CEB 4 design planning - Revision history

Marcin: /* Press Foot- P3 vs. "piston" type */

2012-06-22T17:04:35Z

Press Foot- P3 vs. "piston" type

← Older revision		Revision as of 17:04, 22 June 2012
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	*More parts to fab		*More parts to fab
	*supposedly longer fabrication time (according to marcin)		*supposedly longer fabrication time (according to marcin)
			*Does not follow industry standard for best proprietary vertical machine on the market (AECT)

	==Hopper Changes==		==Hopper Changes==

Zdwiel: typo

2012-06-22T17:01:25Z

typo

← Older revision		Revision as of 17:01, 22 June 2012
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	General design is intended to be one where we assume the availability of a CNC Torch table for rapid fabrication. The machine is intended to be producible as a kit. It is designed to be collapsable into a 3x3x6 foot crate for ease of shipping. Welding is minimized to allow quick fixing via disassembly - with modular, easy-to-source parts. The intent of bolt-together structure is to facilitate fabrication. We are determining whether the fabrication time can be brought down from about 50 hours per machine, excluding electronics, to approximately 25 hour per machine. To achieve this, we aim to cut most parts on a torch table, followed by bolting together, so that a user can receive a kit and put it together like IKEA furniture. Since bolting is quicker than welding - under the assumption that a CNC torch table produces accurate pieces - bolts are favored over welding wherever possible. This is different than standard custom fabrication practice, but it is intended to produce superior results in terms of lifetime design and ease of fabrication. We are exploring the feasibility of production straight from a CNC plasma torch table + welding to a finished, replicable product that can be sold directly as a kit without the producer needing to assemble the machine at all. To achieve this, we are aiming for strict quality control to allow all components to fit together with 99.9% success rate for each machine - such that only 1 of 1000 components of the ~100 components per machine needs to be recut.		General design is intended to be one where we assume the availability of a CNC Torch table for rapid fabrication. The machine is intended to be producible as a kit. It is designed to be collapsable into a 3x3x6 foot crate for ease of shipping. Welding is minimized to allow quick fixing via disassembly - with modular, easy-to-source parts. The intent of bolt-together structure is to facilitate fabrication. We are determining whether the fabrication time can be brought down from about 50 hours per machine, excluding electronics, to approximately 25 hour per machine. To achieve this, we aim to cut most parts on a torch table, followed by bolting together, so that a user can receive a kit and put it together like IKEA furniture. Since bolting is quicker than welding - under the assumption that a CNC torch table produces accurate pieces - bolts are favored over welding wherever possible. This is different than standard custom fabrication practice, but it is intended to produce superior results in terms of lifetime design and ease of fabrication. We are exploring the feasibility of production straight from a CNC plasma torch table + welding to a finished, replicable product that can be sold directly as a kit without the producer needing to assemble the machine at all. To achieve this, we are aiming for strict quality control to allow all components to fit together with 99.9% success rate for each machine - such that only 1 of 1000 components of the ~100 components per machine needs to be recut.

	For the ~~electro*nics~~, we are streamlining controller production to approximately 3 hours per machine starting from raw circuit boards, followed by milling on a [[CNC Circuit Mill]], followed by populating with components and assembling a controller box with sensors, in a time under 6 hours per controller. This time should be reduced to under 5 hours per controller with ready-made controller boards.		For the electronics, we are streamlining controller production to approximately 3 hours per machine starting from raw circuit boards, followed by milling on a [[CNC Circuit Mill]], followed by populating with components and assembling a controller box with sensors, in a time under 6 hours per controller. This time should be reduced to under 5 hours per controller with ready-made controller boards.

	'''BK:''' Bolt-together doesn't necessarily facilitate fabrication. I would argue bolting often takes far more time than welding. You have to make a minimum of 2 holes, often in difficult to access locations, line them up, and then insert a bolt. Welding will often take less time and will make it easier in Kit form, as less asssembly will be required. '''For Example:''' In mounting the hopper, P3 had bolt on supports on the back of the hopper. This was time consuming because the bolt needs to go close to the bottom, and you are bolting to a large piece. If the supports are welded, you can simply put the hopper onto the frame without any extra work.		'''BK:''' Bolt-together doesn't necessarily facilitate fabrication. I would argue bolting often takes far more time than welding. You have to make a minimum of 2 holes, often in difficult to access locations, line them up, and then insert a bolt. Welding will often take less time and will make it easier in Kit form, as less asssembly will be required. '''For Example:''' In mounting the hopper, P3 had bolt on supports on the back of the hopper. This was time consuming because the bolt needs to go close to the bottom, and you are bolting to a large piece. If the supports are welded, you can simply put the hopper onto the frame without any extra work.

