Yoonseo Log 2012: Difference between revisions

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=November 2012=
#REDIRECT [[Yoonseo Log]]
 
Testing new log strategy...
 
==21/11/2012==
 
Sweiger trip with Gabi ([[CEB Press]], [[Caster]], [[Light Screen]])... done
 
[[CEB Press]] Electronics - Circuit Assembly... done
 
[[Terminal Case]]... that perfect tungsten end is really tough to get -_-
 
[http://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=5&ved=0CFgQFjAE&url=http%3A%2F%2Fwww.ehow.com%2Fhow_7772645_ball-tungsten-aluminum-welding.html&ei=vqGtUIWQHoaVyQGryoCICw&usg=AFQjCNEhLrqiJc4M1nhQxhWCnofr4rYgLw&cad=rja Ehow on Balling Tungsten]
 
[http://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=2&cad=rja&ved=0CDoQFjAB&url=http%3A%2F%2Fwww.millerwelds.com%2Fresources%2Farticles%2FTIG-gtaw-aluminum-tungsten-AC-controls%2F&ei=tqqtUIn4EMqFywGqt4CQBA&usg=AFQjCNG5Sg8s3r-2xCsijV9LMTp920MPGg Miller TIG Tips]
 
From [http://www.weldingtipsandtricks.com/tig-welding-supplies.html WeldingTipsandTricks]
stuck with 2% thoriated for a long time. It worked great ... but on A/C the tip kind of got jacked up at high amperage. I tried 1.5% and 2% lanthanated and learned that both work fine but the 2% lanthanated works great and even better on A/C. And For TIG inverters like the Miller Dynasty 200dx or the Lincoln Invertec v205t, it is Da shizz.
 
It holds up really well at high frequencies like 120-150 HZ.It stays sharp on DC too.
 
'''The only drawback is that is does not break easily...you have to cut it with a grinder.''' Duly noted. Thought I was doing something wrong by having to grind-cut the lanthanted but guess that's standard practice.
 
==20/11/2012==
 
Hablab Cleaning! Jacob is coming.
 
Make [[Terminal Case]]... Needs argon gas refill, new ceramic cups. Make a light tack weld. Then, starting from 1 end (but give enough space for the other aluminum walls), get a junction puddle (between baseplate and wall) then travel along junction edge. Filler adding technique is to insert the filler rod at the junction edge coming from the opposing direction as the weld. Keep the weld small and tight. If for some reason the weld turns big, skip it and do the junction puddle + edge travel again. You can grind off the big part and reweld the gap later.
 
When balling the tungsten before welding, set material-to-tungsten electron % higher and the current lower instead of just increasing the current. This will keep the copper plate cooler while still heating-balling the tungsten correctly. Make sure that the end of the tungsten is a ball.
 
Make [[PCB Mount]]...
 
==19/11/2012==
 
Make [[Hall Effect Sensor Module]] x2... done
 
Test [[Hall Effect Sensor Module]] x2... done, both operational.
 
Make [[Solenoid Driver]]... done
 
Prepare for making [[Terminal Case]]... done
 
Organizing personal information at [[Yoonseo Kang]]...
 
Organizing development webpage at [[Open Source Technologies]] and adding material supplier links...
 
[http://www.sciencedirect.com/science/article/pii/S0924013608002094 Coconut Oil Tests as Cutting Fluid]
 
[[File: cococutting.pdf]]
 
[http://www.jeepforum.com/forum/f37/drilling-taping-machining-coconut-oil-699831/ Coco Cutting Fluid, Forums]
 
Ordering Coconut Oil... done Haha! This will be fun! You can eat it, you can machine with it!
 
Safety and health is incredibly important at the minor level because hazards that take off years off your life are actually cutting, say, 5 years of living in *the future*, at which point you can be doing things x10000%+ higher quality and faster than you are doing now. Furthermore, you would be missing out on 5 years of health and safety innovation in *the future* which could further extend longetivity and ability by orders of magnitude more. Critical stuff. Don't miss out. Safety and health gives you a lot more than you might realize, and you don't notice that you haven't been seriously injured so it doesn't enter your mind that much. Chronically underestimated factor of life...
 
Ordering earmuffs (we are darn low on these, and disposable earplugs aren't that great as a cluttery consummable)... done
 
==18/11/2012==
 
Deploying [[Magdrill]] x2... done
 
Design [[Boxed Way]] machined dimensions...
 
Order aluminum flat for [[Hall Effect Sensor Module]] x2... done
 
Prepare [[Terminal Case]] welding for [[CEB Press]]...
 
Organize [[Drill Bit]]s...
 
