Open Source Ecology - User contributions [en]

Universal Rotor Construction Set

2014-03-02T14:20:35Z

KhalidH: +cat

Concept:

<html><img src="https://docs.google.com/drawings/d/1OBgVCJJKcZpcUn6vGVEf4yqsgmZcrR62xv5ZFzATkB8/pub?w=1000&h=1034"></html>

[https://docs.google.com/a/opensourceecology.org/drawings/d/1OBgVCJJKcZpcUn6vGVEf4yqsgmZcrR62xv5ZFzATkB8/edit edit]

<html><img src="https://docs.google.com/drawings/d/1hHjO1O7WQzxuO3RP0n190edmX4r0evFNC6kH_Y2pR_s/pub?w=700&h=500"></html>

[https://docs.google.com/a/opensourceecology.org/drawings/d/1hHjO1O7WQzxuO3RP0n190edmX4r0evFNC6kH_Y2pR_s/edit edit]

[[category:Universal Rotor]]

Category:Universal Rotor

2014-03-02T14:20:11Z

KhalidH: Created page with "Universal Rotor Category"

Universal Rotor Category

Category:Design Sprint

2013-12-29T23:32:12Z

KhalidH:

Design Sprint category
[[Category:GVCS]]

Category:Design Sprint

2013-12-29T23:31:45Z

KhalidH: +cat

Design Sprint category
[[Category:Design Sprint]]

Category:Design Sprint

2013-12-29T23:30:20Z

KhalidH: Created page with "Design Sprint category"

Design Sprint category

Design Sprint FAQ

2013-12-29T23:29:43Z

KhalidH:

==What is a Design Sprint?==

Design Sprints are Open Source Ecology's rapid, remote collaboration events. Right now, we are building out 6 of our open source Global Village Construction Set machines in 60 days. See video introduction:

<html><iframe width="560" height="315" src="https://www.youtube.com/embed//EXau4L6Ghk8" frameborder="0" allowfullscreen></iframe></html>

See this 2 minute video for an introduction -
http://www.youtube.com/watch?feature=player_embedded&v=EXau4L6Ghk8

==How do I join the Design Sprint?==
*Complete the [[Tech Team Culturing Survey]]
*Download [http://www.sketchup.com/ Sketchup] and check out our [[Sketchup Cube Test]] for a quick tutorial

==I'm not familiar with Google Hangout, how do I join a Hangout?==
*Check out our [[Google Hangout Instructional]]. You will need a gmail account to participate in Google Hangout.

==I don't have a Google account, and don't want one, but want to participate.==
*Contact our Technical Community Manager at TechCommunity@opensourceecology.org to coordinate participation.

==I can't participate in the tech check--can I still participate in the Design Sprint?==
*Yes, please do! The purpose of the Friday evening Tech Check/Planning is for those who:

#Would like an opportunity to use Google Hangout before the Sprint.
#Would like to work on/provide an update on a project, but can't make it to the Sprint.
#Would like a head start/task assignment before the Sprint.

==I can't participate at the start time/all day/etc, can I still participate?==
*Yes, please email the Technical Community Manager at TechCommunity@opensourceecology.org to coordinate participation.

==I'm not an engineer, can I still help?==
*Yes, there are tasks applicable to multiple skill levels. From beginner design work, internet research, progamming, to video work, to script writing, to product research, to engineering analysis--we have tasks for any person.

[[Category:Design Sprint]]

Sprint Contributions

2013-12-29T23:29:26Z

KhalidH: +cat

=Introduction=

Designs Sprints allow OSE to harness contributions of various people throughout the world by keeping open boundaries to participation. This log is a record of who has contributed what, such that future activity can leverage these contributions.

=Spreadsheet=

[https://docs.google.com/a/opensourceecology.org/spreadsheet/ccc?key=0ArpE5Y9PpJCXdEl4WVRNYy1rRFNtZU5zdFBpNEZWYXc&usp=drive_web#gid=0 edit]
[[Category:Design Sprint]]

Past Design Sprint Announcements

2013-12-29T23:28:56Z

KhalidH: +cat

<div style="margin-bottom: 2em; padding: .5em 1em; background: #e8f1ff; border: 2px solid #000;">
<p style="text-align:justify; font-size:115%;">'''Design Sprint Announcements'''

*'''13 July 2013''': Agenda--Focusing on the CNC Torch Table, Hydrafabber, Open Source Welder, Agriculture and Mechanics. See plan - [http://opensourceecology.org/wiki/Development_Status_and_Needs#July_13.2C_2013_Plan]. join technical hangout - https://plus.google.com/hangouts/_/23ce6013fb3b49156e00bc929a7c2b5cf6b6ca08?hl=en
*'''6 July 2013''': Agenda--Focusing on the CNC Torch Table, the Lifetrac, the Hydrafabber, the Open Source Car, Documentation & Graphics/UI. See the [https://docs.google.com/document/d/1ZIzR06Cs5G27BfoW66K6f_WZEMbg1wO5EXpQ0RLNfH0/pub Announcement and Schedule] for more detailed information.
</p>
</div>
[[Category:Design Sprint]]

Design Sprint Members

2013-12-29T23:28:35Z

KhalidH: +cat

https://docs.google.com/a/opensourceecology.org/spreadsheet/ccc?key=0Aqfjnh3lOWcCdGNONk5LOUVLNXZQUE1COGp4Z1hUV2c#gid=0

[[Category:Design Sprint]]

3D Printer Workshop

2013-12-29T22:59:27Z

KhalidH: cat

=Introduction=
#Project Title: 3-D Printer Workshop
#Time/Date/Start: March 28-30, 2014
#Location: ?
#Leader: Rob Kirk
#Target Audience: 12 students paying $300 each for 3 days of instruction. Can leave with 3-D printer for an added $700.

'''Measures of Success:'''
#Complete workshop DVD published
#Target audience met or exceeded in number
#90% positive reviews
#Budget was adequate to +/- 10% — no cost over-runs
#Complete procedure results in timely build of 3D printer with no documentation-related build mistakes

'''Milestones:'''

#Conference Evaluations assessed/improvements for next session made
#Conference concluded with 12+ clients @ $300 -- gross $3600+. #Conference Evaluations filled out by participants and organizers.
#3 days of instruction complete—3-D printer constructed
#Students arrive—settle in get food and program details Introductions
#Payment completed and receipted
#Advertising all media sent out
#Workshop organizational and revenue model is documented so others can be trained to run the workshop
#Build instructions complete
#Curriculum completed/evaluations approved and printed
#Curriculum draft complete
#Budget estimate approved by MJ
#Workshop scheduled, and costs estimated, Presenter approved, Budget estimate in hand
#Attend 3-Printer Conference
#Planning for 3-D Workshop/build for March 28

=3D Printer Critical Path=
<html><img src="https://docs.google.com/drawings/d/1kFoUxVkCSfuXphav1jyCIeB4QwWApV4PAzJR-zUdsLQ/pub?w=800&h=600"></html>

[https://docs.google.com/a/opensourceecology.org/drawings/d/1kFoUxVkCSfuXphav1jyCIeB4QwWApV4PAzJR-zUdsLQ/edit edit]

=Milestones and Tasks=

<html><iframe width=100% height='500' frameborder='0' src='https://docs.google.com/spreadsheet/pub?key=0ArpE5Y9PpJCXdEpkZm9jUG45MEdwT19oTVVfWG5SbEE&output=html&widget=true'></iframe></html>

[https://docs.google.com/a/opensourceecology.org/spreadsheet/ccc?key=0ArpE5Y9PpJCXdEpkZm9jUG45MEdwT19oTVVfWG5SbEE&usp=drive_web#gid=0 edit]

