Open Source Ecology - User contributions [en]

Nickel-Iron Battery

2012-06-16T14:26:02Z

ERos: /* Detailed Description */

{{GVCS Header}}

==Overview==
[[File:Nickel-Iron Batterypic.png|thumb|400px|Nickel Iron Battery]]

The '''Nickel Iron Battery''' is the primary electrical energy storage device for the [[GVCS]].

Advantages:
*Long lifetime of 50 years
*Open source design of electrodes
*Cells scalable: from 1 to 50kW hrs
*Nickel and iron obtained from scrap stream, reprocessed via [[Induction Furnace]]
*Completely closed loop material cycle ecology

{{Video}}

==Detailed Description==

The '''nickel-iron battery''' (NiFe battery) or "edison cell" is a storage battery having a nickel oxide-hydroxide cathode and an iron anode, with an electrolyte of potassium hydroxide (lye can be used as a substitute).

The active materials are held in nickel-plated steel tubes or perforated pockets.

It is a very robust battery which is tolerant of abuse, (overcharge, overdischarge, and short-circuiting) and can have very long life even if so treated.

It is often used in backup situations where it can be continuously charged and can last for more than 20 years.

'''Nickel-iron batteries''' have ~50 year lifetimes, compared to a few-year lifetime of lead acid batteries. They are environmentally more benign, and lend themselves to local recycling and fabrication. They can have higher discharge rates and faster charge times than lead-acid batteries depending on mechanical design of the electrodes etc, so they lend themselves not only to off-grid power, but also to power electronics applications such as welding and heavy workshop power. In China a company by the name of changhong batteries makes a version of them for use in automotive starter batteries. Their energy density is half that of lead-acid batteries, but their long lifetime and deep discharge ability makes them highly relevant to the [[GVCS]], including to electric farming equipment as the next generation of [[LifeTrac]] infrastructure.

The [[Edison Battery]] was developed and promoted primarily by Thomas A Edison.

==Product Ecology==
[[Image:Electricalpowereco.png|600px|thumb|[[Product Ecology]]]]

{{Product Ecology

|Product={{Battery}}

|From=
*{{3D Printer}} - Casing
*[[Controller Box]] - Power
*{{Rod and Wire Mill}} - Wires, Tubes

|Creates=
*[[Electricity]]

|Uses=

|Enables=
*{{Universal Power Supply}} - Stores energy
*[[Charge Controller]]
*[[Inverter]]

|Components=

}}

==Components==
===Anode Compound===

* iron plate - low carbon, mild steel (demo)
* iron graphite compounded (Edison)
* iron oxide

===node Construction===

* plain plate (demo)
* pocket plate with mesh inserts (Edison)

===Cathode Compounds===

* [http://en.wikipedia.org/wiki/Nickel%28III%29_oxide-hydroxide Nickel(III) oxide-hydroxide]
* nickel hydrate and pure nickel flake (Edison)

===Cathode Construction===

* plain plate (demo)
* pocket plate with mesh inserts (Edison)
* generally nickel-plated rather than pure nickel

* Nickel sponge
* Sintered nickel powder
* Nickel mesh/cloth

===Electrolyte===

* potassium hydroxide
* sodium hydroxide (alternate, lower voltage)
* lithium (modern additive)

===Cell Casing===

* nickel-plated steel box, rubber seals (Edison)
* plastic box (modern commercial)
* glass jars (demo projects)
* pvc cylinders (Ed's Workshop)

==Status==
The '''Nickel-Iron Battery''' is currently in the [[Nickel-Iron_Battery/Research_Development|research phase of development]].

==See Also==
* [http://en.wikipedia.org/wiki/Battery_(electricity) Wikipedia: Battery]
* [http://en.wikipedia.org/wiki/Nickel_iron_battery Wikipedia: Nickel Iron Battery]
* [http://www.beutilityfree.com/content/index.php?option=com_content&view=article&id=44&Itemid=129 Battery Lifetimes]

{{GVCS Footer}}

Aluminum Extraction From Clays

2012-06-13T20:03:35Z

ERos: /* Aluminum making */

{{Category=Materials}}
[[Category:Chemical_engineering_for_OSE_use]]

== Aluminum making ==

Aluminum making needs huge amount electricity (15kwh/kg), some carbon source to smelter electrodes, little fluoride to lower melting point and lot of pure alumina (Al2O3). It is known Hall process http://en.wikipedia.org/wiki/Hall_process. There are no other more economical process.

Key material to aluminum is ultra pure alumina and cheap energy. There are many process to make pure alumina, we should select some best fit to small scale production. Clays are posible start material or feldspar mineral (weather to clay). Bauxite are rare.

There are some Hall process modifications, like titaniumborate bed help reduce electrode distance (normal 4.5cm = ~4.5vol). Graphite electrodes can maybe changed to hematite electrodes to overcome graphite consumption. There are also method to electrolyse aluminum chloride (no CO2 exhaust but Cl, maybe recycleable to clay extraction)

== Diffrent Alumina extraction processes ==

=== Acid process from clay ===
Alumina (alumium ore) extraction from clay. Bauxite are rare minera, clay are common so chemical process based on clay- not bauxite. Aluminumcloride are leached out with hydrochloric acid: http://www.freepatentsonline.com/4388280.html.

- sulphurous acid process
- nitric acid process

=== Alkali process from clay===
- bayer process (very limited, high viscosity if SiO2 present)
- Soda sintering process
- Lime sintering process

=== Carbon dioxide process from feldspar ===
- Feldspar mineral (sand) and high pressure carbon dioxide can be used to produce alumina. CaAl_2Si_2O_8 + 2CO_2 +4H_2O -> CaCO_3 + 2SiO_2 + 2Al(OH)_3

== High temperature proceses ==
Kaolin clay is composed of aluminum and silicon (Si2Al2O5(OH)4). Reduction of Kaolin would then result in an aluminum/silicon alloy. In practice, carbides (usually SiC) resist further reduction except at very high temperatures (2050°C). Thus, the smelted product is likely some aluminum-rich alloy with various highly refractory simple and complex carbides. (Halman tests suggest that product are aluminum and silicon carbides, not pure metal/alloy)

Parent material is reduced ''carbothermically'', that is, it is reduced in the presence of carbon and the absence of oxygen at high temperatures. The carbon is oxidized to produce carbon mon- and di-oxide and the metal oxides are reduced (but converted to carbides).

The paper [http://www.sciencedirect.com/science?_ob=ArticleURL&_udi=B6V2S-4PF0X6V-1&_user=521384&_rdoc=1&_fmt=&_orig=search&_sort=d&view=c&_acct=C000059563&_version=1&_urlVersion=0&_userid=521384&md5=beeacd8e14dee1a7cb0059b6bb739790 carbothermal reduction of alumina] by m.halmann (at) weizmann.ac.il describes the carbothermic reduction of alumina rich material in an atmosphere of methane gas at high temperatures. Internal copy of this paper: [[File:halman.pdf]] (laboratory test at 2200C produced AlC, no test with methane atmosphere calculation show aluminum at 2800K)

Such temperatures could be produced with a point focusing solar collector (see [[Metal Refining]] for more)

----

Page 66 in this online book talks about a plant in the Ukraine that smelts kaolin into an aluminum/silicon alloy: [http://books.google.com/books?id=XlmAKOjvnrgC&pg=PA66&lpg=PA66&dq=reduction+kaolin+aluminum&source=web&ots=2vF1okG5iX&sig=oh_J4JdI6XQDxZ68-j2i-b767Tw&hl=en#PPA65,M1 The Handbook of Aluminum] by George E Totten, D Scott MacKenzie. (are you sure, it is well know that soviet used kaoline/clays + lime smelt to produce alumina, feeded to normal Hall cells. I don't have such book to check.)

At temperatures below 2000°C, I assume aluminum metal may be separated from silicon carbide (SiC).

=Collaboration=
==Review of Project Status==
==Aluminum - Current Work==

[[Metal_Refining]]
== Aluminum - Developments Needed==
=== Aluminum - General===

==links==

all about aluminium:
http://sam.davyson.com/as/physics/aluminium/siteus/index.html

how aluminum is made
http://findarticles.com/p/articles/mi_gx5205/is_1997/ai_n19124810/
&
http://www.rocksandminerals.com/aluminum/process.htm
&
http://science.howstuffworks.com/aluminum3.htm

aluminum recycling and processing for sustainability
http://books.google.at/books?id=t-Jg-i0XlpcC&pg=PA197&lpg=PA197&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=dyGaESjSJu&sig=uhSUFo2Bc9UYzCGMKFII7OmpqF8&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=3

environmental chemistry of aluminum
http://books.google.at/books?id=lNxltQeVP9UC&pg=PA253&lpg=PA253&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=7Akaax7fNZ&sig=Q6v9n37jOf_FEDAjaN4aaqpSJZY&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=6

environmental guidelines for aluminum manufactoring
http://www.miga.org/documents/AluminumManufacturing.pdf
&
http://www.ifc.org/ifcext/enviro.nsf/AttachmentsByTitle/gui_alummfg_WB/$FILE/alum_PPAH.pdf
(world bank and investment guarantee agency)

pollution prevention in manufactoring aluminunm
http://www.p2pays.org/ref/21/20400.htm

why aluminum smelting is not good
http://planet.wwu.edu/archives/2006/articles/fall/popping-the-top.php

national environmental health report on aluminium
http://enhealth.nphp.gov.au/council/pubs/pdf/alumin.pdf

Handbook of corrosion engeneering
http://www.scribd.com/doc/9402306/Handbook-of-Corrosion-Engineering-

extraction of aluminum
http://www.tms.org/pubs/Books/4062.chapter2.pdf

the evolution of the world aluminum industry
http://books.google.at/books?hl=de&lr=&id=1NS2ja36QckC&oi=fnd&pg=PA39&dq=aluminum+production+from+clays&ots=dQn5uYR_vZ&sig=Afp24-4CYgPIkWPhM0UjSF-4iXw

aluminum alloy castings
http://books.google.at/books?id=JM0u1vwrS5UC&pg=PA21&lpg=PA21&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=VwQAbCkL-o&sig=vMXAQovuSJOIYroY8VfQJYFfKE4&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=9

article: hydrolysis products of solution and exchangeable aluminum in acidic soil
http://scholar.google.at/scholar?q=info:VxZNUwsol1IJ:scholar.google.com/&output=viewport&pg=1&hl=de

Aluminum Extraction From Clays

2012-06-13T19:54:13Z

ERos: /* Acid process from clay */

{{Category=Materials}}
[[Category:Chemical_engineering_for_OSE_use]]

== Aluminum making ==

Aluminum making needs huge amount electricity (15kwh/kg), some carbon source to smelter electrodes, little fluoride to lower melting point and lot of pure alumina (Al2O3). It is known Hall process http://en.wikipedia.org/wiki/Hall_process. There are no other more economical process.

Key material to aluminum is ultra pure alumina and cheap energy. There are many process to make pure alumina, we should select some best fit to small scale production. Clays are posible start material or feldspar mineral (weather to clay). Bauxite are rare.

== Diffrent Alumina extraction processes ==

=== Acid process from clay ===
Alumina (alumium ore) extraction from clay. Bauxite are rare minera, clay are common so chemical process based on clay- not bauxite. Aluminumcloride are leached out with hydrochloric acid: http://www.freepatentsonline.com/4388280.html.

- sulphurous acid process
- nitric acid process

=== Alkali process from clay===
- bayer process (very limited, high viscosity if SiO2 present)
- Soda sintering process
- Lime sintering process

=== Carbon dioxide process from feldspar ===
- Feldspar mineral (sand) and high pressure carbon dioxide can be used to produce alumina. CaAl_2Si_2O_8 + 2CO_2 +4H_2O -> CaCO_3 + 2SiO_2 + 2Al(OH)_3

== High temperature proceses ==
Kaolin clay is composed of aluminum and silicon (Si2Al2O5(OH)4). Reduction of Kaolin would then result in an aluminum/silicon alloy. In practice, carbides (usually SiC) resist further reduction except at very high temperatures (2050°C). Thus, the smelted product is likely some aluminum-rich alloy with various highly refractory simple and complex carbides. (Halman tests suggest that product are aluminum and silicon carbides, not pure metal/alloy)

Parent material is reduced ''carbothermically'', that is, it is reduced in the presence of carbon and the absence of oxygen at high temperatures. The carbon is oxidized to produce carbon mon- and di-oxide and the metal oxides are reduced (but converted to carbides).

The paper [http://www.sciencedirect.com/science?_ob=ArticleURL&_udi=B6V2S-4PF0X6V-1&_user=521384&_rdoc=1&_fmt=&_orig=search&_sort=d&view=c&_acct=C000059563&_version=1&_urlVersion=0&_userid=521384&md5=beeacd8e14dee1a7cb0059b6bb739790 carbothermal reduction of alumina] by m.halmann (at) weizmann.ac.il describes the carbothermic reduction of alumina rich material in an atmosphere of methane gas at high temperatures. Internal copy of this paper: [[File:halman.pdf]] (laboratory test at 2200C produced AlC, no test with methane atmosphere calculation show aluminum at 2800K)

Such temperatures could be produced with a point focusing solar collector (see [[Metal Refining]] for more)

----

Page 66 in this online book talks about a plant in the Ukraine that smelts kaolin into an aluminum/silicon alloy: [http://books.google.com/books?id=XlmAKOjvnrgC&pg=PA66&lpg=PA66&dq=reduction+kaolin+aluminum&source=web&ots=2vF1okG5iX&sig=oh_J4JdI6XQDxZ68-j2i-b767Tw&hl=en#PPA65,M1 The Handbook of Aluminum] by George E Totten, D Scott MacKenzie. (are you sure, it is well know that soviet used kaoline/clays + lime smelt to produce alumina, feeded to normal Hall cells. I don't have such book to check.)