Ordering [[Label]]s... done
 
==17/11/2012==
 
[[Hablab]] Ground Insulation Day
 
Documentation feedback for Chris Olah regarding www.implicitcad.org... done
 
==16/11/2012==
 
Upload [[Tooling Plate]] Documentation... done
 
Make [[Surface Grinder]] Video... done
 
[[Power Cube VII]] Electronics... awaiting someone to mount battery, solenoid and reveal 2AWG copper stranded wire
 
Upload [[Surface Grinder]] Video... done
 
Ordering [[Hall Effect Sensor]]... done
 
Stove sealing - Cement the gasket to the front top frame... done
 
Asking Andy about submersible pump wiring splice... done
 
Ask Josh about any available 120VAC/240VAC hydraulic power supplies... done
 
[[Website Setup]] Documentation
 
Get [[ImplicitCAD]] to [[Inkscape]] with [[Gcodetools]] for gcode toolchain working error-free... done
 
==15/11/2012==
 
Make [[Tooling Plate]]... done
 
Ordering [[Steppernug]] x6... done
 
[http://www.practicalmachinist.com/vb/cnc-machining/endmill-slipping-collet-244933/ Preventing Collet Slip]
 
==14/11/2012==
 
Organize [[CEB Press]] Electronics Materials... done.
 
[[CNC Torch Table]] V2 Test 1... Y Axis jog test success. Needs 2 more steppernugs for complete control. y axis gear setscrew needs tightening.
 
Design [[C Clamp]] with linear interface for [[Hall Effect Sensor Module]]... done. Might end up better to just use off-shelf C-Clamps despite 2-piece assembly until [[C Clamp]] fabrication efficiency increases.
 
Contact Chris Olah about [[ImplicitCAD]] use instructions... done
 
Ordering [[Power Supply]]... done
 
Contacting Darren about [[Steppernug]]... done
 
Ordering [[Solderable Breadboard]]... done
 
Ordering [[LED]]s and [[MOSFET]]s... done
 
Test [[ImplicitCAD]]... done
 
Test [[Gcodetools]]... [[Inkscape]] internal errors?!
 
Ordering small [[C Clamp]]s... done
 
Designing [[Funnel]]...done
 
Ordering [[Aluminum]] [[Tube]]... done
 
Fixing Ubuntu Shutdown... no good [[File: grubexamplefix.txt]] sudo shutdown -P now
 
Ordering [[Aluminum]] [[Sheet]]... done
 
Ordering [[Gasket]] for [[Stove]]... done
 
==13/11/2012==
 
[[CEB Press]] Electronics Coordination 1:30pm with Marcin... done
 
[[Power Cube VII]] Electronics... needs more touch safe terminal blocks
 
Laundry trip... done
 
Battery bank is too low for workshop use...
 
Organized Workshop with Drawers
 
Ordering touch safe [[Terminal Block]]s... done
 
Ordering iron for [[Boxed Way]]... done
 
Ordering [[Flashlight]]s...done
 
==12/11/2012==
 
[[Power Cube VII]] Production Run with Others Day 2...
 
[[CNC Electronics]] Wiring... done
 
[[Computer to Microcontroller]] troubleshooting...
 
http://code.google.com/p/processing/issues/detail?id=151
 
http://stackoverflow.com/questions/6459042/processing-how-to-write-to-the-serial-port
 
[[CNC]] troubleshooting... success.
 
Documentation spree.
 
[[Tooling Plate]] [[Fabrication Drawing]]
 
==11/11/2012==
 
[[Power Cube VII]] Production Run with others
 
[[CNC Electronics]] Mounting... done
 
Personal reminder that the [[Boxed Way]] module can be used as linear guides for [[Lathe]]
 
Ordering [[Annular Cutter]]s... done
 
Began [[Computer Platform]]
 
[[CNC Electronics]] [[Wiring]]...
 
==10/11/2012==
 
[[Power Cube VII]] Materials Preparation with Tom and Marcin... done
 
[[Bandsaw]] blade replacing with Kavitha... done
 
[[Power Cube VII]] Production Run Preparation... done
 
[[Bandsaw]] blade replacement video... done
 
Use Gparted with a live cd or usb in order to repartition your computer's internal hard drive.
 
Began [[Adjustable Platform]]
 
Designing [[Caster]]... done
 
==9/11/2012==
 
Ordered [http://www.amazon.com/gp/product/B008I1ILRC/ref=oh_details_o00_s00_i00  Portable Light]
 
[[CNC Electronics]] Wire to Terminal Tech... tinned wire vs fork connector resolved...
 
[[CNC Electronics]] Intra-connection Tech... male/female headers with twist connectors for now...
 
Analyzed on-site cordless chuck drills... no good. low torque and frustrating battery removal
 
Ordering [[Gloves]]... done
 
Documenting [[Extension Cord]] assembly... done
 
==8/11/2012==
 
Fabricate [[PCB Mount]] compressors... done
 
Install PCB Mount compressors... done
 
Deploying organizing drawer shipment... done
 
More drawers... ordered.
 
CNC Electronics Wiring Prep... heatsinks mounted, mounting holes drilled.
 
Ordering mcmaster-carr shipment (edge finders, iron for [[Tooling Plate]], cable gland and rubber rod for [[Terminal Case]])... done
 
==7/11/2012==
 
Ordering LIN steppers... done
 
Fabricating stove interface...done
 
Deploying (installing) stove door... done
 
Documenting stove door at [[Modular Stove Fabrication Procedure]]... done
 
Deploying extension cord shipment... done
 
Wrapping up hospital bill... itemization sheet on its way from hospital.
 