*Workshop Design - Jan 10
:*Proposed Workshop Date (March 28-30?) and Location; inquiry on venues?
:*Planning and milestone timeline based on first event, March 28-30. Draw up a Google Doc with timeline on the bottom axis that includes:
:**Milestones, working backwards from March 28-30
:**Expected duration for completion of milestone
:**For each milestone, tasks required
:**Link to the actual work being done from this Master Index - so we can track product readily from this Google Doc
:*3 day outline of curriculum - hour by hour for 3 days - Google Spreadsheet, Text, or Google Drawing
:**4 tracks of education as in World Expo Seminar Tracks?
:**How to go from a physical object to a Scan to a 3D print
:*Open Source Toolchains - Modeling in Sketchup, and toolchain for generating printing files
:**How to work with FreeCAD and Sketchup files
:**How to download and print files; repositories
:**OpenBeam - would be interesting to collaborate with them (I think it's Sam Putnam)
:*Building your own printer (our Main Course)
:*How to document the build - pictures, video (OpenShot)?, video title screens, etc.
:*Logistics for the event, Signup procedure, payments, etc.
:*Documentation Plan - Teaching audience about OSE Documentation
:*How we will capture documentation for improving future workshops?
:*Plan for realtime documentation during build
:*Division between instructional writing, photos, uploads to Dozuki
:*Curriculum Development - Until Feb 15
:**Promotional materials - by Feb 1 to start publicity (2 months lead)
:**Flyer - 1 pager to post electronically on FaceBook
:**Promo Brochure (to go on website) - 2 pages about workshop
:**Promotional video - script - Jan 18
:**Promo video - edit
:**Social Media publicity plan - timeline and venues - Jan 18
:**Instructional Procedure - Feb 1
:**Materials list
:**Dozuki instructional procedure
:**CAD - screenshots
:**Picture
:**Video of assembly
:**Animation video of assembly in Sketchup or FreeCAD
:**Work Flow Design - Feb 7
:**Fabrication diagram - which steps are taken at which time, which in parallel
:**Facility Layout for Production Day
:**Based on number of people - what each person does
:**Financials - Feb 14
:**Costs, budget, accounting
:**Revenue Plan and Breakeven Graph for 3 scenarios - good, expected, and bad for workshop participants
:**Food and venue costs

=Links=
*[[Project Review]]

=Review Comments=
[[category:3D Printer]]

3D Printer Development

2013-12-29T22:58:20Z

KhalidH:

==Overview==
{{3D Printer}} Development

*[[MOSFET Discussion]]

==Update - 9.20.09 ==

Chris of [http://hydraraptor.blogspot.com/2009/07/hydraraptors-second-child.html HydraRaptor] just printed a set of parts for the [[Factor e Farm]] [[RepRap]]. See his [http://hydraraptor.blogspot.com/2009/07/hydraraptors-second-child.html blog post] on the replication.

Here are some additional pictures:

<gallery>
Image:fefrepstrap1.jpg

Image:fefrepstrap2.jpg

Image:fefrepstrap3.jpg

Image:fefrepstrap4.jpg

Image:fefrepstrap5.jpg

</gallery>

=Electronics=

The newest generation of reprap electronics is Generation 3. http://reprap.org/bin/view/Main/Generation3Electronics

Here is Edward, one of our [[True Fans]], holding up the semi-completed Motherboard which he will use to build Factor e Farm's first

RepRap machine:
[[File:Reprap13.jpg]]

The chips come in kits that must be soldered and surface mounted.

[[File:Reprap9.jpg]]

[[File:Reprap7.jpg]]

Here is Edward and a friend working on the Motherboard and Extruder Controller.

[[File:Reprap5.jpg]]

=Sourcing=
[[RepRap Part Sourcing]]

== open questions ==

* Can the RepRap print out a working steam engine? See [[Steam Engine Construction Set]].

=See Also=
*{{3D Printer}}
*[[Digital Fabrication]]
[[Category:3D Printer]]

3D printed beehives

2013-12-29T22:57:26Z

KhalidH:

{{Template:Category=Beekeeping}}

==Proposal==
To make beehives and other beekeeping equipment from plastic by [[Digital Fabrication|digital fabrication]] rather than carving them from wood.

==Rationale==
A billion people are undernourished. Most are subsistence farmers with little money. Finding very cheap ways to enable people to grow more food is therefore the best way to combat malnutrition.

Bees increase the productivity of flowering plants by about one-third. They also produce commercially-valuable substances, like wax, and honey, a very energy-rich food. It would be great to spread beekeeping to malnourished subsistence farmers. What are the costs of doing this?

[http://www.bothar.ie/boVineSpring2009-4.html Bóthar] are quoting €50 per hive. [http://oxfamunwrapped.oxfam.org.hk/Product.php?productid=83&lang=eng Oxfam] quote $200, but this includes training. Commercially-available hives from thorne.co.uk cost £100-200GBP. I suspect that the main component of the cost is the labour needed to craft the hives. (I'll inquire with charities promoting bees to confirm this.)

Enter [[Digital Fabrication|digital fabrication]] - I believe that if we print hives with a [[RepRap]] we can reduce the time and labour by a factor of 100. The only cost is materials (polylactic acid), which should be at most a few bucks per hive.

Extending the idea, supplying RepRaps to small farmers would allow them to effortlessly make their own beekeeping equipment and also earn extra income by selling beehives.

==Potential disadvantages==
There is a small chance that bees won't like the plastics used. This is an open question that can only be settled by experiment. They tolerate styrofoam hives without complaint, so I don't anticipate a problem.

Bees will often cover areas in 'propolis', so the specific material the hive is made of is not that crucial to the bee, except for its insulating characteristics and its capacity for absorption of humidity to keep the climate inside of the beehive acceptable, especially in winter. A good design of the hive could avoid heat-loss through drafts while ensuring sufficient ventilation of humid air.

==To do==
#Draw up CAD files based on these (public domain) designs: [http://www.agf.gov.bc.ca/apiculture/construction.pdf Langstroth hive design] or [http://www.scottishbeekeepers.org.uk/Portals/0/Documents/TDS%20number%204%20national%20hive.pdf National hive design].
#Try one out on some real live bees.

I have a 3d printer and am a beekeeper, some help with the models i will be glad to try this.
[[category:3D Printer]]

Category:3D Printer

2013-12-29T22:55:38Z

KhalidH:

The Main article in this category is [[3D Printer]]
[[category:GVCS]]
[[category:Digital Fabrication]]

Category:3D Printer

2013-12-29T22:54:01Z

KhalidH: +cat

The Main article in this category is [[3D Printer]]
[[category:Digital Fabrication]]

HydraFabber

2013-12-29T22:50:33Z

KhalidH: +cat

See also [[Equipment\HydraFabber]]

See description of HydraFabber in this video -

<html><iframe width="560" height="315" src="https://www.youtube.com/embed//EXau4L6Ghk8" frameborder="0" allowfullscreen></iframe></html>

HydraFabber - after [[HydraRaptor]] - is a portable, multi-headed CNC fabrication machine that can do 3D printing, circuit milling, and laser cutting. It is intended to be a portable machine that can be brought to [[OSE Design Sprint]]s for prototyping. During the sprints, we design machines in [[Sketchup]], and then prototype them by printing out modular parts with a [[3d_printer|3D printer]] and [[Laser_cutter|laser cutter]]. The laser cutter cuts out flat sheets that are folded to make 3D beams and other parts, and these beams form 3D frames and other 3D parts. Then the [[CNC_Machine|circuit mill]] functionality can be used to prototype [[Circuit_boards|circuit boards]], such as controllers for automated machines.

*Please coordinate between [[John Log]], [[Leo Log]], [[Tim Boyd]], and [[Nate Log]] - all work related to [[HydraFabber]].