At temperatures below 2000°C, I assume aluminum metal may be separated from silicon carbide (SiC).

=Collaboration=
==Review of Project Status==
==Aluminum - Current Work==

[[Metal_Refining]]
== Aluminum - Developments Needed==
=== Aluminum - General===

==links==

all about aluminium:
http://sam.davyson.com/as/physics/aluminium/siteus/index.html

how aluminum is made
http://findarticles.com/p/articles/mi_gx5205/is_1997/ai_n19124810/
&
http://www.rocksandminerals.com/aluminum/process.htm
&
http://science.howstuffworks.com/aluminum3.htm

aluminum recycling and processing for sustainability
http://books.google.at/books?id=t-Jg-i0XlpcC&pg=PA197&lpg=PA197&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=dyGaESjSJu&sig=uhSUFo2Bc9UYzCGMKFII7OmpqF8&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=3

environmental chemistry of aluminum
http://books.google.at/books?id=lNxltQeVP9UC&pg=PA253&lpg=PA253&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=7Akaax7fNZ&sig=Q6v9n37jOf_FEDAjaN4aaqpSJZY&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=6

environmental guidelines for aluminum manufactoring
http://www.miga.org/documents/AluminumManufacturing.pdf
&
http://www.ifc.org/ifcext/enviro.nsf/AttachmentsByTitle/gui_alummfg_WB/$FILE/alum_PPAH.pdf
(world bank and investment guarantee agency)

pollution prevention in manufactoring aluminunm
http://www.p2pays.org/ref/21/20400.htm

why aluminum smelting is not good
http://planet.wwu.edu/archives/2006/articles/fall/popping-the-top.php

national environmental health report on aluminium
http://enhealth.nphp.gov.au/council/pubs/pdf/alumin.pdf

Handbook of corrosion engeneering
http://www.scribd.com/doc/9402306/Handbook-of-Corrosion-Engineering-

extraction of aluminum
http://www.tms.org/pubs/Books/4062.chapter2.pdf

the evolution of the world aluminum industry
http://books.google.at/books?hl=de&lr=&id=1NS2ja36QckC&oi=fnd&pg=PA39&dq=aluminum+production+from+clays&ots=dQn5uYR_vZ&sig=Afp24-4CYgPIkWPhM0UjSF-4iXw

aluminum alloy castings
http://books.google.at/books?id=JM0u1vwrS5UC&pg=PA21&lpg=PA21&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=VwQAbCkL-o&sig=vMXAQovuSJOIYroY8VfQJYFfKE4&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=9

article: hydrolysis products of solution and exchangeable aluminum in acidic soil
http://scholar.google.at/scholar?q=info:VxZNUwsol1IJ:scholar.google.com/&output=viewport&pg=1&hl=de

Aluminum Extraction From Clays

2012-06-13T12:49:44Z

ERos: /* High temperature proceses */

{{Category=Materials}}
[[Category:Chemical_engineering_for_OSE_use]]

== Aluminum making ==

Aluminum making needs huge amount electricity (15kwh/kg), some carbon source to smelter electrodes, little fluoride to lower melting point and lot of pure alumina (Al2O3). It is known Hall process http://en.wikipedia.org/wiki/Hall_process. There are no other more economical process.

Key material to aluminum is ultra pure alumina and cheap energy. There are many process to make pure alumina, we should select some best fit to small scale production. Clays are posible start material or feldspar mineral (weather to clay). Bauxite are rare.

== Diffrent Alumina extraction processes ==

=== Acid process from clay ===
Alumina (alumium ore) extraction from clay. Bauxite are rare minera, clay are common so chemical process based on clay- not bauxite. Alumina are leached out with hydrochloric acid: http://www.freepatentsonline.com/4388280.html.

- sulphurous acid process
- nitric acid process

=== Alkali process from clay===
- bayer process (very limited, high viscosity if SiO2 present)
- Soda sintering process
- Lime sintering process

=== Carbon dioxide process from feldspar ===
- Feldspar mineral (sand) and high pressure carbon dioxide can be used to produce alumina. CaAl_2Si_2O_8 + 2CO_2 +4H_2O -> CaCO_3 + 2SiO_2 + 2Al(OH)_3

== High temperature proceses ==
Kaolin clay is composed of aluminum and silicon (Si2Al2O5(OH)4). Reduction of Kaolin would then result in an aluminum/silicon alloy. In practice, carbides (usually SiC) resist further reduction except at very high temperatures (2050°C). Thus, the smelted product is likely some aluminum-rich alloy with various highly refractory simple and complex carbides. (Halman tests suggest that product are aluminum and silicon carbides, not pure metal/alloy)

Parent material is reduced ''carbothermically'', that is, it is reduced in the presence of carbon and the absence of oxygen at high temperatures. The carbon is oxidized to produce carbon mon- and di-oxide and the metal oxides are reduced (but converted to carbides).

The paper [http://www.sciencedirect.com/science?_ob=ArticleURL&_udi=B6V2S-4PF0X6V-1&_user=521384&_rdoc=1&_fmt=&_orig=search&_sort=d&view=c&_acct=C000059563&_version=1&_urlVersion=0&_userid=521384&md5=beeacd8e14dee1a7cb0059b6bb739790 carbothermal reduction of alumina] by m.halmann (at) weizmann.ac.il describes the carbothermic reduction of alumina rich material in an atmosphere of methane gas at high temperatures. Internal copy of this paper: [[File:halman.pdf]] (laboratory test at 2200C produced AlC, no test with methane atmosphere calculation show aluminum at 2800K)

Such temperatures could be produced with a point focusing solar collector (see [[Metal Refining]] for more)

----

Page 66 in this online book talks about a plant in the Ukraine that smelts kaolin into an aluminum/silicon alloy: [http://books.google.com/books?id=XlmAKOjvnrgC&pg=PA66&lpg=PA66&dq=reduction+kaolin+aluminum&source=web&ots=2vF1okG5iX&sig=oh_J4JdI6XQDxZ68-j2i-b767Tw&hl=en#PPA65,M1 The Handbook of Aluminum] by George E Totten, D Scott MacKenzie. (are you sure, it is well know that soviet used kaoline/clays + lime smelt to produce alumina, feeded to normal Hall cells. I don't have such book to check.)

At temperatures below 2000°C, I assume aluminum metal may be separated from silicon carbide (SiC).

=Collaboration=
==Review of Project Status==
==Aluminum - Current Work==

[[Metal_Refining]]
== Aluminum - Developments Needed==
=== Aluminum - General===

==links==

all about aluminium:
http://sam.davyson.com/as/physics/aluminium/siteus/index.html

how aluminum is made
http://findarticles.com/p/articles/mi_gx5205/is_1997/ai_n19124810/
&
http://www.rocksandminerals.com/aluminum/process.htm
&
http://science.howstuffworks.com/aluminum3.htm

aluminum recycling and processing for sustainability
http://books.google.at/books?id=t-Jg-i0XlpcC&pg=PA197&lpg=PA197&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=dyGaESjSJu&sig=uhSUFo2Bc9UYzCGMKFII7OmpqF8&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=3

environmental chemistry of aluminum
http://books.google.at/books?id=lNxltQeVP9UC&pg=PA253&lpg=PA253&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=7Akaax7fNZ&sig=Q6v9n37jOf_FEDAjaN4aaqpSJZY&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=6

environmental guidelines for aluminum manufactoring
http://www.miga.org/documents/AluminumManufacturing.pdf
&
http://www.ifc.org/ifcext/enviro.nsf/AttachmentsByTitle/gui_alummfg_WB/$FILE/alum_PPAH.pdf
(world bank and investment guarantee agency)

pollution prevention in manufactoring aluminunm
http://www.p2pays.org/ref/21/20400.htm

why aluminum smelting is not good
http://planet.wwu.edu/archives/2006/articles/fall/popping-the-top.php

national environmental health report on aluminium
http://enhealth.nphp.gov.au/council/pubs/pdf/alumin.pdf

Handbook of corrosion engeneering
http://www.scribd.com/doc/9402306/Handbook-of-Corrosion-Engineering-

extraction of aluminum
http://www.tms.org/pubs/Books/4062.chapter2.pdf

the evolution of the world aluminum industry
http://books.google.at/books?hl=de&lr=&id=1NS2ja36QckC&oi=fnd&pg=PA39&dq=aluminum+production+from+clays&ots=dQn5uYR_vZ&sig=Afp24-4CYgPIkWPhM0UjSF-4iXw

aluminum alloy castings
http://books.google.at/books?id=JM0u1vwrS5UC&pg=PA21&lpg=PA21&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=VwQAbCkL-o&sig=vMXAQovuSJOIYroY8VfQJYFfKE4&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=9

article: hydrolysis products of solution and exchangeable aluminum in acidic soil
http://scholar.google.at/scholar?q=info:VxZNUwsol1IJ:scholar.google.com/&output=viewport&pg=1&hl=de

Aluminum Extraction From Clays

2012-06-13T12:44:11Z

ERos: /* High temperature proceses */

{{Category=Materials}}
[[Category:Chemical_engineering_for_OSE_use]]

== Aluminum making ==

Aluminum making needs huge amount electricity (15kwh/kg), some carbon source to smelter electrodes, little fluoride to lower melting point and lot of pure alumina (Al2O3). It is known Hall process http://en.wikipedia.org/wiki/Hall_process. There are no other more economical process.

Key material to aluminum is ultra pure alumina and cheap energy. There are many process to make pure alumina, we should select some best fit to small scale production. Clays are posible start material or feldspar mineral (weather to clay). Bauxite are rare.

== Diffrent Alumina extraction processes ==

=== Acid process from clay ===
Alumina (alumium ore) extraction from clay. Bauxite are rare minera, clay are common so chemical process based on clay- not bauxite. Alumina are leached out with hydrochloric acid: http://www.freepatentsonline.com/4388280.html.

- sulphurous acid process
- nitric acid process

=== Alkali process from clay===
- bayer process (very limited, high viscosity if SiO2 present)
- Soda sintering process
- Lime sintering process

=== Carbon dioxide process from feldspar ===
- Feldspar mineral (sand) and high pressure carbon dioxide can be used to produce alumina. CaAl_2Si_2O_8 + 2CO_2 +4H_2O -> CaCO_3 + 2SiO_2 + 2Al(OH)_3

== High temperature proceses ==
Kaolin clay is composed of aluminum and silicon (Si2Al2O5(OH)4). Reduction of Kaolin would then result in an aluminum/silicon alloy. In practice, carbides (usually SiC) resist further reduction except at very high temperatures (2050°C). Thus, the smelted product is likely some aluminum-rich alloy with various highly refractory simple and complex carbides. (Halman tests suggest that product are aluminum and silicon carbides, not pure metal/alloy)

Parent material is reduced ''carbothermically'', that is, it is reduced in the presence of carbon and the absence of oxygen at high temperatures. The carbon is oxidized to produce carbon mon- and di-oxide and the metal oxides are reduced (but converted to carbides).

The paper [http://www.sciencedirect.com/science?_ob=ArticleURL&_udi=B6V2S-4PF0X6V-1&_user=521384&_rdoc=1&_fmt=&_orig=search&_sort=d&view=c&_acct=C000059563&_version=1&_urlVersion=0&_userid=521384&md5=beeacd8e14dee1a7cb0059b6bb739790 carbothermal reduction of alumina] by m.halmann (at) weizmann.ac.il describes the carbothermic reduction of alumina rich material in an atmosphere of methane gas at high temperatures. Internal copy of this paper: [[File:halman.pdf]] (laboratory test at 2200C produced AlC, no test with methane atmosphere calculation show aluminum at 2800K)

Such temperatures could be produced with a point focusing solar collector (see [[Metal Refining]] for more)

----

Page 66 in this online book talks about a plant in the Ukraine that smelts kaolin into an aluminum/silicon alloy: [http://books.google.com/books?id=XlmAKOjvnrgC&pg=PA66&lpg=PA66&dq=reduction+kaolin+aluminum&source=web&ots=2vF1okG5iX&sig=oh_J4JdI6XQDxZ68-j2i-b767Tw&hl=en#PPA65,M1 The Handbook of Aluminum] by George E Totten, D Scott MacKenzie

At temperatures below 2000°C, I assume aluminum metal may be separated from silicon carbide (SiC).

