do you endorse open source culture?''
Absolutely. I found the OSE project when looking for 'open source hardware.' At one time, though, I was almost fanatically free software-centric. Since then, I have matured, and have recognized open source organizations for their fundamental value. To me, open source is a step beyond transparency, and it is a goal toward which we should strive if we want an effective and genuine democratic society.

*''Why are you interested in this work?''
I see OSE has made tremendous progress doing something modern 'conventional' wisdom might say is impossible, and I see more great successes coming in the future. As well, this project appears to aim for a structure not unlike a 'dream' city concept I've been obsessed with since high school.

*''Are you interested in teaching about the GVCS?''
Very much so, but I am not certain of my ability to teach effectively about it. The concept is brilliant, and more people should be taught about it, so even if I am unsure of my ability, I would be perfectly willing to try.

*Are you interested in economic relocalization possibilities arising from the GVCS?'
Centering economic structures within the communities they serve is central and beneficial in too many ways to count. Resiliency of smaller scale operations, minimization of logistic costs, maximum capacity for responsible use of local resources--the list goes on and on.

*''Do you want to use the GVCS technologies yourself? Do you want to build them yourself?''
I would love to build the technologies listed, and I would love even more to build them with other GVCS technologies. The so-called 'dwarf-principle' has fascinated me for several years. (the dwarf-principle is the idea that technology builds on itself-or evolution of technology)

*''Are you interested in starting up enterprise using the GVCS technologies?''
Eventually yes, but I am more interested in using the open source economic model to put enterprise into the hands of the masses.

*''Are you interested in having the GVCS technologies fabricated by your local custom fabricator?''

*''Are you interested in applying the GVCS to third world development? To redevelopment of crisis areas? To development of derelict areas in the developed world?''
Definitely. Some of the most torn regions on Earth are the most fertile for development; and using a distributed and open sourced model provides the greatest involvement to the people of the region. I believe open source development methods have the capacity to turn a would-be economic occupancy into a welcome opportunity for the local population while providing the necessities of life.

*''Are you interested in starting up Industry 2.0 flexible fabrication enterprises for your local community, by drawing from a global repository of freely down-loadable designs and fabricating using open source fabrication equipment?''
Very much so-the community level is probably the best place to establish manufacturing and enterprise in a distributed economy, and what better way is there to become involved in your community?

*''Are you interested in the potential of the GVCS for developing local food systems?''
Food production, even more than manufacturing, has the greatest potential benefit and effectiveness at a local level. This benefit applies as much to the land as it does to the communities these systems would serve.

*''Are you interested in doing academic studies/papers, publishing books, or doing other analysis of our efforts?''
This is a possibility I hadn't yet considered-it sounds like it could be worthwhile. I am honestly more interested in direct involvement, but I see the tremendous value in the documentation and peer-review that academic study would provide.

*Are you interested in financial investment opportunities arising from our work?
If I had the resources to invest, yes. I would certainly invest whatever I could to bring this project to even greater fruition.

*''Are you interested in the distributive economic aspects of our work, and if so, how do you see this playing out?''
I think I've already talked about this a lot, but I see the capacity for undermining many of the detrimental qualities of our current mass-manufacture model such as planned obsolescence and rigid design. With a distributed system, each tool or system can be tailored to its life-long purpose, performing each task that a tool must as effectively as possible.

*''Are you interested in building renewable energy production facilities based on open hardware (solar concentrator electric, wind, biomass power).''
How many times can I say yes? I am particularly interested in solar thermal and biomass gasification and/or pyrolysis. Conceptually, wind turbines are a good renewable source of power, but technologically, biomass and solar-thermal are more interesting systems. Actually, I have a concept that I'd like to try to develop for a mobile gasification mechanism. I know this isn't critical, but I would appreciate the chance to discuss it with people knowledgeable in gasification (particularly plasma-based) systems.

*''Are you interested in building resilient communities based on access to the GVCS?''
Yes, yes, and yes.

*''Are you interested in creating a bug-out hut using GVCS technologies?''
Until filling this form, I wasn't familiar with the term. I'm still not quite sure what it means.

*''How do you think that the GVCS can help alleviate the instabilities of global monetary systems?''
Much the same way that a biological body responds to disease or injury-if many parts act autonomously, but in communication with the other parts, the system as a whole becomes more resilient. This won't necessarily alleviate the short-term instabilities of any global economic system, but the system itself will begin to trend toward greater resiliency and long-term dynamic stability.

*''How do you think that the GVCS can address issues related to resource conflicts?''
I see two mechanisms involved, both related to scarcity as a source of conflict: 
1.) Alleviation of scarcity economics. All the necessary resources for survival and civilization are relatively abundant. Today, 'scarcity' is largely artificial. 
2.) alleviation of scarcity itself. In a consumer-based mass-market economy, the economic solution to poverty, war, and overpopulation falls short because we fail to distinguish between necessities and desires, as the market makes no effort to do so either. By producing on a smaller scale in a distributed fashion, the people become responsible for their own subsistence, becoming producer-consumers and learn to distinguish between needs and wants, so that the necessities can be provided for all before providing for desires.

*''How do you think that the GVCS can address issues of overpopulation?''
Overpopulation, as studies show, is linked directly to poverty. All other factors aside, in an impoverished state, mindsets likely return to a subsistence mode, and in a subsistence economy, children are effectively worth. If the capacity for self-sufficiency can be established, and there is no longer a fight for subsistence, opportunity will grow, and it is likely, though not 'proven' that population should stabilize.

