Open Source Ecology - User contributions [en]

Power Cube VII

2013-02-07T04:56:42Z

MrAshley: /* Steps for Instructional Assembly Vidoe Script */

Assembly Video:

<html><iframe src="https://player.vimeo.com/video/55341689?title=0&byline=0&portrait=0&badge=0&color=ffffff" width="500" height="281" frameborder="0" webkitAllowFullScreen mozallowfullscreen allowFullScreen></iframe> <p><a href="http://vimeo.com/55341689">Powercube v7 Assembly.</a> from <a href="http://vimeo.com/opensourceecology">Open Source Ecology</a> on <a href="http://vimeo.com">Vimeo</a>.</p></html>

[[Image:pclight.jpg|500px]]

=Rahul Dhinakaran-Custom Machine Designer - 14 November, 2012=

'''Manufacturing Drawings of some of the PowerCube parts.''' [http://opensourceecology.org/wiki/File:PowerCube_manufacturing_drawings.pdf]

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]].

<html><iframe width="420" height="315" src="https://www.youtube.com/embed//Coaa3GByUQQ" frameborder="0" allowfullscreen></iframe></html>

=Value Proposition=
*'''Power Cube VII marks the next level of modularity in the power cube with quick-connected: engine assembly, pump assembly, hydraulic tank, fuel tank, control panel.''' This is on top of the hydraulic quick connects that allow the power cube to function as a power module for any power equipment in the Global Village Construction Set.
*Date: Sun Nov 11 - Monday Nov 12, 2012.
*[[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]]
*Ordering hose crimping dies from Sweiger
*Getting 2 more [[Millermatic 200]] Welders.

=BOM=
*Using http://opensourceecology.org/wiki/Power_Cube_6/Bill_of_Materials
**Hydraulics, Metal, engine, other, hardware - all good
**Get hose crimper and avoid hoses from Surpluscenter
**<span style="color:red">Need to add 1/4"x2" tank quick attach mounts </span>
*[[Power Cube VII Surplus Center Order]]
*[[Power Cube VII Steel Order]]
*[[27_hp_Briggs_and_Stratton_Engine]]

=Fabrication Diagrams =
See [[Fabrication Diagram]] explanation.

Overview:

<html><img src="https://docs.google.com/drawings/pub?id=1IXDQSA27WpAqFh5GFz8u_sdhBnmEMWsNgSee1UpJ544&w=300&h=200"></html>

[https://docs.google.com/drawings/d/1IXDQSA27WpAqFh5GFz8u_sdhBnmEMWsNgSee1UpJ544/edit edit]

==Overview Diagram==

<html><img src="https://docs.google.com/drawings/pub?id=1KmkEsN6OPySaH11YeaQg51PJVuTzHqHMuWSajwRU8_4&w=700&h=450"></html>

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

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

==Frame==
<html><img src="https://docs.google.com/drawings/pub?id=1VlRCncqfWr7CKJ78d7detJyPD6mvG0ri7UntTCcgeDE&w=480&h=360"></html>

[https://docs.google.com/drawings/d/1VlRCncqfWr7CKJ78d7detJyPD6mvG0ri7UntTCcgeDE/edit edit]

===Notes===
# Use ironworker for mitered cuts
# 3 corners should fit so there is no more than 1/8" space anywhere
# When welding each member check for parallelism and flat planes

'''Notes''': 1 hour 15 minutes to cut all of mitered frame, 2 tank hangers, 4 hanger fingers and 4 spacers, pump mount plate (6"x6"), and to troubleshoot slow cutting on bandsaw and helping Graham align frame welding. Started approximately 10:30 after discussions.

