Solar Power Cube v17.10 - Revision history

Eric: Added a Category to the Page

2022-11-05T22:55:22Z

Added a Category to the Page

← Older revision		Revision as of 22:55, 5 November 2022
Line 192:		Line 192:
	[[file:Solar_Power_Cube_V1.0_BOM.pdf]]		[[file:Solar_Power_Cube_V1.0_BOM.pdf]]

	[[Category: Dead Links]]		[[Category: Dead Links]] [[Category: Power Cube]]

Eric: Marked some dead links for necromancy

2022-11-05T22:55:05Z

Marked some dead links for necromancy

← Older revision		Revision as of 22:55, 5 November 2022
Line 43:		Line 43:
	Roller Width: 0.16in		Roller Width: 0.16in
	Reversible		Reversible
	[http://www.ebay.com/itm/450W-36-V-DC-electric-motor-f-bicycle-bike-gokart-scooter-MY1020z-gear-reduction-/162291507158?hash=item25c953dfd6:g:J6YAAOSwiDFYNHRH EBAY MY1020z $67.05]		[http://www.ebay.com/itm/450W-36-V-DC-electric-motor-f-bicycle-bike-gokart-scooter-MY1020z-gear-reduction-/162291507158?hash=item25c953dfd6:g:J6YAAOSwiDFYNHRH EBAY MY1020z $67.05] ( [[Dead Link]] )

	===Hydraulic Power Unit===		===Hydraulic Power Unit===
Line 191:		Line 191:
	[[file:Solar_Power_Cube_V1.0.skp]]		[[file:Solar_Power_Cube_V1.0.skp]]
	[[file:Solar_Power_Cube_V1.0_BOM.pdf]]		[[file:Solar_Power_Cube_V1.0_BOM.pdf]]

			[[Category: Dead Links]]

Dorkmo: /* =12 Volt Auxilary Power */

2017-10-28T17:21:58Z

=12 Volt Auxilary Power

← Older revision		Revision as of 17:21, 28 October 2017
Line 175:		Line 175:
	http://shop.polybelt.com/25T5-390-Polyurethane-Steel-Timing-Belt-78-Tooth-B25T5-390FPS.htm		http://shop.polybelt.com/25T5-390-Polyurethane-Steel-Timing-Belt-78-Tooth-B25T5-390FPS.htm

	==12 Volt Auxilary Power=		==12 Volt Auxilary Power==

	*need to convert solr panel's 36V to 12V to use for solenoids and arduino		*need to convert solr panel's 36V to 12V to use for solenoids and arduino

Dorkmo at 03:10, 28 October 2017

2017-10-28T03:10:36Z

@@ Line 174: / Line 174: @@
 Strangely, this is the same part number (the previous one was oversized a bit):
 http://shop.polybelt.com/25T5-390-Polyurethane-Steel-Timing-Belt-78-Tooth-B25T5-390FPS.htm
 ==Files==

Marcin: /* Power Cube Working Document */

2017-10-18T05:28:42Z

Power Cube Working Document

← Older revision		Revision as of 05:28, 18 October 2017
Line 157:		Line 157:

	["https://docs.google.com/spreadsheets/d/1KNVP2O3KogC6jyxMuRALWTxrYjyCJ4ChjeZsJVdqHsg/edit#gid=1"]		["https://docs.google.com/spreadsheets/d/1KNVP2O3KogC6jyxMuRALWTxrYjyCJ4ChjeZsJVdqHsg/edit#gid=1"]

			=Discussion=
			EBay has pulleys, but I don’t see bar stock:

			https://www.ebay.com/itm/36T5-40-2-T5-Aluminium-Precision-Timing-Belt-Pulley-25mm-Wide-x-40-Tooth-/201616982777?epid=1089974188&hash=item2ef14f02f9:g:3BMAAOSwzJ5Xen8D