=Collaboration=
==Review of Project Status==
==Aluminum - Current Work==

[[Metal_Refining]]
== Aluminum - Developments Needed==
=== Aluminum - General===

==links==

all about aluminium:
http://sam.davyson.com/as/physics/aluminium/siteus/index.html

how aluminum is made
http://findarticles.com/p/articles/mi_gx5205/is_1997/ai_n19124810/
&
http://www.rocksandminerals.com/aluminum/process.htm
&
http://science.howstuffworks.com/aluminum3.htm

aluminum recycling and processing for sustainability
http://books.google.at/books?id=t-Jg-i0XlpcC&pg=PA197&lpg=PA197&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=dyGaESjSJu&sig=uhSUFo2Bc9UYzCGMKFII7OmpqF8&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=3

environmental chemistry of aluminum
http://books.google.at/books?id=lNxltQeVP9UC&pg=PA253&lpg=PA253&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=7Akaax7fNZ&sig=Q6v9n37jOf_FEDAjaN4aaqpSJZY&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=6

environmental guidelines for aluminum manufactoring
http://www.miga.org/documents/AluminumManufacturing.pdf
&
http://www.ifc.org/ifcext/enviro.nsf/AttachmentsByTitle/gui_alummfg_WB/$FILE/alum_PPAH.pdf
(world bank and investment guarantee agency)

pollution prevention in manufactoring aluminunm
http://www.p2pays.org/ref/21/20400.htm

why aluminum smelting is not good
http://planet.wwu.edu/archives/2006/articles/fall/popping-the-top.php

national environmental health report on aluminium
http://enhealth.nphp.gov.au/council/pubs/pdf/alumin.pdf

Handbook of corrosion engeneering
http://www.scribd.com/doc/9402306/Handbook-of-Corrosion-Engineering-

extraction of aluminum
http://www.tms.org/pubs/Books/4062.chapter2.pdf

the evolution of the world aluminum industry
http://books.google.at/books?hl=de&lr=&id=1NS2ja36QckC&oi=fnd&pg=PA39&dq=aluminum+production+from+clays&ots=dQn5uYR_vZ&sig=Afp24-4CYgPIkWPhM0UjSF-4iXw

aluminum alloy castings
http://books.google.at/books?id=JM0u1vwrS5UC&pg=PA21&lpg=PA21&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=VwQAbCkL-o&sig=vMXAQovuSJOIYroY8VfQJYFfKE4&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=9

article: hydrolysis products of solution and exchangeable aluminum in acidic soil
http://scholar.google.at/scholar?q=info:VxZNUwsol1IJ:scholar.google.com/&output=viewport&pg=1&hl=de

Aluminum Extractor from Clay Concept

2012-06-13T12:08:33Z

ERos:

{{Breadcrumb|Materials}}
{{mergeto|Aluminum Extractor}}
{{mergeto|Aluminum_Extraction_From_Clays}}

This is a machine for processing clay, an abundant feedstock in many parts of the world (already in fine particles) into [[Aluminum]] - a high value, industrial metal. Note the energy requirement:

*About 15kW-hours requirement for 1 kg aluminum produced (1.5 kg diesel energy equivalent at 100% conversion). About 1 gallon fuel consumption per kilogram of aluminum produced assuming 30% conversion of diesel to electrolysis current- super energy intensive if done with traditional fuels
*Process design for producing 1 ton of aluminum per day
*Fueled by [[Solar Concentrator]] electrical power, and [[Modern Steam Engine]] as backup only, for economic sense on a micro-scale
*About 300kW energy requirement for 24 hours per day - huge
**Practical conversion: 2 acres of biomass fuel required to produce 1 ton of aluminum per year
**For 15MW-hours of energy per year - solar concentrator requres under 100 square meters of area to fuel this production (assuming 10% solar conversion efficiency). Less than 1/40th of an acre. 100 times as area efficient as biomass. (btw 1t/day=5.5Gwh/a, typical solar radiation 1Mwh/m²/a at 10% efficiency ->55000m²)
*About 100 grams of hydroflouric acid are required in a closed loop cycle to carry out the first hydrofluoric acid leaching process phase of aluminosilicate to alumina (please add link or something, this part should merge alumina from clay page)
*Second phase is standard [http://en.wikipedia.org/wiki/Hall-H%C3%A9roult Hall-Héroult] electrolysis.
*Approximately a 6000 square foot facility is required for housing the above process.

** process should scale to 50kw range, suitable to feed 50kw windmill etc. so 80kg/24hrs size for single (stackable, like power cube?) unit.
** So there should be ~50kw Hall cell unit and some separate units to generate alumina for such cell. Some people have bauxite, some only clay. There are no reason lock only to clays.

Strategically speaking - lunar regolith and Mars settlers are quite interested in this. This process has been developed for extraterrestrial applications initially, where there may be no bauxite.

Subject Matter Experts

Aluminum Extraction From Clays

2012-06-12T21:07:23Z

ERos:

{{Category=Materials}}
[[Category:Chemical_engineering_for_OSE_use]]

== Aluminum making ==

Aluminum making needs huge amount electricity (15kwh/kg), some carbon source to smelter electrodes, little fluoride to lower melting point and lot of pure alumina (Al2O3). It is known Hall process http://en.wikipedia.org/wiki/Hall_process. There are no other more economical process.

Key material to aluminum is ultra pure alumina and cheap energy. There are many process to make pure alumina, we should select some best fit to small scale production. Clays are posible start material or feldspar mineral (weather to clay). Bauxite are rare.

== Diffrent Alumina extraction processes ==

=== Acid process from clay ===
Alumina (alumium ore) extraction from clay. Bauxite are rare minera, clay are common so chemical process based on clay- not bauxite. Alumina are leached out with hydrochloric acid: http://www.freepatentsonline.com/4388280.html.

- sulphurous acid process
- nitric acid process

=== Alkali process from clay===
- bayer process (very limited, high viscosity if SiO2 present)
- Soda sintering process
- Lime sintering process

=== Carbon dioxide process from feldspar ===
- Feldspar mineral (sand) and high pressure carbon dioxide can be used to produce alumina. CaAl_2Si_2O_8 + 2CO_2 +4H_2O -> CaCO_3 + 2SiO_2 + 2Al(OH)_3

== High temperature proceses ==
Kaolin clay is composed of aluminum and silicon (Si2Al2O5(OH)4). Reduction of Kaolin would then result in an aluminum/silicon alloy. In practice, carbides (usually SiC) resist further reduction except at very high temperatures (2050°C). Thus, the smelted product is likely some aluminum-rich alloy with various highly refractory simple and complex carbides.

Parent material is reduced ''carbothermically'', that is, it is reduced in the presence of carbon and the absence of oxygen at high temperatures. The carbon is oxidized to produce carbon mon- and di-oxide and the metal oxides are reduced.

The paper [http://www.sciencedirect.com/science?_ob=ArticleURL&_udi=B6V2S-4PF0X6V-1&_user=521384&_rdoc=1&_fmt=&_orig=search&_sort=d&view=c&_acct=C000059563&_version=1&_urlVersion=0&_userid=521384&md5=beeacd8e14dee1a7cb0059b6bb739790 carbothermal reduction of alumina] by m.halmann (at) weizmann.ac.il describes the carbothermic reduction of alumina rich material in an atmosphere of methane gas at high temperatures. Internal copy of this paper: [[File:halman.pdf]]

Such temperatures could be produced with a point focusing solar collector (see [[Metal Refining]] for more)

----

Page 66 in this online book talks about a plant in the Ukraine that smelts kaolin into an aluminum/silicon alloy: [http://books.google.com/books?id=XlmAKOjvnrgC&pg=PA66&lpg=PA66&dq=reduction+kaolin+aluminum&source=web&ots=2vF1okG5iX&sig=oh_J4JdI6XQDxZ68-j2i-b767Tw&hl=en#PPA65,M1 The Handbook of Aluminum] by George E Totten, D Scott MacKenzie

At temperatures below 2000°C, I assume aluminum metal may be separated from silicon carbide (SiC).

=Collaboration=
==Review of Project Status==
==Aluminum - Current Work==

[[Metal_Refining]]
== Aluminum - Developments Needed==
=== Aluminum - General===

==links==

all about aluminium:
http://sam.davyson.com/as/physics/aluminium/siteus/index.html

how aluminum is made
http://findarticles.com/p/articles/mi_gx5205/is_1997/ai_n19124810/
&
http://www.rocksandminerals.com/aluminum/process.htm
&
http://science.howstuffworks.com/aluminum3.htm

aluminum recycling and processing for sustainability
http://books.google.at/books?id=t-Jg-i0XlpcC&pg=PA197&lpg=PA197&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=dyGaESjSJu&sig=uhSUFo2Bc9UYzCGMKFII7OmpqF8&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=3

environmental chemistry of aluminum
http://books.google.at/books?id=lNxltQeVP9UC&pg=PA253&lpg=PA253&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=7Akaax7fNZ&sig=Q6v9n37jOf_FEDAjaN4aaqpSJZY&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=6

environmental guidelines for aluminum manufactoring
http://www.miga.org/documents/AluminumManufacturing.pdf
&
http://www.ifc.org/ifcext/enviro.nsf/AttachmentsByTitle/gui_alummfg_WB/$FILE/alum_PPAH.pdf
(world bank and investment guarantee agency)

pollution prevention in manufactoring aluminunm
http://www.p2pays.org/ref/21/20400.htm

why aluminum smelting is not good
http://planet.wwu.edu/archives/2006/articles/fall/popping-the-top.php

national environmental health report on aluminium
http://enhealth.nphp.gov.au/council/pubs/pdf/alumin.pdf

Handbook of corrosion engeneering
http://www.scribd.com/doc/9402306/Handbook-of-Corrosion-Engineering-

extraction of aluminum
http://www.tms.org/pubs/Books/4062.chapter2.pdf

the evolution of the world aluminum industry
http://books.google.at/books?hl=de&lr=&id=1NS2ja36QckC&oi=fnd&pg=PA39&dq=aluminum+production+from+clays&ots=dQn5uYR_vZ&sig=Afp24-4CYgPIkWPhM0UjSF-4iXw

aluminum alloy castings
http://books.google.at/books?id=JM0u1vwrS5UC&pg=PA21&lpg=PA21&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=VwQAbCkL-o&sig=vMXAQovuSJOIYroY8VfQJYFfKE4&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=9

article: hydrolysis products of solution and exchangeable aluminum in acidic soil
http://scholar.google.at/scholar?q=info:VxZNUwsol1IJ:scholar.google.com/&output=viewport&pg=1&hl=de

Talk:Aluminum Extraction From Clays

2012-06-12T15:47:23Z

ERos:

The patent is dealing with the extraction of an aluminum compound, not aluminum metal.

But pure alumina Al2O3 is key material to feed cells. Patent is important. Also other alumina from clays are important because bauxite (low silicon clay) are rare and expensive. For 99% sure we need produce our alumina from clays, using acid or alkaline process.

Currenty "alumium_from_clays" page don't tell anything usable how get alumina/alumium from clays. Please fix it. Other alumium links currently on page can be moved new "alumium_general" (or "alumium_useless_data" ;) etc. pages.

== acid ==

was it hydrochloric or hydrofluoric? i thought i remember flouride beinging involved in the process.
:Hydrofluoric acid.

Some alumina from clays process use HCl. Alumium cells use some fluorine to lower melting point. Please don't distub pages, few google search give needed data - no need to ask here.

==Concept for combined soil remediation/ aluminium manufacturing==
If we had a cheap, open-source way of extracting aluminium from soils, it might have potential in areas where aluminium toxicity has made soils unusable. People could extract aluminium and sell it while simultaneously remediating their farmland. That helps food security in two ways: more money to buy food and more soil to grow it. These soils can have aluminium levels of 50mg/kg, so the extraction should work better than elsewhere. The exciting thing is that the greatest opportunity is in the same place as the greatest need; there are 4.3 million km2 affected in sub-Saharan Africa [http://www.fao.org/docrep/005/y6831e/y6831e-10.htm]. There could be huge potential for development here.

Good idea, but usable. Typical clays have 10-20% alumium. Clays can be used for alumium source. This page should tell how to get alumium from clays, other pages maybe how make farmland beter.

==Bioaccumulators==
Tea accumulates aluminium from soil; might be a good first step in concentrating the aluminium before the chemical extraction. [http://www.eplantscience.com/botanical_biotechnology_biology_chemistry/plant_nutrition/beneficial_elements/aluminum/aluminum_accumulating_plants.php]

:IMHO, better to use fungi or bacteria for such tasks. Also see [[Biomining]] page. [http://www.academicjournals.org/AJB/PDF/pdf2007/4Jun/Ghorbani%20et%20al.pdf Related paper here] --[[User:Rasmus|Rasmus]] 12:26, 18 March 2011 (PDT)

Blah, clays have 10-20% alumium. Plant etc alumium concentration <1%. Plants can give carbon to use electrodes, but it is other story, maybe in future page how OSE alumium cell should construct.

Well-Drilling Rig/Research Development

2012-06-08T22:24:18Z

ERos: /* General Drill tool */

{{GVCS Header}}
{{Category=Water}}

=Design Goals=
what goals should we have for the rig?

should it be an old fashioned wooden derrick?
*errected on site
*wood could be used for something else later
*for drilling one hole for a single community (worktime/price per hole come high!)

reusable and on wheels?
*drill multiple holes quickly and easily
*metal? more expensive?
*[[lifetrac]] additional tool, so only need drill & feed mechanisim & additional length drill strings?
*2nd drill head to change Liftrac full cave/mine making machine?
*Software for automate Lifetrac to drill hole groups? (like for blasting construction stones?)

how deep should it drill?
geothermal or just water?
*200m (600') is typical for geothermal, for water 100m is usually enough. Basically deeper only needs larger drill strings reservour.

==Well - Current Work==

== Water/Mud Swivel ==

link to some basic ideas about a swivel
[https://docs.google.com/document/d/1WOnl3w9CkWP1KnZFTtmace5eB3hGcGAvxYfA6sPqtX0/edit?hl=en google doc]

[[image:Waterwellswivelmach1.png]]

[[image:Photowaterswivelbetapressuretest1.JPG|400px]]

i rigged it up where i could put my hose on. but when i was screwing it all together i accidentally cracked the PVC plug at one end. wasnt sure how it woudl effect it so went ahead. it leaked from there first, at the threads. it leaked from the other end, where the o-rings should have been hodling, and also some from the collars that i only hand tightened. when i moved the T side to side it seemed to move the o-rings around and some places held better than others, indicatign to me that the o-rings were coming out of the pvc area. there were 4 orings on either end. i might try with more orings and maybe ill also get some string gasket material and see how that goes. 5/22/11 dorkmo

[[image:Photowaterswivelbetapressuretest2.JPG|400px]]

k i went back and made a new pvc plug with a hole. and got a better clamp for the hose hook up.