==Engine Mount==
Download [[27 hp Briggs and Stratton Engine]] Manual

<html><img src="https://docs.google.com/drawings/pub?id=1mPI_l_Js4OaAqvSQuPtmpwc7dxnVtnHROR-zTvoTIHM&w=480&h=360"></html>

[https://docs.google.com/drawings/d/1mPI_l_Js4OaAqvSQuPtmpwc7dxnVtnHROR-zTvoTIHM/edit edit]

==Hydraulic Fluid Tank and Fuel Tank==

'''Note on welding from [[Ben Horton]]''': The three "C's" of welding are clean, clean, clean. Tack the entire tank together, then after you clean the work pieces leave a gap between them about 1/6" and fixture the joints so that it is very uniform then weld down hill with minimal torch manipulation (mig). The next thing is to listen you will be able to hear the arc in side the tank as it penetrates. Remember watch the puddle not the arc. With 1/4" material you shouldn't have to stitch weld it but move from joint to joint opposite the one prior. Call me if you have questions. '''Results'''- Using above procedure, I welded the fuel tank (1/4" steel, so easy on High-4, 70 wire speed, [[Millermatic 200]]) on first pass (except for filler cap, which is sheet metal)! That's a first, as I always had at least one pinhole leak, and about 8-10 at worst in prior production runs. For the end caps - grind edge + top and bottom around edge to 3/8" away from edge, with no factory scale on metal - just clean shiny metal. Grind edges of 6"x12" tube also 3/8" from edge. If cut by bandsaw (our case)

<html><img src="https://docs.google.com/drawings/pub?id=136i_LHjaeS5gkVad3xEZl9ebXpYYUutvhcx6RuJgzNg&w=700&h=500"></html>

[https://docs.google.com/drawings/d/136i_LHjaeS5gkVad3xEZl9ebXpYYUutvhcx6RuJgzNg/edit edit]

Instructions:
#Cut stock 6x12" tube into [2] 25" sections
#Cut End Plates on Ironworker
#Weld quick connect hangers at ______" above bottom

Fuel Tank:
#Torch out hole for fuel tank
#Drill 7/16" hole for tapping a 1/4" fuel connection
#Tap 1/4" NPT hole for fuel barb

Hydraulic Tank:
#Torch out all bungs
##Suction on side
##Sight gauge on side
##Filler
##Case Drain
##Return line filter

Both:
#Weld end caps

=Diagrams=

==Hydraulics Diagram==

<html><img src="https://docs.google.com/drawings/pub?id=12KjXSTFw8w9ThfdXFT1XaH91UX5_z5S5jqFkT8ooZ_I&w=480&h=360"></html>

[https://docs.google.com/drawings/d/12KjXSTFw8w9ThfdXFT1XaH91UX5_z5S5jqFkT8ooZ_I/edit edit]

==Electrical Diagram==
::[[File:PC6_Wiring_FAB.png|Wiring Diagram|600px]]

[[File: power7elec1.jpg|200px]]
[[File: power7elec2.jpg|200px]]
[[File: power7elec3.jpg|200px]]
[[File: power7elec4.jpg|200px]]

[[File: power7elec5.jpg|200px]]
[[File: power7elec6.jpg|200px]]
[[File: power7elec7.jpg|200px]]

==Resolving Correct Labeling on Key Switch==
Note: Convention on back of key switch. M and B have different label on the metal stud - I am assuming we go by the label imprinted in the plastic.

<html><img src="https://docs.google.com/drawings/pub?id=14sKP8bw0pvIXgpXrXbzYvp6MmNKw-dqUMjk7FDI4ky4&w=300&h=200"></html>

[https://docs.google.com/drawings/d/14sKP8bw0pvIXgpXrXbzYvp6MmNKw-dqUMjk7FDI4ky4/edit edit]

*Verification of wiring from Tom - Metal tab / plastic / Connection
**C / M / Magneto
**S / S / starter
**" " / B / Battery
**G / G / Ground
**L / L / Lights

=Power HyperCube VII=

HyperCube for Hypermodularity. Concept:

*Quick attach tanks
*Quick-attach, self-contained engine unit with engine controls - disconnectable by 2 large bolts
*Quick-attach hydraulic pump unit - disconnectable via 2 bolts

<html><img src="https://docs.google.com/drawings/pub?id=1YYZBY_p2aQgqtSqWPkUsxobEfX67Edc_B75mfpW6R_g&w=480&h=360"></html>

[https://docs.google.com/drawings/d/1YYZBY_p2aQgqtSqWPkUsxobEfX67Edc_B75mfpW6R_g/edit edit]

==Quick Connect Plate for Power Cube Pump Detail==

<html><img src="https://docs.google.com/drawings/pub?id=1NWPOwqrX-lcUZzmg073TT0rtvWSU3PkZUCa2_EOpWTM&w=480&h=360"></html>