			We could keep the pulley ratios and go with 21 tooth bar and 42 tooth pulley - which are both in stock:

			http://shop.polybelt.com/T5-21-Pulley-Bar-Stock-Aluminum-PBT5-21-160A.htm
			http://shop.polybelt.com/36T5-42-2-Aluminum-42-Tooth-Pulley-P36T5-42-2A.htm

			Of course, we would have to re-calculate the belt length:

			pi * (d1 + d2)/2 + 2 * d = pi * (32.7mm + 66mm)/2 + 2 * 117mm = 389mm (15.3")
			#teeth = 384mm / 5 mm/tooth = 77.8 or about 78 teeth
			Strangely, this is the same part number (the previous one was oversized a bit):
			http://shop.polybelt.com/25T5-390-Polyurethane-Steel-Timing-Belt-78-Tooth-B25T5-390FPS.htm

	==Files==		==Files==

Tom Griffing: /* Calculations */

2017-10-14T13:48:59Z

Calculations

← Older revision		Revision as of 13:48, 14 October 2017
Line 103:		Line 103:
	RPM ratios of motor to pump input is: 450:218 (approx 2:1). This should be used to select pulleys for the motor and pump.		RPM ratios of motor to pump input is: 450:218 (approx 2:1). This should be used to select pulleys for the motor and pump.

	~~===RPM input/output===~~

	~~Max electric motor~~ RPM~~: 450~~		===Hydraulic Fluid Flow===
	~~Max Hydraulic~~ Pump ~~RPM:~~ 3600		Use pump specs to calculate displacement:
	~~Max Hydraulic Motor RPM~~: ~~150~~		RPM * CIPR = flow => CIPR = flow / rpm
			Pump CIPR = (2 GPM * 231 cu-in/gal) / 3600 = 0.128
	~~Estimated Max Wheel~~ RPM~~: 1~~
			Use displacement to calculate flow when driven by solar panel:
			0.128 CIPR * 218 RPM =

	===~~Hydraulic Fluid Flow===~~		PUMP CIPR: 2 GPM @ 3600 RPM = 2 GPM * 231 / 3600 =
			GPM from pump at 218 RPM: 0.128 GPM * 218 RPM / 231 cu-in/gal) = 0.12 GPM

	~~GPM required for 1 RPM @wheel: 45.6 cu in/min or 45.6 / 231 = 0.197 GPM~~
	~~Max Pump Output: 2 GPM @ 3600 RPM => Pump CIPR = (2 GPM * 231 cu in/Gal) / 3600 RPM = 0.128 CIPR (Cubic Inches Per Revolution)~~
	~~RPM required from pump for 0.138 GPM output: (0.197 GPM * 231 cu in/Gal) / 0.128 CIPR = 355 RPM~~

	===Pulley and Belt Sizing===		===Pulley and Belt Sizing===

	The RPM of the electric motor at 36VDC is 450 RPM and must drive the pulley on the hydraulic pump at ~~355~~ RPM, so the ratio of pulleys is 450:~~355~~ or roughly 1:1~~.27~~.		The RPM of the electric motor at 36VDC is 450 RPM and must drive the pulley on the hydraulic pump at 218 RPM, so the ratio of pulleys is 450:218 or roughly 2:1.

	The smaller pulley must accommodate the motor's 20 mm shaft, so its "OD" must be 20mm + 2 * 5mm to allow 5mm thickness to allow for a set screw. According to PolyBelt.com (http://polybelt.com/5mb.php), the smaller pulley must have at least 20 teeth.		The smaller pulley must accommodate the motor's 20 mm shaft, so its "OD" must be 20mm + 2 * 5mm to allow 5mm thickness to allow for a set screw. According to PolyBelt.com (http://polybelt.com/5mb.php), the smaller pulley must have at least 20 teeth.

	~~Applying~~ the 1:1.~~27 ratio, this gives us 20:25~~.~~4 teeth (round down~~ to 20~~:25)~~.		The motor shaft is 13/16" and the shaft on the pump is 1/2". Both pulleys must be machined for their respective shaft sizes and allow enough material for set screws. The smaller pulley requires an OD of about 30mm to allow for machining, making it a 20 tooth pulley.