[[image:Photowaterswivelbetapressuretest3.JPG|400px]]

so i opened the valve it didnt seem too bad. there was a small steady leak from a few places. i could spin it by hand it seemed to do fine. next i'd like to somehow get it to spin at operating speed to see how the orings hold up. i might change it to have the water go into the T and then put some sort of hand crank on the 1" pipe. maybe in a week or two

== Drill String Raising/Lowering ==

idea for a lifetrac enabled pulling apparatus [https://docs.google.com/drawings/edit?id=1TEIcJUDySpRGLfPKMXHu9YUtS0iti0YQwTOHEtlltP8 google doc]

[[Image:LifeTracWaterWellPullingUnit.png]]

square tubing could be reused on other projects after well is complete

could wooden 4x4s work? need extra support beams?

== A Preliminary Design ==

[[Image:Well-Drilling_RigRender.png|thumb|right|400px]]

Here is a first rendering of the well drilling rig as rendered in BRL-CAD. The hydraulic pump (green) from the [[MicroTrac]] is shown mounted with the shaft downwards on the blue sliding frame which moves up and down the side tracks. The mounting of the motor to the green frame will use the same two bolt quick release system employed by the MicroTrac to allow for interoperability and quick changeovers from one device to the other. The rotating shaft from the hydraulic pump is connected to the purple section of drill string piping which stays centered in the swivel tee allowing drilling mud to flow into it and down the drill string (shown in light green). The purple section of piping is held horizontally by the holes in the top and bottom of the frame which are only slightly bigger than the purple pipe. This purple section of piping is supported vertically by the rotating bearing assembly which rides on the top of the sliding frame. If rock is encountered while drilling the small circular plate above the bearing will push the bearing down putting extra weight on the drill string. This allows weights to be hung along the back panel of the frame allowing the amount of downward force on the drill string to be manipulated. In the reverse situation, when tripping the drill string out of the hole, the purple section will pull down on the bearing causing it to move off the circular plate and against the frame below, pushing down on the frame and holding up the drill string as it is withdrawn from the well.

At ground level the the drill string passes through the red drill collar which bolts down to the gray baseplate allowing it to be easily removed or swapped for a smaller diameter collar (the square collar flange plate will be the same for all collars allowing for interchangeability). The machine currently is shown with a 6 inch inside diameter collar allowing a 6 inch well casing ti exactly fit inside it. At the bottom of the drill string a simple gray bit is shown which is just a section of 6" pipe with partially covered end caps connected to the bottom of the lowest section of drill string piping. Since the actual drill string piping is much smaller than 6 inches (probably only 3 or 4 inches at most for a water well drilling rig) the collar can also serve analogous to the function of a rotary table on an oil rig allowing a slip to be used to support the drill string when it is detached from the turning head at the top of the rig.

The vertical side tracks can either be composed of three flat pieces of steel welded along the edges to form a channel or can be made from large (~10 cm or bigger square tubing which has been cut in half lengthwise). If additional ground stability on the baseplate is required, four long steel stakes can be driven through the corners of the baseplate to prevent it from sliding. If these stakes are just simple pieces of re-bar they can even be left in place after the baseplate is removed (when the drilling rig is lifted straight up, or tipped down to one side the baseplate would just lift off the top of the stakes), these could then be cemented into the top pad when the wellhead is capped preventing it from sliding off the top of the well, or they can be removed for re-use as well.

The side tracks bolt to the baseplate and to each other with additional plates on the outside of the tracks a pair of bolts at each end (outer plates not shown). Since the bolt holes on all pieces of this side track material are 10 cm and 20 cm in from the ends of the piece they are interchangeable with or attachable to any other piece no matter whether they bolt to the baseplate, the top crown, or another section. This interchangeability on the side rails means you can build a small test rig with short rails for prototyping and shallow well drilling and then later on you can add additional height to the drill rig by adding on longer tracks letting you run deeper before having to break the drill string to add another section (making digging very deep wells much faster). Disassembling the side tracks would be easy to do (only 4 bolts per section) allowing the tracks to be disassembled for long distance transport and the re-assembled at the well site. In order to make room for the bolt heads on the inside of the tracks, the blue frame has 4 cm by 4 cm channels cut into each side; this lets the bolts securing the side tracks pass by without affecting the guiding done by the outside corners of the frame.

For short distance transport the rig can be tipped down and pulled on the wheels (a hitch could be attached at the top of the crown). When the rig is at the well site it is tipped up (which should be possible for 2 people to do) and it is held upright by the red arm on the top which will attach to a specially designed ground stake. The red support rod also prevents torsion of the top of the machine due to the length of the crossmember. The support rod can be used either in front of, or behind the drilling rig depending on the layout of the site and the ground conditions. A second mode of transport can be achieved if you want to drill many wells in a small area, for example along the edge of a field. When the rig is upright the wheels can be easily removed by removing the pins holding in the red wheel supports. Once the wheels are off the rig can be picked up by the tractor using the small red lifting brackets seen on the rails behind the sliding frame. These brackets should fit perfectly on the mounting for the tractor, it would be like picking up the bucket or any of the other front end tools. This allows the rig to be easily repositioned since the tractor can just set it down right on the wellhead. After it is set in place the red rod is secured on the front side of the rig. The tractor can then detach from the drill rig and use the bail spike to raise and lower the sliding frame (instead of using the manual winch which some builders of the rig may choose to omit entirely).

The side tracks can also be a mounting point for a simple hand cranked, direct drive winch; similar to the winches on boat trailers. The winch, shown in brown in the rendering dispenses a cable up over the two pulleys on the top of the crown. The pulley near the centerline of the machine then supports the sliding frame below it allowing it to travel freely up the center of the side channels. Instead of a hand winch and two pulleys as shown a [http://en.wikipedia.org/wiki/Chain_hoist chain hoist] could also be used.

Please let me know what you think about the pictured design, once I have added the rest of the drilling equipment and after making any changes suggested here, I will post the .g file so other people can play around with it.

== Drill Bits ==
'''open source tricone bit'''

i think we should start thinking about ways to make tricone bits

Recommend you build "drag" bit, tricone or roller cone bit rely on weight of drill string to break up rock. Most of the designs shown will not have sufficient weight on bit for tricone bit to drill rock.

*Light wehicle can be drilled & bolted to groundrock to generate enough forces for big drill and downwards drill directions. No need to carry extra mass. Water tanks are also usable to temporaly weight machine.

stack plate steel?

rivet to housing?

== Drill String ==
=== welded pipe ===

want to look into rolling flat plate into tubes and welding seams?

Commercial drill strings have some hard steel pipe ~100m diameter (maybe welded from ~10mm plate?) and machined & welded blocks on both heads with conical threads (male+female).

=== Purchased Pipe ===

For phase I communities that don't have the ability to produce their own piping for drill string we should find suppliers for it and get price estimates. We should also find a good, common pipe size that we should use for the machine making it easy to buy drill string and once the community can produce their own piping for drill string, since it is a commonly used size they can produce extra for sale by other users (for things other than drill string).

== Well Casing ==

After the well is finished the walls of the well need to be prevented from caving in and collapsing the well, this is the job of well casing. Well casing is usually installed after the well is drilled out (i.e. casing is not present during the drilling operations), however in very soft soil the well may need to be cased even during the drilling phase. If this is required you can drill for some distance with the largest bit you have, then case that section, then use a smaller bit to drill further, case that section with smaller well casing, etc. The well casing for most of the well can be simple pipe, approximately 4 to 6 inches in diameter for a typical well; the bottom section should have holes drilled in it and/or sections of screen to allow the water to infiltrate into the well bore from the aquifer.

could poly pipe work for well casing?

Yes, PVC pipe is often used to case small water wells, under 8"/200mm diameter borehole.

[[Polyethylene_from_Ethanol]]

what size casing is typically used in water well?

You need a minimum of 4"/100mm to allow for installation of cast iron cylinder for India MKII or MKIII by AOV. This will also allow installation of the Afri-Dev type pump.

== Mud Pump ==

[https://docs.google.com/document/d/1PAcyqGPgeuKy5Jzi__wPtyHz5arqQmvT1MzEVwFoNDQ/edit?hl=en google doc]

[http://www.fao.org/docrep/010/ah810e/AH810E06.htm pump types]

what kind of simple designs could be utilized for pumping mud down the drill pipe?

possible plans for reuse of mud pump materials after well is drilled?

does factory farm need this type of pump for other things?

what were some of the pros and cons of the hydraulic pump used on the first drill attempt.

[[image:OpenSourceMudPumpIdea_screwpump.png]]

Wood should be replaced gum plates to improve wear resistance.

== Well Pump ==

was the design used on first factory farm well successful? does the design need improvement?

== Well - Developments Needed==
=== Well - General===
The ability to dig wells allows communities to access underground resources:

-water

-geothermal

Not to mention the power of being able to dig deep holes for support posts or pilings.

Normal heat pumpheating for typical house needs 200m deep hole or two. Typical sale price for one hole is near 5000eur per customer. (60N, granite bed rock). Hole field is also great way to store summer solar heat and use it winter. Only problem is current price for hole fields .

= General Drill tool =

*if Lifetrac equiped with [[backhoe|toolarm]] having diffrent drill tools for wide drill purposes, 80% components (mainly lifetrac) are usable for other things after drill & mining works are done. Drill toolhead can be then store, disassemble or sell.
*General drill needs ability to drill wall and cave roof. Drill mechanisim is ~same, but support needs more axles so it is arm.

http://www.posiva.fi/files/685/Louhinta3.jpg (picture free to use for non commercial purposes)

= Rock blasting =

*Use non explosives methods mainly because "how to make own explosives" are too dangerous data to share public.
*Stones in Pyramids are blasted with unhydrated lime. Lime powder pressed to hole, closed with wood tap and watered. It can generate ~500Mpa pressure.
*There are lot of old "expansive concrete" patents free to use.

{{GVCS Footer}}

Well-Drilling Rig/Research Development

2012-06-08T22:13:54Z

ERos: /* Design Goals */

{{GVCS Header}}
{{Category=Water}}

=Design Goals=
what goals should we have for the rig?

should it be an old fashioned wooden derrick?
*errected on site
*wood could be used for something else later
*for drilling one hole for a single community (worktime/price per hole come high!)

reusable and on wheels?
*drill multiple holes quickly and easily
*metal? more expensive?
*[[lifetrac]] additional tool, so only need drill & feed mechanisim & additional length drill strings?
*2nd drill head to change Liftrac full cave/mine making machine?
*Software for automate Lifetrac to drill hole groups? (like for blasting construction stones?)

how deep should it drill?
geothermal or just water?
*200m (600') is typical for geothermal, for water 100m is usually enough. Basically deeper only needs larger drill strings reservour.

==Well - Current Work==

== Water/Mud Swivel ==

link to some basic ideas about a swivel
[https://docs.google.com/document/d/1WOnl3w9CkWP1KnZFTtmace5eB3hGcGAvxYfA6sPqtX0/edit?hl=en google doc]

[[image:Waterwellswivelmach1.png]]

[[image:Photowaterswivelbetapressuretest1.JPG|400px]]

i rigged it up where i could put my hose on. but when i was screwing it all together i accidentally cracked the PVC plug at one end. wasnt sure how it woudl effect it so went ahead. it leaked from there first, at the threads. it leaked from the other end, where the o-rings should have been hodling, and also some from the collars that i only hand tightened. when i moved the T side to side it seemed to move the o-rings around and some places held better than others, indicatign to me that the o-rings were coming out of the pvc area. there were 4 orings on either end. i might try with more orings and maybe ill also get some string gasket material and see how that goes. 5/22/11 dorkmo

[[image:Photowaterswivelbetapressuretest2.JPG|400px]]

k i went back and made a new pvc plug with a hole. and got a better clamp for the hose hook up.

[[image:Photowaterswivelbetapressuretest3.JPG|400px]]

so i opened the valve it didnt seem too bad. there was a small steady leak from a few places. i could spin it by hand it seemed to do fine. next i'd like to somehow get it to spin at operating speed to see how the orings hold up. i might change it to have the water go into the T and then put some sort of hand crank on the 1" pipe. maybe in a week or two

== Drill String Raising/Lowering ==

idea for a lifetrac enabled pulling apparatus [https://docs.google.com/drawings/edit?id=1TEIcJUDySpRGLfPKMXHu9YUtS0iti0YQwTOHEtlltP8 google doc]

[[Image:LifeTracWaterWellPullingUnit.png]]

square tubing could be reused on other projects after well is complete

could wooden 4x4s work? need extra support beams?

== A Preliminary Design ==

[[Image:Well-Drilling_RigRender.png|thumb|right|400px]]

Here is a first rendering of the well drilling rig as rendered in BRL-CAD. The hydraulic pump (green) from the [[MicroTrac]] is shown mounted with the shaft downwards on the blue sliding frame which moves up and down the side tracks. The mounting of the motor to the green frame will use the same two bolt quick release system employed by the MicroTrac to allow for interoperability and quick changeovers from one device to the other. The rotating shaft from the hydraulic pump is connected to the purple section of drill string piping which stays centered in the swivel tee allowing drilling mud to flow into it and down the drill string (shown in light green). The purple section of piping is held horizontally by the holes in the top and bottom of the frame which are only slightly bigger than the purple pipe. This purple section of piping is supported vertically by the rotating bearing assembly which rides on the top of the sliding frame. If rock is encountered while drilling the small circular plate above the bearing will push the bearing down putting extra weight on the drill string. This allows weights to be hung along the back panel of the frame allowing the amount of downward force on the drill string to be manipulated. In the reverse situation, when tripping the drill string out of the hole, the purple section will pull down on the bearing causing it to move off the circular plate and against the frame below, pushing down on the frame and holding up the drill string as it is withdrawn from the well.