[https://docs.google.com/drawings/d/1NWPOwqrX-lcUZzmg073TT0rtvWSU3PkZUCa2_EOpWTM/edit edit]

=Fabrication=

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

<iframe width="420" height="315" src="https://www.youtube.com/embed//WgdjabT8738" frameborder="0" allowfullscreen></iframe>

Rubber Vibration Mounts

<iframe width="420" height="315" src="https://www.youtube.com/embed//p9h8YgQZDEI" frameborder="0" allowfullscreen></iframe>

Wiring Harness:

<iframe width="420" height="315" src="https://www.youtube.com/embed//eLLylgc73sI" frameborder="0" allowfullscreen></iframe>

Hydraulic Cooler:

<iframe width="420" height="315" src="https://www.youtube.com/embed//iwBNc46jN_M" frameborder="0" allowfullscreen></iframe>

Battery Terminals:

<iframe width="420" height="315" src="https://www.youtube.com/embed//pn9nxd9DBr0" frameborder="0" allowfullscreen></iframe>

Engine Connections:

<iframe width="420" height="315" src="https://www.youtube.com/embed//v8aDXRBKHKw" frameborder="0" allowfullscreen></iframe>

Hydraulic Sight Gauge:

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

Hydraulic Pump and Coupler:

<iframe width="420" height="315" src="https://www.youtube.com/embed//WgdjabT8738" frameborder="0" allowfullscreen></iframe>
</html>

=Power Cube Assembly Video Script=
==Steps for Instructional Assembly Video Script==
<html><iframe width='100%' height='300' frameborder='0' src='https://docs.google.com/spreadsheet/pub?key=0Av4ZjQn4DHJHdFVVekI0NWxuMlBpS3VQRGU2UnFYeVE&output=html&widget=true'></iframe></html>

=Research=
*Mechanical shaft quick coupling patent - [http://www.google.com/patents?id=JOU1AAAAEBAJ&pg=PA2&source=gbs_selected_pages&cad=4#v=onepage&q&f=false]

Power Cube VII

2013-02-07T04:55:46Z

MrAshley: /* Value Proposition */

Assembly Video:

<html><iframe src="https://player.vimeo.com/video/55341689?title=0&byline=0&portrait=0&badge=0&color=ffffff" width="500" height="281" frameborder="0" webkitAllowFullScreen mozallowfullscreen allowFullScreen></iframe> <p><a href="http://vimeo.com/55341689">Powercube v7 Assembly.</a> from <a href="http://vimeo.com/opensourceecology">Open Source Ecology</a> on <a href="http://vimeo.com">Vimeo</a>.</p></html>

[[Image:pclight.jpg|500px]]

=Rahul Dhinakaran-Custom Machine Designer - 14 November, 2012=

'''Manufacturing Drawings of some of the PowerCube parts.''' [http://opensourceecology.org/wiki/File:PowerCube_manufacturing_drawings.pdf]

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]].

<html><iframe width="420" height="315" src="https://www.youtube.com/embed//Coaa3GByUQQ" frameborder="0" allowfullscreen></iframe></html>

=Value Proposition=
*'''Power Cube VII marks the next level of modularity in the power cube with quick-connected: engine assembly, pump assembly, hydraulic tank, fuel tank, control panel.''' This is on top of the hydraulic quick connects that allow the power cube to function as a power module for any power equipment in the Global Village Construction Set.
*Date: Sun Nov 11 - Monday Nov 12, 2012.
*[[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]]
*Ordering hose crimping dies from Sweiger
*Getting 2 more [[Millermatic 200]] Welders.

=BOM=
*Using http://opensourceecology.org/wiki/Power_Cube_6/Bill_of_Materials
**Hydraulics, Metal, engine, other, hardware - all good
**Get hose crimper and avoid hoses from Surpluscenter
**<span style="color:red">Need to add 1/4"x2" tank quick attach mounts </span>
*[[Power Cube VII Surplus Center Order]]
*[[Power Cube VII Steel Order]]
*[[27_hp_Briggs_and_Stratton_Engine]]

=Fabrication Diagrams =
See [[Fabrication Diagram]] explanation.