Ordering measuring tapes... done
 
Ordering wire... 18 gauge 500' red, 500' black ordered.
 
https://en.wikipedia.org/wiki/Nichrome
 
PCB Mount HDPE Plate cutting... done
 
Ordering hex to chuck converters... done
 
[[PCB Mount]] Mounting concept... done
 
Researching iron suppliers... mcmaster-carr is a supplier (http://www.mcmaster.com/#iron-sheets/=k2j66h)
 
http://www.wwgoa.com/articles/one-great-tip/do-i-really-need-an-impact-driver/
 
http://toolguyd.com/you-can-use-an-impact-driver-to-drill-holes-but-should-you/
 
http://www.familyhandyman.com/DIY-Tools---Tips/DIY-Tools/Power-Tools/choosing-the-best-impact-driver/View-All
 
http://www.candlepowerforums.com/vb/showthread.php?258999-NiMh-AA-Powered-LED-light-Current-Draw
 
http://batteryuniversity.com/learn/article/serial_and_parallel_battery_configurations
 
==6/11/2012==
 
240VAC Extension Cord... done
 
Food trip with Parker... done
 
TIG Welding Setup Video... done
 
CNC Torch Table mechanical assembly finishing... done
 
Ordering more winterwear... done
 
Ordering screwdrivers... done
 
Powercube Troubleshooting with Graham... fixed. The fuse was loose.
 
==5/11/2012==
 
Sweiger Trip for powercube/lathe accessories + stove metal. Done. Sweiger does not supply or have connections for iron.
 
Ordering more extension cords... 25ft x3, 50ft x2, 100ft x1 (Yellow Jacket from Amazon)... done
 
Ordering mass discrete component organizers... done
 
Wrapping up hospital bill... no response, message left.
 
Saw Blade Store response to order question... done. they were just confused with billing/shipping addresses
 
Septic system troubleshooting... fixed.
 
==4/11/2012==
 
Group clean Hablab!
 
Pictures for [[Light Screen]], [[Trencher]], [[Flashlight Mount]]
 
Light Screen from Josh missing a few parts - must search in Tristan's car...
 
[[CNC Torch Table]] Steppers' electronics interface wired up.
 
Set up camera tripod
 
[[Terminal Case]] interface with PCB mount...
 
Ordering HDPE plate for CNC electronics... done
 
==3/11/2012==
 
[[Tooling Plate]] fabrication preparation...
 
[[Terminal Case]] V3 welding... done - TIG welding aluminum isn't TOO hard...
 
We'll need to recharge our argon canister soon. Medium size canister is easier to transport, but must price check on medium and large refills.
 
Design, prototype, documentation [[Thermal Shield]] for TIG welding... done, done, and done
 
Preparing for next sweiger trip. Lathe/powercube accessories, iron for tooling plate, metal for stove door, pure argon gas refill... done
 
Must order edge finder (ex. from mcmaster-carr), but waiting on further items to optimize shipping.
 
Husking Walnuts!
 
http://www.cnccookbook.com/MTLatheCNCAccuracy.htm
 
http://www.gearsolutions.com/article/detail/5663/the-details-of-ductile-iron
 
[[Hinge]] redesign for stove
 
==2/11/2012==
 
New stove door design... mostly done.
 
Ordered aluminum bar for [[Terminal Case]] V3 construction (with welded seams for rigidity and waterproofing)
 
Tested and documented [[Trencher]] V1.5 with Aaron. It works pretty good!
 
Began TIG welding [[Terminal Case]]. Started using filler rod for the first time. The aluminum gets HOT. Don't touch it, even with gloves you will get burned. Cannot TIG weld continuously without heat shield. Must design heat shield for hand.
 
We need more 240VAC extension cords. Must order male and female plugs, as well as more large 3-strand wire.
 
Ordered 2 bandsaw blades
 
http://www.stepperworld.com/Tutorials/pgBipolarTutorial.htm
 
Stepper Motor considering: bipolar super torque steppers from Lin Engineering (http://www.linengineering.com/LinE/contents/stepmotors/5818.aspx)
 
Flexible shaft coupling considering: from http://www.mcmaster.com/#standard-shaft-couplings/=jzypil
 
Plan: organize drill bits
 
Plan: work on improving flashlight mount - magnetic mounting, adjustable angle
 
==1/11/2012==
 
TIG Welding tests... still no good. Grinded the aluminum and reduced the length of tungsten alloy tip sticking out to 1/8" but instead of puddling properly the aluminum totally melts underneath a film of oxide...
 
Bandsaw blade ordering [Emailed Parker and Marshall for previous bandsaw blade source]...
 
Thiel Fellowship monthly review... done
 
Thiel Fellowship annual update... done
 
Sweiger trip with Gabi for farmer's bank credit card form, powercube materials and TIG welding troubleshooting... success, success and success.
 
TIG welding aluminum test... success! Minor change was to mount the tungsten collet in the opposite direction. The major change was to ball the end of the tungsten by applying some high current 150-200A at ~50% AC balance to the tungsten tip but using copper plate.
 
Prototyped flashlight mount.
 
 
=October 2012=
 
==31/10/2012==
 
Workshop organizing.
 
Ordered fittings for water infrastructure, screws for [[CNC Torch Table]]
 
Cold Saw Test 3- clean cut, successful automated cooling, lots of vibration.
 