At ground level the the drill string passes through the red drill collar which bolts down to the gray baseplate allowing it to be easily removed or swapped for a smaller diameter collar (the square collar flange plate will be the same for all collars allowing for interchangeability). The machine currently is shown with a 6 inch inside diameter collar allowing a 6 inch well casing ti exactly fit inside it. At the bottom of the drill string a simple gray bit is shown which is just a section of 6" pipe with partially covered end caps connected to the bottom of the lowest section of drill string piping. Since the actual drill string piping is much smaller than 6 inches (probably only 3 or 4 inches at most for a water well drilling rig) the collar can also serve analogous to the function of a rotary table on an oil rig allowing a slip to be used to support the drill string when it is detached from the turning head at the top of the rig.

The vertical side tracks can either be composed of three flat pieces of steel welded along the edges to form a channel or can be made from large (~10 cm or bigger square tubing which has been cut in half lengthwise). If additional ground stability on the baseplate is required, four long steel stakes can be driven through the corners of the baseplate to prevent it from sliding. If these stakes are just simple pieces of re-bar they can even be left in place after the baseplate is removed (when the drilling rig is lifted straight up, or tipped down to one side the baseplate would just lift off the top of the stakes), these could then be cemented into the top pad when the wellhead is capped preventing it from sliding off the top of the well, or they can be removed for re-use as well.

The side tracks bolt to the baseplate and to each other with additional plates on the outside of the tracks a pair of bolts at each end (outer plates not shown). Since the bolt holes on all pieces of this side track material are 10 cm and 20 cm in from the ends of the piece they are interchangeable with or attachable to any other piece no matter whether they bolt to the baseplate, the top crown, or another section. This interchangeability on the side rails means you can build a small test rig with short rails for prototyping and shallow well drilling and then later on you can add additional height to the drill rig by adding on longer tracks letting you run deeper before having to break the drill string to add another section (making digging very deep wells much faster). Disassembling the side tracks would be easy to do (only 4 bolts per section) allowing the tracks to be disassembled for long distance transport and the re-assembled at the well site. In order to make room for the bolt heads on the inside of the tracks, the blue frame has 4 cm by 4 cm channels cut into each side; this lets the bolts securing the side tracks pass by without affecting the guiding done by the outside corners of the frame.

For short distance transport the rig can be tipped down and pulled on the wheels (a hitch could be attached at the top of the crown). When the rig is at the well site it is tipped up (which should be possible for 2 people to do) and it is held upright by the red arm on the top which will attach to a specially designed ground stake. The red support rod also prevents torsion of the top of the machine due to the length of the crossmember. The support rod can be used either in front of, or behind the drilling rig depending on the layout of the site and the ground conditions. A second mode of transport can be achieved if you want to drill many wells in a small area, for example along the edge of a field. When the rig is upright the wheels can be easily removed by removing the pins holding in the red wheel supports. Once the wheels are off the rig can be picked up by the tractor using the small red lifting brackets seen on the rails behind the sliding frame. These brackets should fit perfectly on the mounting for the tractor, it would be like picking up the bucket or any of the other front end tools. This allows the rig to be easily repositioned since the tractor can just set it down right on the wellhead. After it is set in place the red rod is secured on the front side of the rig. The tractor can then detach from the drill rig and use the bail spike to raise and lower the sliding frame (instead of using the manual winch which some builders of the rig may choose to omit entirely).

The side tracks can also be a mounting point for a simple hand cranked, direct drive winch; similar to the winches on boat trailers. The winch, shown in brown in the rendering dispenses a cable up over the two pulleys on the top of the crown. The pulley near the centerline of the machine then supports the sliding frame below it allowing it to travel freely up the center of the side channels. Instead of a hand winch and two pulleys as shown a [http://en.wikipedia.org/wiki/Chain_hoist chain hoist] could also be used.

Please let me know what you think about the pictured design, once I have added the rest of the drilling equipment and after making any changes suggested here, I will post the .g file so other people can play around with it.

== Drill Bits ==
'''open source tricone bit'''

i think we should start thinking about ways to make tricone bits

Recommend you build "drag" bit, tricone or roller cone bit rely on weight of drill string to break up rock. Most of the designs shown will not have sufficient weight on bit for tricone bit to drill rock.

*Light wehicle can be drilled & bolted to groundrock to generate enough forces for big drill and downwards drill directions. No need to carry extra mass. Water tanks are also usable to temporaly weight machine.

stack plate steel?

rivet to housing?

== Drill String ==
=== welded pipe ===

want to look into rolling flat plate into tubes and welding seams?

Commercial drill strings have some hard steel pipe ~100m diameter (maybe welded from ~10mm plate?) and machined & welded blocks on both heads with conical threads (male+female).

=== Purchased Pipe ===

For phase I communities that don't have the ability to produce their own piping for drill string we should find suppliers for it and get price estimates. We should also find a good, common pipe size that we should use for the machine making it easy to buy drill string and once the community can produce their own piping for drill string, since it is a commonly used size they can produce extra for sale by other users (for things other than drill string).

== Well Casing ==

After the well is finished the walls of the well need to be prevented from caving in and collapsing the well, this is the job of well casing. Well casing is usually installed after the well is drilled out (i.e. casing is not present during the drilling operations), however in very soft soil the well may need to be cased even during the drilling phase. If this is required you can drill for some distance with the largest bit you have, then case that section, then use a smaller bit to drill further, case that section with smaller well casing, etc. The well casing for most of the well can be simple pipe, approximately 4 to 6 inches in diameter for a typical well; the bottom section should have holes drilled in it and/or sections of screen to allow the water to infiltrate into the well bore from the aquifer.

could poly pipe work for well casing?

Yes, PVC pipe is often used to case small water wells, under 8"/200mm diameter borehole.

[[Polyethylene_from_Ethanol]]

what size casing is typically used in water well?

You need a minimum of 4"/100mm to allow for installation of cast iron cylinder for India MKII or MKIII by AOV. This will also allow installation of the Afri-Dev type pump.

== Mud Pump ==

[https://docs.google.com/document/d/1PAcyqGPgeuKy5Jzi__wPtyHz5arqQmvT1MzEVwFoNDQ/edit?hl=en google doc]

[http://www.fao.org/docrep/010/ah810e/AH810E06.htm pump types]

what kind of simple designs could be utilized for pumping mud down the drill pipe?

possible plans for reuse of mud pump materials after well is drilled?

does factory farm need this type of pump for other things?

what were some of the pros and cons of the hydraulic pump used on the first drill attempt.

[[image:OpenSourceMudPumpIdea_screwpump.png]]

Wood should be replaced gum plates to improve wear resistance.

== Well Pump ==

was the design used on first factory farm well successful? does the design need improvement?

== Well - Developments Needed==
=== Well - General===
The ability to dig wells allows communities to access underground resources:

-water

-geothermal

Not to mention the power of being able to dig deep holes for support posts or pilings.

Normal heat pumpheating for typical house needs 200m deep hole or two. Typical sale price for one hole is near 5000eur per customer. (60N, granite bed rock). Hole field is also great way to store summer solar heat and use it winter. Only problem is current price for hole fields .

= General Drill tool =

*if Lifetrac equiped with [[backhoe]toolarm] have diffrent drill tools for many drill purposes, 80% components (mainly lifetrac) are usable for other things after drill works are done. Drill tool can be then store, disassemble or sell.
*General drill needs ability to drill wall and cave roof. Drill mechanisim is ~same, but support needs more axles so it is arm.

http://www.posiva.fi/files/685/Louhinta3.jpg (picture free to use for non commercial purposes)

= Rock blasting =

*Use non explosives methods mainly because "how to make own explosives" are too dangerous data to share public.
*Stones in Pyramids are blasted with unhydrated lime. Lime powder pressed to hole, closed with wood tap and watered. It can generate ~500Mpa pressure.
*There are lot of old "expansive concrete" patents free to use.

{{GVCS Footer}}

Well-Drilling Rig

2012-06-08T19:54:57Z

ERos: /* Overview */

{{GVCS Header}}

{{Category=Water}}

==Overview==

[[Image:Well-Drilling Rigpic.png|thumb|400px|Well-Drilling Rig]]

The '''Well Drilling Rig''' enables the construction of [[water]] wells. Water is crucial for human and animal consumption, washing, irrigation, and industrial processes. Access to clean [[drinking water]] is one of the key challenges facing many countries today. Addressing this need with the [[GVCS]] has the potential for far reaching impact.
If this machine plans are changed little to "General Drilling Rig" it can be used also mining purposes,
to drill & blast caves, make bolt holes, drill water and geothermal wells etc. There can be two
changeable drill heads. One for bigger holes (compressed air driven) and second hydraulic driven
(fast) for smaller holes. And modified [[LifeTrac]] may carry them. Modified [[Backhoe]] offer enough
movement for drill head tool.

{{Video}}

==Description==
Well drilling can be broken down into three basic phases:

#breaking up the rock/soil in the well column
#removing the cuttings from the well column
#stabilising the well column and preparing it for production.

'''Breaking'''
Breaking of rock/soil to produce cuttings is achieved by a cutting tool, either a rotating drill bit or a raised and dropped 'chisel-like' device; for the ''GVCS well drilling rig'' we will likely employ the rotating bit design as it is a much more common method of well preparation. The bit is rotated by attaching it to the end of a long series of pipes connected together called the drill string, turning the drill string turns the cutting bit.

'''Pumping'''
Once the bit has cut up the rock/dirt it needs to be lifted up out of the well. The most common way of doing this is to pump water/mud down the center of the piping that makes up the drill string, and letting it flow out the end of the bit. By continuously pumping more drilling mud into the well, it eventually fills up and the only place left for the mud to go is to be pushed up to the top of the well and spill over the side, carrying the cuttings along with it. This flow of mud and broken up rock spills over the top of the well and is sent to a small settling pond where the rocks and sand settle out of it. After some time in the settling pond the mud is recycled by the mud pump and pushed back down the well again to pick up and remove more cuttings allowing the well to be contiuously drilled deeper and deeper, stopping only to add new sections of drill string.

'''Stabilizing'''
After the well is drilled to the desired depth it must be finished and put into production. The drill string is withrawn from the well, but the well is left full of water/drilling mud to prevent the sides from caving in until the well is finished. After the drill string is out the casing pipe is slid into the well to prevent caving in of the sides. Once this is done, the drilling mud is removed from the well column leaving it empty. At this point a water bucket or temporary well pump is placed in the well and as much water as possible is drawn up for a test period of 1 to 3 days to clean out any remaining drilling mud and stabilize the aquifer for production. Also during this time the water extraction rate is measured to verify that it is worth continuing to finish the well (poor producing wells may have the casing withdrawn and be re-drilled at a more favorable location). Once the well is shown to be a producing well it is capped with a cement cap, and the water pump is installed making the well operational.

==Product Ecology==
[[Image:4b-Constructioneco.png|thumb|600px|[[Product Ecology]]]]

'''Made with'''
*{{Induction Furnace}} - Steel
*{{Torch Table}} - Parts
*{{Power Cube}} - Power
*{{Hydraulic Motor}} - Drill, Ram, Vacuum Pump

'''Uses'''
*{{Hydraulic Motor}} - Pump
*{{Power Cube}} - Power
*{{Cement Mixer}} - Cement Cap

'''Creates'''
*[[Water]] Wells

==Components==
*Steel
*Drill
*Pipe Casing
*Drill String
*Hoses
*Mud Pump
*Vacuum

==Status==
The [[Well Drilling Rig]] is currently in [http://opensourceecology.org/wiki/Well-Drilling_Rig/Research_Development the research phase of product development].

==Links==
*[http://opensourceecology.org/wiki/Well-Drilling_Rig/Research_Development| GVCS Research]
*[http://www.hydromissions.com/products.htm HydroMissions - Products]
*[http://www.practicafoundation.org/services/publications/ Practica Foundation - Publications]
*[http://drillingfab.com/ Drilling Fab]
*[http://www.lifewater.org/technical-library Life Water - Technical Library]
*[http://vimeo.com/emas/videos EMAS - Vimeo: Well Drilling Videos]

{{GVCS Footer}}

Well-Drilling Rig

2012-06-08T19:46:19Z

ERos: /* Overview */

{{GVCS Header}}

{{Category=Water}}

==Overview==

[[Image:Well-Drilling Rigpic.png|thumb|400px|Well-Drilling Rig]]

The '''Well Drilling Rig''' enables the construction of [[water]] wells. Water is crucial for human and animal consumption, washing, irrigation, and industrial processes. Access to clean [[drinking water]] is one of the key challenges facing many countries today. Addressing this need with the [[GVCS]] has the potential for far reaching impact.
If this machine are changed little to "General Drilling Rig" it can be used also mining purposes, to drill & blast caves, make bolt holes, drill water and geothermal wells etc. There can be two changeable drill heads. One for bigger holes (compressed air driven) and second hydraulic driven (fast) for smaller holes. And modified [LifeTrac] may carry them. Modified [Backhoe] offer enough movement for drill head tool.

{{Video}}

==Description==
Well drilling can be broken down into three basic phases:

#breaking up the rock/soil in the well column
#removing the cuttings from the well column
#stabilising the well column and preparing it for production.

'''Breaking'''
Breaking of rock/soil to produce cuttings is achieved by a cutting tool, either a rotating drill bit or a raised and dropped 'chisel-like' device; for the ''GVCS well drilling rig'' we will likely employ the rotating bit design as it is a much more common method of well preparation. The bit is rotated by attaching it to the end of a long series of pipes connected together called the drill string, turning the drill string turns the cutting bit.