Bkufa at 15:52, 22 June 2012

2012-06-22T15:52:42Z

← Older revision		Revision as of 15:52, 22 June 2012
Line 5:		Line 5:
	General design is intended to be one where we assume the availability of a CNC Torch table for rapid fabrication. The machine is intended to be producible as a kit. It is designed to be collapsable into a 3x3x6 foot crate for ease of shipping. Welding is minimized to allow quick fixing via disassembly - with modular, easy-to-source parts. The intent of bolt-together structure is to facilitate fabrication. We are determining whether the fabrication time can be brought down from about 50 hours per machine, excluding electronics, to approximately 25 hour per machine. To achieve this, we aim to cut most parts on a torch table, followed by bolting together, so that a user can receive a kit and put it together like IKEA furniture. Since bolting is quicker than welding - under the assumption that a CNC torch table produces accurate pieces - bolts are favored over welding wherever possible. This is different than standard custom fabrication practice, but it is intended to produce superior results in terms of lifetime design and ease of fabrication. We are exploring the feasibility of production straight from a CNC plasma torch table + welding to a finished, replicable product that can be sold directly as a kit without the producer needing to assemble the machine at all. To achieve this, we are aiming for strict quality control to allow all components to fit together with 99.9% success rate for each machine - such that only 1 of 1000 components of the ~100 components per machine needs to be recut.		General design is intended to be one where we assume the availability of a CNC Torch table for rapid fabrication. The machine is intended to be producible as a kit. It is designed to be collapsable into a 3x3x6 foot crate for ease of shipping. Welding is minimized to allow quick fixing via disassembly - with modular, easy-to-source parts. The intent of bolt-together structure is to facilitate fabrication. We are determining whether the fabrication time can be brought down from about 50 hours per machine, excluding electronics, to approximately 25 hour per machine. To achieve this, we aim to cut most parts on a torch table, followed by bolting together, so that a user can receive a kit and put it together like IKEA furniture. Since bolting is quicker than welding - under the assumption that a CNC torch table produces accurate pieces - bolts are favored over welding wherever possible. This is different than standard custom fabrication practice, but it is intended to produce superior results in terms of lifetime design and ease of fabrication. We are exploring the feasibility of production straight from a CNC plasma torch table + welding to a finished, replicable product that can be sold directly as a kit without the producer needing to assemble the machine at all. To achieve this, we are aiming for strict quality control to allow all components to fit together with 99.9% success rate for each machine - such that only 1 of 1000 components of the ~100 components per machine needs to be recut.

	For the ~~electronics~~, we are streamlining controller production to approximately 3 hours per machine starting from raw circuit boards, followed by milling on a [[CNC Circuit Mill]], followed by populating with components and assembling a controller box with sensors, in a time under 6 hours per controller. This time should be reduced to under 5 hours per controller with ready-made controller boards.		For the electro*nics, we are streamlining controller production to approximately 3 hours per machine starting from raw circuit boards, followed by milling on a [[CNC Circuit Mill]], followed by populating with components and assembling a controller box with sensors, in a time under 6 hours per controller. This time should be reduced to under 5 hours per controller with ready-made controller boards.

	'''BK:''' Bolt-together doesn't necessarily facilitate fabrication. I would argue bolting often takes far more time than welding. You have to make a minimum of 2 holes, often in difficult to access locations, line them up, and then insert a bolt. Welding will often take less time and will make it easier in Kit form, as less asssembly will be required. '''For Example:''' In mounting the hopper, P3 had bolt on supports on the back of the hopper. This was time consuming because the bolt needs to go close to the bottom, and you are bolting to a large piece. If the supports are welded, you can simply put the hopper onto the frame without any extra work.		'''BK:''' Bolt-together doesn't necessarily facilitate fabrication. I would argue bolting often takes far more time than welding. You have to make a minimum of 2 holes, often in difficult to access locations, line them up, and then insert a bolt. Welding will often take less time and will make it easier in Kit form, as less asssembly will be required. '''For Example:''' In mounting the hopper, P3 had bolt on supports on the back of the hopper. This was time consuming because the bolt needs to go close to the bottom, and you are bolting to a large piece. If the supports are welded, you can simply put the hopper onto the frame without any extra work.