==30/10/2012==
 
Kdenlive Codecs Troubleshooting -
 
Mpeg-4 Resolved. Installed the mp3 encoding library "lame" using synaptic package manager, then opened kdenlive and went settings>run config wizard, then was able to render in mpeg-4.
 
Installed libavcodec-extra-53 and reran kdenlive config wizard and further render options enabled.
 
Ordered 4 welding helmets from Harbor Freight- http://www.harborfreight.com/blue-flame-design-auto-darkening-welding-helmet-91214.html
 
Ordered from Mcmaster-carr:
 
T Slot Cutter: 8789A12
 
Reduced Shank Endmill: 8827A19
 
Roughing Endmill: 8817A52
 
Touch-Safe Terminal Block: 7618K618
 
Terminal Block: 7527K53
 
Organized Workshop - deployed more tables, mechanical assembly of cnc torch table almost complete - awaiting screws to be ordered.
 
https://en.wikipedia.org/wiki/Gender_of_connectors_and_fasteners
 
==29/10/2012==
 
Ordered supplies
 
Troubleshooted plasma cutter - it works! Changed control connector to more compatible interface.
 
Video'd
 
Realized tripod is absolutely necessary to take video because 1 handed everything just doesn't work. For the same reasons, flashlight mount is crucial for nighttime work; headlights interfere too much with welding helmets and such.
 
Ordered tripod
 
Designed flashlight mount
 
==28/10/2012==
 
OSE general topic meeting
 
Organized workshop, fitted flats in cnc torch table
 
==27/10/2012==
 
Welding woes... TIG welder does not work even with the 2% lanthanated tungsten...
 
Organized workshop.
 
Designing [[Boxed Way]]
 
==26/10/2012==
 
[[Workshop Tools]]
 
Fixed tractor hose leak.
 
Organized workshop.
 
[[Boxed Way]] Fabrication Preparation
 
==25/10/2012==
 
[[Boxed Way]] Way-to-Base and antifrictionmaterial-to-saddle info acquired. Blocks - iron supplier and machined leadscrew supplier...
 
Finished up installation of stove. Review and modifications in progress- sealing all top gaps and replacing front door mechanism with hinge + latch.
 
[[Workshop Tools]] for hardware transparency and ease of analysis.
 
==24/10/2012==
 
With Aaron: picked up Gabrielle from bus station, acquired some winter gear, acquired Fairshare Farm food.
 
Wood Stove Deployment Run, Day 7 with Aaron. Installation almost complete (flue pipe hole needs to get cobbed up some more). Tested with big fire in stove. Success - flue has no leaks. Near complete combustion. However... chain handle is dangerously close to front panel (<1") at 100 degrees celsius (water boiling point)- burn hazard. Front panel acting as door is difficult to open- non-ergonomic. Leaks in top panels and front panel causing great smoke especially during the fire startup process before a draft is created. Rebar damper gets too hot to touch- safer damper handle necessary; damper placement could be better, placed to the side of the stove instead of over the top panel. But... the fire burns, the thermal energy radiates. Warmth!
 
Analyzed inverter electronics - we are much closer to the universal power supply (any input, any output) than we previously thought.
 
Deployed more tables in workshop and organized tools for superb accessibility during production runs and open tech development.
 
... accidentally erased the latter half of the stove pictures in the camera... darn...
 
[[File:stovepics.zip]]
 
Ordered sheet metal power shear
 
Contacted Gilman USA about way-base adhesion
 
Updated [http://opensourceecology.org/wiki/File:Cnclinear.svg boxed way diagram]
 
==23/10/2012==
 
Wood Stove Deployment Run, Day 6 with Aaron. Flue fabrication complete. Installation in progress.
 
Plastic welder test. Success.
 
[http://www.copper.org/applications/electrical/pq/casestudy/nebraska.html Grounding Case Study]
 
[http://www.solacity.com/Grounding.htm Grounding Tips from Solacity]
 
[[Inverter]] Control Waveform Diagrams
 
Ordered [http://www.amazon.com/Copper-PC-Board-Single-Sided/dp/B000P7ALZC/ref=sr_1_1?s=electronics&ie=UTF8&qid=1351065215&sr=1-1&keywords=copper+clad+board Copper Clad Board]
 
==22/10/2012==
 
Wood Stove Deployment Run, Day 5 with Aaron. Got all the materials from Sweiger, established full design, completed long assembly.
 
[[Inverter]] documentation with Aaron.
 
Workshop organization. Deploying lots of tables.
 
Ordered aluminum rods, tubes, bars.
 
Ordered bench grinder.
 
==21/10/2012==
 
[http://home.howstuffworks.com/question376.htm Forging Types]
 
[[Caster]]
 
Discussed budget creation process with Aaron [[Budget Creation Process]]
 
Organized Workshop
 
Laundry and food trip.
 
Ordered various fulcrum hand tools.
 
==20/10/2012==
 
Wood Stove Deployment Run Day 4 with Aaron. Took lots of pictures and videos. 400MB+!. Spent lots of time designing and preparing fabrication and looking for tools that we didn't find after all. Time for technological saturation. Quality tools will always save the day. Bad tools, no matter low prices, are super-expensive in practice... but not having tools is worse.
 