Overview:

<html><img src="https://docs.google.com/drawings/pub?id=1IXDQSA27WpAqFh5GFz8u_sdhBnmEMWsNgSee1UpJ544&w=300&h=200"></html>

[https://docs.google.com/drawings/d/1IXDQSA27WpAqFh5GFz8u_sdhBnmEMWsNgSee1UpJ544/edit edit]

==Overview Diagram==

<html><img src="https://docs.google.com/drawings/pub?id=1KmkEsN6OPySaH11YeaQg51PJVuTzHqHMuWSajwRU8_4&w=700&h=450"></html>

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

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

==Frame==
<html><img src="https://docs.google.com/drawings/pub?id=1VlRCncqfWr7CKJ78d7detJyPD6mvG0ri7UntTCcgeDE&w=480&h=360"></html>

[https://docs.google.com/drawings/d/1VlRCncqfWr7CKJ78d7detJyPD6mvG0ri7UntTCcgeDE/edit edit]

===Notes===
# Use ironworker for mitered cuts
# 3 corners should fit so there is no more than 1/8" space anywhere
# When welding each member check for parallelism and flat planes

'''Notes''': 1 hour 15 minutes to cut all of mitered frame, 2 tank hangers, 4 hanger fingers and 4 spacers, pump mount plate (6"x6"), and to troubleshoot slow cutting on bandsaw and helping Graham align frame welding. Started approximately 10:30 after discussions.

==Engine Mount==
Download [[27 hp Briggs and Stratton Engine]] Manual

<html><img src="https://docs.google.com/drawings/pub?id=1mPI_l_Js4OaAqvSQuPtmpwc7dxnVtnHROR-zTvoTIHM&w=480&h=360"></html>

[https://docs.google.com/drawings/d/1mPI_l_Js4OaAqvSQuPtmpwc7dxnVtnHROR-zTvoTIHM/edit edit]

==Hydraulic Fluid Tank and Fuel Tank==

'''Note on welding from [[Ben Horton]]''': The three "C's" of welding are clean, clean, clean. Tack the entire tank together, then after you clean the work pieces leave a gap between them about 1/6" and fixture the joints so that it is very uniform then weld down hill with minimal torch manipulation (mig). The next thing is to listen you will be able to hear the arc in side the tank as it penetrates. Remember watch the puddle not the arc. With 1/4" material you shouldn't have to stitch weld it but move from joint to joint opposite the one prior. Call me if you have questions. '''Results'''- Using above procedure, I welded the fuel tank (1/4" steel, so easy on High-4, 70 wire speed, [[Millermatic 200]]) on first pass (except for filler cap, which is sheet metal)! That's a first, as I always had at least one pinhole leak, and about 8-10 at worst in prior production runs. For the end caps - grind edge + top and bottom around edge to 3/8" away from edge, with no factory scale on metal - just clean shiny metal. Grind edges of 6"x12" tube also 3/8" from edge. If cut by bandsaw (our case)

<html><img src="https://docs.google.com/drawings/pub?id=136i_LHjaeS5gkVad3xEZl9ebXpYYUutvhcx6RuJgzNg&w=700&h=500"></html>

[https://docs.google.com/drawings/d/136i_LHjaeS5gkVad3xEZl9ebXpYYUutvhcx6RuJgzNg/edit edit]

Instructions:
#Cut stock 6x12" tube into [2] 25" sections
#Cut End Plates on Ironworker
#Weld quick connect hangers at ______" above bottom

Fuel Tank:
#Torch out hole for fuel tank
#Drill 7/16" hole for tapping a 1/4" fuel connection
#Tap 1/4" NPT hole for fuel barb

Hydraulic Tank:
#Torch out all bungs
##Suction on side
##Sight gauge on side
##Filler
##Case Drain
##Return line filter

Both:
#Weld end caps

=Diagrams=

==Hydraulics Diagram==

<html><img src="https://docs.google.com/drawings/pub?id=12KjXSTFw8w9ThfdXFT1XaH91UX5_z5S5jqFkT8ooZ_I&w=480&h=360"></html>