=Specifications=

==Functional Spec==

* 200x200x120mm mininimum build volume
* Quick change heads with accurate repeatable alignment
* Complete system includes robust carry case
* At most 10 minutes for a competent user to set up or prepare for travel

* Printer
** One material at a time
** heated bed to at least 140C
** reliable extruder
** hot end to at least 245C
** Glass print surface for flatness
*** Optional tape over glass for ABS adhesion
** Fan to cool print
** at least 60mm/s practical print speed (more is better)

* Laser
** 1.5W laser cutter diode

* Circuit mill
** depth of cut control relative to surface of PCB
** easy tool change
** effective quick change PCB holddown

* Folds up into a portable suitcase so it can be brought to design sprints and other events

===Functional Spec Questions===
'''General Comment: study of open source industry standards is our best bet. It appears the 3D printer part is all go. Shapeoko has sold 1500 of their routers - so let's assume they work well enough. Search for laser diode paper cutters on the web. Combine RepRap, Shapeoko - and come up with a design. I could foresee that the Router Module is just 2 reinforcement plates for the sides of the machine to provide rigidity. Perhaps use Shapeoko as base, add a 3D printer head or laser diode head to convert to the other 2 functions? Then we have structure all worked out. Does Shapeoko appear to get us the right accuracy?'''

* Is 1.5w optimum? '''See discussion at [[SLS_Wax_Printer]]. Requirement is anything that cuts paper.'''
* What wavelength? '''That which cuts paper, may have to work with black paper'''
* What laser radiation safety measures (1.5w is plenty to blind)? '''Good question. Let's research industry standards'''
* Fixed laser + moving optics or moving laser? '''Replacement for extruder head on the triple machine'''
* What feed rates would be ideal? '''Need to look at specs of laser diode or other projects'''
* How accurate do we need to be for circuit milling?'''Same performance as Shapeoko'''
* What is our target track pitch? '''What is this'''
** Are we aiming for through hole or SMT? If SMT, then how small (just SOICs or QFNs and BGAs)? '''Same as Shapeoko'''
* Is a Dremel-type spindle good enough? '''Appears so'''
** Noise? '''What kind of noise?'''
** Speed (RPM)? '''5,000 - 35,000'''
** Accuracy (TIR)?
** Mass - is it too heavy?
** Size - is it too big? '''No.'''
* Are there any reasonable off the shelf alternatives to the dremmel? '''Don't know. First prototype with dremel appears sound. Based on Shapeoko.'''
* How hard/expensive would it be to make a good small open source spindle? '''I wouldn't worry about it in the first iteration.'''
* What feed rates would be ideal? '''See Shapeoko'''
* What cutting forces are we going to get? '''I would say 2 lbs of force'''
* How do we hold down the PCB? '''Paper Clamps in first version?'''
* Will the dust from the PCB milling interfere with the 3D printing? '''We will have to get data on that.'''

=Process=

== Quick Route to Functional Prototype ==

Almost any RepRap will fulfil the printer part of the functional spec. The need for quick-change heads without recalibration requires a new head mount that will position the head very repeatably each time it's mounted. A kinematic mount is under development for this purpose.

https://github.com/leodearden/kinematic-mount

[[File:2013-06-09-kinematic-mount-scad-03.jpeg]]
[[File:2013-06-09-kinematic-mount-scad-04.jpeg]]
[[File:2013-06-09-kinematic-mount-scad-05.jpeg]]

The more rigid RepRap the better. A Mendel90, MendelMax, ORD Bot, or TAZ would be particularly suitable.

== Complete design process ==

Start with Window 7, presentation page 2 - concept design.

#Do [[Systems Engineering Breakdown Diagram]]

* Software
** CAD
** CAM/slicing
** Device control
** firmware
* Control Electronics
** Embedded microcontroller
** I/O
*** motor drivers
*** high current digital drivers (fans, heaters, etc)
*** digital inputs (eg: limit switches)
*** analog inputs (eg: thermistors)
* 3 axis positioning robot
** X
** Y
** Z
** Quick change head mount
*** mechanical
*** electrical/electronic
**** ID for head available to controller
** Quick change bed (reversible?)
** fold down mechanism
* heads
** print
** laser
** mill
* beds
** print
** laser
** mill

Diagram to follow.

#Potentially do an interface design that shows how modules fit together
#Then embed the original i3 RepRap STL via an [[STL Viewer]] in the wiki

=Printer Reliability=
*Leo's RepRap Kit had at best 4/5 print success on 8 hour overnight prints. Drift in mechanical calibration, failure of print adhesion, nozzle blockage, filament feed slip, and filament spool tangles are the main cause of failures in long prints.
*For short prints, once print parameters are established for a particular object for a particular printer with a particular material. Once you are dialed in, ~1% failure rate for prints of 1 hour. This is for unambitious - ie, safe zone - prints. Wall thickness safe, fairly thick layers, not too fast, etc.

=Links=
*[[CNC Circuit Mill Spindle]]
*[[Leo Dearden]]
*Opencreators Korean printer - [http://cafe.naver.com/makerfac]
*[[Suitcase 3D Printer]]
*[[Lulzbot]]
*[[RepRap Kit]]
*[RepRap Prusa i3|http://reprap.org/wiki/Prusa_i3]
*[http://www.youtube.com/watch?v=40id30dChnU pursa mendel laser]

[[category:3D Printer]]

Category:Microhouse

2013-12-28T13:12:09Z

KhalidH:

''The main articles in this category are [[OSE Microhouse]] and [[Microhouse]]''

[[Category:Housing and construction]]

Category:Power Cube

2013-12-28T09:29:39Z

KhalidH:

''The main article in this category is [[Power cube]]''

''Definition'' - The Power Cube1 is a universal power unit, and it is a module that can be attached to the [[LifeTrac]], [[Microtrac]], [[Bulldozer]], and Open Source Car (OSCar) platforms. As such, any of these platforms can be used as power sources for other devices, such as workshop tools, power generators, ironworker machines, or any other devices which require a power source. The key to this flexibility is the self-contained nature of the Power Cube, where quick-connect hoses and quick-connect physical mounting allow the Power Cube to be coupled to used with other devices. It has frame-integrated fuel and hydraulic reservoirs. It currently contains an 18 or 27 hp gasoline engine, coupled to a hydraulic pump, and produces fluid flow up to 15 gallons per minute and up to 3000 pounds per square inch (PSI) pressure. It connects to other devices via quick couplers and quick-connect hydraulic hoses. A modern steam engine will be retrofitted as soon as it is developed to allow complete fuel flexibility

''Problem Statement'' – Power machinery and equipment typically uses dedicated engine units, such that a large number of different engines is required to power a large number of powered equipment. The engine unit is the heart of any powered device.

''Solution'' – By decoupling the power unit from a powered device via quick-attach coupling – it is possible to turn a dedicated power unit into a flexible power module. We have shown proof of concept – in that power units can be shared between different machines. This allows for drastic cost reduction in the overall cost of mechanical infrastructures.