Time to order some more tools and materials... Metal protractors. Bronze rod.
 
[http://weldingweb.com/showthread.php?t=4313 Oxyacetylene Torch vs Plasma Cutting]
 
==19/10/2012==
 
[http://heli-cal.com/cm/Products/Flexible-Couplings/Home.html Heli-cal Shaft Couplings]
 
[[File: helicalcouplings.pdf]]
 
[http://www.mcmaster.com/#standard-shaft-couplings/=jsh8so Mcmaster-Carr Helical Beam Couplings]
 
[http://www.youtube.com/watch?v=dzIsR4Mg158 Machining a Ballscrew Video]
 
Received C Clamps and Tables
 
Replacing back wall of chicken coop with Parker
 
Wood Stove Production/Deployment Run Day 3
 
Received and deployed digital camera
 
Ordered AA Battery Holders
 
Fablab Tool Organization
 
Searching for a leadscrew and leadscrew nut supplier that provides end machining services
 
Tested Geiger Counter
 
Sent torch table pictures to Chuck Harrison - Internet connection timed out, resending in multiple emails... Success,
 
Ordered more tables. Extremely useful.
 
Researching animation software...
 
[http://idolinux.blogspot.com/2010/10/open-source-animation.html Sintel- Blender-animated Short Film]
 
[http://www.youtube.com/watch?v=n18lavQK60g Pencil Basics]
 
Researching Vises...
 
Responded to Kevin Harrington ([http://neuronrobotics.com/bio/kevin-harrington/ Kevin Harrington at Neuron Robotics])
 
==18/10/2012==
 
Received batch of shipments
 
[http://embraceubuntu.com/2006/06/08/how-to-create-a-screencast-in-ubuntu/ ffmpeg guide]
 
[[Boxed Way]]
 
[[Spindle]]
 
[[CNC Circuit Mill]]
 
[http://www.youtube.com/watch?v=UQ43XnHM8gI FFmpeg GUI for screen capture: Screencastor]
 
[http://www.iloveubuntu.net/powerful-screencasting-app-screencastor-10-released-english-support-and-new-features Screencastor Installation Guide]
 
Wood Stove Production Run Day 2
 
Trying to install screencastor... Success. ''How about also XVidCap?''-Marcin --- screencastor is just a screencapture GUI for ffmpeg and ffmpeg is much stronger (more configurable, more codec support, higher max video quality) than xvidcap-Yoonseo
 
[http://www.linuxquestions.org/questions/ubuntu-63/how-to-fix-broken-package-904637/ How to Fix Broken Packages]
 
[http://forum.ubuntu-fr.org/viewtopic.php?id=440555 Screencastor Main Thread]
 
[http://maketecheasier.com/remove-repositories-in-ubuntu/2010/05/27 How to Remove Repositories in Ubuntu]
 
Researching shaft coupling type between leadscrew and stepper motor. Flexible couplings (helical slit type) used to accommodate slightly misaligned shafts.
 
[http://www.ruland.com/shaft-collars.asp Shaft Couplings]
 
[[File: rigidshaftcouplings.pdf]]
 
[[File:Servocouplingguide.pdf]]
 
Requested 5618L-54P stepper motor quote from [http://www.linengineering.com Lin Engineering]
 
[[Tooling Plate]]
 
==17/10/2012==
 
Learning with Aaron about plasma cutting- [[Everlast PowerPro 256]]
 
Setting up FFmpeg as screen capture for video recording of desktop
 
[http://forum.doom9.org/showthread.php?t=143851 FFmpeg Noise Reduction]
 
[http://ffmpeg.org/pipermail/ffmpeg-user/2011-August/002047.html FFmpeg Video/Audio Separation]
 
Pre-Production Run Preparation for [http://opensourceecology.org/wiki/Wood_Stove_with_Heat_Exchanger Wood Stove] with On-site Team
 
Wood Stove Production Run - Learned how to plasma cut!
 
Ordered welding magnets
 
Installed Cinelerra and Kdenlive
 
Starting Google Sketchup
 
[http://www.dyers.org/blog/archives/2007/11/15/10-tips-to-get-you-started-with-google-sketchup/ Starting with Google Sketchup]
 
==16/10/2012==
 
Ordered self-adjusting clamps and pipe clamps
 
Troubleshooting internet - testing wired connection to router.
 
Mechanical diagrams for [[CNC Circuit Mill]]
 
[http://www.youtube.com/watch?v=HvV9a3lEe2g Plastic Welding]
 
Ordered plastic welder
 
[http://www.flexsoundproofing.com.au/ Work Screen Distributor]
 
Contacted flexsoundproofing for free welding screen sample.
 
Acquired food and cast iron kitchenware with Aaron and Parker
 
Discussed [[OSE Specifications]] with Aaron
 
Called Everlast for TIG Welder troubleshooting - pure tungsten is not compatible with inverter welders' square waves and must be replaced by lanthanated or ceriated tungsten
 
[http://www.youtube.com/watch?v=bpanERwagaU TIG Welding Tungsten Electrode Current Test]
 
Ordered 2% Lanthanated tungsten 3/32" x 7"
 
Tested TIG welding steel to some success with pure tungsten.
 