	The larger pulley goes on the pump and the smaller on the electric motor.		With motor pulley having 20 teeth, the 2:1 ratio yields 40 teeth for the pump pulley. The larger pulley goes on the pump and the smaller on the electric motor.

	The shaft on the electric motor is 13/16" and the shaft on the pump is 1/2". Both pulleys must be machined for their respective shaft sizes and allow enough material for set screws. The smaller pulley requires an OD of about 30mm to allow for machining, making it a 19 tooth pulley. Applying the pulley ratio, we calculate the size of the larger pulley in teeth:

	~~20 teeth * 1.27 = 25.4 teeth (round down to 25 teeth)~~

	Looking up the pulleys on the vendor webpage shows the following part pages:		Looking up the pulleys on the vendor webpage shows the following part pages:

	[http://shop.polybelt.com/36T5-20-2-Aluminum-20-Tooth-Pulley-P36T5-20-2A.htm 20 Tooth Pulley with flanges]		[http://shop.polybelt.com/36T5-20-2-Aluminum-20-Tooth-Pulley-P36T5-20-2A.htm 20 Tooth Pulley with flanges]
	[http://shop.polybelt.com/36T5-25-2-Aluminum-25-Tooth-Pulley-P36T5-25-2A.htm 25 Tooth Pulley with flanges]		[http://shop.polybelt.com/36T5-40-2-Aluminum-40-Tooth-Pulley-P36T5-40-2.htm 40 Tooth Pulley with flanges]

	They don't seem to carry a 20 tooth pulley without the flanges, so we can purchase the bar stock instead, which we can cut and machine to our specs:		They don't seem to carry a 20 tooth pulley without the flanges, so we can purchase the bar stock instead, which we can cut and machine to our specs:
Line 142:		Line 137:
	This will be better for the smaller pulley, as we need more height to make up for the sort motor shaft.		This will be better for the smaller pulley, as we need more height to make up for the sort motor shaft.

	~~This yields~~ pulley ~~pitch~~ diameters of 31.83mm ~~and 39.8mm.~~		Calculate pulley diameters:
			Diameter = Pitch * #teeth / pi
	~~The approximate distance between shaft centers is 5.1" (129.54mm)~~		Motor pulley dia: 5mm * 20 / pi = 31.83mm
			Pump pulley dia: 5mm * 40 / pi = 63.66mm
	The "formal" calculation of belt length with different size pulleys is rather complex, but as our pulleys are close and we have an adjustment, we can use a simple approximation for the belt length (d = 5.1" = ~~129~~.~~54mm):~~

	~~pi * (d1 + d2)/2 + 2 * d = pi * (31~~.~~83mm + 39.8mm)/2 + 2 * 115.9mm = 344.3mm~~ (~~13.55"~~)		The approximate distance between shaft centers is 4.625" (117mm)

	~~Calculate the~~ belt length ~~in terms of 5mm teeth: 344.3 / 5 = 68.9. This~~ is ~~roughly 69 teeth in length of~~ a ~~5mm pitch~~ belt~~. Looking it up on vendor's page:~~		The "formal" calculation of belt length with different size pulleys is rather complex, but as our pulleys are close and we have an adjustment, we can use a simple approximation for the belt length (d = 117mm):
	~~[http~~:~~//shop.polybelt.com/25T5-Urethane-Truly-Endless-25mm-Wide_c344.htm Polybelt Timing Belts]~~

	~~We see that the 69~~ tooth ~~belt has the following web page:~~		pi * (d1 + d2)/2 + 2 * d = pi * (31.83mm + 63.66mm)/2 + 2 * 117mm = 384mm (15.11")
			#teeth = 384mm / 5 mm/tooth = 76.8 or about 77 teeth

