Power Cube VII

Rahul Dhinakaran-Custom Machine Designer - 14 November, 2012

Manufacturing Drawings of some of the PowerCube parts. [1]

See Power Cube 6 for latest Power Cube Documentation. Tom is currently building Power Cube VII - optimizing form factor for ergonomics. The power cube after that is Power Cube VIII. See Machine Naming Convention.

Value Proposition

• Power Cube VII marks the next level of modularity in the power cube with qiuick-connected: engine assembly, pump assembly, hydraulic tank, fuel tank, control panel. This is on top of the hydraulic quick connects that allow the power cube to function as a power module for any power equipmnent in the Global Village Construction Set.
• Date: Sun Nov 11 - Monday Nov 12, 2012.
• Tom Griffing is Guest Collaborative Production Run Director

Preparation

• Lathe up and running for spline coupler
  • Tom has a coupler jig
• Lathe gearing via PowerCube + 6 Spline PTO Motor
• Ordering hose crimping dies from Sweiger
• Getting 2 more Millermatic 200 Welders.

BOM

• Using http://opensourceecology.org/wiki/Power_Cube_6/Bill_of_Materials
  • Hydraulics, Metal, engine, other, hardware - all good
  • Get hose crimper and avoid hoses from Surpluscenter
  • Need to add 1/4"x2" tank quick attach mounts
• Power Cube VII Surplus Center Order
• Power Cube VII Steel Order
• 27_hp_Briggs_and_Stratton_Engine

Fabrication Diagrams

See Fabrication Diagram explanation.

Overview:

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Overview Diagram

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https://docs.google.com/drawings/d/1KmkEsN6OPySaH11YeaQg51PJVuTzHqHMuWSajwRU8_4/edit

Frame

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Notes

1. Use ironworker for mitered cuts
2. 3 corners should fit so there is no more than 1/8" space anywhere
3. When welding each member check for parallelism and flat planes

Notes: 1 hour 15 minutes to cut all of mitered frame, 2 tank hangers, 4 hanger fingers and 4 spacers, pump mount plate (6"x6"), and to troubleshoot slow cutting on bandsaw and helping Graham align frame welding. Started approximately 10:30 after discussions.

Engine Mount

Download 27 hp Briggs and Stratton Engine Manual

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Hydraulic Fluid Tank 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, I 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)

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Instructions:

1. Cut stock 6x12" tube into [2] 25" sections
2. Cut End Plates on Ironworker
3. Weld quick connect hangers at ______" above bottom

Fuel Tank:

1. Torch out hole for fuel tank
2. Drill 7/16" hole for tapping a 1/4" fuel connection
3. Tap 1/4" NPT hole for fuel barb

Hydraulic Tank:

1. Torch out all bungs
   1. Suction on side
   2. Sight gauge on side
   3. Filler
   4. Case Drain
   5. Return line filter

Both:

1. Weld end caps

Diagrams

Hydraulics Diagram

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Electrical Diagram

Resolving Correct Labeling on Key Switch

Note: Convention on back of key switch. M and B have different label on the metal stud - I am assuming we go by the label imprinted in the plastic.

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Power HyperCube VII

HyperCube for Hypermodularity. Concept:

• Quick attach tanks
• Quick-attach, self-contained engine unit with engine controls - disconnectable by 2 large bolts
• Quick-attach hydraulic pump unit - disconnectable via 2 bolts

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Quick Connect Plate for Power Cube Pump Detail

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Fabrication

Coupler - Rubber Vibration Mounts Wiring Harness: Hydraulic Cooler: Battery Terminals: Engine Connections: Hydraulic Sight Gauge: Hydraulic Pump and Coupler:

Research

• Mechanical shaft quick coupling patent - [2]