	'''BK:''' The [[XM Design Rationale]] page states that reduced time and complexity of fabrication process takes priority over modularity.		'''BK:''' The [[XM Design Rationale]] page states that reduced time and complexity of fabrication process takes priority over modularity.

			==Press Foot- P3 vs. "piston" type==
			'''BK 6/22:''' Both James Slade and Dan Schellenberg have decided to use a "piston" type of press foot, which mounts on a clevis type cylinder. I've heard replicators from both sides say that theirs is superior for pressing bricks and the wear on the cylinder; however I have seen no proof either way. So, from my perspective, here are a list of proven benefits of using this design over the P3 version:

			*Enables use of clevis ($258-$362) cylinder vs. the more pricey cross tube ($520).
			*The cylinder can be recycled with this version; in P3, after the press foot is welded to the cylinder, you can't use it for anything else.
			*Welding on the cylinder risks melting the seal at it's entrance, which would cause leaking. Also, the welding is very tricky, as you can't warp the plate you are welding. and with that much welding, boy, is that tough!
			*A normal cylinder is serviceable by machine shops; after one has been welded on, many shops will refuse to service because of liability.

			Disadvantages:
			*More parts to fab
			*supposedly longer fabrication time (according to marcin)


	==Hopper Changes==		==Hopper Changes==

Bkufa: /* Shaker */

2012-06-21T04:37:12Z

Shaker

← Older revision		Revision as of 04:37, 21 June 2012
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	'''Problem Statement:''' The old shaker took a lot of time and materials to make.		'''Problem Statement:''' The old shaker took a lot of time and materials to make.

	'''Solution:''' Dan's CEB used an entirely different shaker process. The motor attached directly to a circular plate, with a hole drilled off center. It attached via some special adapter for lawn mowers. Photos to come. The circular plate was enclosed between a sandwich of 3 plates, which sheilds the user from any shrapnel. This considerably lowers part count and labor. The only possible disadvantages are that it may not provide as much shaking as the previous model. However, it seemed to shake plenty when I watched it.		'''Solution: BK 6/19''' Dan's CEB used an entirely different shaker process. The motor attached directly to a circular plate, with a hole drilled off center. It attached via some special adapter for lawn mowers. Photos to come. The circular plate was enclosed between a sandwich of 3 plates, which sheilds the user from any shrapnel. This considerably lowers part count and labor. The only possible disadvantages are that it may not provide as much shaking as the previous model. However, it seemed to shake plenty when I watched it.

			'''BK 6/19''' Spoke with Marcin, and he informed me that since this is not a "wheel" motor, having the eccentric attached directly to the motor will ruin the bearings inside. I need to investigate the cost difference in the motors.

	==Arms==		==Arms==

Bkufa: /* Shape */

2012-06-21T04:32:32Z

Shape

← Older revision		Revision as of 04:32, 21 June 2012
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	*The lip should be eliminated as much as possible. If the hopper can be fitted directly to the input hole on the frame, this is best.		*The lip should be eliminated as much as possible. If the hopper can be fitted directly to the input hole on the frame, this is best.
	*Welding plates between the hopper and the frame is an option, so that the soil will flow better between the two.		*Welding plates between the hopper and the frame is an option, so that the soil will flow better between the two.

			'''BK 6/20''' Some issues I've run into with designing, is that it is virtually impossible to design so that the side pieces don't need to twist a bit to match on both sides. To have the least twisting possible, either the top side, or the bottom must be out of square.

	===Mounting, on sides===		===Mounting, on sides===

Bkufa: /* Shape */

2012-06-21T04:07:47Z

Shape

← Older revision		Revision as of 04:07, 21 June 2012
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	'''Problem Statement''': In Prototype 3 (P3 for short), the hopper had gaps at the top, and the seams didn't go together well; the 4 sides ended at different heights, making it difficult to mount the grate.		'''Problem Statement''': In Prototype 3 (P3 for short), the hopper had gaps at the top, and the seams didn't go together well; the 4 sides ended at different heights, making it difficult to mount the grate.

	'''Solution''': Dan Schellenberg's CEB used the same general shape of OSE's prototype, but cut off some of the top section, and a portion of the sides. [http://sketchup.google.com/3dwarehouse/details?mid=242db108c35b8694367c66ca14350bfd Link] to hopper model. This saves material and simplifies mounting the grate. No disadvantages are seen.		'''Solution BK 6/19''': Dan Schellenberg's CEB used the same general shape of OSE's prototype, but cut off some of the top section, and a portion of the sides. [http://sketchup.google.com/3dwarehouse/details?mid=242db108c35b8694367c66ca14350bfd Link] to hopper model. This saves material and simplifies mounting the grate. No disadvantages are seen.

