April 2011 Production Run BOM: Difference between revisions

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[http://openfarmtech.org/weblog/2010/09/extreme-traction/ Update] as of Sep. 7, 2010:


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<object width="500" height="310"><param name="allowfullscreen" value="true" /><param name="allowscriptaccess" value="always" /><param name="movie" value="http://vimeo.com/moogaloop.swf?clip_id=14718706&amp;server=vimeo.com&amp;show_title=1&amp;show_byline=1&amp;show_portrait=1&amp;color=&amp;fullscreen=1&amp;autoplay=0&amp;loop=0" /><embed src="http://vimeo.com/moogaloop.swf?clip_id=14718706&amp;server=vimeo.com&amp;show_title=1&amp;show_byline=1&amp;show_portrait=1&amp;color=&amp;fullscreen=1&amp;autoplay=0&amp;loop=0" type="application/x-shockwave-flash" allowfullscreen="true" allowscriptaccess="always" width="500" height="310"></embed></object><p><a href="http://vimeo.com/14718706">Extreme Traction</a> from <a href="http://vimeo.com/user2016419">Marcin Jakubowski</a> on <a href="http://vimeo.com">Vimeo</a>.</p>
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Revision as of 04:15, 26 April 2011

Lt24.jpg Lt25.jpg Lt26.jpg

Download open source tractor 3D source code

Cut List

Square tube:

  • 4 × 76"×4"×4" tubes for base (shortened by 16")
  • 3 × 5'×4"×4" under base tubes.
  • 2 × 52"×4"×4" vertical chassis centre tubes.
  • 2 × 55"×4"×4" vertical chassis tubes for front corners.
  • 2 × 59"×4"×4" vertical chassis tubes for rear corners (PC mounting area).
  • 2 × 68"×4"×4" top chassis tubes.
  • 3 × 44"×4"×4" top chassis tubes.

Rounds:

  • [4] 28" × 1-7/8" axle shafts (22" before; turn gussets around for easy wheel takeoff)
  • [1] 56"×1-7/8" loader shaft.

Rectangle:

  • [2] 100"×6"×3" 3/8" tubes for front loader arms.
  • [4] 6"×4" 1/2" angle-iron to attach re-enforcing tunes to Loader arms.
  • [4] 4-1/2" 1-7/8" DOM to mount shafts through the frame.
  • [4] 3-1/2" 1-7/8" DOM to mount loader shafts to loader arms.
  • [8] thrust bearings - in the form of large washers with 1-7/8" hole to go between frame-shaft-DOM-mounts and loader arm mounts.
  • [4] 6" bushings/DOM to weld in gussets and wheel mounts.

Plate:

  • [12] 10"×8"×0.5" steel plates to mount flange bearings and hydraulic motors to frame.
  • [4] 6"×8"×1/2" QA-plate to mount motors to QA-motor plate.
  • [2] 6?"×12"×1/2" plate to mount H-cylinders to frame base.
  • [4] 6"×4"×1/2" plate to weld to H-cylinder base plates.
  • [8] 1" diameter-hole nuts to weld into above plates.
  • [1] 1/4" 4or5"×36" plate to mount Valves to.
  • [4] 8"×12"×3/8" plate to connect Front H-cylinders to loader-arms.
  • [4] 12×10×1/2" plates to make wheel mounts.
  • [8] 4"×4"×1/2" plate cut diagonally to make [16] gussets.
  • [4] × 32"diameter × 9" wheels.
  • [16] thrust bearings - in the form of large washers with 1-7/8" hole - torch these on torch table from 1/8" stock

P.C. & Seat mounting metal:

  • [1] 144" 4×4" 1/4" thick angle Iron
  • [1] 88" 2×2" 1/4" angle iron
  • [1] 192"×4" 3/8" plate

Bolts

Functionality list:

  • [22] 5"bolts+nuts + [44] washers to suit to attach re-enforcing tubes, angle-irons & H/cylinders to L-arms.
  • [40] 3/4x5-1/2", with [40] washers for one side and [40] metal lock nuts for the other side. For wheel plates & cylinder plates.
  • [42] 3/4"x9" bolts, [80] washers, and [40] metal lock nuts. This is for the assembly of the main frame.
  • [16] 1/2"x2" bolts + [16] nylon lock nuts + [16] lock washers to suit. Motor attachment to motor QA/interface plate. Equivalent to 32" of threaded rod.
  • [8] 3/4"x2" bolts for motor; [8] nuts to weld; [8] lock washers. Attachment of motor interface plate to frame.
  • [32] 5/8"x2"bolts + [32] metal lock nuts, [32] lock washers to suit. Mounting of bearings to frame.
  • [32] 9/16"x2" fine thread bolts, [32] washers, [32] nylon lock nuts. Attachment of wheel to wheel hub. Includes studs, nuts, and washers.
  • [4] 3/4"x4.5" bolts; [8] nuts; [4] nylon lock nuts. Mounting of wheel bushings to wheel shafts.

TOTALS:

  • [40] 3/4"x5.5" bolts
  • [42] 3/4"x9" bolts
  • [4] 3/4"x4.5" bolts
  • [8] 3/4"x2" bolts
  • [120] 3/4" washers
  • [80] 3/4" metal lock nuts
  • [16] 3/4" nuts
  • [4] 3/4" nylon lock nuts
  • [8] 3/4" lock washers
  • [16] 1/2"x2" bolts
  • [16] 1/2" nylon lock nuts
  • [16] 1/2" lock washers
  • [32] 5/8"x2" bolts
  • [32] 5/8" metal lock nuts
  • [32] 5/8" lock washers
  • [32] 9/16"x2" bolts
  • [32] 9/16" washers
  • [32] 9/16" nylon lock nuts

Hydraulics

Note that the following list involves 2 loaders. For a simpler version, a single front loader is sufficient. Two loaders are used for extreme flexibility.

Blenderhydraulics.jpg (download Blender file here)

Main

Parts from Surplus Center:

Functionality list:

Note: Green indicates finalized shopping list from Surplus Center. Blue indicates list from McMaster Carr. Red is Dalton Hydralics. See Parts Sourcing for contact information.

  1. [8] 1-7/8" Flange Bearings - [1] or 2-1/2" Flange Bearings [2]
  2. [2] Front Loader cylinders - 36" - $174 - 48 5/8" retracted length - [3]
  3. [4] 3/8 NPTM x 1/2 NPTF 90 SWIVEL [4] for Front Loader Cylinders up to hose
    1. 4.9 square inch area at 2500 PSI implies 12000 lb of force for each cylinder
  4. [4] QA plate hydraulic cylinders & 2 Rear Loader [5]
  5. [4] Motors - [6]
    1. [8] SAE M 10 to NPT M 1/2" for Ports [7]
    2. [4] SAE 4M TO 1/4" NPTM CONNECTOR for Case Drains [8]
    3. [8] 1/2" QC for Motors [9]
    4. [4] 1/4" QC for motors [10]
  6. [2] 1-1/4 SHAFT COUPLER W 5/16" KEYWAY - [11]
  7. [2] 1-3/8" 6T fully splined shafting - [12]
  8. [2] Female 1-3/8" 6T spline coupling - [13], $30 each
  9. [12] 1.875" double split shaft collars - [14]
    1. got 10 double split
    2. got 2 single split - [15]
  10. [1] 1/2" male QC tip, which already have female part [16]

Valves

  • [1] 3-spool motor valve, 25 gpm - [17], $288
  • [4] 1/2" Quick Couplers [18] - for motor valve work ports
  • [4] 1/2" NPT M to NPT M 90deg Elbow for Motor Valve working ports [19] - for 2 sets of work ports to wheel motors
  • [4] 3/4" NPT quick couplers - Dalton Hydraulics - 2 for in/out, 2 for auxiliary work ports
  • [2] 1/2 NPT hex nipples [20]-for auxiliary pair of motor valve work ports
  • [2] 3/4 NPT hex nips [21] - in and out of valve
  • [2] 3/4 NPT to 1/2 NPT bushing [22] - auxiliary work ports

OSE Danfoss Black 2 Spool

  • [4] SAE 8M TO 1/2" NPTM CONNECTOR for working ports [23]
  • [6] 1/2" NPT QUICK COUPLER F/F S20-4 [24]
  • [1] SAE 10 PLUG for OSE BLACK 2 Spool [25]
  • [2] SAE 10M TO 1/2" NPT CONNECTOR [26]

2 Spool Prince Valve

  • [1] 3/4" Quick Coupler for outlet (already included in central 3-spool motor valve)
  • [2] 3/4" NPT nip for inlet/outlet - [27]
  • [1] 3/4" NPT tee (already have these) for inlet
  • [2] 3/4" to 1/2" bushings - [28]
  • [1] 1/2" NPT male elbow - [29]
  • [2] 1/2" quick coupler pairs - [30]

Cushion Valves

  • [2] 1/2 NPT 30 GPM 1500-3000 PSI HYD CUSHION VALVES - [31]
  • [4] 1/2" male QC tips to plug into valves, which already have female QCs [32]
  • [2] 1/2 NPTM x 1/2 NPTF swivel [33] for cushion valve to mount tees, for separating to right and left cylinders; only one swivel needed per cushion valve
  • [4] 1/2" nip - [34] - going from between swivel and tee.
  • [4] NPTF Tee [35]- 4 for loaders only, not QA plates

Power Cube

  • Note: pump is already obtained
  • [1] Coupler half, 5/8" - $10
  • [1] Coupler half, 1" - $10
  • [1] Solid spider - $14
  • [1] Breather cap - [36] - $8
    • [1] 3/4 NPT coupling - found at big box hardware stores
  • [1] Suction strainer, 2" to 1-1/4" - [37] - $23
    • Use for dual Power Cubes
    • [1] Use 2" coupler from bix box store to thread into Power Cube frame
  • [1] Pressure relief for power cube bypass- [38]
  • [1] 20 GPM return Line Filter - [39]
  • [1] 3/4" NPT Swivel for return line filter going into frame - [40]
  • [2] 3/4" NPT hex nip on both sides of filter - [41]
  • [1] 1"-3/4" NPT reducer bushing for frame receptacle for return filter - [42]
  • [1] 3/4" quick coupler for return line to filter
  • [2] 1/2" quick couplers for main power lines

Hoses:

  • [1] 2 foot hose from pump outlet to return line filter - [43]
  • [2] 10 foot hoses, already have these - [44]

Pressure Bypass:

  • [1] 1/2" NPT Bypass valve - [45]
  • [3] 1/2" Quick couplers - 1 complete for tee near pump, one going from return filter to tee, and male tip for return line. This gives one extra female quick coupler left over. This set of 3 QCs does not cover hoses going from and to the PowerCube.
  • [4] 1/2" NPTF hex nip for one and other side of tee, on both tees - [46]
  • [2] 1/2" NPTF tee - from outlet of pump to pressure bypass, and from bypass valve into return line filter - [47]

Hoses

Between Motor Valves & Motors

  • [4] 1/2" X 36" 1/2 NPTM X 1/2 NPTM 3000 PSI HYD HOSE for in/out of the valves [48]
  • [4] 1/2" X 36" 1/2 NPTM X 1/2 NPTM 3000 PSI HYD HOSE for in/out of front motors [49]
  • [4] 1/2 X 1/2 X 1/2 NPTF TEE [50]
  • [4] 1/2" X 48" 1/2 NPTM X 1/2 NPTM 3000 PSI HYD HOSE for rear motors [51]

Motor Case Drains

  • [2] 1/4" X 72" NPTM 2750 PSI HYD HOSE to run parallel with tractor sides [52]
  • [1] 1/4" X 30" NPTM 2750 PSI HYD HOSE from Tee to Tee in return hose [53]
  • [1] 1/4" X 36" NPTM 2750 PSI HYD HOSE to Rear Motors [54]
  • [3] 1/4 X 1/4 X 1/4 NPTF TEE [55]
  • [3] 1/4 NPT hex nipples [56]
  • [4] 1/4" NPT quick couplers are already with the motors

Front Loader

  • [2] 1/2" X 12" 1/2 NPTM X 1/2 NPTM 3000 PSI HYD HOSE from Valves to Cushion [57]
  • [2] 1/2" X 36" 1/2 NPTM X 1/2 NPTM 3000 PSI HYD HOSE for left front loader cylinder [58]
  • [1] 1/2" X 48" 1/2 NPTM X 1/2 NPTM 3000 PSI HYD HOSE for right front loader cylinder [59]
  • [1] 1/2" X 60" 1/2 NPTM X 1/2 NPTM 3000 PSI HYD HOSE for right front loader cylinder [60]

Front loader QA Cylinder Hoses

  • [4] 3/8" NPTM x 1/2" NPTF swivel - [61] - swivels for QA cylinders
  • [2] 1/2" nips - going from cylinder swivels to tees - [62]
  • [2] 1/2" NPTF tees - from cylinder to hoses - [63]
  • [2] male QC tips - for plugging into control valves - [64]
  • [2] 1/2" X 48" NPTM 3000 PSI HYD HOSE [65]
  • [1] 1/2" X 120" NPTM 3000 PSI HYD HOSE [66]
  • [1] 1/2" X 144" NPTM 3000 PSI HYD HOSE [67]

Rear Loader Hoses

  • [2] 1/2" X 12" 1/2 NPTM X 1/2 NPTM 3000 PSI HYD HOSE to Cushion Valve [68]
  • [1] 1/2" X 60" 1/2 NPTM X 1/2 NPTM 3000 PSI HYD HOSE [69]
  • [1] 1/2" X 96" 1/2 NPTM X 1/2 NPTM 3000 PSI HYD HOSE [70]
  • [1] 1/2" X 84" 1/2 NPTM X 1/2 NPTM 3000 PSI HYD HOSE [71]
  • [1] 1/2" X 120" 1/2 NPTM X 1/2 NPTM 3000 PSI HYD HOSE [72]

Rear loader Q.A. Cylinder Hoses

  • [4] 3/8" NPTM x 1/2" NPTF swivel - [73] - swivels for QA cylinders
  • [2] 1/2" nips - going from cylinder swivels to tees - [74]
  • [2] 1/2" NPTF tees - from cylinder to hoses - [75]
  • [2] male QC tips - for plugging into control valves - [76]
  • [2] 1/2" X 48" NPTM 3000 PSI HYD HOSE [77]
  • [1] 1/2" X 120" NPTM 3000 PSI HYD HOSE [78]
  • [1] 1/2" X 144" NPTM 3000 PSI HYD HOSE [79]

Seat

  • [1] Tractor Seat [80]
Wheel bearings
Front loader cylinder
Front loader cylinder fittings
Rear loader cylinder

|

Rear loader cylinder fittings
Quick attach plate cylinder
Wheel motors
Wheel motor fittings
File:Lt2wheelmotorcdfittings.jpg
Wheel motor case drain fittings
Spline coupler, female part
Spline shaft, male
Wheel motor shaft coupler
Shaft collars, 3 per wheel
2 spool motor valve, 25 gpm
5 spool valve, 20 gpm
Cushion valve for front and rear loaders
1/2 inch NPT swivel
1/2 inch NPT nip
Half inch tee
Pressure relief valve for Power Cube
Spline shaft, male

Total Weight

  • Frame 4x4x1/4" square tubing - 1277 lb
  • Loader arms (2 sets), 3x6x3/8" tubing - 900 lb
  • Loader arm shafts, angles - 150 lb (even)
  • Loader arm cylinder mount plates (base (66lb) and top(80)) - 146 lb
  • Loader arm bottom eyes - 46
  • Hydraulics, wheel bearings - 811 lb
  • Wheel mounting plates, gussets, tubes - 112 lb
  • Bearing and motor plates - 160 lb
  • Wheels - 200 lb
  • Wheel tracks (140 lb chain, 209 lb rebar (2.6 lb/ft for 1" rebar)) - 349 lb
  • Bolts - 75 lb
  • Pins - 30 lb
  • Power Cube (1) - 420 lb
  • Quick Attach Plates (2 sets) - 234 lb

Total weight of tractor with 2 sets of loader arms, 1 small Power Cube, and wheel tracks 4910 lb dry weight, with 2 Power Cubes - 5330 lb. Weight of loader arms with cylinders and Quick Attach plates: 940 front, 900 back, for total of about 1840 lb. Weight of 2 Power Cube version with only front loader - 4430 lb.

Cost

Basic Structure

LT-frame-BOM.jpg

This is about a buck fifty per pound of the 2214 lb machine, or about the going price of tomatoes. That is without the PowerCube. If you use an off-shelf 18 hp engine – the price may be $1225 ($500 for 18 hp engine + $200 pump + $225 frame + $300 balance of system). The total is then $4808.

Front Loader

  • Heavy duty front loader arm metal (3/8″x3″x6″ rectangular tube) – $500
  • Cylinders – $600
  • Control valve – $200
  • Hoses – $100
  • Couplers and fittings – $100
  • Quick Attach plate – $150Cushion valve – $66

TOTAL FRONT LOADER COST – $1716

Rear Loader

  • Rear Loader Cylinders – $520
  • Heavy duty rear loader arm metal (3/8″x3″x6″ rectangular tube)- $340
  • Selector valve (4) – $180
  • Quick attach plate – $150
  • Cushion valve – $66

TOTAL REAR LOADER COST – $1256

Steel Tracks

  • Chain - 80 feet - $270 at $3.37/foot
  • Links - $28
  • Rebar - 140' at $1.57/foot - $220

TOTAL for Wheel Tracks - $518

Quick Attach Plates

Quick attach plate with levers.

(See Open Pario for design)

  • [6]1"x5" pins (30") - $10
  • [129"] 3/16"x3" sq tubing - $46
  • [113"] 1/2"x3" flat - $34
  • [6"] 1" DOM tubing - $15
  • [24"] 1" rebar - $3
  • [66"] 1/4"x2" flat - $6
  • [6"] 1/2" rebar - $1
  • [15"] 3/4" threaded rod - $3
  • [8] 3/4" lock nuts - $1.60
  • [2] 3/4" nuts - $0.40

MATERIALS FOR EACH QA PLATE - $124

Overall cost for a dual loader tractor – wheel base of about 7×7 feet, designed to handle 3 Power Cubes, for a power limit up to approximately 150 hp – $6550 without the PowerCubes. Design is absolutely scalable, such that a half-size version – or MicroTrac, may be made – and it can be designed readily from our Blender model drawings.

Package Options

Package 1

  • Basic 4 wheel drive tractor - $3583
  • Tracks - $520
  • Front loader with quick attach plate- $1840 (with quick attach plate)
  • Power Cube - $1236 for 18 hp

Total cost is $7179 in materials. The 18 hp may be undersized, so we recommend 2 PowerCubes for 35 hp

Package 2

  • Basic 4 wheel drive tractor - $3583
  • Tracks - $520
  • Front loader with quick attach plate- $1840
  • Quick Attach plate - $124
  • Front loader bucket - $400
  • 2 Power Cubes - $2472 for 35 hp

Total cost is $8815 in materials fpr 35 hp.

Package 3

Now here’s the good part. We aim to develop the induction furnace within 2 years, with which we will be able to produce all tractor structure and components, minus the rubber parts, from scrap steel. This means that we will demonstrate how to build a tractor at the cost of scrap metal plus rubber, plus energy to run the induction furnace. This should be about $1k in materials such as hoses and hydraulic seals, plus labor. This indicates a possibility of closing the industrial divide between the developed and developing worlds.

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