[https://docs.google.com/drawings/d/12KjXSTFw8w9ThfdXFT1XaH91UX5_z5S5jqFkT8ooZ_I/edit edit]

==Electrical Diagram==
::[[File:PC6_Wiring_FAB.png|Wiring Diagram|600px]]

[[File: power7elec1.jpg|200px]]
[[File: power7elec2.jpg|200px]]
[[File: power7elec3.jpg|200px]]
[[File: power7elec4.jpg|200px]]

[[File: power7elec5.jpg|200px]]
[[File: power7elec6.jpg|200px]]
[[File: power7elec7.jpg|200px]]

==Resolving Correct Labeling on Key Switch==
Note: Convention on back of key switch. M and B have different label on the metal stud - I am assuming we go by the label imprinted in the plastic.

<html><img src="https://docs.google.com/drawings/pub?id=14sKP8bw0pvIXgpXrXbzYvp6MmNKw-dqUMjk7FDI4ky4&w=300&h=200"></html>

[https://docs.google.com/drawings/d/14sKP8bw0pvIXgpXrXbzYvp6MmNKw-dqUMjk7FDI4ky4/edit edit]

*Verification of wiring from Tom - Metal tab / plastic / Connection
**C / M / Magneto
**S / S / starter
**" " / B / Battery
**G / G / Ground
**L / L / Lights

=Power HyperCube VII=

HyperCube for Hypermodularity. Concept:

*Quick attach tanks
*Quick-attach, self-contained engine unit with engine controls - disconnectable by 2 large bolts
*Quick-attach hydraulic pump unit - disconnectable via 2 bolts

<html><img src="https://docs.google.com/drawings/pub?id=1YYZBY_p2aQgqtSqWPkUsxobEfX67Edc_B75mfpW6R_g&w=480&h=360"></html>

[https://docs.google.com/drawings/d/1YYZBY_p2aQgqtSqWPkUsxobEfX67Edc_B75mfpW6R_g/edit edit]

==Quick Connect Plate for Power Cube Pump Detail==

<html><img src="https://docs.google.com/drawings/pub?id=1NWPOwqrX-lcUZzmg073TT0rtvWSU3PkZUCa2_EOpWTM&w=480&h=360"></html>

[https://docs.google.com/drawings/d/1NWPOwqrX-lcUZzmg073TT0rtvWSU3PkZUCa2_EOpWTM/edit edit]

=Fabrication=

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

<iframe width="420" height="315" src="https://www.youtube.com/embed//WgdjabT8738" frameborder="0" allowfullscreen></iframe>

Rubber Vibration Mounts

<iframe width="420" height="315" src="https://www.youtube.com/embed//p9h8YgQZDEI" frameborder="0" allowfullscreen></iframe>

Wiring Harness:

<iframe width="420" height="315" src="https://www.youtube.com/embed//eLLylgc73sI" frameborder="0" allowfullscreen></iframe>

Hydraulic Cooler:

<iframe width="420" height="315" src="https://www.youtube.com/embed//iwBNc46jN_M" frameborder="0" allowfullscreen></iframe>

Battery Terminals:

<iframe width="420" height="315" src="https://www.youtube.com/embed//pn9nxd9DBr0" frameborder="0" allowfullscreen></iframe>

Engine Connections:

<iframe width="420" height="315" src="https://www.youtube.com/embed//v8aDXRBKHKw" frameborder="0" allowfullscreen></iframe>

Hydraulic Sight Gauge:

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

Hydraulic Pump and Coupler:

<iframe width="420" height="315" src="https://www.youtube.com/embed//WgdjabT8738" frameborder="0" allowfullscreen></iframe>
</html>

=Power Cube Assembly Video Script=
==Steps for Instructional Assembly Vidoe Script==
<html><iframe width='100%' height='300' frameborder='0' src='https://docs.google.com/spreadsheet/pub?key=0Av4ZjQn4DHJHdFVVekI0NWxuMlBpS3VQRGU2UnFYeVE&output=html&widget=true'></iframe></html>

=Research=
*Mechanical shaft quick coupling patent - [http://www.google.com/patents?id=JOU1AAAAEBAJ&pg=PA2&source=gbs_selected_pages&cad=4#v=onepage&q&f=false]