'''Pumping'''
Once the bit has cut up the rock/dirt it needs to be lifted up out of the well. The most common way of doing this is to pump water/mud down the center of the piping that makes up the drill string, and letting it flow out the end of the bit. By continuously pumping more drilling mud into the well, it eventually fills up and the only place left for the mud to go is to be pushed up to the top of the well and spill over the side, carrying the cuttings along with it. This flow of mud and broken up rock spills over the top of the well and is sent to a small settling pond where the rocks and sand settle out of it. After some time in the settling pond the mud is recycled by the mud pump and pushed back down the well again to pick up and remove more cuttings allowing the well to be contiuously drilled deeper and deeper, stopping only to add new sections of drill string.

'''Stabilizing'''
After the well is drilled to the desired depth it must be finished and put into production. The drill string is withrawn from the well, but the well is left full of water/drilling mud to prevent the sides from caving in until the well is finished. After the drill string is out the casing pipe is slid into the well to prevent caving in of the sides. Once this is done, the drilling mud is removed from the well column leaving it empty. At this point a water bucket or temporary well pump is placed in the well and as much water as possible is drawn up for a test period of 1 to 3 days to clean out any remaining drilling mud and stabilize the aquifer for production. Also during this time the water extraction rate is measured to verify that it is worth continuing to finish the well (poor producing wells may have the casing withdrawn and be re-drilled at a more favorable location). Once the well is shown to be a producing well it is capped with a cement cap, and the water pump is installed making the well operational.

==Product Ecology==
[[Image:4b-Constructioneco.png|thumb|600px|[[Product Ecology]]]]

'''Made with'''
*{{Induction Furnace}} - Steel
*{{Torch Table}} - Parts
*{{Power Cube}} - Power
*{{Hydraulic Motor}} - Drill, Ram, Vacuum Pump

'''Uses'''
*{{Hydraulic Motor}} - Pump
*{{Power Cube}} - Power
*{{Cement Mixer}} - Cement Cap

'''Creates'''
*[[Water]] Wells

==Components==
*Steel
*Drill
*Pipe Casing
*Drill String
*Hoses
*Mud Pump
*Vacuum

==Status==
The [[Well Drilling Rig]] is currently in [http://opensourceecology.org/wiki/Well-Drilling_Rig/Research_Development the research phase of product development].

==Links==
*[http://opensourceecology.org/wiki/Well-Drilling_Rig/Research_Development| GVCS Research]
*[http://www.hydromissions.com/products.htm HydroMissions - Products]
*[http://www.practicafoundation.org/services/publications/ Practica Foundation - Publications]
*[http://drillingfab.com/ Drilling Fab]
*[http://www.lifewater.org/technical-library Life Water - Technical Library]
*[http://vimeo.com/emas/videos EMAS - Vimeo: Well Drilling Videos]

{{GVCS Footer}}

Open Source Stepper Motor Controller

2012-06-01T20:05:38Z

ERos: /* Design Rationale */

{{Category=RepLab Tools}}

'' See also [[Stepper Motor]]'' and see also [[Problem_Statement_for_a_Universal_Power_Supply]]

=Factor e Farm Status=
[[SnapLock CNC]] and [[Open Source Torch Table Prototype II]] are being built in January 2012.
=Introduction=

See [[Open Source Stepper Motor Controller Problem Statement]] as a start.

Stepper motors are the simplest drive for moderate precision motion control applications (such as CNC plasma cutting). They provide the best price:performace for low to moderate mechanical power (<200W) at low to moderate RPM (<500 RPM). There is no open source stepper driver, AFAIK. This project will fill that need.
There are many L297 + L298 based circuits (2.5A 50V). L297 is cheap (~1.5$) but can do only full and half steps. Early repraps used L297+L298 controller. If put more money can use microcontroller like pic16F877 and that route can be cheaper if need six ore more axles. AD pin shortage usually renders microcontroller and steppers out, because every steppermotor needs two AD pin for current sense. But microcontroller can handle multiple brush motors with encoders, like some cheap handdrills. That way generate cheap and powerful route to produce multiple axles in EMC controlled robot arm etc.

=Concept=

The output of this project will be a family of general purpose electronic drivers for a variety of electromechanical actuators. The first of them will be a stepper motor driver http://reprap.org/wiki/Stepper_Motor_Driver_1.1. With the appropriate alternative firmware (embedded software) the same hardware might be used as a servo driver for a brush-DC servo. With a modified output stage we could drive brushless DC or AC servos, or linear motors.

=Design Rationale=

Adaptability is good. Software is usually easier than hardware. Microprocessors are cheap. Simple circuits are better than complicated ones (other things being equal).

We keep the circuit simple and general, and we implement the control algorithm in software. We can tweak it most easily that way, and even replace it with something totally different.

This design should give good performance, excellent versatility, good replicability, and moderate cost.

If want use EMC (capable of nine axles actuators, like robot arm, easy and ready) it need direct connection to encoders and motor pwm/dir or step/dir level. It don't need complicated drivers/boards, only simple dir/step or dir/pwm board one per motor. EMC take G-code input and is 100% software in easy enviroment (pc-linux).

=Block Diagram and Modules=

Major functional units:
* Computational logic. An Arduino could be used in the initial prototype, for speed of development. Later versions would want a cost reduced and/or higher performance microprocessor, or an FPGA for minimum latency and maximum bandwidth. The logic must be shielded from electromagnetic interference by the other parts of the system, especially the output drive (and the plasma cutter, if there is one). Independent power and small signal power supplies, and careful grounding, are likely to be needed.
* Fast A/D converters. Allows the logic to monitor the current flowing through the load.
* High power robust drive circuit. N-channel power MOSFETs in an H bridge, with appropriate protection. Select MOSFETs with plenty of current and voltage headroom, and favour ones with built in clamp diodes. A stepper motor is a heavily inductive load, so it can generate voltages substantially outside the supply rails.

[[File:Stepper-drive-block-diagram.jpg|200px|Stepper drive block diagram.]]

[[File:Stepper-drive-H-bridge.jpg|200px|Stepper drive H-bridge.]]

An H-bridge allows the voltage to be applied to the load (to motor winding) in either direction.

[[File:Stepper-drive-schematic-symbols.jpg|200px|Stepper drive schematic symbols.]]

[[File:Stepper-drive-normal-operation.jpg|200px|Stepper drive normal operation.]]

Top row: active current path. Bottom row: Corresponding Current (I) and Voltage (V) graphed against time.

From left to right: Positive applied voltage, rapidly increasing current; No voltage (except due to the resistance of the wires, gradually decreasing current; Negative applied voltage, rapidly falling current.

[[File:Stepper-drive-failure-modes.jpg|200px|Stepper drive failure modes.]]

Shoot-through occurs when both transistors on one side of the H are turned on at the same time. It shorts the rails together and blows the transistors in a few us.

The overvoltage shown occurs when all the transistors are turned off simultaneously while current is flowing. Stopping the current near instantly creates a huge voltage spike. The same effect can occur if a motor lead comes loose while the driver is operating.

[[File:Stepper-drive-waveforms.jpg|200px|Stepper drive waveforms.]]

Contrast stepping with microstepping. The microstepping gives less vibration and smoother movement, and makes it possible to stop between the steps.

[[File:Stepper-drive-MOSFET-timing.jpg|200px|Stepper drive MOSFET timing.]]

MOSFETS take some time to turn on and off. We need to take account of this for optimum performance (or even for to avoid the above failure modes?). See the MOSFET data sheet for exact timings.

=== Method of operation: ===

*Position instructions come to the drive from EMC. These could be step and direction pulses or some more structured data.
*The drive determines target current for each winding.
*The drive uses software [http://en.wikipedia.org/wiki/PID_controller PID] compensation to achieve and maintain those drive currents.
** sensor: voltage induced across sense resistor by the drive current.
** actuator: [http://en.wikipedia.org/wiki/Pulse-width_modulation PWM] of applied voltage between the three normal operation modes.
*The drive determines new target current for next (micro-)step.

=Prior Art=

This design offers a higher power version (up to 75 amps) of a stepper motor controller, and addresses the feedback loop:

http://www.piclist.com/techref/io/stepper/hipwrbp-gm.htm

[[Image:steppermotorcontroller.gif]]

==Comment by Chris Palmer==
That is only part of a driver circuit. The current sense circuit is not shown and it looks like the firmware will have to do the sequencing, current control and microstepping. The LM5101 is not recommended for new designs.

There are more modern chips that you just add external FETs and sense resistors to get a complete microstepping chopper driver. For example: http://www.allegromicro.com/en/Products/Part_Numbers/3986/index.asp

=References=
*RepRap wiki - good references on stepper controllers - [http://reprap.org/wiki/StepperMotor]
*[http://en.wikipedia.org/wiki/Stepper_motor Stepper Motor in Wikipedia]
*[http://www.cs.uiowa.edu/~jones/step/index.html An excellent discussion of concepts]
*Control of DC motors explained - [http://www.tigoe.net/pcomp/code/circuits/motors/controlling-dc-motors]
*Sample stepper motor controlled with Arduino using EasyDriver - [http://translate.google.com/translate?js=n&prev=_t&hl=en&ie=UTF-8&layout=2&eotf=1&sl=pt&tl=en&u=http%3A%2F%2Flusorobotica.com%2Findex.php%2Ftopic%2C106.0.html&act=url]
*Dr. Iguana's open source stepper motor based on a pic microcontroller : http://www.dr-iguana.com/prj_StepperDriver/

=Research=
*[http://www.google.com/search?client=ubuntu&channel=fs&q=stepper+motor&ie=utf-8&oe=utf-8 Google: stepper motor]
*[http://www.google.com/search?client=ubuntu&channel=fs&q=stepper+controller+integrated+circuit&ie=utf-8&oe=utf-8 Google: stepper controller integrated circuit]
*[http://www.google.com/search?client=ubuntu&channel=fs&q=stepper+controller+chip&ie=utf-8&oe=utf-8 Google: stepper controller chip]
*[http://www.google.com/search?client=ubuntu&channel=fs&q=NEMA+34+stepper+motors&ie=utf-8&oe=utf-8 Google: NEMA 34 stepper motors]

=Development Team=

*[[Leo.dearden]] - Ideas. I'm too busy to do very much at the moment, but I'll do what I can.
*[[Yoonseo Kang]]
*[[Darren Vandervort]]
*[[Stefan Ludwig]]

=See Also=
* [[Stepper Motor]]
* [[Open Source Stepper Motor]]

[[Category:Torch Table]]

Open Source Stepper Motor Controller

2012-06-01T19:55:25Z

ERos: /* Concept */

{{Category=RepLab Tools}}

'' See also [[Stepper Motor]]'' and see also [[Problem_Statement_for_a_Universal_Power_Supply]]

=Factor e Farm Status=
[[SnapLock CNC]] and [[Open Source Torch Table Prototype II]] are being built in January 2012.
=Introduction=

See [[Open Source Stepper Motor Controller Problem Statement]] as a start.

Stepper motors are the simplest drive for moderate precision motion control applications (such as CNC plasma cutting). They provide the best price:performace for low to moderate mechanical power (<200W) at low to moderate RPM (<500 RPM). There is no open source stepper driver, AFAIK. This project will fill that need.
There are many L297 + L298 based circuits (2.5A 50V). L297 is cheap (~1.5$) but can do only full and half steps. Early repraps used L297+L298 controller. If put more money can use microcontroller like pic16F877 and that route can be cheaper if need six ore more axles. AD pin shortage usually renders microcontroller and steppers out, because every steppermotor needs two AD pin for current sense. But microcontroller can handle multiple brush motors with encoders, like some cheap handdrills. That way generate cheap and powerful route to produce multiple axles in EMC controlled robot arm etc.

=Concept=

The output of this project will be a family of general purpose electronic drivers for a variety of electromechanical actuators. The first of them will be a stepper motor driver http://reprap.org/wiki/Stepper_Motor_Driver_1.1. With the appropriate alternative firmware (embedded software) the same hardware might be used as a servo driver for a brush-DC servo. With a modified output stage we could drive brushless DC or AC servos, or linear motors.

=Design Rationale=

Adaptability is good. Software is usually easier than hardware. Microprocessors are cheap. Simple circuits are better than complicated ones (other things being equal).

We keep the circuit simple and general, and we implement the control algorithm in software. We can tweak it most easily that way, and even replace it with something totally different.

This design should give good performance, excellent versatility, good replicability, and moderate cost.

=Block Diagram and Modules=

Major functional units:
* Computational logic. An Arduino could be used in the initial prototype, for speed of development. Later versions would want a cost reduced and/or higher performance microprocessor, or an FPGA for minimum latency and maximum bandwidth. The logic must be shielded from electromagnetic interference by the other parts of the system, especially the output drive (and the plasma cutter, if there is one). Independent power and small signal power supplies, and careful grounding, are likely to be needed.
* Fast A/D converters. Allows the logic to monitor the current flowing through the load.
* High power robust drive circuit. N-channel power MOSFETs in an H bridge, with appropriate protection. Select MOSFETs with plenty of current and voltage headroom, and favour ones with built in clamp diodes. A stepper motor is a heavily inductive load, so it can generate voltages substantially outside the supply rails.

[[File:Stepper-drive-block-diagram.jpg|200px|Stepper drive block diagram.]]

[[File:Stepper-drive-H-bridge.jpg|200px|Stepper drive H-bridge.]]

An H-bridge allows the voltage to be applied to the load (to motor winding) in either direction.

[[File:Stepper-drive-schematic-symbols.jpg|200px|Stepper drive schematic symbols.]]

[[File:Stepper-drive-normal-operation.jpg|200px|Stepper drive normal operation.]]

Top row: active current path. Bottom row: Corresponding Current (I) and Voltage (V) graphed against time.

From left to right: Positive applied voltage, rapidly increasing current; No voltage (except due to the resistance of the wires, gradually decreasing current; Negative applied voltage, rapidly falling current.