[[Category: Energy]]
[[Category: GVCS]]
[[category: modular]]

PowerCube Tools

2013-12-27T22:50:03Z

KhalidH:

===Tools===
*Welder - OSE uses Millermatic 200 series welders, I use a Hobart IronMan
*Angle Grinders - A 4" grinder is good for small grinds and tight spots and a 7" grinder is good for grinding larger areas

*Hand Tools
**Vise Grip pliers - handy for clamping and manipulating steel (very handy with hot steel)
**Crescent wrench - Useful for handling hot steel and tightening bolts
**Socket set - Faster tightening of bolts
**Hammer - Very useful in many instances
**Barrel Crimper (for engine connector)
**Spade crimper (for other connectors)

*Metal Cutting Tools
**Bandsaw - must be metal cutting band saw with ability to cut 45 degree angles
**Cutting Torch - makes rough cuts

*Paint Tools
**Paint Brush
- or -
**Gravity Fed Paint Sprayer
**Air compressor - If using pneumatic tools
[[category:Power Cube]]

Module - Power Cube

2013-12-27T22:49:48Z

KhalidH:

==Module - Power Cube Product Development Board (BETA V.08-13-13)==

<html><iframe width='100%' height='500' frameborder='0' src='https://docs.google.com/spreadsheet/pub?key=0AlCf1fl002zpdG1UQzg1Q3NnX0gzNXRWWnBwSjUzOHc&output=html&widget=true'></iframe></iframe></html>

[https://docs.google.com/a/opensourceecology.org/spreadsheet/ccc?key=0AlCf1fl002zpdG1UQzg1Q3NnX0gzNXRWWnBwSjUzOHc#gid=1 edit/comment]
[[category:Power Cube]]

Assemble Power Cube

2013-12-27T22:49:27Z

KhalidH:

*Weld frame using jig.
*Weld hydraulic tank onto frame, with suction strainer assembly in place. Orientation faces the operator when looking backwards at the Power Cube.
*Weld fuel tank to frame. Orientation is away from operator (safety) on the rear left corner of frame.
*Mount Engine and Pump:
**Trim engine shaft to 2"
**Put hydraulic fittings on hydraulic pump, and connect lovejoy coupler to pump
**[1] Cut plate for Engine Mount - 1/4"x8"x20"?
**[1] Cut plate for hydraulic pump - 1/4"x8"x?
**[1] Cut 1/4"x8"x3"? connecting plate
**[1] Cut 1/4"x2" angle for Power Cube Mount
**Torch engine mount plate pattern- best is plasma cutter
**Torch hydraulic pump mount plate pattern
**Measure distance from bottom of pump to bottom plane of engine
**Use this measurement to determine height of engine mount plate in frame
**Tack weld angle to frame
**Tack weld engine mount plate to hydraulic tank and angle
**Place engine in position
**Attach lovejoy coupler to engine
**Verify that height of engine makes pump stick out 1" above bottom plane of the Power Cube
**Tack weld hydraulic pump plate, and connecting vertical plate
**Take off engine and finish weld the mounting plates
*Attach return line filter assembly
*Attach battery box and holding strap mechanism
*Wire up switch, charging, and battery cables.
*Attach suction hose to pump
*Attach fuel hose from fuel tank barb to inlet of engine
*Attach throttle cable
*Attach filler/breather cap
*Fill engine with engine oil
*Fill fuel tank, verify that there are no leaks

Start engine.

[[Category:Fabrication Procedures]]
[[category:Power Cube]]

Framed PowerCube Module

2013-12-27T22:49:07Z

KhalidH:

[[File:PowerCube Module (15 Jun '13).skp]]

The XYZ is not completely closed off in this drawing because this is what would be removed from the MicroTrac. The tube that is missing from this drawing would be "left behind" as part of the frame of the MicroTrac. The 48" tubes (one on each side) will have to be added as needed in other applications.

For now, There is extra height (4") is left on the design so that if we decide that we want the PowerCube to be removed out of the side of the structural frame instead of out of the top, we have that option of raising the 4' tube up 4".
[[category:Power Cube]]

Mount Power Cube

2013-12-27T22:48:54Z

KhalidH:

*Measure Power Cube and location of mount for tractor
*[2] Drill Mounts – 2 holes on ends each, top and bottom
*Prepare eye - 1/4"x3"x3"
*Transfer punch mount hole locations for top and bottom mount
*Mark mount hole locations on other side of beams
*Weld Mount eye on bottom of Power Cube
*Weld mount eye on bottom Power Cube Mount
*Mag drill holes in frame -
*Mount Power Cube on Tractor

[[Category:Fabrication Procedures]]
[[category:Power Cube]]

Power Cube Mechanical and hydraulic integration

2013-12-27T22:48:41Z

KhalidH:

[http://youtu.be/nNVVfaXQ3W0 Power Cube connection to LifeTrac.]
[[category:Power Cube]]

Power Cube VII Collaborative Production Run

2013-12-27T22:48:27Z

KhalidH:

To Tom G:

Thanks. See review:

http://opensourceecology.org/wiki/Power_Cube_VI_Review

So how would you feel about visiting us for 2 days to do a Collaborative Production Run of Prototype VII?

I propose we get full cad, fab drawings, fab diagram (see CEB blog post) - and full sourcing - and build in 2 days using a crew of 6 plus you as Guest Production Director? We've had 4-day results on the CEB press, not bad, but absolutely unprepared for and it should take 1 day next time with torch table. That's my plan.

=Schedule=

Collaborative Production run is slated for Nov 1-2 at present, Thu-Fri.
[[category:Power Cube]]

Power Cube Tank Welding Procedure

2013-12-27T22:47:52Z

KhalidH:

=Overview=

=Procedure=
#Tack in Hydraulic Tank
#Cut and Tack Tabs (for making tank flush)
#Tack Tank
#Tack Fuel Tank Support
#Tack in the Tank (top of the cap, top of the frame)
#Put in the engine support angle
#Bolt Engine Support Plate
#Place 29" Mount in place and Bolt
#Tack 29" in location, tack perpendicular plates
#Put on Engine.
#Put on Engine Mount Boltsa and tack in place)
#Finish Weld
#Trim Bolts, Mount Engine

==See Also==
[[category:Power Cube]]

Power Cube/Intro Video Script

2013-12-27T22:47:34Z

KhalidH:

The first step in construction of the power cube is to fabricate several parts prior to assembly. Detailed specifications for fabrication of materials for the power cube are available on the Open Source Ecology wiki page Power Cube/Manufacturing Instructions.

If you are planning on constructing multiple power cubes it saves time to first create a jig to use in assembling the power cube frame. The frame on the bottom of the jig keeps the power cube frame square while assembling, and the two upright guides ensure that the vertical sides of the frame under construction are plumb. Angled spacers are inserted tightly into the corners of the jig between the frame during construction. The spacers are then driven out to free the completed power cube frame from the jig.

The frame is constructed out of twelve angle iron pieces tacked and welded together. Position two 29” pieces angle iron on top of two 27” angle pieces. Check that all joints are square, then tack and weld joints. With one welded rectangle on the bottom, position two 24” pieces outside corner joints. Check that the angles are square, then tack and weld. Repeat the procedure and for another half of the frame assembly. Position the two half cubes together, then tack and weld. Inspect all corners to verify secure welds.

The Fuel Tank for the power cube is constructed from a steel tube with two end plates. The welds on the tank must be quality to prevent leaking. Make sure to thoroughly clean the inside of the tank. Pour soapy water over the tank after welding and look for new air bubbles to spot any air leaks. Repeat the process of welding and checking for holes with soapy water until perfection.

The Hydraulic Reservoir also requires careful welding to ensure it is liquid tight. Thoroughly clean the edges of the tube, the inside, and clean grind tank bungs. Tack and weld plates to either end of the tube. Insert the strainer into the flange and make sure it doesn't bottom out. Remove the strainer from the flange, then tack and weld the flange to the tank. Keep the strainer away from the welding and flames, as its thin wires burn easily. Perform a soapy water test on the tank.

Now you can begin to assemble the elements of the power cube inside the frame. Attach the gas tank mount to the frame. Position it so the gas tank will be 3" from the nearest vertical angle iron support. Tack and weld the gas tank to the gas tank mount.

Tack and weld the hydraulic tank to the frame. Cover holes to prevent debris from entering tank while welding. Any debris stuck inside the hydraulic tank will reduce the life of the hydraulic pump.

Tack the 2" x 2" engine support plate to the Hydraulic Tank. Bolt the horizontal engine mount plate to the angle plate. Bolt the vertical engine mount plate to the 29" angle support and set it into the frame so the vertical engine mount plate and the horizontal engine mount plate meet at a 90 degree angle. Weld the 90 degree angle. Unbolt the engine mount assembly from the supports and bolt it onto the engine outside of the cube.