	'''MJ''': For materials use efficiency, P3 requires one 5'x10' sheet of 1/8" steel. If this requirement is still met, then we should continue.		'''MJ 6/19''': For materials use efficiency, P3 requires one 5'x10' sheet of 1/8" steel. If this requirement is still met, then we should continue.

	'''BK''': After more investigation, I realized Dan's hopper was made from the ~~old~~ hopper design, which ~~didn't use~~ so ~~we won~~'t be ~~able~~ to ~~copy it~~.		'''BK 6/20''': After more investigation, I realized Dan's hopper was made from the original hopper design. Marcin said this design had too shallow of a slope, and that soil tended to sit on top rather than roll into the hopper. So, it became necessary to re-design shape from dan's.

			'''BK 6/20'''This afternoon, James Slade and I discussed issues with the hopper, and came up with the following:
			*Hopper interface plate lip causes soil to load up at those spots this is a real issue, as user must climb on machine to clean out clay with a stick.
			*Walls should be as close to vertical as possible, as clay tends to stick to sides if they are too horizontal.
			*The grate was not as steep as James would have liked it to be.

			Some possible solutions we came up with are:
			*The grate to be mounted on a hinge, which can slide up and down on the hopper mounts. This would allow user to easily change steepness of the grate as necessary to fit their soil type.
			*We can make a hole in the bottom of the hopper, and keep it capped, either with threads or some sort of plug. This would be for when "bridging" happens, so the user doesn't need to climb up the machine.
			*The lip should be eliminated as much as possible. If the hopper can be fitted directly to the input hole on the frame, this is best.
			*Welding plates between the hopper and the frame is an option, so that the soil will flow better between the two.

	===Mounting, on sides===		===Mounting, on sides===

Zdwiel: /* Arms */

2012-06-21T02:18:51Z

Arms

← Older revision		Revision as of 02:18, 21 June 2012
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	[[Category:CEB IV]]		[[Category:CEB IV]]

			=Electronics=

			==Controller Board==

			[[CEB_Press/Manufacturing_Instructions/Detroit_Fab_Lab_Solenoid_Driver_v4\|Detroit_Fab_Lab_Solenoid_Driver_v4]]

Zdwiel: /* Introduction */

2012-06-21T02:08:14Z

Introduction

← Older revision		Revision as of 02:08, 21 June 2012
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	General design is intended to be one where we assume the availability of a CNC Torch table for rapid fabrication. The machine is intended to be producible as a kit. It is designed to be collapsable into a 3x3x6 foot crate for ease of shipping. Welding is minimized to allow quick fixing via disassembly - with modular, easy-to-source parts. The intent of bolt-together structure is to facilitate fabrication. We are determining whether the fabrication time can be brought down from about 50 hours per machine, excluding electronics, to approximately 25 hour per machine. To achieve this, we aim to cut most parts on a torch table, followed by bolting together, so that a user can receive a kit and put it together like IKEA furniture. Since bolting is quicker than welding - under the assumption that a CNC torch table produces accurate pieces - bolts are favored over welding wherever possible. This is different than standard custom fabrication practice, but it is intended to produce superior results in terms of lifetime design and ease of fabrication. We are exploring the feasibility of production straight from a CNC plasma torch table + welding to a finished, replicable product that can be sold directly as a kit without the producer needing to assemble the machine at all. To achieve this, we are aiming for strict quality control to allow all components to fit together with 99.9% success rate for each machine - such that only 1 of 1000 components of the ~100 components per machine needs to be recut.		General design is intended to be one where we assume the availability of a CNC Torch table for rapid fabrication. The machine is intended to be producible as a kit. It is designed to be collapsable into a 3x3x6 foot crate for ease of shipping. Welding is minimized to allow quick fixing via disassembly - with modular, easy-to-source parts. The intent of bolt-together structure is to facilitate fabrication. We are determining whether the fabrication time can be brought down from about 50 hours per machine, excluding electronics, to approximately 25 hour per machine. To achieve this, we aim to cut most parts on a torch table, followed by bolting together, so that a user can receive a kit and put it together like IKEA furniture. Since bolting is quicker than welding - under the assumption that a CNC torch table produces accurate pieces - bolts are favored over welding wherever possible. This is different than standard custom fabrication practice, but it is intended to produce superior results in terms of lifetime design and ease of fabrication. We are exploring the feasibility of production straight from a CNC plasma torch table + welding to a finished, replicable product that can be sold directly as a kit without the producer needing to assemble the machine at all. To achieve this, we are aiming for strict quality control to allow all components to fit together with 99.9% success rate for each machine - such that only 1 of 1000 components of the ~100 components per machine needs to be recut.