[[File:Stepper-drive-failure-modes.jpg|200px|Stepper drive failure modes.]]

Shoot-through occurs when both transistors on one side of the H are turned on at the same time. It shorts the rails together and blows the transistors in a few us.

The overvoltage shown occurs when all the transistors are turned off simultaneously while current is flowing. Stopping the current near instantly creates a huge voltage spike. The same effect can occur if a motor lead comes loose while the driver is operating.

[[File:Stepper-drive-waveforms.jpg|200px|Stepper drive waveforms.]]

Contrast stepping with microstepping. The microstepping gives less vibration and smoother movement, and makes it possible to stop between the steps.

[[File:Stepper-drive-MOSFET-timing.jpg|200px|Stepper drive MOSFET timing.]]

MOSFETS take some time to turn on and off. We need to take account of this for optimum performance (or even for to avoid the above failure modes?). See the MOSFET data sheet for exact timings.

=== Method of operation: ===

*Position instructions come to the drive from EMC. These could be step and direction pulses or some more structured data.
*The drive determines target current for each winding.
*The drive uses software [http://en.wikipedia.org/wiki/PID_controller PID] compensation to achieve and maintain those drive currents.
** sensor: voltage induced across sense resistor by the drive current.
** actuator: [http://en.wikipedia.org/wiki/Pulse-width_modulation PWM] of applied voltage between the three normal operation modes.
*The drive determines new target current for next (micro-)step.

=Prior Art=

This design offers a higher power version (up to 75 amps) of a stepper motor controller, and addresses the feedback loop:

http://www.piclist.com/techref/io/stepper/hipwrbp-gm.htm

[[Image:steppermotorcontroller.gif]]

==Comment by Chris Palmer==
That is only part of a driver circuit. The current sense circuit is not shown and it looks like the firmware will have to do the sequencing, current control and microstepping. The LM5101 is not recommended for new designs.

There are more modern chips that you just add external FETs and sense resistors to get a complete microstepping chopper driver. For example: http://www.allegromicro.com/en/Products/Part_Numbers/3986/index.asp

=References=
*RepRap wiki - good references on stepper controllers - [http://reprap.org/wiki/StepperMotor]
*[http://en.wikipedia.org/wiki/Stepper_motor Stepper Motor in Wikipedia]
*[http://www.cs.uiowa.edu/~jones/step/index.html An excellent discussion of concepts]
*Control of DC motors explained - [http://www.tigoe.net/pcomp/code/circuits/motors/controlling-dc-motors]
*Sample stepper motor controlled with Arduino using EasyDriver - [http://translate.google.com/translate?js=n&prev=_t&hl=en&ie=UTF-8&layout=2&eotf=1&sl=pt&tl=en&u=http%3A%2F%2Flusorobotica.com%2Findex.php%2Ftopic%2C106.0.html&act=url]
*Dr. Iguana's open source stepper motor based on a pic microcontroller : http://www.dr-iguana.com/prj_StepperDriver/

=Research=
*[http://www.google.com/search?client=ubuntu&channel=fs&q=stepper+motor&ie=utf-8&oe=utf-8 Google: stepper motor]
*[http://www.google.com/search?client=ubuntu&channel=fs&q=stepper+controller+integrated+circuit&ie=utf-8&oe=utf-8 Google: stepper controller integrated circuit]
*[http://www.google.com/search?client=ubuntu&channel=fs&q=stepper+controller+chip&ie=utf-8&oe=utf-8 Google: stepper controller chip]
*[http://www.google.com/search?client=ubuntu&channel=fs&q=NEMA+34+stepper+motors&ie=utf-8&oe=utf-8 Google: NEMA 34 stepper motors]

=Development Team=

*[[Leo.dearden]] - Ideas. I'm too busy to do very much at the moment, but I'll do what I can.
*[[Yoonseo Kang]]
*[[Darren Vandervort]]
*[[Stefan Ludwig]]

=See Also=
* [[Stepper Motor]]
* [[Open Source Stepper Motor]]

[[Category:Torch Table]]

Open Source Stepper Motor Controller

2012-06-01T19:52:02Z

ERos: /* Introduction */

{{Category=RepLab Tools}}

'' See also [[Stepper Motor]]'' and see also [[Problem_Statement_for_a_Universal_Power_Supply]]

=Factor e Farm Status=
[[SnapLock CNC]] and [[Open Source Torch Table Prototype II]] are being built in January 2012.
=Introduction=

See [[Open Source Stepper Motor Controller Problem Statement]] as a start.

Stepper motors are the simplest drive for moderate precision motion control applications (such as CNC plasma cutting). They provide the best price:performace for low to moderate mechanical power (<200W) at low to moderate RPM (<500 RPM). There is no open source stepper driver, AFAIK. This project will fill that need.
There are many L297 + L298 based circuits (2.5A 50V). L297 is cheap (~1.5$) but can do only full and half steps. Early repraps used L297+L298 controller. If put more money can use microcontroller like pic16F877 and that route can be cheaper if need six ore more axles. AD pin shortage usually renders microcontroller and steppers out, because every steppermotor needs two AD pin for current sense. But microcontroller can handle multiple brush motors with encoders, like some cheap handdrills. That way generate cheap and powerful route to produce multiple axles in EMC controlled robot arm etc.

=Concept=

The output of this project will be a family of general purpose electronic drivers for a variety of electromechanical actuators. The first of them will be a stepper motor driver. With the appropriate alternative firmware (embedded software) the same hardware might be used as a servo driver for a brush-DC servo. With a modified output stage we could drive brushless DC or AC servos, or linear motors.

=Design Rationale=

Adaptability is good. Software is usually easier than hardware. Microprocessors are cheap. Simple circuits are better than complicated ones (other things being equal).

We keep the circuit simple and general, and we implement the control algorithm in software. We can tweak it most easily that way, and even replace it with something totally different.

This design should give good performance, excellent versatility, good replicability, and moderate cost.

=Block Diagram and Modules=

Major functional units:
* Computational logic. An Arduino could be used in the initial prototype, for speed of development. Later versions would want a cost reduced and/or higher performance microprocessor, or an FPGA for minimum latency and maximum bandwidth. The logic must be shielded from electromagnetic interference by the other parts of the system, especially the output drive (and the plasma cutter, if there is one). Independent power and small signal power supplies, and careful grounding, are likely to be needed.
* Fast A/D converters. Allows the logic to monitor the current flowing through the load.
* High power robust drive circuit. N-channel power MOSFETs in an H bridge, with appropriate protection. Select MOSFETs with plenty of current and voltage headroom, and favour ones with built in clamp diodes. A stepper motor is a heavily inductive load, so it can generate voltages substantially outside the supply rails.

[[File:Stepper-drive-block-diagram.jpg|200px|Stepper drive block diagram.]]

[[File:Stepper-drive-H-bridge.jpg|200px|Stepper drive H-bridge.]]

An H-bridge allows the voltage to be applied to the load (to motor winding) in either direction.

[[File:Stepper-drive-schematic-symbols.jpg|200px|Stepper drive schematic symbols.]]

[[File:Stepper-drive-normal-operation.jpg|200px|Stepper drive normal operation.]]

Top row: active current path. Bottom row: Corresponding Current (I) and Voltage (V) graphed against time.

From left to right: Positive applied voltage, rapidly increasing current; No voltage (except due to the resistance of the wires, gradually decreasing current; Negative applied voltage, rapidly falling current.

[[File:Stepper-drive-failure-modes.jpg|200px|Stepper drive failure modes.]]

Shoot-through occurs when both transistors on one side of the H are turned on at the same time. It shorts the rails together and blows the transistors in a few us.

The overvoltage shown occurs when all the transistors are turned off simultaneously while current is flowing. Stopping the current near instantly creates a huge voltage spike. The same effect can occur if a motor lead comes loose while the driver is operating.

[[File:Stepper-drive-waveforms.jpg|200px|Stepper drive waveforms.]]

Contrast stepping with microstepping. The microstepping gives less vibration and smoother movement, and makes it possible to stop between the steps.

[[File:Stepper-drive-MOSFET-timing.jpg|200px|Stepper drive MOSFET timing.]]

MOSFETS take some time to turn on and off. We need to take account of this for optimum performance (or even for to avoid the above failure modes?). See the MOSFET data sheet for exact timings.

=== Method of operation: ===

*Position instructions come to the drive from EMC. These could be step and direction pulses or some more structured data.
*The drive determines target current for each winding.
*The drive uses software [http://en.wikipedia.org/wiki/PID_controller PID] compensation to achieve and maintain those drive currents.
** sensor: voltage induced across sense resistor by the drive current.
** actuator: [http://en.wikipedia.org/wiki/Pulse-width_modulation PWM] of applied voltage between the three normal operation modes.
*The drive determines new target current for next (micro-)step.

=Prior Art=

This design offers a higher power version (up to 75 amps) of a stepper motor controller, and addresses the feedback loop:

http://www.piclist.com/techref/io/stepper/hipwrbp-gm.htm

[[Image:steppermotorcontroller.gif]]

==Comment by Chris Palmer==
That is only part of a driver circuit. The current sense circuit is not shown and it looks like the firmware will have to do the sequencing, current control and microstepping. The LM5101 is not recommended for new designs.

There are more modern chips that you just add external FETs and sense resistors to get a complete microstepping chopper driver. For example: http://www.allegromicro.com/en/Products/Part_Numbers/3986/index.asp

=References=
*RepRap wiki - good references on stepper controllers - [http://reprap.org/wiki/StepperMotor]
*[http://en.wikipedia.org/wiki/Stepper_motor Stepper Motor in Wikipedia]
*[http://www.cs.uiowa.edu/~jones/step/index.html An excellent discussion of concepts]
*Control of DC motors explained - [http://www.tigoe.net/pcomp/code/circuits/motors/controlling-dc-motors]
*Sample stepper motor controlled with Arduino using EasyDriver - [http://translate.google.com/translate?js=n&prev=_t&hl=en&ie=UTF-8&layout=2&eotf=1&sl=pt&tl=en&u=http%3A%2F%2Flusorobotica.com%2Findex.php%2Ftopic%2C106.0.html&act=url]
*Dr. Iguana's open source stepper motor based on a pic microcontroller : http://www.dr-iguana.com/prj_StepperDriver/

=Research=
*[http://www.google.com/search?client=ubuntu&channel=fs&q=stepper+motor&ie=utf-8&oe=utf-8 Google: stepper motor]
*[http://www.google.com/search?client=ubuntu&channel=fs&q=stepper+controller+integrated+circuit&ie=utf-8&oe=utf-8 Google: stepper controller integrated circuit]
*[http://www.google.com/search?client=ubuntu&channel=fs&q=stepper+controller+chip&ie=utf-8&oe=utf-8 Google: stepper controller chip]
*[http://www.google.com/search?client=ubuntu&channel=fs&q=NEMA+34+stepper+motors&ie=utf-8&oe=utf-8 Google: NEMA 34 stepper motors]

=Development Team=

*[[Leo.dearden]] - Ideas. I'm too busy to do very much at the moment, but I'll do what I can.
*[[Yoonseo Kang]]
*[[Darren Vandervort]]
*[[Stefan Ludwig]]

=See Also=
* [[Stepper Motor]]
* [[Open Source Stepper Motor]]

[[Category:Torch Table]]

Open Source Stepper Motor Controller

2012-06-01T19:49:37Z

ERos: /* Introduction */

{{Category=RepLab Tools}}

'' See also [[Stepper Motor]]'' and see also [[Problem_Statement_for_a_Universal_Power_Supply]]

=Factor e Farm Status=
[[SnapLock CNC]] and [[Open Source Torch Table Prototype II]] are being built in January 2012.
=Introduction=

See [[Open Source Stepper Motor Controller Problem Statement]] as a start.

Stepper motors are the simplest drive for moderate precision motion control applications (such as CNC plasma cutting). They provide the best price:performace for low to moderate mechanical power (<200W) at low to moderate RPM (<500 RPM). There is no open source stepper driver, AFAIK. This project will fill that need.
There are many L297 + L298 based circuits (2.5A 50V). L297 is cheap (~1.5$) but can do only full and half steps. Early repraps used L297+L298 controller. If put more money can use microcontroller like pic16F877 and that route can be cheaper if need six ore more axles. AD pin shortage usually renders microcontroller out, because every motor needs two AD pin for current sense. But microcontroller can handle multiple brush motors with encoders, like some cheap handdrills. That way generate cheap and powerful route to produce multiple axles in EMC controlled robot arm etc.

=Concept=

The output of this project will be a family of general purpose electronic drivers for a variety of electromechanical actuators. The first of them will be a stepper motor driver. With the appropriate alternative firmware (embedded software) the same hardware might be used as a servo driver for a brush-DC servo. With a modified output stage we could drive brushless DC or AC servos, or linear motors.

=Design Rationale=

Adaptability is good. Software is usually easier than hardware. Microprocessors are cheap. Simple circuits are better than complicated ones (other things being equal).

We keep the circuit simple and general, and we implement the control algorithm in software. We can tweak it most easily that way, and even replace it with something totally different.

This design should give good performance, excellent versatility, good replicability, and moderate cost.

=Block Diagram and Modules=

Major functional units:
* Computational logic. An Arduino could be used in the initial prototype, for speed of development. Later versions would want a cost reduced and/or higher performance microprocessor, or an FPGA for minimum latency and maximum bandwidth. The logic must be shielded from electromagnetic interference by the other parts of the system, especially the output drive (and the plasma cutter, if there is one). Independent power and small signal power supplies, and careful grounding, are likely to be needed.
* Fast A/D converters. Allows the logic to monitor the current flowing through the load.
* High power robust drive circuit. N-channel power MOSFETs in an H bridge, with appropriate protection. Select MOSFETs with plenty of current and voltage headroom, and favour ones with built in clamp diodes. A stepper motor is a heavily inductive load, so it can generate voltages substantially outside the supply rails.

