Power Cube v17.08: Difference between revisions

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=Working Doc=
=Image=
<html><iframe src="https://www.facebook.com/plugins/post.php?href=https%3A%2F%2Fwww.facebook.com%2Fmarcin.jakubowski.378%2Fposts%2F10212113959861414&width=500" width="500" height="582" style="border:none;overflow:hidden" scrolling="no" frameborder="0" allowTransparency="true"></iframe></html>


=Development Template=
<html><iframe src="https://docs.google.com/spreadsheets/d/e/2PACX-1vRwKVP-LpQoNqqB8L3F6H5JOZnOwYkKXXjSXzL671DPkGhJamz0_PNgbNsONMj6Y9DGBeN_vos9s6hT/pubhtml?widget=true&amp;headers=false" height=500 width=500></iframe></html>
[https://docs.google.com/spreadsheets/d/1QcCknOFmX6KMrJjAiLlcJDOaPHEohe9zzWp5ITba6UY/edit#gid=1 edit]
=Visual BOM=
<html><iframe src="https://docs.google.com/presentation/d/1_0upal4AxXcXTAwsGRlZ_-dmfgahoYbuk7uQ7T5mI3E/embed?start=false&loop=false&delayms=3000" frameborder="0" width="480" height="299" allowfullscreen="true" mozallowfullscreen="true" webkitallowfullscreen="true"></iframe></html>
[https://docs.google.com/presentation/d/1_0upal4AxXcXTAwsGRlZ_-dmfgahoYbuk7uQ7T5mI3E/edit#slide=id.g2445af3d00_2_11 edit]
=Design Sprints=
==August 19, 2017==
<html><iframe width="560" height="315" src="https://www.youtube.com/embed/X3by_FqXBII" frameborder="0" allowfullscreen></iframe></html>
<html><iframe src="https://docs.google.com/presentation/d/1qFTCY8NBRKJCVjVTwvB_5yZROeEpCg_LLxgLip-GoRI/embed?start=false&loop=false&delayms=3000" frameborder="0" width="480" height="299" allowfullscreen="true" mozallowfullscreen="true" webkitallowfullscreen="true"></iframe></html>
[https://docs.google.com/presentation/d/1qFTCY8NBRKJCVjVTwvB_5yZROeEpCg_LLxgLip-GoRI/edit#slide=id.g244eeabb5b_0_0]
===Master CAD Checklist===
<html><iframe src="https://docs.google.com/spreadsheets/d/1ahDoGZIcGmyn55SfkNl6-K5-XY9GRMlOjQpcNwZqJVM/pubhtml?widget=true&amp;headers=false" height=500 width=1000></iframe></html>
[https://docs.google.com/spreadsheets/d/1ahDoGZIcGmyn55SfkNl6-K5-XY9GRMlOjQpcNwZqJVM/edit#gid=0 edit]
==August 5, 2017==
<html><iframe src="https://docs.google.com/presentation/d/17sdF8ByUDI5o6Ivxao410x7GDtIX1-eMVDXT0SJHeqU/embed?start=false&loop=false&delayms=3000" frameborder="0" width="480" height="299" allowfullscreen="true" mozallowfullscreen="true" webkitallowfullscreen="true"></iframe></html>
<html><iframe src="https://docs.google.com/presentation/d/17sdF8ByUDI5o6Ivxao410x7GDtIX1-eMVDXT0SJHeqU/embed?start=false&loop=false&delayms=3000" frameborder="0" width="480" height="299" allowfullscreen="true" mozallowfullscreen="true" webkitallowfullscreen="true"></iframe></html>


[https://docs.google.com/presentation/d/17sdF8ByUDI5o6Ivxao410x7GDtIX1-eMVDXT0SJHeqU/edit#slide=id.g2414dfd1e7_0_24 edit]
[https://docs.google.com/presentation/d/17sdF8ByUDI5o6Ivxao410x7GDtIX1-eMVDXT0SJHeqU/edit#slide=id.g2414dfd1e7_0_24 edit]


=CAD=
=BOM=
*[[File:PC_1708_Frame_module.fcstd]]
 
Other choices:
*12 gpm hydraulic pump - [https://www.ebay.com/sch/i.html?_odkw=.77+cu+in+hydraulic+pump&_osacat=11773&_from=R40&_trksid=p2045573.m570.l1313.TR0.TRC0.H0.X.77+cu+in+gear+hydraulic+pump.TRS0&_nkw=.77+cu+in+gear+hydraulic+pump&_sacat=11773]
<html><iframe src="https://docs.google.com/spreadsheets/d/1gSEDpCuw396kT4vpgTbN5oE7AvCyfc5D_9iEDvg9U5c/pubhtml?widget=true&amp;headers=false" height=500 width=900></iframe></html>
 
[https://docs.google.com/spreadsheets/d/1gSEDpCuw396kT4vpgTbN5oE7AvCyfc5D_9iEDvg9U5c/edit#gid=0 edit]
 
=Hydraulics=
<html><iframe src="https://docs.google.com/presentation/d/14iQzih2qhDux-Jg7hpEas_uV-CUXFNVd8e6vqfEMcls/embed?start=false&loop=false&delayms=3000" frameborder="0" width="480" height="299" allowfullscreen="true" mozallowfullscreen="true" webkitallowfullscreen="true"></iframe></html>
 
[https://docs.google.com/presentation/d/14iQzih2qhDux-Jg7hpEas_uV-CUXFNVd8e6vqfEMcls/edit#slide=id.g1861bf60d5_0_6 edit]
 
=Part Library - CAD Modules=
==Master File==
<gallery perrow=6>
File:Power Cube v17.08.png|[[File:PC1708_Master.fcstd]]
</gallery>
 
==Frame module==
 
<gallery perrow=6>
File:PC_1708_Frame_module.png|[[File:PC_1708_Frame_module.fcstd]]
File:PC_1708_Frame_right_side.png|[[File:PC_1708_Frame_right_side.fcstd]] - [[File:PC_1708_Frame_right_side.dxf]]
File:PC_1708_Frame_Tank_inner_side.png|[[File:PC_1708_Frame_Tank_inner_side.fcstd]] - [[File:PC_1708_Frame_Tank_inner_side.dxf]]
File:PC_1708_Frame_Tank_inner_side_single_hole.png|[[File:PC_1708_Frame_Tank_inner_side_single_hole.fcstd]] - [[File:PC_1708_Frame_Tank_inner_side_single_hole.dxf]]
File:PC_1708_Frame_Tank_side.png|[[File:PC_1708_Frame_Tank_side.fcstd]] - [[File:PC_1708_Frame_Tank_side.dxf]]
File:PC_1708_Frame_common_sides.png|[[File:PC_1708_Frame_common_sides.fcstd]] - [[File:PC_1708_Frame_common_sides.dxf]]
File:PC_1708_Frame_top_side.png|[[File:PC_1708_Frame_top_side.fcstd]] - [[File:PC_1708_Frame_top_side.dxf]]
File:PC_1708_Frame_bottom_side.png|[[File:PC_1708_Frame_bottom_side.fcstd]] - [[File:PC_1708_Frame_bottom_side.dxf]]
</gallery>
 
==Frame Fittings==
 
===See the ISO 7241-1 A for hydraulic couplers [http://opensourceecology.org/wiki/ISO_7241-1_A]===
 
'''Fittings for frame and pump are: 3/4" for hex nip, 1" for hose barb. The ones below are 1/2" and 3/4" barb.'''
 
<gallery perrow=6>
File:hex_nipple_0.5in.png|[[File:hex_nipple_0.5in.stp]]
File:hex_nipple_0.25in.png|[[File:hex_nipple_0.25in.stp]]
File:barb_to_nptm.png|[[File:barb_to_nptm.stp]]
File:3Quarter NPT Hex Nipple.png|[[File:3Quarter NPT Hex Nipple.fcstd]]
File:1 2 to 3 4 Swivel.png|[[File:1 2 to 3 4 swivel.FCStd]]
File:1 2 to 3 4 NPT HexNipple.png|[[File:1 2 to 3 4 NPT HexNipple.FCStd]]
File:3 4 quick coupler female img.png|[[File:3 4 quick coupler female.FCStd]]
File:3 4 quick coupler male img.png |[[File:3 4 quick coupler Male.FCStd]]
 
</gallery>
 
==Other Parts==
 
<gallery perrow=6>
File:PC_1708_engine.jpg|[[File:Xp16hp.FCStd]]
File:Hydraulic Pump.png|[[File:Hydraulic Pump.fcstd]]
File:Two stage hydraulic pump.png|[[File:2 Stage Hydraulic Pump.fcstd]]
File:PC_1708_coupler.png|[[File:PC_1708_coupler.fcstd]]
File:PC_1708_cooler.png|[[File:PC_1708_cooler.fcstd]]
File:PC_1708_fan.png|[[File:PC_1708_fan.fcstd]]
File:PC_fan_12inch.jpg|[[File:PC_fan_12inch.fcstd]]
File:PC_1708_oil_filter.png|[[File:PC_1708_oil_filter.fcstd]]
File:PC Cooler 1240.png|[[File:PC 1240 cooler.fcstd]]
 
</gallery>
 
 
*[[File:PC_1708_engine.fcstd]]
*[[File:PC_1708_engine.fcstd]]
*[[File:PC_1708_enginemount.fcstd]]
*[[File:PC_1708_enginemount.fcstd]]
*[[File:Hydraulic Pump.fcstd]]
*[[File:PC_1708_coupler.fcstd]]
*[[File:PC_1708_reservoir.fcstd]]
*[[File:PC_1708_reservoir.fcstd]]
*[[File:PC_1708_cooler.fcstd]]
*[[File:PC_1708_battery.fcstd]]
*[[File:PC_1708_battery.fcstd]]
*[[File:PC_1708_fan.fcstd]]
*[[File:PC_1708_oil_filter.fcstd]]


=Concept=
=Concept=
Line 50: Line 135:
*10 hp - no cooler - [https://www.grainger.com/product/MONARCH-10-HP-208-230-460VAC-Hydraulic-38VP33?functionCode=P2IDP2PCP]
*10 hp - no cooler - [https://www.grainger.com/product/MONARCH-10-HP-208-230-460VAC-Hydraulic-38VP33?functionCode=P2IDP2PCP]
*13 hp - no cooler - [https://www.grainger.com/product/CHIEF-24-x-40-x-24-20-gal-Hydraulic-19NE38?s_pp=false&picUrl=//static.grainger.com/rp/s/is/image/Grainger/19NE38_AS01?$smthumb$]
*13 hp - no cooler - [https://www.grainger.com/product/CHIEF-24-x-40-x-24-20-gal-Hydraulic-19NE38?s_pp=false&picUrl=//static.grainger.com/rp/s/is/image/Grainger/19NE38_AS01?$smthumb$]
=BOM=
https://docs.google.com/spreadsheets/d/17A2_Cz06kJ4zdmLwL8ztUeKRhsdrs7s2f8Z_URgP-Yo/edit#gid=0


=Parts=
=Parts=
*18hp,  
*18hp,  
*Log splitter pump - [http://www.ebay.com/itm/16-GPM-Hydraulic-Log-Splitter-Pump-2-Stage-Hi-Lo-Gear-Pump-Logsplitter-NEW-/271448842407] - only 8 hp for 13/3 gpm 650/2500 PSI
*Log splitter pump - [http://www.ebay.com/itm/16-GPM-Hydraulic-Log-Splitter-Pump-2-Stage-Hi-Lo-Gear-Pump-Logsplitter-NEW-/271448842407] - only 8 hp for 13/3 gpm 650/2500 PSI
=Data Collection=
*One of starter switch attachment bolts broke off
*Fuel tank is too hard to fill with fan on top of power cube
*Pull cord got tied up inside pull cord case
=Future Quality Control Learnings - verify bolt tightness on engine for all attachments
=Future Work=
*Verification of fuel tank and engine attachments longevity - fuel tank or starter switch breaking off from vibration
*Open source scalable engine with throttle control, gasifier-based


=Links=
=Links=
*[[Power_Cube_Design_Sprint_2017]]
*[[Power_Cube_Design_Sprint_2017]]
*[[Hydraulic Cooler Sizing]]
*[[Hydraulic Hose Sizing]]
*[[Power Cube Library]]
[[Category:Power_Cube]]

Latest revision as of 18:51, 26 May 2018

Image

Development Template

edit

Visual BOM

edit

Design Sprints

August 19, 2017

[1]

Master CAD Checklist

edit

August 5, 2017

edit

BOM

Other choices:

  • 12 gpm hydraulic pump - [2]

edit

Hydraulics

edit

Part Library - CAD Modules

Master File

Frame module

Frame Fittings

See the ISO 7241-1 A for hydraulic couplers [3]

Fittings for frame and pump are: 3/4" for hex nip, 1" for hose barb. The ones below are 1/2" and 3/4" barb.

Other Parts


Concept

In order to make the Power Cube much more accessible, we can use a smaller engine - 18 hp - which is approximately 1/3 the effective cost of a 27 HP engine. This would allow us to make smaller machines possible, such as an 18hp walk-behind tractor. The lower cost of the 18hp option allows for wider replicability, and may allow operation without a hydraulic cooler in some applications - reducing cost and complexity significantly. Several major improvements include:

  • Design for stable operation with biomass charcoal pellets to move in the direction of renewable energy biofuels that are 10x as efficient as liquid biofuels to produce
  • Design for modularity - allowing for interchangeable hydraulic pumps. To date, we have not been using design-for-interchange (completely modular hydraulic pumps) due to the complexity of pump-to-motor coupling. By creating a smart coupling interface, hydraulic pump modularity is feasible, and is the next logical step. This would allow use of the Power Cube
  • Simplified frame CNC cut from metal sheet, as opposed to angle, as developed for D3D and as was discovered is easier to fabricate. With 13 IPM Welding Travel Speed - a frame can be laid up quickly and welded 24", 12 sides - in 1/2 hour. That is quicker than the standard power cube with angle, where most of the time was spent in setup and squaring. Squaring is automatic in the next case.
  • Material waste could be significant, but not if each side is cut in 2 pieces, so that 12 frame pieces are first welded into 6 sides, then the assembly is welded into the finished product. This moves steel sheet use efficiency from 30% to about 90% efficient for 2' frames.
  • Focus on even easier access to parts.
  • Remote throttle and starting cable.
  • Pull start for use without battery

Minimum viable product:

  1. Engine
  2. Pump with quick connects.

No hydraulic cooler, cooler fan, cooler grate and battery. Good for intermittent use, or coninuous below 75F ambient temperature.

Pumping

  • 2 stage 28 gpm pump at high flow, 7 gpm at low flow, requires 16 hp of engine drive. [4]
  • High flow rate would require a larger 3.5" hydraulic cylinder on the drawer.
  • Solenoids are 26.4 - just 6% undersize but that is minimal and the machine runs at this flow only a small fraction of the time.

Thermal Design

  • With 18hp, there are conditions under which hydraulic cooling is not necessary.
  • Piston efficiency - 90-95% - [5]
  • Hydraulic gear pump efficiency - 85%
  • Dissipation is 25-40% of input power - 4.5 hp to 7.2 hp
  • For 18 hp, 5.4kW of heat dissipation may occur passively through the metal in the Power Cube
  • Heat goes into the hydraulic oil at every place in the system where there is a PSI pressure loss due to flow of oil without mechanical work being produced. -[Heat goes into the hydraulic oil at every place in the system where there is a PSI pressure loss due to flow of oil without mechanical work being produced.- [6]
  • Every square foot of tube heat exchanger at 50F difference dissipates 2hp of heat - [7]. Same source indicates about 1 hp heat loss from a hydraulic reservoir of 10 sq feet area at a 100F temperature difference.

Products

  • 10 hp - no cooler - [8]
  • 13 hp - no cooler - [9]

Parts

  • 18hp,
  • Log splitter pump - [10] - only 8 hp for 13/3 gpm 650/2500 PSI

Data Collection

  • One of starter switch attachment bolts broke off
  • Fuel tank is too hard to fill with fan on top of power cube
  • Pull cord got tied up inside pull cord case

=Future Quality Control Learnings - verify bolt tightness on engine for all attachments

Future Work

  • Verification of fuel tank and engine attachments longevity - fuel tank or starter switch breaking off from vibration
  • Open source scalable engine with throttle control, gasifier-based

Links

Retrieved from "https://wiki.opensourceecology.org/index.php?title=Power_Cube_v17.08&oldid=172532"