	[http://shop.polybelt.com/25T5-~~345~~-Polyurethane-Steel-Timing-Belt-69-Tooth-B25T5-~~345CPS~~.htm Polyurethane Steel Timing Belt 69 Tooth]		Looking it up on vendor page, the nearest larger size has 78 teeth (part #B25T5/390FPS):
			[http://shop.polybelt.com/25T5-390-Polyurethane-Steel-Timing-Belt-78-Tooth-B25T5-390FPS.htm 25T5/390 Polyurethane Steel Timing Belt 78 Tooth]

	==Power Cube Working Document==		==Power Cube Working Document==

Tom Griffing: /* Power */

2017-10-14T13:08:07Z

Power

← Older revision		Revision as of 13:08, 14 October 2017
Line 79:		Line 79:

	===Power===		===Power===

	~~Torque (ft-lb) = HP * 33000 / 2 * pi * RPM~~
	~~HP = Torque * 2 * pi * RPM / 33000 =~ Torque * RPM / 5252~~
	~~RPM = HP * 33000 / 2 * pi * Torque~~

	~~Max Input from solar panel: 290 W or 290W / (746 W/HP) = 0.388 HP~~
	~~Hydraulic pump rated for 5HP or 3600 RPM => torque = 5 HP * 33000 / 2 * pi * 3600 = 7.29 ft-lb~~
	~~Driving the pump with .303HP and the same torque the pump RPM would be slower, but would deliver the same pressure, but less flow~~

	RPM ~~= .303 * 33000 / 2 * pi * 7~~.~~29 = 218~~		Use max solar panel output (290 watts @ 36VDC) to power the motor and calculate motor torque. Then use this torque to calculate the corresponding pump RPM at its rated torque.

	So, the ~~ratios of motor output~~ to pump ~~input is: 450:218~~. ~~This should also~~ be the ~~ratios in pulleys for~~ the ~~motor & pump~~.		The idea is to use the maximum power available from the solar panel to power the motor, then calculate the pulley ratio for delivering the rated torque to the hydraulic pump. The hydraulic flow from the pump will be less than the rated 2GPM, but will deliver the same pressure.

			Reference:
			Torque (ft-lb) = HP * 33000 / 2 * pi * RPM
			HP = Watts / (746 Watts/HP)
			HP = Torque * 2 * pi * RPM / 33000 =~ Torque * RPM / 5252
			RPM = HP * 33000 / 2 * pi * Torque (ft-lb)

			Rated Solar panel output:
			Max Input from solar panel: 290 W or 290W / (746 W/HP) = 0.388 HP

			Motor Output:
	36V motor efficiency: 78%, so output power is: 0.388 HP * 78% / 100 motor/gearbox efficiency = 0.303 HP		36V motor efficiency: 78%, so output power is: 0.388 HP * 78% / 100 motor/gearbox efficiency = 0.303 HP
	~~Rated motor torque when powered by solar panel: 0.303 HP * 33000 / 2 * pi * 450 = 3.53 ft-lbs~~
	~~Motor to pump RPM ratios:~~


	~~To deliver max pressure with rated input (.303 HP & 450 RPM)~~

	~~Rated motor torque @ 450 RPM: 4.54 ft-lb~~
	~~HP = 4.54 ft-lb * 5252 / 450 RPM =~~
	~~Max motor torque @ max HP: 0.303 HP * 450 RPM / 5252 = 0.0259 ft lb~~

			Pump Input:
			Torque at rated input (5HP and 3600 RPM): torque = 5 HP * 33000 / 2 * pi * 3600 = 7.29 ft-lb
			Solve for pump RPM: RPM = .303 HP * 33000 / 2 * pi * 7.29 ft-lb =~ 218

	~~These numbers are for the electric~~ motor ~~and will~~ be used to ~~determine pulley~~ and ~~belt specs~~		Pulley Ratio:
			RPM ratios of motor to pump input is: 450:218 (approx 2:1). This should be used to select pulleys for the motor and pump.