[[File:Stepper-drive-block-diagram.jpg|200px|Stepper drive block diagram.]]

[[File:Stepper-drive-H-bridge.jpg|200px|Stepper drive H-bridge.]]

An H-bridge allows the voltage to be applied to the load (to motor winding) in either direction.

[[File:Stepper-drive-schematic-symbols.jpg|200px|Stepper drive schematic symbols.]]

[[File:Stepper-drive-normal-operation.jpg|200px|Stepper drive normal operation.]]

Top row: active current path. Bottom row: Corresponding Current (I) and Voltage (V) graphed against time.

From left to right: Positive applied voltage, rapidly increasing current; No voltage (except due to the resistance of the wires, gradually decreasing current; Negative applied voltage, rapidly falling current.

[[File:Stepper-drive-failure-modes.jpg|200px|Stepper drive failure modes.]]

Shoot-through occurs when both transistors on one side of the H are turned on at the same time. It shorts the rails together and blows the transistors in a few us.

The overvoltage shown occurs when all the transistors are turned off simultaneously while current is flowing. Stopping the current near instantly creates a huge voltage spike. The same effect can occur if a motor lead comes loose while the driver is operating.

[[File:Stepper-drive-waveforms.jpg|200px|Stepper drive waveforms.]]

Contrast stepping with microstepping. The microstepping gives less vibration and smoother movement, and makes it possible to stop between the steps.

[[File:Stepper-drive-MOSFET-timing.jpg|200px|Stepper drive MOSFET timing.]]

MOSFETS take some time to turn on and off. We need to take account of this for optimum performance (or even for to avoid the above failure modes?). See the MOSFET data sheet for exact timings.

=== Method of operation: ===

*Position instructions come to the drive from EMC. These could be step and direction pulses or some more structured data.
*The drive determines target current for each winding.
*The drive uses software [http://en.wikipedia.org/wiki/PID_controller PID] compensation to achieve and maintain those drive currents.
** sensor: voltage induced across sense resistor by the drive current.
** actuator: [http://en.wikipedia.org/wiki/Pulse-width_modulation PWM] of applied voltage between the three normal operation modes.
*The drive determines new target current for next (micro-)step.

=Prior Art=

This design offers a higher power version (up to 75 amps) of a stepper motor controller, and addresses the feedback loop:

http://www.piclist.com/techref/io/stepper/hipwrbp-gm.htm

[[Image:steppermotorcontroller.gif]]

==Comment by Chris Palmer==
That is only part of a driver circuit. The current sense circuit is not shown and it looks like the firmware will have to do the sequencing, current control and microstepping. The LM5101 is not recommended for new designs.

There are more modern chips that you just add external FETs and sense resistors to get a complete microstepping chopper driver. For example: http://www.allegromicro.com/en/Products/Part_Numbers/3986/index.asp

=References=
*RepRap wiki - good references on stepper controllers - [http://reprap.org/wiki/StepperMotor]
*[http://en.wikipedia.org/wiki/Stepper_motor Stepper Motor in Wikipedia]
*[http://www.cs.uiowa.edu/~jones/step/index.html An excellent discussion of concepts]
*Control of DC motors explained - [http://www.tigoe.net/pcomp/code/circuits/motors/controlling-dc-motors]
*Sample stepper motor controlled with Arduino using EasyDriver - [http://translate.google.com/translate?js=n&prev=_t&hl=en&ie=UTF-8&layout=2&eotf=1&sl=pt&tl=en&u=http%3A%2F%2Flusorobotica.com%2Findex.php%2Ftopic%2C106.0.html&act=url]
*Dr. Iguana's open source stepper motor based on a pic microcontroller : http://www.dr-iguana.com/prj_StepperDriver/

=Research=
*[http://www.google.com/search?client=ubuntu&channel=fs&q=stepper+motor&ie=utf-8&oe=utf-8 Google: stepper motor]
*[http://www.google.com/search?client=ubuntu&channel=fs&q=stepper+controller+integrated+circuit&ie=utf-8&oe=utf-8 Google: stepper controller integrated circuit]
*[http://www.google.com/search?client=ubuntu&channel=fs&q=stepper+controller+chip&ie=utf-8&oe=utf-8 Google: stepper controller chip]
*[http://www.google.com/search?client=ubuntu&channel=fs&q=NEMA+34+stepper+motors&ie=utf-8&oe=utf-8 Google: NEMA 34 stepper motors]

=Development Team=

*[[Leo.dearden]] - Ideas. I'm too busy to do very much at the moment, but I'll do what I can.
*[[Yoonseo Kang]]
*[[Darren Vandervort]]
*[[Stefan Ludwig]]

=See Also=
* [[Stepper Motor]]
* [[Open Source Stepper Motor]]

[[Category:Torch Table]]

Aluminum Extractor

2012-06-01T12:14:07Z

ERos: /* Detail */

{{GVCS Header}}

{{Category=Materials}}
[[Category:Chemical_engineering_for_OSE_use]]

[[Image:AluminumExtractor.png|thumb|400px|Aluminum Extractor]]

=Overview=
The Aluminum Extractor extracts raw aluminum from alumina common clay (alumina silicate).

{{Video}}

=Detail=
Using a closed-loop cycle involving hydroflouric acid and a large amount of electricity, it is possible to extract raw aluminum directly from clay deposits. This is in contrast to the typical aluminum extraction technique from strategic bauxite mineral reserves.

There is posibility also produce bauxite from very common feldspar mineral (sand) and carbon dioxide. This is natural process that produce clays, but it is posible to speed up usable level with increasing carbon dioxide partial pressure. Easy source for carbon dioxide are biogas reactors. Biogas cleaning produce large amounts pressurized carbon dioxide water solution. It is even posible to directly feed pressurized biogas through feldspar sand column and combine both process.

Alumium electrolyze process should be combined to localized power grid and its power consume should be tied to grid frequency after 50.5Hz or 60.5hz it should start itself and come full power until 51.0Hz or 61Hz so alumium making can be used to dump excess energy. Very useful combined with windpower.

<html>
<iframe src="https://player.vimeo.com/video/18095549?title=0&byline=0&portrait=0" width="400" height="233" frameborder="0"></iframe>
</html>

=Product Ecology=
{{Product Ecology|

|From=
* {{Induction Furnace}}
* {{Torch Table}}

|Uses=
* [[Power]]

|Creates=
* [[Aluminum]]

|Enables=
* {{Induction Furnace}}
}}

=Components=

=See Also=
*[http://blog.opensourceecology.org/2010/12/open-source-aluminum/ Blog Post]
*[[Metal Refining]]
*[[Aluminosilicate chemistry]]

*[http://en.wikipedia.org/wiki/Aluminium Wikipedia: Aluminum]
*[http://en.wikipedia.org/wiki/Clay Wikipedia: Clay]
*[http://en.wikipedia.org/wiki/Hydrofluoric_acid Wikipedia: Hydroflouric Acid]
*[http://en.wikipedia.org/wiki/Hall%E2%80%93H%C3%A9roult_process Wikipedia:Hall–Héroult process]

{{GVCS Footer}}

Easy pcb making

2012-06-01T11:24:51Z

ERos: Created page with "{{breadcrumb|Digital Fabrication}} == Needs == * You need access for printer or photocopier able to print slides. * You need pcb plate material coated with photoresistive lack o..."

{{breadcrumb|Digital Fabrication}}

== Needs ==
* You need access for printer or photocopier able to print slides.
* You need pcb plate material coated with photoresistive lack or buy such lack from shop.
* you need ferrocloride and 2-5% lye (sodium/potassium ok)
* you need lamp. Spot style is better than pipe. Some old mercury steet light is fine.

== Method ==
Print/copy circuit to slides. If ink is weak you can stack several slides to get black enough film.

Get dark room/night, some red lamps don't harm. Open pcb protecting slide. Put slide film on pcb. Some people use glass plate for weight. Put dark cloth or something on film. Put lamp on. When lamp is full warmed take darkening cower off. Keep light on about 5min (400w mercury, 1 meter distance). When time is full shut off lamp. Put board in lye liquids. 5% lye is aggressive, it melt lack almost instantly, 2% give more time. When lack is fine take board and wash it with water. If some parts are missing you can fix it special pen. Put board to ferrocloride solution to melt unwanted copper away.

== Plus/Minus ==
This process is fast (can use big area same time). It is non contact so no wear out tools. Less energy. Needed chemicals are cheap and are posible to manufacture. This is common industrial process to make pcbs.
"Vitamins": Printer, slides. Half vitamins: (currently buy, later maybe own produce), pcb plate, [lye], ferrocloride.
Three step production and every need separate machine (or machine sectors).

== Future ==
* Todo: plans to automate process. Use Mendel to print parts for light chamber etc.
* Method to recycle copper from ferrocloride.
* Plans for pcb plate material production (induction furnace, upcast, rodex machine + rollers to thin copper plate. Glass fiber is best (heat resistive), but cotton/lina/paper works too. Some epoxy or permanent plastics like bakerlite (phenol+urea) for binder.)
* integrate pcb cnc drill.

[[Category: Circuit Board Fabrication]]

Eerin Rosenström

2012-05-28T13:49:22Z

ERos: /* WHY are you motivated to support/develop this work? */

==Team Culturing Information==
Last updated: May 27, 2012

==='''WHO''' are you?===
*''Name'' - Eerin Rosenström
*''Location (city, country)'' - Espoo, Finland
*''Contact Information (email, skype, phone)'' - eerin et woodgas (dot) fi
*''Picture'' - http://www.facebook.com/eerini
*''Introductory Video'' -
*''Resume/CV'' - Inventor

==='''WHY''' are you motivated to support/develop this work?===
*''Do you endorse open source culture?''
Yes it is future. Data should be free. Manufacturing have data side that can/should be shared.

*''Why are you interested in collaborating with us?''
Well, like other opensource, give something get what community creates. So I can benefit if I help. Other side I hate corporates, their stupid leaders etc -> change little bit world today and lot in future.

*''What should happen so that you become more involved with the project?''
I have involved (similiar project) more than twenty years. I like to share data I have collected.

*''What is missing in the project?''
Things are not rock solid foundation (some pure errors, some unpractical step/machines in 50pcs table etc. But it is only slight tweaking). Main idea is correct. Share all manufacturing data. Give freedom (atleast some persons) from corporative economics. Automate manufacturing to free your labour. Spread manufacturing to all parts, nuts etc. and trim to lab suitable carry to moon etc. Free manufacturing give stars to us.

*''What are your suggestions for improvement of the project?''
Iĺl write to wiki when I have time. Robotics, Robotics, Robotics. They give machines, machines make stuff. Labour (we) controll computers and make plans.

==='''WHAT''' are your skills?===

*'''List all of your skills in these areas: Communications - Organizational - Computer Support - Finances - Design - Natural Building - Electronics - Automation - Metallurgy - Engineering - Fabrication - Agriculture - Energy - Architecture - Video/Graphics/Art - PR/Marketing - Education - Construction - Industry - CNC - Chemistry - Product Design - Other'''
Organizational - some union leading, political activity
 Computer Support - have some cpus + cheap energy, but bad net. fifteen years linux user/admin.
 Design - solidworks, qcad, eagle.
 Electronics - basic skils, some analog and digital experience.
 Automation - some experience
 Metallurgy - some alumium casting, more theory than practice.
 Engineering - yes
 Fabrication - lasercut sheetmetal + bend/roll & weld
 Agriculture - ~18ha farmland five years
 Energy - water powerplant, woodgas, windmil theory, CSP theory.
 Architecture - mainly engineering, not artistic aspects
 Education - university, but still ungraduated.
 Construction - lot of things
 Industry - some
 CNC - practicing
 Chemistry - basic theory (university class), I have some books _very_ usefull.
 Product Design - one patented wood gasifier.
 Other - inventor

*''How have you already contributed to the project?''
I have some data + ideas free to share

===HOW can you help?===

*''How are you interested in contributing to the work of GVCS development?''
cnc robotics 1.st priority. 2.nd organize our 50pcs table realistic/usefull things.

*''Can you volunteer to work with us, and if so, how many hours per week?''
0-80. Depends, I need to to other things for money, because I need eat also.

*''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?''
I do for free and use my own time table (which is quite busy now)

*''Are you interested in a [[Dedicated Project Visit]]?
No too distant now. I generate own cell here, but it takes years.

*''Are you interested in purchasing equipment from us to help bootstrap development?''
No, only data should share

*''Are you interested in bidding for consulting/design/prototyping work?''
maybe

*''Are you a [[True Fans|True Fan]]? If not, why not?''
read too little data yet, but usually I am not fan.

*''Would you like to see yourself working with us on a full-time basis?''
Yes and no. I can work for community full time some periods, but it is same time work for my own purposes. But I can usually share what I do so community don't need reinvent it. No leaders so there is no "us". There is only community.
 Only need is to keep things difficult enough so there stay some intelligence border.

*''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 â€“ 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.''
I live too far, but I want produce own freedom cell here. Sharing data spreads this out.

[[Category: Team Culturing]]

User:ERos

2012-05-28T13:36:33Z

ERos:

[Eerin_Rosenström]
blah
bloh

http://opensourceecology.org/wiki/Eerin_Rosenström

User:ERos

2012-05-28T13:29:22Z

ERos:

[Eerin_Rosenström]
blah
bloh

User:ERos

2012-05-28T13:27:26Z

ERos:

[Eerin_Rosenström]
blah

User:ERos

2012-05-28T12:52:31Z

ERos: Created page with "[Eerin_Rosenström]"

[Eerin_Rosenström]