Ordered wire brushes x3
 
Ordered tables x2
 
Internet soooooo slowwwww... Efficiency at <10%...
 
[http://www.macworld.com/article/1137117/buyingguide_cameras.html Point and Shoot Camera Buying Guide]
 
[http://reviews.photographyreview.com/outdoor-waterproof-digital-cameras Outdoor Rugged Digital Camera Guide]
 
When getting any portable, data-focused electronics (meaning you need energy storage and data storage), consider the following 3 factors to be the most important:
 
*Uses common replaceable batteries. Ex. AA batteries. Necessary for ease of continuous use (otherwise it will sit collecting dust, you never having the time or money to spend on getting another proprietary battery; also makes charging/having extra charged batteries much less of a hassle).
 
*Uses common data storage cards. Ex. SD cards. Necessary for ease of compatible use. Last thing you want is to be unable to transfer your pictures and videos to your computer.
 
*Is rugged! Expect falls and pressure, immersion in water, extreme temperatures, and more.
 
Ordered [http://www.amazon.com/Transcend-Class-Flash-Memory-TS16GSDHC10E/dp/B003VNKNEQ/ref=sr_1_11?ie=UTF8&qid=1350456177&sr=8-11&keywords=SD+card SDHC card 16gb]
 
Ordered [http://www.amazon.com/Fujifilm-FinePix-S4200-Digital-Camera/dp/B006T7QWGO/ref=sr_1_1?s=photo&ie=UTF8&qid=1350453705&sr=1-1&keywords=AA+batteries Camera]
 
Ordered many AA and AAA batteries [http://www.amazon.com/Sanyo-eneloop-Pre-Charged-Rechargeable-Batteries/dp/B004UG41XW/ref=sr_1_1?s=electronics&ie=UTF8&qid=1350456416&sr=1-1&keywords=eneloop+aa Enerloop Batteries]
 
Ordered [http://www.amazon.com/La-Crosse-Technology-Battery-BC1000/dp/B004J6DLD4/ref=sr_1_2?ie=UTF8&qid=1350456732&sr=8-2&keywords=la+crosse+charger Smart Battery Charger]
 
==15/10/2012==
 
[http://www.youtube.com/watch?v=5u4Efn1twUo TIG Welding Advanced Settings]
 
[http://www.youtube.com/watch?v=YXa1Pxcr_Ww&feature=relmfu TIG Welding Advanced Settings 2]
 
[http://www.youtube.com/watch?v=T3vBH59VF0s&feature=relmfu TIG Welding Advanced Settings 3]
 
[http://www.youtube.com/watch?v=y5di20Mtlpk&feature=relmfu TIG Welding Advanced Settings 4]
 
[http://www.practicalmachinist.com/vb/fabrication-cnc-laser-waterjet-plasma-welding-fab/cant-get-aluminum-puddle-tig-131843/ TIG Welding - Getting a Puddle]
 
[http://www.weldcraft.com/2006/11/basics-for-tig-welding-aluminum/ TIG Welding Aluminum Basics]
 
[http://www.gmtruckhq.com/fab-shop/tig-welding-basics-236.html TIG Welding Basics]
 
[http://www.hobartwelders.com/weldtalk/archive/index.php/t-40288.html TIG Welding Residue Troubleshooting]
 
[http://www.millerwelds.com/resources/tech_tips/TIG_tips/troubleshooting.html TIG Welding Troubleshooting]
 
[http://www.millerwelds.com/resources/calculators/tig_amperage_calculator.php TIG Current Calculator]
 
Completed Thiel Fellowship review session
 
Ordered wire strippers, welding gloves, work gloves
 
==14/10/2012==
 
[http://www.youtube.com/watch?v=qadXgdzUZWc Heidendan Vertical Machining Center]
 
[http://www.youtube.com/watch?v=Z9RIYUwQ7Sk Feeler Taiwan Vertical Machining Center]
 
[http://www.youtube.com/watch?v=hhQz-b_C8N0 Moriseiki VMC]
 
Mechanical diagrams for [[CNC Circuit Mill]]
 
[[File: vmcex.pdf]]
 
[http://www.cuttingtoolengineering.com/dynamic.articles.php?id=193 Benefits of Linear Ways]
 
[[File: vmcex2.pdf]]
 
[http://www.climaxmetal.com/faq_result_2.htm Shaft Collars and Rigid Couplings]
 
How to connect two shafts together - use shaft couplings. A shaft coupling has 3 main considerations: how does it connect to one shaft, how does it connect to the other shaft, and how does the coupling connect in the middle? Shaft connection-wise, unless a weld is made (molecular bond between the coupling and shaft), either setscrews are used to tension down on the shaft, OR, a screw is tightened on the wall of the coupling to clamp the coupling on the shaft.
 