	===RPM input/output===		===RPM input/output===

Tom Griffing: /* Power */

2017-10-14T03:24:04Z

Power

← Older revision		Revision as of 03:24, 14 October 2017
Line 79:		Line 79:

	===Power===		===Power===

	~~The torque -> HP conversion formula is: HP = T * RPM / 5252~~
	~~The Hydraulic pump is rated for 5HP @ 3600 RPM, or 7.29 ft lb torque~~

	~~Max Motor Input: 290 W~~ * ~~78%~~ * ~~100~~ = ~~226.~~2 ~~Watts~~		Torque (ft-lb) = HP * 33000 / 2 * pi * RPM
	~~Motor Output: 226 W~~ / ~~(746 W~~/~~HP) = 0.303 HP~~		HP = Torque * 2 * pi * RPM / 33000 =~ Torque * RPM / 5252
	~~Motor Torque @ 450~~ RPM = ~~4.54 ft-lb~~		RPM = HP * 33000 / 2 * pi * Torque

	~~Torque~~ (~~ft-lb~~) = (HP * 33000) / (2 * pi * ~~rotational speed)~~ = (.303 * 33000) / (2 * 3.~~14159~~ * ~~450)~~ = 3.~~54 ft-lbs~~		Max Input from solar panel: 290 W or 290W / (746 W/HP) = 0.388 HP
	~~Torque (NM) = Watts~~ / (2 * pi * ~~rotational speed)~~ = ~~226 W /~~ (~~2 * 3~~.14159 * 450 RPM) ~~= 0.08 NM~~		Hydraulic pump rated for 5HP or 3600 RPM => torque = 5 HP * 33000 / 2 * pi * 3600 = 7.29 ft-lb
			Driving the pump with .303HP and the same torque the pump RPM would be slower, but would deliver the same pressure, but less flow

			RPM = .303 * 33000 / 2 * pi * 7.29 = 218

			So, the ratios of motor output to pump input is: 450:218. This should also be the ratios in pulleys for the motor & pump.




			36V motor efficiency: 78%, so output power is: 0.388 HP * 78% / 100 motor/gearbox efficiency = 0.303 HP
			Rated motor torque when powered by solar panel: 0.303 HP * 33000 / 2 * pi * 450 = 3.53 ft-lbs
			Motor to pump RPM ratios:


			To deliver max pressure with rated input (.303 HP & 450 RPM)

			Rated motor torque @ 450 RPM: 4.54 ft-lb
			HP = 4.54 ft-lb * 5252 / 450 RPM =
			Max motor torque @ max HP: 0.303 HP * 450 RPM / 5252 = 0.0259 ft lb


	These numbers are for the electric motor and will be used to determine pulley and belt specs		These numbers are for the electric motor and will be used to determine pulley and belt specs

Tom Griffing: /* Power */

2017-10-13T13:52:53Z

Power

← Older revision		Revision as of 13:52, 13 October 2017
Line 80:		Line 80:
	===Power===		===Power===

			The torque -> HP conversion formula is: HP = T * RPM / 5252
			The Hydraulic pump is rated for 5HP @ 3600 RPM, or 7.29 ft lb torque

	Max Motor Input: 290 W * 78% * 100 = 226.2 Watts		Max Motor Input: 290 W * 78% * 100 = 226.2 Watts
	Motor Output: 226 W / (746 W/HP) = 0.303 HP		Motor Output: 226 W / (746 W/HP) = 0.303 HP

Tom Griffing: /* DC Motor */

2017-10-13T13:29:07Z

DC Motor

← Older revision		Revision as of 13:29, 13 October 2017
Line 34:		Line 34:
	Current Type: DC		Current Type: DC
	Gear Ratio: 6.67:1		Gear Ratio: 6.67:1
	Shaft Diameter: ~~20 mm~~ (13/16")		Shaft Diameter: 19mm (3/4"), threaded 7/16" x 16TPI, screws m4.5 x 15
	Motor Body Diameter: 4 1/4"		Motor Body Diameter: 4 1/4"
	Motor Body Length: 5 1/4"		Motor Body Length: 5 1/4"