	For the electronics, we are streamlining controller production to approximately 3 hours per machine starting from raw circuit boards, followed by milling on a [[CNC Circuit Mill]], ~~fderollowed~~ by populating with components and assembling a controller box with sensors, in a time under 6 hours per controller. This time should be reduced to under 5 hours per controller with ready-made controller boards.		For the electronics, we are streamlining controller production to approximately 3 hours per machine starting from raw circuit boards, followed by milling on a [[CNC Circuit Mill]], followed by populating with components and assembling a controller box with sensors, in a time under 6 hours per controller. This time should be reduced to under 5 hours per controller with ready-made controller boards.

	'''BK:''' Bolt-together doesn't necessarily facilitate fabrication. I would argue bolting often takes far more time than welding. You have to make a minimum of 2 holes, often in difficult to access locations, line them up, and then insert a bolt. Welding will often take less time and will make it easier in Kit form, as less asssembly will be required. '''For Example:''' In mounting the hopper, P3 had bolt on supports on the back of the hopper. This was time consuming because the bolt needs to go close to the bottom, and you are bolting to a large piece. If the supports are welded, you can simply put the hopper onto the frame without any extra work.		'''BK:''' Bolt-together doesn't necessarily facilitate fabrication. I would argue bolting often takes far more time than welding. You have to make a minimum of 2 holes, often in difficult to access locations, line them up, and then insert a bolt. Welding will often take less time and will make it easier in Kit form, as less asssembly will be required. '''For Example:''' In mounting the hopper, P3 had bolt on supports on the back of the hopper. This was time consuming because the bolt needs to go close to the bottom, and you are bolting to a large piece. If the supports are welded, you can simply put the hopper onto the frame without any extra work.

Bkufa: /* Introduction */

2012-06-20T23:27:39Z

Introduction

← Older revision		Revision as of 23:27, 20 June 2012
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	'''BK:''' Bolt-together doesn't necessarily facilitate fabrication. I would argue bolting often takes far more time than welding. You have to make a minimum of 2 holes, often in difficult to access locations, line them up, and then insert a bolt. Welding will often take less time and will make it easier in Kit form, as less asssembly will be required. '''For Example:''' In mounting the hopper, P3 had bolt on supports on the back of the hopper. This was time consuming because the bolt needs to go close to the bottom, and you are bolting to a large piece. If the supports are welded, you can simply put the hopper onto the frame without any extra work.		'''BK:''' Bolt-together doesn't necessarily facilitate fabrication. I would argue bolting often takes far more time than welding. You have to make a minimum of 2 holes, often in difficult to access locations, line them up, and then insert a bolt. Welding will often take less time and will make it easier in Kit form, as less asssembly will be required. '''For Example:''' In mounting the hopper, P3 had bolt on supports on the back of the hopper. This was time consuming because the bolt needs to go close to the bottom, and you are bolting to a large piece. If the supports are welded, you can simply put the hopper onto the frame without any extra work.

	'''BK:''' The [XM Design Rationale] page states that reduced time and complexity of fabrication process takes priority over modularity.		'''BK:''' The [[XM Design Rationale]] page states that reduced time and complexity of fabrication process takes priority over modularity.

	==Hopper Changes==		==Hopper Changes==

Bkufa: /* Shape */

2012-06-20T17:34:12Z

Shape

← Older revision		Revision as of 17:34, 20 June 2012
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	'''MJ''': For materials use efficiency, P3 requires one 5'x10' sheet of 1/8" steel. If this requirement is still met, then we should continue.		'''MJ''': For materials use efficiency, P3 requires one 5'x10' sheet of 1/8" steel. If this requirement is still met, then we should continue.

	'''BK''': After more investigation, I realized Dan's hopper was made from the old hopper design, so we won't be able to copy it.		'''BK''': After more investigation, I realized Dan's hopper was made from the old hopper design, which didn't use so we won't be able to copy it.

	===Mounting, on sides===		===Mounting, on sides===