*''How do you think that the GVCS can address issues of resource depletion and environmental degradation?''
In a distributed system, each actor becomes relatively small. Being that each unit is so small, the force it can exert on its environment is also relatively small, and likely within nature's capacity for restoration. This is compared to large industry, which blindly exerts a massive force based on limited information, causing more damage to its environment faster than nature can recover. In this sense, one community may utterly destroy its ecology, but the damage done is much smaller, and the environment is much more likely to recover on a shorter timespan.

*''Other comments''
The more I try to put OSE into context, the more sense it makes.

==='''WHAT'''===
*''What have you already contributed to the OSE project? (technical contributions, blogging about us, financial support, organizing events, translations, interviews, video editing, publications, publicity work, behind-the-scenes work, CAD work, wiki contributions, computer support, etc)''
Nothing yet, but I would love to start.

'''Communications'''
*About the only 'reaching' communications I'm involved in are on Facebook and anonymous web-forums, but if I had a closer relationship with the project, I would definitely document my experience for the world to see.

'''Organizational'''
*Not particularly

'''Computer Support'''
*I am familiar with linux, and use it daily. I only know enough code to roughly read an existing program, but given some instruction and projects, I could definitely learn. I know plenty of html, and a little bit of the structure of PHP, but not enough to do anything useful. Again, I could definitely learn how to administrate web services, but I do not have any experience yet.

'''Finances'''
*No.

'''Sociology'''
*If I knew how to, sure.

'''Home Economics'''
*I roughly know my way around a kitchen and I can handle just about any utensil. If I have a recipe or a little guidance, my cooking usually turns out well. (but it never looks like the photos)

'''Design'''
*Not yet, but I'll surely have to learn in the course of my studies at University.

'''Building'''
*I can lay quality beads using Oxy-Acetylene, TIG, Stick, and can learn MIG. I know the basic operations of an engine lathe and vertical milling machine, and if I had access to the equipment, I have a decent idea (principly) of how to machine gears and other such parts.

'''Electronics and Magnetics'''
*I've taken university level calculus based Physics focused on electricity and magnetism. I'm a bit rusty, but given a text-book, I could calculate just about anything about an electric or magnetic field. I'm reasonably skilled with a soldering iron, and started building circuits when I was around 12 years old. Within the next year or so, I will likely have taken an electrical engineering course, and should have the knowledge and some practice in designing most of the items listed in this question.

'''Automation'''
*I am highly interested in this area, but I do not have any real experience. I should know the design side of the circuitry after taking the EE courses listed in the previous answer.

'''Metallurgy'''
*No, but I definitely want to.

'''Engineering'''
*No, but I hope to be. I will be majoring in Industrial Engineering at the University of Illinois.

==='''HOW''' can you help?''===
*''How are you interested in contributing to the work of GVCS development?''
I would like to help design systems and tools suited to distributed economic models, automation, and help fabricate the same.

*''Can you volunteer to work with us, and if so, how many hours per week?''
I would love to volunteer, but I will only be available for a few weeks a time and possibly summers (not including 2011) until I graduate from the University of Illinois (likely after two more years of study). This year, I should be available near the end of July to the middle of August, and possibly all of the following summer.

*''Are you interested in working with us for pay? If so, what services can you offer, and what is your hourly or per-project rate?''
If possible, yes. However, I am not yet a professional in any particular field. I would be happy to volunteer my help, but some pay would help pay a few expenses and possibly offset college costs.

*''Are you interested in purchasing equipment from us to help bootstrap development?''
If I had the resources, I would probably consider starting a venture and purchasing equipment from Factor e Farm. As it stands, I feel I would much more likely help build said equipment.

*''Are you interested in bidding for consulting/design/prototyping work?''
Not at this time.

*''Are you a [http://openfarmtech.org/index.php?title=True_Fans True Fan]? If not, why not?''
No, but I am considering it. My finances are quite limited, and I do not feel I can make too many financial commitments yet. At this time, I am, you might say, a professional student.

*''Would you like to see yourself working with us on a full-time basis?''
I would definitely like to work full time with OSE following my graduation.

*''Are you interested in using the technologies that we are developing directly?''
Absolutely. I am most interested in using the manufacturing technologies soon to be developed at Factor e Farm for personal prototyping and potential small-scale production purposes.

*''Are you interested in being part of the world's first, open source, resilient community? The GVCS is the preparatory step for the OSE Village Experiment – a 2 year, immersion experiment (2013-2014) for testing whether a real, thriving, modern-day prototype community of 200 people can be built on 200 acres using local resources and open access to information? We are looking for approximately 200 people to fill a diverse array of roles, according to the Social Contract that is being developed. This may be the boldest social experiment on earth - a pioneering community whose goal is to extend the index of possibilities regarding harmonious existence of humans, ecology, and technology – as a beacon of light to benefit of all people on Earth.
This sounds like an opportunity of a lifetime. I've always fantasized about starting a new village for just these reasons.

[[Category:Team Culturing]]

Hob

2011-04-23T18:32:19Z

Colin:

http://en.wikipedia.org/wiki/Hobbing

Hob

2011-04-23T18:30:46Z

Colin: Created page with "see [http://en.wikipedia.org/wiki/Hobbing]"

see [http://en.wikipedia.org/wiki/Hobbing]

Involute Gear

2011-04-23T18:29:35Z

Colin:

Involute Gear

2011-04-23T18:29:03Z

Colin:

Involute Gear

2011-04-23T18:25:34Z

Colin: