Power Cube v15.6: Difference between revisions

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=Instructional=
=Instructional=
==Frame Assembly==
<html><iframe width="560" height="315" src="https://www.youtube.com/embed/AgxTk7EZtNc" frameborder="0" allowfullscreen></iframe></html>
=Other Modules=
All the modules are linked on Page 1 of this document:
<html><iframe src="https://docs.google.com/presentation/d/1KJWzIyvMWcBeTGwfwGl9oNQn1V3dKXnyISVlqUzCwXE/embed?start=false&loop=false&delayms=3000" frameborder="0" width="960" height="569" allowfullscreen="true" mozallowfullscreen="true" webkitallowfullscreen="true"></iframe></html>
<html><iframe src="https://docs.google.com/presentation/d/1KJWzIyvMWcBeTGwfwGl9oNQn1V3dKXnyISVlqUzCwXE/embed?start=false&loop=false&delayms=3000" frameborder="0" width="960" height="569" allowfullscreen="true" mozallowfullscreen="true" webkitallowfullscreen="true"></iframe></html>
==Sample 3D Print==
==Sample 3D Print==
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=Introduction=
=Introduction=


The Power Cube, Version 7s is a powerful, portable hydraulic power supply that operates efficiently and with minimal noise.  The design combines a 28 HP Briggs & Stratton engine and a fixed-displacement hydraulic pump that has proven to work well with OSE machines and for other compatible hydraulic machines. This version includes a frame of 4" x 4" tubular steel that provides a strong structural frame for mounting other power cubes or attachments.
The Power Cube, Version 15.6 is a powerful, portable hydraulic power supply that operates efficiently and with minimal noise.  The design combines a 28 HP Briggs & Stratton engine and a fixed-displacement hydraulic pump that has proven to work well with OSE machines and for other compatible hydraulic machines. This version includes a frame of 4" x 4" tubular steel that provides a strong structural frame for mounting other power cubes or attachments.


The Power Cube 7s marks the next level of quick connect modularity, making it easy to assemble, use and maintain and is standard for all hydraulic equipment in the Global Village Construction Set.
The Power Cube marks the next level of quick connect modularity, making it easy to assemble, use and maintain and is standard for all hydraulic equipment in the Global Village Construction Set.


NOTE: This document is still under development and is not ready yet for "Prime Time" fabrication. This note will be removed when it has reached a "comfortable" level of completion.
NOTE: This document is still under development and is not ready yet for "Prime Time" fabrication. This note will be removed when it has reached a "comfortable" level of completion.
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=Files=
=Files=
These is the latest release.  See file revision history for other versions.
These is the 15.6 release.  See file revision history for other versions.


'''Bill Of Materials''' (BOM): [https://docs.google.com/spreadsheets/d/1ncYW6sCtBuj71nHp1o_hJvjoZYJWA-tSDTGV05P44kY/edit#gid=606109794 Power Cube BOM]
'''Bill Of Materials''' (BOM): [https://docs.google.com/spreadsheets/d/1ncYW6sCtBuj71nHp1o_hJvjoZYJWA-tSDTGV05P44kY/edit#gid=606109794 Power Cube BOM]
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The Power Cube is a modular design.  The modules are built separately, then combined for the complete Power Cube. The order of module fabrication is not important, but they are all necessary to complete a Power Cube.
The Power Cube is a modular design.  The modules are built separately, then combined for the complete Power Cube. The order of module fabrication is not important, but they are all necessary to complete a Power Cube.


Module fabrication procedures are detailed below:
Module fabrication procedures are detailed in the following document:


==Fuel Tank Module==
[https://docs.google.com/presentation/d/1KJWzIyvMWcBeTGwfwGl9oNQn1V3dKXnyISVlqUzCwXE Module Assembly]
* Drawings: [[media:Fuel_tank.pdf]], [[media:Fuel_tank_assy.pdf]]


* Cut Steel: 3/16" x 6" x 12" x 22" tube and 2 each: 1/4" x 6" x 12", 1/4" x 4" x 4" and 1/4" x 1" x 4"
* Cut holes in tube per drawing (drill small hole, torch large hole)
* Test that fuel pickup fits in small hole - grind / file hole to fit
* Grind ends of tube square if cut with torch
* Weld end plate to tube end nearest fuel filler
** See note below for welding: Hydraulic_Reservoir_and_Fuel_Tank
* Weld fuel filler neck (use low setting for thin steel)
* Assemble Fuel Pickup
** Insert tube into compression fitting and tighten hand-tight, then wrench-tighten 1/2 turn. Loosen and set the tube part down. Wrap teflon tape on threads of hose barb and thread into top of compression fitting and tighten (don't overdo it: we're working with brass).
:: [[File:Fuel_Pickup.png|600px]]


* Let tank cool, apply gasket sealant to smaller hole and install fuel pickup
==Wiring Harness==
** Reach inside the open end of the tank with tube, align with hole and screw top of compression fitting from above, then tighten.
* Weld remaining end plate
* Weld mounting brackets together, then to tank (do not weld inside edge of bracket)
:: [[File:Tank_Bracket.png|300px]] [[File:Tank_Bracket_Weld.png|450px]]
* Weld control panel bracket to tank
* Weld bolts to tank, using upper pump plate for alignment
* Put cap on fuel filler and rubber hose on hose barb.  Pressure test with compressed air and soapy water and re-weld as necessary until all leaks stopped.
* Paint entire fuel tank except for hose barb, top of fuel filler and cap.
:: [[File:Fuel_Tank.png|600px]]


==Hydraulic Reservoir==
The Wiring Harness now includes a plug to allow the keyswitch to be repositioned outside the Power Cube.


Fabrication of the Hydraulic reservoir is now an online document:
* '''Drawing''' (click for larger view)
[[File:wiringharness.png|600px]]


[https://docs.google.com/presentation/d/1n_qFxVvpho6jdH10fcJ7wr-xI0ZTKe01cXbjoivsTB4/edit#slide=id.p Hydraulic Reservoir]
* '''Photo'''
[[File:wiringharnessphoto.png|600px]]


[[File:Hydraulic_Reservoir.png|600px]]
<html><iframe width="420" height="315" src="https://www.youtube.com/embed//eLLylgc73sI" frameborder="0" allowfullscreen></iframe></html>


==Engine Module==
* '''Battery Terminals'''
* Drawings: [[media:engine.pdf]]


* Cut plate: 8“ x 15 1/2“, grind edges
<html><iframe width="420" height="315" src="https://www.youtube.com/embed//pn9nxd9DBr0" frameborder="0" allowfullscreen></iframe></html>
* Torch and grind large holes
* Drill small (5/16“) holes, grind slots
* Paint plate, let dry
* Bolt plate to engine
* Bolt muffler to engine with gaskets between muffler and engine ports
* Bolt muffler extension to muffler with 1 1/2" "U" bolt
[[File:Engine_Module.png|600px]]


* Shaft Coupler
* '''Engine Connections'''
** Cut both shaft couplings in half, set aside one half of each coupling
** Insert alignment plug, clamp end-to-end with C-clamp and weld couplers together
*** Note: Touching coupling faces should be machined faces (not cut faces)
** Remove plug (use hammer & blunt punch)
** Let cool, then insert key into engine shaft slot, then secure coupling to engine shaft with set screw
** Note that once engine is mated with pump, the shaft coupler should be checked to insure that it fully engages teeth of pump shaft.  This may require loosening the set screw and sliding the coupler down - but don't let it rest against pump casing.


[[File:Shaft_Coupling.png|Shaft Coupling Detail]]
<html><iframe width="420" height="315" src="https://www.youtube.com/embed//v8aDXRBKHKw" frameborder="0" allowfullscreen></iframe></html>
 
<html><iframe width="420" height="315" src="https://www.youtube.com/embed//GDALEaHXt1g" frameborder="0" allowfullscreen></iframe></html>


* Note: The alignment of the shaft coupler must be precise.  The plug aligns the couplers while welding.  See the OSE order page for completed couplings.
===Wiring Harness Extension===


==Pump Module==
This version of the wiring harness is designed with a connector allowing the switch to be replaced with a switch with longer wires so it can be used remotely - say from the cab of a tractor.
* Drawings: [[media:pump.pdf]], [[media:pump_assy.pdf]]


* Cut plates and angle iron
The assembly for this extension is the same as for the original switch wiring, except with longer wires:
* Torch large holes, drill small  (5/16“) holes
* Grind edges, test fit pump & bolts
* Space angle iron evenly on 6“ plate as shown below, 1/4 from edges. Tackweld inside corner of angle iron, then outer corners
* Weld outer and inner edges
[[File:Pump_Module1.png|400px]]


* Stack pump plates as shown in diagram below (pay attention to 3/4" holes in larger plate)
[[File:wiringharnessextension.png|400px]]
* Add 4 1/4" spacers between plates as shown
** Note: Spacers should provide 1/8" standoff from other angle iron and have VERY perpendicular and smooth edges
* Use two C-clamps to clamp plates securely to spacers - they should be directly inline with spacers
** Precision note: Plates must be parallel else shaft may bind.  Before welding, check that plates are spaced evenly.
* Tackweld inside corners (do not weld spacers)
* Weld inside and out, remove clamps & spacers
[[File:Pump_Module2.png|600px]]


* Bolt pump to plate assembly
The parts for this extended switch are:
* Install hosebarb on pump
* Install elbow on pump loosely
* Note: keep holes on pump plugged to prevent debris
[[File:Pump_Module_Final.png|600px]]
* Note: The alignment of the upper and lower pump plates are critical for proper shaft alignment.  Completed pump brackets are available from the OSE Store.


==Oil Cooler Module==
* Stens Switch 430-538 http://www.amazon.com/Stens-Starter-Switch-AM102551-430-538/dp/B000VYNG7E/ref=sr_1_1?ie=UTF8&qid=1434834238&sr=8-1&keywords=430-538
* Drawing: [[media:oil_cooler.pdf]]


* Carefully unbox oil cooler
* Stens Wiring Harness 430-223 http://www.amazon.com/Stens-UNIVERSAL-WIRING-HARNESS-430-223/dp/B001OK9ZDI/ref=sr_1_1?ie=UTF8&qid=1434833949&sr=8-1&keywords=430-223
* Wrap NPTM elbow threads with teflon tape
* Screw NPTM ends of elbows into cooler, tighten so JIC elbow ends point as in illustration
* Secure fan to cooler
[[File:Oil_Cooler.png|600px]]


==Control Panel Module==
* 5-Way Trailer Connector:
* Drawings: [[media:PC7s_control_panel.pdf]], [[media:PC7s_control_panel_assy.pdf]]


* Torch large holes, drill small holes
** 4 ft: http://www.amazon.com/Wesbar-Trailer-Connector-Wishbone-Harness/dp/B0009TNRS4/ref=sr_1_3?ie=UTF8&qid=1439331487&sr=8-3&keywords=5-way+trailer+connector
* File key hole to fit switch
* Grind all edges
* Weld bracket for throttle
* Install throttle and keyswitch
* Install quick connectors using teflon tape


[[File:PC7s_Control_Panel_front.png|600px]]
* 30 ft: http://www.amazon.com/Trailer-Wishbone-Wire-Harness-Flat/dp/B007NU2Z7G/ref=pd_sim_sbs_263_5?ie=UTF8&refRID=06CNS4DVVD5EXT4D2J6F


[[File:PC7s_Control_Panel_back.png|600px]]
* Switch Mounting Bracket, nuts and bolts to secure the bracket


==Frame Module==
* Flexible Conduit: http://www.amazon.com/BLACK-SPLIT-TUBING-Cover-Polyethylene/dp/B00KDN9IGQ
* Drawing: [[media:PC7s_frame.pdf]]
 
* Cut tube steel, flat bar, rebar and expanded steel
* Weld the battery box and tank supports
* Cut holes in the expanded steel and bolt in place
 
[[File:PC7s_Frame.png|600px]]
 
==Solenoid Module==
* Drawing: [[media:Solenoid Module.png]]
 
* Bend one cooler support to match holes on fuel tank
* Mount solenoid on support braket (made above)
 
[[File:Solenoid_Module.png|600px]]
 
[[File:Solenoid_Photo.png|600px]]
 
==Wiring Harness==
 
The Wiring Harness now includes a plug to allow the keyswitch to be repositioned outside the Power Cube.
 
* '''Drawing''' (click for larger view)
[[File:wiringharness.png|600px]]
 
* '''Photo'''
[[File:wiringharnessphoto.png|600px]]
 
<html><iframe width="420" height="315" src="https://www.youtube.com/embed//eLLylgc73sI" frameborder="0" allowfullscreen></iframe></html>
 
* '''Battery Terminals'''
 
<html><iframe width="420" height="315" src="https://www.youtube.com/embed//pn9nxd9DBr0" frameborder="0" allowfullscreen></iframe></html>
 
* '''Engine Connections'''
 
<html><iframe width="420" height="315" src="https://www.youtube.com/embed//v8aDXRBKHKw" frameborder="0" allowfullscreen></iframe></html>


==Final Assembly==
==Final Assembly==
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* Install hoses to connect hydraulics and tighten appropriately
* Install hoses to connect hydraulics and tighten appropriately
* Install Wiring Harness to key switch, connect to fan and solenoid (do not connect "+" battery connection yet)
* Install Wiring Harness to key switch, connect to fan and solenoid (do not connect "+" battery connection yet)
* Install Engine module:
* Install Engine module:
** Lower Engine Module gently until shaft coupling contacts pump shaft, rock/turn engine until shaft engages pump
** Lower Engine Module gently until shaft coupling contacts pump shaft, rock/turn engine until shaft engages pump
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** Connect cable from solenoid to starter and tighten carefully
** Connect cable from solenoid to starter and tighten carefully
* Install battery in battery box
* Install battery in battery box
** Connect "+" battery cable to battery
** Connect battery cables to battery


Overview: [[File:PC7s_Fabrication.pdf]]
Overview: [[File:PC7s_Fabrication.pdf]]

Latest revision as of 02:53, 7 September 2016

Latest version: (download here - you can also download STL for printing)

Development Spreadsheet

edit


Instructional

Frame Assembly

Other Modules

All the modules are linked on Page 1 of this document:

Sample 3D Print

Does not come out well if it's a monolithic small print of about 1 cubic inch size.

Smallcube3dprint.jpg

Introduction

The Power Cube, Version 15.6 is a powerful, portable hydraulic power supply that operates efficiently and with minimal noise. The design combines a 28 HP Briggs & Stratton engine and a fixed-displacement hydraulic pump that has proven to work well with OSE machines and for other compatible hydraulic machines. This version includes a frame of 4" x 4" tubular steel that provides a strong structural frame for mounting other power cubes or attachments.

The Power Cube marks the next level of quick connect modularity, making it easy to assemble, use and maintain and is standard for all hydraulic equipment in the Global Village Construction Set.

NOTE: This document is still under development and is not ready yet for "Prime Time" fabrication. This note will be removed when it has reached a "comfortable" level of completion.


Features

  • Compact hydraulic power source for OSE and other compatible hydraulic tools
  • Electric start, 28 horsepower air-cooled engine
  • Briggs & Stratton muffler for low noise level
  • Controls easily accessible for safety and comfort
  • Standard quick connect hydraulic couplers
  • Modular design simplifies maintenance and parts replacement
  • Removable 7 gallon oil reservoir and fuel tank
  • Heavy duty 6-tube oil cooler with fan cool the hydraulic fluid
  • Sturdy tubular frame protects unit from damage and provides a simple means for adding attachments
  • Pressure relief valve limits the output pressure for safety
  • Pressure gauge

Specifications

  • Model: OSE Power Cube, Version 7s
  • Engine: Briggs & Stratton Professional Series, 28 HP
  • Fuel Capacity: 7 Gallons
  • Pressure (maximum): 3000 PSI
  • Flow (maximum): 15.2 GPM
  • Weight (approximate): 400 lbs

Development

The Power Cube has gone through a series of updates and this page reflects the current designs of Version 7s of the Power Cube.

Power Cube 7s

This design has proven to work well and has had few updates lately. Here are the latest updates: 

Oct 2014: Added a pressure relief valve and associated plumbing - TLG.
Oct 2014: Changed sight gauge to shorter model and moved above the suction strainer for greater visibility - TLG.
Apr 2015: Added a pressure gauge - TLG.
May 2015: Moved the filler neck near the center of the tank to prevent fuel leaks due to side-to-side "sloshing".
Jun 2015: Changed fuel filler to use extended neck (from coyote-gear.com) to reduce leaks due to "sloshing":

ExtendedFuelFillerNeck.png Extended Fuel Filler Neck

Files

These is the 15.6 release. See file revision history for other versions.

Bill Of Materials (BOM): Power Cube BOM

Power Cube Working Document: ["https://docs.google.com/presentation/d/1oJbd8zQPIdDcFlyZn8Gj6_swQh8RWOkQLQ6hae8pHZ0/embed?start=false&loop=false&delayms=3000"]

Wiring Diagram: File:PC15.6WiringDiagram.dia Wiring Diagram

Fabrication Steps

The Power Cube is a modular design. The modules are built separately, then combined for the complete Power Cube. The order of module fabrication is not important, but they are all necessary to complete a Power Cube.

Module fabrication procedures are detailed in the following document:

Module Assembly


Wiring Harness

The Wiring Harness now includes a plug to allow the keyswitch to be repositioned outside the Power Cube.

  • Drawing (click for larger view)

Wiringharness.png

  • Photo

Wiringharnessphoto.png

  • Battery Terminals

  • Engine Connections

Wiring Harness Extension

This version of the wiring harness is designed with a connector allowing the switch to be replaced with a switch with longer wires so it can be used remotely - say from the cab of a tractor.

The assembly for this extension is the same as for the original switch wiring, except with longer wires:

Wiringharnessextension.png

The parts for this extended switch are:

  • 5-Way Trailer Connector:
  • Switch Mounting Bracket, nuts and bolts to secure the bracket

Final Assembly

  • Install Fuel Tank module in frame (fuel tank goes beside battery box)
  • Install Hydraulic Reservoir module in frame
  • Install Pump module and Solenoid module
  • Install oil cooler and fan to expanded steel
  • Install hoses to connect hydraulics and tighten appropriately
  • Install Wiring Harness to key switch, connect to fan and solenoid (do not connect "+" battery connection yet)
  • Install Engine module:
    • Lower Engine Module gently until shaft coupling contacts pump shaft, rock/turn engine until shaft engages pump
    • Install 3/4" bolts / washers / nuts, securing engine plate to pump plate
    • Remove nut from right rear engine bolt, place black battery on bolt, replace nut and tighten
    • Connect electrical connector from wiring harness to engine
    • Connect fuel hose from fuel tank to engine
    • Connect cable from solenoid to starter and tighten carefully
  • Install battery in battery box
    • Connect battery cables to battery

Overview: File:PC7s Fabrication.pdf

Note: Welding Hydraulic Reservoir 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, Marcin 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).

Fabrication

Hydraulic Sight Gauge


Power Cube Assembly Video Script

Steps for Instructional Assembly Video Script

Research

  • Mechanical shaft quick coupling patent - [1]

July 2014 - Structural Power Cube

The frame of the Structural Power Cube is designed for stacking of multiple power cubes. This documents is about the angle iron frame Power Cube for applications where only one or two Power Cubes are required. Here is the link to the Structural Power Cube: 

Link: Structural Power Cube
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