[http://makeprojects.com/Project/CNC+Mini+Mill+Conversion+Kit+%28Hardware%29/1295/3 Make Project Article with nice stepper motor to ballscrew pictures]
 
Based on everything I've learned so far about precision machine design: [http://opensourceecology.org/wiki/Precision_Machine_Design Precision Machine Design Tips]
 
Preparing for Thiel Fellowship review
 
==13/10/2012==
 
Recoveredering from minor sickness
 
Troubleshooting internet slowdowns - [https://en.wikibooks.org/wiki/Tomato_Firmware/Menu_Reference#Conntrack_.2F_Netfilter Tomato Wikibook] - Success!
 
Winterizing, organizing, cleaning Hablab with others. Great results.
 
TIG welder argon flowing! Solution was to use hose clamps on the regulator barb and machine barb.
 
Huge C Clamp order.
 
==12/10/2012==
 
Successfully troubleshooted hablab internet system
 
Oscilloscope on Arduino with Direct Digital Synthesis
 
Acquired tungsten rods and foods
 
Prototyped and documented [[Light Screen]]
 
Continued setting up TIG welder - argon not flowing?! - ah read the manual [[File: TIGTorchmanual.pdf]] and should try adjusting the knob of the regulator with a wrench.
 
[http://www.youtube.com/watch?v=pkeeBRpoJCc Advanced TIG Welding Setup]
 
Ordered 3/4"MPT to 3/4"FPT Lead-Free Brass Elbow
 
Ordered Geiger Counter after thoriated tungsten spook
 
==Thu Oct 11, 2012==
 
[[Inverter]] Development - Extent of Arduino's Functions
 
Successful materials for [[Light Screen]] from Sweiger Shop with Gabi
 
Setting up TIG welder
 
[http://www.youtube.com/watch?v=pg-kLHfXvLg How to Set Up a TIG Welder]
 
[http://www.youtube.com/watch?v=tAJUszNNudc&feature=relmfu How to TIG Weld]
 
Pure tungsten is appropriate for AC TIG welding (ex. 99.5%+ tungsten)
 
[http://www.millerwelds.com/resources/articles/tungsten-electrode-guide TIG Welding: Tungsten Electrode Guide]
 
==10/10/2012==
 
[[Inverter]] Development - Further topology development at [[Inverter Log]] and learnings from [https://en.wikipedia.org/wiki/Buck-boost_converter Buck Boost Converter at Wikipedia]
 
Discussion with Alexander Kiselev
 
[[CNC Circuit Mill]] Electronics Sourcing Research - Stepper Motors
 
[http://machinedesign.com/article/dynamics-of-hybrid-stepper-motors-0217 Dynamics of Hybrid Stepper Motors]
 
Winterizing items
 
==9/10/2012==
 
Organized [[Inverter]] development documentation
 
Produced and documented [[Terminal Block]] x2
 
[http://www.youtube.com/watch?v=1fiJupfbSpg Journey Inside the Cell: Information to Proteins]
 
[http://www.youtube.com/watch?v=i8c5JcnFaJ0&feature=related How Cells Obtain Energy]
 
[[Perspective]]
 
==8/10/2012==
 
Ordered more power strips and a light for the hablab
 
[http://askubuntu.com/questions/132640/dell-d630-with-ubuntu-12-04-fail-to-shut-down Fix for Ubuntu 12.04 Stuck at Shutdown]
 
Successful food acquisition trip with Gabi, Graham, and David
 
Successfully uploaded [[GRBL]] to Arduino Uno R3 using Ubuntu 12.04 - followed documentation from before, adding ruby and avrdude installation steps
 
Successful troubleshooting of [[Powercube]] V6 with Graham - faulty relay, temporary fix with connector-to-connector switching solution
 
Successfully started coordination of [[Inverter]] development, with the [[Inverter Log]] with Aaron
 
==7/10/2012==
 
Preparation for winterizing and organizing personals.
 
Civ5 and starcraft LAN party. Great mental exercise- lots of information processing.
 
==6/10/2012==
 
Mainly group construction work- sealing up gaps to winterize the hablab and organizing the backroom for better tool accessibility
 
Ordered various electronics parts for [[CNC Circuit Mill]] V2
 
==5/10/2012==
 
Specifying and hyperlinking mechanical/electronics/software for [http://opensourceecology.org/wiki/CNC_Circuit_Mill#Electronics CNC Circuit Mill V2]
 
Minor revisions to documentation presentation for the electronics projects in [[Open Source Technologies]]
 
Research into motor selection for spindle designs at [http://opensourceecology.org/wiki/Electronics_Info Electronics Design Info]
 
==4/10/2012==
 
The way to prevent premature latching on the CEB Press is to keep the hall effect sensors mounted parallel to the magnets' moving plane. This resolved all premature latching issues. CEB Press 4.0 fully operational. Optimized CEB Press Testing and Operation Code: [http://opensourceecology.org/wiki/File:CEBOperationTest.ino CEB Test and Operation Code]
 
Restocked food inventory.
 
Performed first aid and health operations on hurt/sick members of on-site team. Arrythmia and pre-hypertension concerns.
 
Improved documentation for the [[CEB Press]]
 
Ordered more aluminum flat bar, mainly for [[Terminal Block]] production
 
==3/10/2012==
 
Installed [[Hall Effect Sensor Module]] x2 on [[CEB Press]] V4.0 with bent pieces of aluminum flat bar and small C-Clamps.
 