Proper mounting and alignment of the pump is essential for the longevity of the power cube. Bolt the hydraulic pump to the pump mounting plate. Thread one nut on each of the four 3/4" x 4 1/2" bolts and insert the bolts through the holes on the hydraulic pump mounting plate and then put on and tighten the second set of nuts. Put the coupler on the hydraulic pump and tighten set screw. Put the pump and coupler on the engine shaft. With the hydraulic pump properly in place the four bolts will self align against the engine plate. Tighten the set screw on the engine shaft. Align the hydraulic mounting plate so its edges are parallel with the engine plate and weld the four 3/4" bolt heads to the engine plate. The point of using the bolts is to allow for adjustment to line up the engine and pump perfectly. Tack the four bolts to the plate making sure that weld contraction does not misalign the pump and engine. Finish weld the bolts. If the pump and engine are aligned, you should be able to spin the top of the engine with your hands.

Lower the engine assembly into the cube. The engine assembly will rest on the hydraulic tank support angle and the 29" cross support. Bolt into place using two bolts per plate.

Weld the two battery mounts to the frame to form a seat for the battery.

Attach the oil cooler to mounting bars. Tack mounting to the frame. Attach fan to its mounting bars and tack to the frame. When everything fits properly finish weld. You may need to use short bar pieces to space the vertical supports.

Connect the hydraulic suction hose from the barb of the hydraulic tank to the barb inlet of the pump. Use 1" suction hose cut to the proper length. Attach the return line filter and hardwire to the hydraulic cooler.

Next, clamp the keyswitch bracket to the frame and weld in place. Clamp the throttle bracket to the frame in respective position and weld in place.

Weld the solenoid mounting bolts to the hydraulic reservoir. Install the solenoid by securing it on the bolts with two nuts.

Now the power cube can be wired. The keyswitch has spade connectors for wiring and and is tightened with its own nut onto the keyswitch bracket. Install the throttle cable if the engine does not have electronic throttle control.

Mufflers are fabricated and attached to either side of the engine to direct exhaust flow.

Weld the two quick attach plates to the top sides of the frame. Secure at an angle so the opening at the bottom of the angle is approximately 2 1/8" before welding in place. Use solid, strong welds the entire length of the plates, as they will bear the load of the entire power cube.

Prior to painting, check all external surfaces for sharp edges and smooth with angle grinder. Remove any surface rust with wire brush and / or sandpaper. Apply a thorough coating of paint to all steel surfaces. When painting the power cube, cover any place that should not be painted.

For more detailed instructions and diagrams, visit the open source ecology wiki page on power cube manufacturing instructions.
[[category:Power Cube]]

PowerCube Fuel tank

2013-12-27T22:47:12Z

KhalidH:

==Fuel Tank and Mount==

* [2] ¼” x 4” x 8” Plates
* 4” x 8” x 14 ½” Tube
* 1/4" x 3" x 2" dia Black pipe
* ¼” x 2” x 22” Plate

* All welds assembling the tank must be quality welds, as they must not leak. Be careful not to “over weld” the tank to the mount.
* Cut one end of the black pipe at a 30 degree angle for mounting on the plate.
* Place the black pipe on the top plate, center the holes and weld together.
* Clean the inside of the ¼” x 4” x 8” tube and the two ¼” x 4” x 8” plates – anything left on these surfaces will end up in the gasoline and could clog the engine when started. Tack and weld the plates on each end of the tube, taking care to orient the top plate with the filler hole as shown in the diagram below.
* Weld the 1/4” tank flange to the small, lower hole.
* After welding, plug the flange holes and perform a leak test to identify any holes for re-welding

::[[Image:FuelTankTopPlate.png|600px]]

::[[Image:FuelTank.png|500px]]
[[category:Power Cube]]

PowerCube Battery mount

2013-12-27T22:46:55Z

KhalidH:

===Battery mount===

*Weld the two mounts to the angle iron and tank to form a rectangle for the battery as shown below.
::[[Image:PowerCubeAssemblyBatteryMount1.png]]

*After the mount has cooled, lower the battery into the rectangle to verify it fits properly.
[[category:Power Cube]]

PowerCube Electrical cables

2013-12-27T22:46:39Z

KhalidH:

=====Electrical cables=====
*Note: The connectors can be purchased from an auto parts store – be aware that they usually require a crimper to attach to the cables. Alternatively, 3/8” copper tubing can be used in 1 ½” long pieces instead. Strip 1 ½” insulation from the cable, fully insert fully into 1 ½” copper tube, flatten end with a hammer and drill hole.
::[[Image:ElectricalCables.jpg]]
*[2] 11” 1 gauge
*8 ½” 1 gauge
::[[Image:ElectricalCables2.jpg]]
[[category:Power Cube]]

Power Cube 6/Research Development

2013-12-27T22:46:24Z

KhalidH:

=Design Requirements - Dream Checklist=

*O-level access parts replaceability for all parts
*Exhaust must be kept away from hoses
*Muffler must be dismountable by itself
*Control panel does not interfere with hose attachment
*Control panel has screw-down terminals or spade terminals for easy attachment of wires
*Return line does not splash out the breather
*Gas filling is readily accessible
*Gas filling is readily accessible with 2 vertically-stacked power cubes
*Engine does not stick out the top
*
[[category:Power Cube]]

Power Cube Maintenance

2013-12-27T22:46:05Z

KhalidH:

==Hydraulic System Maintenance==
===Safety & Cleanliness===
<ref>[http://hydraulics.eaton.com/products/pdfs/694.pdf Hydraulic Hints and Troubleshooting Guide, Eaton]</ref>
'''Wear your Personal Protective Equipment'''

Hydraulic systems operate under very high pressures. Shut the system down and relieve system pressure before opening any part of the system that is under pressure. Do not allow spray from any high pressure leak to contact any part of the body, as serious injection injuries may result. Pumps, valves and motor may become hot; be cautious of incidental contact between bare skin and hot surfaces. Keep hands and clothing away from moving parts of the system

No grinding or welding operations should be done in the area where hydraulic components are being installed.

All cylinder, valve, pump and hose connections should be sealed and/or capped until just prior to use.

When installing pumps or motors, always align coupling halves as closely as possible, within 0.007 inch.

===Generic===
* ''Any intervention must be carried out with pressure and tension released."
* Check for visible leaks (particularly at connections). Tighten or seal if necessary.
* Check state of hydraulic fluid. Completely replace if deteriorating (sunk color, odor, milky aspect).
* Check hydraulic fluid level. Refill with same viscosity and to same line if necessary.
* If system is to be shut down for a long time, leave hydraulic oil in the circuit.
* Replace hydraulic fluid: every 24 months of use
* Replace hydraulic fluid filters: every 12 months
* Inspect hoses for damage, blisters, leaks or fraying. Replace if necessary.
* Ensure pressure relief valve is not held partially open by contamination.
* Check for corroded or loose fasteners.

===Pump/Motor Maintenance===
Performance parameters:
* suction pressure (Ps)
* discharge pressure (Pd)
* flow (Q)
* pump speed (Nr)
* pumpage properties
* power

Measure power with a clip on amp meter. It's not all that accurate, but it's good for a baseline comparison.