Resolved a broken inverter issue with Marcin by connecting the workshop grid to one of the remaining inverters. Reliability is definitely a significant design principle.
 
Discussed short-term implementation of forums/stack overflow-like software to help development process. 2 major factors for the success of such software identified as access and action relevance. Access made easier with invites, action relevance made easier by the right questions to prompt the right answers.
 
Tested the CEB Press with manual control. Teamed up with Marcin to fix some issues. Troubleshooted total non-movement by increasing up the hydraulic pressure from the powercube. Troubleshooted primary cylinder non-movement by loosening front support plate, but discovered that the real problem was a loose quick connector connection from the primary solenoid valve. Full manual control success. Back to solo work.
 
Tested the CEB Press with test code. Troubleshooted weird sensor-triggered movement by examining sensor analog values. So! The hall effect sensors switch and latch on and off, but electrical noise and in-circuit imperfections cause fluctuating output signals. To add to the problem, the magnetic field of the magnets interact with the sensitivity of the sensors as to cause multiple latching events when the sensor passes a single magnet!
 
How to make the sensors work properly?
 
1. Take multiple sample readings and average them into a moderated value; this will diminish the effect of short-lived extreme fluctated signals. Increasing the number of samples per averaged reading and decreasing the delay time after each sample helps, but will be limited by the processing speed of the electronics.
 
2. Use separate upper and lower trigger values for the microcontroller to determine when the sensor has passed a magnet. This ensures that fluctuations that pass a trigger value can be safely ignored to an extent by the microcontroller. 2 values that help determine the upper and lower trigger values are: minimum value in the high-latched sensor state and maximum value in the low-latched sensor state. If possible, have the lower triggger lower than the aforementioned minimum value and the higher trigger higher than the aforementioned maximum value.
 
3. Use post-latch delays. That can be as simple as putting a fixed delay after each latch-switch. This helps minimize the effect of sensor sensitivity to strong irregular magnetic fields but limits the operating speed of the sensor-controlled movement (ex. if the delay is 1 second, then the magnets need to be at least 1 second apart for the microcontroller to have enough time to pick up on the next latch point as it passes the second magnet). CORRECTION: Forget this, the sensor still latches and it's just the microcontroller that doesn't respond until after the delay. No good. We don't want the sensor to prematurely latch in the first place.
 
Made significant revisions to the testing code for extreme troubleshooting ease. [http://opensourceecology.org/wiki/File:CEBOperationTest.ino CEB Press Test Code]
 
Tested the new test code to success after implementing all of the make-sensors-work-properly changes. Started to revise the operation code for continuous brick pressing.
 
Contacted Star Simpson about inverter design topologies.
 
[http://www.youtube.com/watch?v=D1eOQa1gYiU Scraping in a Dovetail - Detailed]
 
[[File: hardenedboxwayslides.pdf]]
 
[[File: dovetailslides.pdf]]
 
[[File: linearwayslides.pdf]]
 
[[File: cartridgeblockspindles.pdf]]
 
==2/10/2012==
 
Using arduino IDE 64-bit on ubuntu 12.04 - [http://blog.markloiseau.com/2012/05/install-arduino-ubuntu/ Guide to Arduino] make sure you open arduino as power user with '''sudo ./arduino''' when in the correct folder! Otherwise the serial port will be greyed out.
 
[http://opensourceecology.org/wiki/Hall_Effect_Sensor_Module Hall Effect Sensor Module V2] x2 complete
 
*Research for choosing between rod, dovetail, or boxed way for linear guide (whoa there's V-ways and half-round ways too!) Gah I need a free download of the book "Foundations of Mechanical Accuracy"
 
'''Dovetail'''
 
You are not under the impression that the dovetail cutter needs to be the full width of the female dovetail are you?The cutter only needs to be as tall as the dovetail.Your remark about not having large dovetail cutters prompts my question.
 
Dovetails only need 1 gib
 
Actually the dovetail is the simpler mechanism. It is simpler to make and simpler to adjust in use. The one gib at 45 or 60 degrees takes up slack both sideways and vertically. One adjustment and you are done.
 
I was afraid of the results before I made my first dovetail, but it is a piece of cake if you plan it properly. The setup is the same for both male and female parts. As mentioned above, you do not use a cutter that is the full width of the female dovetail. You use a standard milling cutter to rough out the center, usually to a depth slightly greater than the actual dovetail. then you cut each side individually. The cutter only needs to be tall enough to cut the whole angle at one time.
 
I used a CAD drawing and placed even sized circles tangent to both the angled sides and the flat top/bottom surfaces to give me a way of measuring the width of the dovetail. You can read the distance between them off the drawing to three or four places and them use drills or ground, round stock of the same size to measure your work. Just mike between them on the female dovetail and across them on the male. Real quick way of checking your work on the mill. Of course, with a gib, you don't need extreme accuracy.
 
'''Box'''
 
Boxed way more rigid than dovetail
 
Boxed way conventionally steel with turcite for anti-friction contact surface OR cast iron with oiling OR metal with high-pressure oil (hydrostatic)
 
Boxed way conventionally ground then scraped

Latest revision as of 03:49, 26 December 2012

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