Locate suction and discharge gauges to determine (Ps) and (Pd).
* normal (perpendicular) to the pipe wall
* on centerline of pipe
* in a straight section of pipe
* not in the bottom or top (avoid air and solids)

Measure flow. It's difficult if a permanent flow meter isn't installed.
* insert a pitot tube into the pipe
* use a doppler or transitime device (non-intrusive)
* each measuring device must be calibrated (don't underestimate the importance of this)

Measure vibration
* There is no absolute vibration reading that indicates a problem.
* Since each installation is unique, the best thing to do is take measurements at first power-on and at regular intervals to establish a baseline and trending.
* When possible, measure vibration amplitude at these locations:
motor outboard & inboard bearing housings in vertical & horizontal direction
motor axial direction
pump outboard & inboard bearing housings in vertical & horizontal direction
pump axial direction
* Also record operating mode of whatever is being measured. The vibration will increase as the pump/motor works outside of its Best Efficiency Point (BEP; that is normal.
* Vibration frequency will indicate what is causing the problem while amplitude indicates how bad the problem is. Bearing manufacturers will publish information on bearing defect frequency as a function of bearing speed.

Measure temperature
* Fluid (oil and water) must remain within certain temperature boundaries.
* Bearings must not exceed a certain temperature.

Measure shaft play
* Use a dial indicator, mounted solidly to something that doesn't move in relation to the shaft, to measure how far out of perfect round the shaft is. Anything more than 2 mil/in (0.002in) is unacceptable at any speed. 1 mil/in is acceptable up to about 4,000RPM.

===Fluid Maintenance===
<ref>[http://www.mobil.com/IND/English/Files/tt-hydraulic-system-care-and-maintenance.pdf Hydraulic System Care & Maintenance, Mobil]</ref>
<ref>[http://www.mobil.com/IND/English/Files/tt-the-basics-of-oil-analysis.pdf Basic Oil Analysis, Mobil]</ref>
* Control the temperature
Excessive temperatures will oxidize the oil and can lead to varnish and sludge deposits
Running the temperature too low will allow condensation in the reservoir and increase the likelihood of pump cavitation
Typical industrial hydraulic system temperatures often range between 110 to 150ºF
Keep systems which operate on a water based fluid below 140ºF to prevent the water from evaporating
To allow heat to radiate from the system, keep the outside of the reservoir clean and the surrounding area clear of obstructions
Keep air-cooled radiators free of dirt
Normal temperature drop for most oil coolers is 5 to 10ºF
Reservoirs should be filled to the proper level to allow enough time for the heat to dissipate
* Keep the area clean
Even new systems may be contaminated and should be cleaned before use. Prevent contaminants such as dirt, water, cutting fluids, and metal particles from entering the system around the reservoir cover, openings for suction and drain lines, through breather fill openings, past piston rod packing, and through leaks in pump suction lines.
* Keep the fluid clean
Reservoirs should be filled to the proper level to allow time to shed water and dirt
Deposits caused by oil degradation can plug valves and suction screens and cause high-tolerance servo valves to seize and/or operate sluggishly
To prevent contamination before use, store new fluid in a protected area and dispense it in clean, DEDICATED containers.
Clean the fill cap before removing it to add hydraulic fluid.
Inspect fluid filters frequently and change or clean them before they go into bypass mode.
* Follow an oil analysis program
Contaminants act as a catalyst for wear. This generated wear debris further acts as a catalyst for additional component wear.
With an effective oil analysis program, you can safely increase the standard 1 year interval while at the same time provide yourself with an “early warning” of possible mechanical problems.
At minimum, check your critical and large volume hydraulic systems at least annually by oil analysis.
Semi-annual or even quarterly sampling intervals may be required for extremely critical machines

In modern equipment using servo valves, oil degradation can be even more damaging. High pressure (up to 4000 psi), high temperatures, and small reservoirs stress the fluid. With minimal residence time and high pressures, entrained air bubbles can cause extreme localized heating of the hydraulic fluid. This results in nitrogen fixation that, when combined with oil oxidation, can form deposits which will plug oil filters and cause servo valves to stick.

On critical NC systems, use quick disconnect hoses and filter all oil added to the reservoir through a 5 micron filter.

Portable filters will supplement permanently installed filters and should be constantly rotated from system to system regardless if you think the system requires filtering or not. Systems should be filtered long enough to pass the total volume of oil through the filter at least 10 times. Portable filters should be used when transferring new oil from drums or storage tank to a system — especially for NC machines.

====10 Point Check====
'''Perform weekly'''
1. Check fluid levels. Add oil (if needed) via portable filtration(if available). DO NOT MIX OILS! Use the same oil brand andviscosity grade that is being used in the system.
2. Inspect breather caps, breather filters and fill screens — DO NOT punch holes in screens in order to expedite adding oil.
3. Check filter indicators and/or pressure differential gages.
4. Visually inspect all system hoses, pipes, pipe connections for leaks and frays. Hydraulic fluid leakage is a common problem for industrial systems. Excessive leakage is an environmental and safety hazard, increases waste streams and oil consumption, and, if ignored, canreduce the system capacity enough to overheat the system.
5. Check system temperature via built-in thermometers or hand-held infrared detectors. Normal temperature range for most systems is110-140ºF. If temperatures are high, check cooler operation andrelief valve settings.
6. Visually inspect the inside of the reservoir for signs of aeration (via the fill hole using a flashlight). Aeration is a condition in which discrete bubbles of air are carried along in the stream of oil as it enters the pump. Visual signs of aeration in the reservoir are generally foaming and/or little whirlpools taking small gulps of air into the suction strainer. Causes of aeration include: low fluid levels; airleaks in the suction line; low fluid temperature; fluid is too viscous to release air or maintain suction at the pump; or faulty shaft seals.When air leaks are suspected on the suction line, smotheringthesepoints with oil will usually pinpoint the leaks by creating a markedchange in pump noise. A pump ingesting air sounds as if it weregargling marbles.
7. Listen to the pump for the signs of cavitation. Cavitation is slightly more complicated than aeration, but bares somesimilarities. Cavitation occurs when air is released from the hydraulic oil during momentary depressurization at the pumpsuction and then imploded onto metal surfaces upon discharge.These implosions are extremely destructive to pump surfaces. A cavitating pump will emit a high-pitched whine or scream. Causes of cavitation are the same as those of aeration with the exception of suction side air leaks. How do you discern aeration from cavitation? One way is to install a vacuum gage on the suction side and make sure the pressure is equal too or greater than that prescribed by the pump manufacturer. Foaming in the reservoir is usually the telltale sign of aeration.
8. Inspect a small sample of fluid for color, signs ofcontamination and odor. Keep in mind that visual inspectionis limited in that it will only detect signs of excess contamination.
9. Scan electrically controlled servo valves with an infraredthermometer. High valve and solenoid temperatures(over 150ºF) usually indicate the valve is sticking.
10. Scan the electric drive motor with for housing hot spots and rotor bearing temperatures using an infrared thermometer.

====Change The Fluid====
1. Drain the system while the fluid is hot to keep contaminants in suspension.
2. Empty fluid from cylinders, accumulators and lines that might not drain properly.
3. Mop, siphon, or pump out oil left in the reservoir.
4. Wipe reservoir clean with lint free rags and remove rust and free paint.
5. Replace or clean filter elements and strainers and clean filter housings.
6. Refill the system with new fluid making sure to vent high points.
7. Restart and check system for proper operation.

====Oil Analysis====
1: '''Identify “Mission Critical” Equipment''' It’s not necessary to perform oil analysis on every single lubricated system. Identify critical applications that would seriously jeopardize production if they were to shut down unexpectedly.
2: '''Register Your Equipment''' It is important to have your equipment properly registered with a lab. This supports routine trending and plays a key role in early detection of lubricant or equipment problems. There’s no need for you to decide which tests are appropriate for a particular application because the lab has already established test slates for specific applications.
3: '''Establish Best Practices''' Establish a consistent “how-to” practice for taking oil samples from your equipment and train your maintenance personnel to use this practice. Correct sampling practices are critical to the value received from the analysis data. This extremely important step rarely gets the attention it needs.
4: '''Sample''' Retrieve samples in accordance with your best practice and send them to the lab as soon as possible. Samples that are set aside may deteriorate and give non-representative results.
5: '''Analyze''' A thorough analysis, keyed on trends, helps determine your systems’ conditions.
6: '''Interpret''' Reviewing the results and determining what, if any, action is required can make or break a successful program. It’s important to remember that an alert sample does not necessarily mean imminent failure. Seek consultation on alert samples and re-sample to confirm present data before taking massive corrective action.
7: '''Take Corrective Action and Document, Document, Document!!!''' As always, documentation is the key to knowing where you’ve been and where you’re going. Document corrective actions resulting from oil analysis.

==Mechanical System Maintenance==

===Engine Maintenance===
* Check oil level: every 5 hours
* Change oil and oil filter: after first five hours
* Change oil: every 50 hours or every season (more often if dirty conditions)
* Change oil filter: every 100 hours or every season
* Replace foam air cleaner: every 25 hours or every season
* Replace paper air filter: every 25 hours or every season
* Replace paper air filter w/ foam air cleaner: every 100 hours or every season
* Replace spark plugs: every 100 hours or every season
* Replace fuel filter: every 100 hours or every season
[http://www.briggsandstratton.com/engines/support/maintenance-how-to/Push%20Mower%20Engines/Tune-Up%20Schedule/ schedule from Briggs & Stratton website]

==References==
<references />
[[category:Power Cube]]

Power Cube VIII Collaborative Production Run

2013-12-27T22:45:43Z

KhalidH:

See [[Power Cube 6]] for latest Power Cube Documentation. [[Tom]] is currently building [[Power Cube VII]] - optimizing form factor for ergonomics. The power cube after that is Power Cube VIII. See [[Machine Naming Convention]].

=Date=
*Slated for Sat Nov 9 - Sun Nov 10.
*[[Tom Griffing]] is [[Guest Collaborative Production Run Director]]
==Preparation==
*Lathe up and running for spline coupler
**Tom has a coupler jig
*Lathe gearing via PowerCube + [[6 Spline PTO Motor]]

=BOM=
*How much of http://opensourceecology.org/wiki/Power_Cube_6/Bill_of_Materials is still accurate?

=Fabrication Diagram=

See [[Fabrication Diagram]] explanation.

<html><img src="https://docs.google.com/drawings/pub?id=1KmkEsN6OPySaH11YeaQg51PJVuTzHqHMuWSajwRU8_4&w=900&h=500"></html>

[https://docs.google.com/drawings/d/1KmkEsN6OPySaH11YeaQg51PJVuTzHqHMuWSajwRU8_4/edit edit]

=Fabrication=

Coupler -
<html> <iframe width="300" height="169" src="https://www.youtube.com/embed//GDALEaHXt1g" frameborder="0" allowfullscreen></iframe> </html>
[[category:Power Cube]]

Power Cube Operation and Safety

2013-12-27T22:45:25Z

KhalidH:

=Overiew of Power Cube Operation, Safety, Maintenance, Troubleshooting, and Repair=
<html><iframe width="600" height="335" src="https://www.youtube.com/embed//HTNZdu0mMdc" frameborder="0" allowfullscreen></iframe>
</html>

=Warnings=
* Never force a hydraulic connection that doesn't seem to fit.
* Use only fasteners of the proper size.
* Beware of corroded, loose or missing fasteners.
* Do not operate hydraulics below minimum rated flow.
* Do not open vent or drain valves while system is pressurized.
* Lock out power before working on system.
* Use proper lifting and support equipment to avoid injury.
* Properly decontaminate skin, clothing and tools.
[[category:Power Cube]]

Power Cube VII Surplus Center Order

2013-12-27T22:43:02Z

KhalidH:

*Notes: 3/4 couplers - need to be more than 12 gpm because pump is 14 gpm. Use 3/4" couplers from Dalton Hydraulics instead.
*Got a spare starter solenoid.

[[Image:pcVIISCorder.jpg]]
[[category:Power Cube]]

Mounted Power Cube VI

2013-12-27T22:42:44Z

KhalidH:

<html><iframe width="420" height="315" src="https://www.youtube.com/embed//crfNzBkeztM" frameborder="0" allowfullscreen></iframe></html>
[[category:Power Cube]]

PowerCube Quick Attach Plates

2013-12-27T22:42:26Z

KhalidH:

===Quick Attach Plates===
*Weld the [2] 3/8” x 4” x 27” plates to the top sides of the frame as shown. Secure at 45 degree angles before welding in place. Use solid, strong welds the entire length of the plates, as they will bear the load of the entire power cube.
::[[Image:QuickAttachMount.png]]
[[category:Power Cube]]

Power Cube VII Steel Order

2013-12-27T22:42:10Z

KhalidH:

=BOM Suggested=

{| class="wikitable" style="text-align: center;"
! Length
! Cross Section
! Description
|-
|26"
|1/8" x 14" x 26"
|Expanded Steel
|-
|14"
|1/8" x 4"
|Plate
|-
|12"
|1" x 1" x 1/8"
|Angle Iron
|-
|5'
|1/4" x 6"
|Plate
|-
|28'
|2" x 2" x 1/4"
|Angle Iron
|-
|13 1/2"
|1/4" x 8"
|Plate
|-
|52"
|1/4" x 6" x 12"
|Rectangular Tube
|-
|52"
|3/8" x 4"
|Plate
|}

=Actual=
*Accounts for standard steel sizes and transportability on back of a 1/2 ton pickup.

{| class="wikitable" style="text-align: center;"
! Length
! Cross Section
! Description
|-
|4'x26" rectangle section
|
|1/8" Expanded Steel
|-
|10'
|1/4" x 6"
|Plate
|-
|60' in 10' sections
|2" x 2" x 1/4"
|Angle Iron
|-
|10'
|1/4" x 8"
|Plate
|-
|104"
|1/4" x 6" x 12"
|Rectangular Tube
|-
|104"
|3/8" x 4"
|Plate
|}
[[category:Power Cube]]

Power Cube VI Review

2013-12-27T22:41:48Z

KhalidH:

<html><iframe width="420" height="315" src="https://www.youtube.com/embed//hXhiHqCPDCw" frameborder="0" allowfullscreen></iframe></html>

=Operation with 1 Power Cube=
<html><iframe width="420" height="315" src="https://www.youtube.com/embed//X8NAT34Nczw" frameborder="0" allowfullscreen></iframe></html>
=Comments=
[[category:Power Cube]]

Category:Power Cube Documentation

2013-12-27T22:41:27Z

KhalidH:

[[Category:Documentation]]
[[category:Power Cube]]

Power Cube Fabrication PDF

2013-12-27T22:41:00Z

KhalidH:

From Tom Griffing:

[[File:Powercube.pdf]]
[[category:Power Cube]]

Power Cube User Manual

2013-12-27T22:40:44Z

KhalidH:

[[Power Cube Operation and Safety]] - video
[[Power Cube Failure Modes and Troubleshooting]]
[[Power Cube Maintenance]]
[[category:Power Cube]]

Power Cube - Development Board

2013-12-27T22:40:29Z

KhalidH:

<html><iframe width=100% height='400' frameborder='0' src='https://docs.google.com/spreadsheet/pub?key=0ArpE5Y9PpJCXdFV4TnFkRmNaOThCYlVoM3d0Q2NBMmc&output=html&widget=true'></iframe></html>

[https://docs.google.com/a/opensourceecology.org/spreadsheet/ccc?key=0ArpE5Y9PpJCXdFV4TnFkRmNaOThCYlVoM3d0Q2NBMmc#gid=1 edit]
[[category:Power Cube]]

PowerCube Wiring

2013-12-27T22:40:12Z

KhalidH:

===Wiring===
* The keyswitch has spade connectors for wiring and bolts to the frame for stability. These should be connected with matching crimp-on connectors.
::[[Image:keyswitch.jpg]]
* Connect the remaining wires, as in the diagram below:
::[[Image:wiringdiagram.png]]

Wiring Diagrams:
*[http://www.stens.com/images/catalog2/430-249_2_C.jpg Wiring Diagram for Prime Line SBRAI ignition switch]
*[http://www.mytractorforum.com/showthread.php?t=216425 For More Information]
*Terminal letters are decoded as follows:

**B - Battery
**A - Accessory
**R - Regulator
**S - Starter Solenoid
**M - Magneto
**I - Ignition
* Note that the thicker lines represent the heavier wires that will carry high electrical current.

===Operation===
* The Magneto is connected to ground in order to kill the engine
[[category:Power Cube]]

PowerCube Workspace

2013-12-27T22:39:54Z

KhalidH:

=Workspace=

This section describes the various workspace areas that we have found to be useful in fabricating the Power Cube. It is provided as a suggestion for preparing your work area.

*Storage: For tools, parts and raw steel
*Cutting Area: For use with cutting torch - Make if from non-flammable materials
*Welding Table: Prefer steel, suitable for use with arc welder (MIG, TIG, stick, etc)
*Ventilation for cutting / welding areas: Especially when working with galvanized steel
[[category:Power Cube]]

Power Cube Prototype V

2013-12-27T22:39:34Z

KhalidH:

=5th Generation Power Cube=

This latest prototype extends the original Power Cube design in the following ways:

* Briggs & Stratton 49M777 28 HP Professional Series engine
* Automatic choke control
* 12 Volt Electric Start with 16 Amp Alternator
* Spin on engine oil filter
* 5.5 gallon fuel tank
* Heavy duty Prince gear pump
* Rugged 7 gallon hydraulic reservoir
* 10 micron return line spin on filter
* Fan cooled heat exchanger with thermoelectric switch
* 1 year commercial warranty on engine

For sale soon - details will appear on this page.

For more information, contact: [mailto:Tom.Griffing@gmail.com Send E-Mail]
[[category:Power Cube]]

Power Cube Failure Modes and Troubleshooting

2013-12-27T22:38:54Z

KhalidH:

==Hydraulic Pump Failure Modes==

<html>
<iframe width='1500' height='500' frameborder='0' src='https://docs.google.com/spreadsheet/pub?hl=en_US&hl=en_US&key=0AhxtAqPj-B8ndE8xaGF4MmZId2N4TjlTdnBCbjVmemc&output=html&widget=true'></iframe>
</html>

(You can save a copy of this troubleshooting spreadsheet from the [https://docs.google.com/spreadsheet/ccc?key=0AhxtAqPj-B8ndE8xaGF4MmZId2N4TjlTdnBCbjVmemc original Google spreadsheet])

==Hydraulic Pump Troubleshooting==

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<iframe width='1500' height='500' frameborder='0' src='https://docs.google.com/spreadsheet/pub?key=0AhxtAqPj-B8ndFRSRTFsdUZGREk1MXJyeU9uNGFlQlE&output=html&widget=true'></iframe>
</html>

(You can save a copy of this troubleshooting spreadsheet from the [https://docs.google.com/spreadsheet/ccc?key=0AhxtAqPj-B8ndFRSRTFsdUZGREk1MXJyeU9uNGFlQlE original Google spreadsheet])
[[Category:Troubleshooting]]
[[category:Power Cube]]

First Power Cube Sold by Tom Griffing

2013-12-27T22:36:09Z

KhalidH:

Prior to shipping -

[[Image:pc5.jpg]]
[[category:Power Cube]]

PowerCube Frame

2013-12-27T22:35:46Z

KhalidH:

===Power Cube Frame===
*Position two ¼” x 2” x 2” x 29” pieces angle iron on top of two 27” angle pieces as shown below. Check that all joints are square, then tack and weld joints.
::[[Image:PowerCubeAssemblyFrame1.png|300px]]

*With one welded rectangle on the bottom, position two 24” pieces outside corner joints as shown below. Check that the angles are square, then tack and weld. Note: The optional jig makes this much easier and accurate. Repeat the prior procedure and this one for another half of the frame assembly.
::[[Image:PowerCubeAssemblyFrame2.png|300px]]

*Position the two half cubes together, then tack and weld. Inspect all corners to verify secure welds.
::[[Image:PowerCubeAssemblyFrame3.png|300px]]

*Video of frame welding in progress:
::[[Image:FrameWelding.png|link=https://player.vimeo.com/video/28589246]]

*When finished, you'll have frames as shown in the following video:
::{{YoutubePopup|fkxypc0sC4I|big|powercube-window}}
[[category:Power Cube]]

Talk:Power Cube

2013-12-27T22:35:05Z

KhalidH:

http://www.youtube.com/watch?v=eutFKyujC3I - talk about some wiring issues

Do we currently have any CAD drawings for v4 of the power cube? If not, I can help with this using OpenSCAD; just let me know what format I should export to, and where I should add it to the wiki (this page, or a page I haven't found yet which contains all the CADs, etc.).

In the Civilization Starter Kit v0.01 the schematics stack tolerances. In contrast, the diagrams for the Compressed Earth Brick Press (page 43) is measured from the bottom left corner. For those who are not familiar with "stacking tolerances," let me explain what this means and why it is important via an example. On page 231, the diagram in the top left: the height is 8" and the holes on the right are to be at 1" from the top and 1" from the bottom. This would better be documented as an 8" height with holes drilled at 1" from the top and 7" from the top. The reason is that cuts are never perfect, and that's okay as long as they're within tolerance (e.g. as long as they're "close enough"). However, lets say the height is only 7 and 15/16" and the bottom hole is drilled 1 and 1/16" from the bottom. Now instead of being 7" from the top, it is off by 1/8". If these same mistakes were made when taking all measurements from a reference point, it'd only be 1/16" off. Also, the reference point should not be chosen arbitrarily. It should be based on the most important point. It also may not be a corner. For example the ideal reference point on the 8"x8" plate on the right (still on page 231), it might be very important that the large hole is "perfectly" centered between the 4 smaller holes and also centered in the plate. In this case, we'd want to make the center of the 3" hole the reference point.

By the way, none of this affects the design of the cube at all. It is merely a matter of documentation. In fact, for the more advanced people who are familiar with manufacturing concepts like stacking tolerances, they can calculate and measure from a reference point, thus there's no issue at all for these people. Updating the documentation to show the measurements differently would just make it easier for new people and also reduce the risk of people making errors in calculations if they're trying to make all measurements from a reference point.

'''From Aaron:'''

We are preparing to fabricate prototypes of [[Power Cube 6]] - the drawings and models are being drafted right now. Would you be willing to create a wiki page about how to implement and account for tolerances when we create fabrication drawings? A brief tutorial for a draftsperson would be great - you can email me at aaron at opensourceecology.org

[[category:Power Cube]]

Modular Power Cube Frame

2013-12-27T22:34:43Z

KhalidH:

=Introduction=

*Draw up Power Cube - download latest model from [[Tom Griffing]], or use [[Power Cube 6]] download of Sketchup
*Draw plain cube with xyz corners. It is basis for microtractor, see [[6 in 60 Initial 3D Models]]
*Draw 1/4"x4"x4" tubing with 1" holes every 4 inches
*Generate STL file for producing 3D prints with 1/2" tubing and 1/8" holes
**Tubing may be filled, as long as holes are present
*Generate toolpath file for [[Lulzbot]] or [[RepRap Kit]], work with [[Leo Dearden]]
*Share file with Leo and FeF Lulzbot
*Video assembly of the frame into an instructional
*Use 1/8" pegs or bolts for connectors.
*Document all results on this wiki page.
[[category:Power Cube]]