CEB Press/Manufacturing Instructions/Sensor Unit: Difference between revisions

From Open Source Ecology
Jump to navigation Jump to search
No edit summary
Line 1: Line 1:
{{Category=CEB press building instructions}}
=Tools=
 
[[Image:main-cyl-sensor.jpg|thumb]]


*Compatible Set of Soldering Iron, Solder, Soldering Stand, and Wet Sponge or Wet Paper Towel


=Tools=
*Straight Pattern Tin Snips


*'''Soldering Iron'''
*Wire Strippers Compatible With 22 Gauge Wire


*'''Soldering Stand'''
*Heat Gun


*'''Solder'''
*Pliers


*'''Wet sponge or wet paper towel'''
*Helping Hand


*'''Heat Gun'''
*Measuring Tape


*'''22AWG-compatible Wire Stripper'''
*Wire Strippers Compatible With 8 Gauge Wire


=Materials=
=Materials=


*'''Hall Effect Sensor'''
*Hall Effect Sensor  
 
*'''PVC Pipe with 1/2" Thickness, 5/8" Outer Diameter, 3.5" Length'''
 
*'''1m of Underground telephone cable (4 wire)'''
 
*'''2-part Potting Compound'''


*'''Disposable Mixing Cups'''
*1.5m of 4 Wire Underground Telephone Cable


*'''Shrink Wrap'''
*Silicone


*'''Electrical Tape'''
*[3] 3cm lengths of Shrink Tubing


=Diagrams=
*PVC Pipe with 2.5cm Outer Diameter, 1.5cm Inner Diameter, 9cm Length


=Steps=
=Steps=


*'''Cut the sleeve 5cm at one end of the underground telephone wire and 20cm at the other end.'''
*Using the tin snips, cut the sleeve of the telephone wire by 5cm and 20cm at both ends. The cutting tolerance is 2cm.
 
*'''Cut the orange-white wire at both ends of the telephone wire.'''
 
*'''Strip the blue, blue-white, and orange wires by 2cm at both ends of the telephone wire.'''
 
*'''Insert shrinkwrap into the 5cm blue, blue-white, and orange wires.'''
 
*'''Solder the hall-effect sensor prongs to the 5cm blue, blue-white, and orange wires. The orientation of the soldering connections is such that, when you can see the sensor text and its prongs pointing downward, from left to right the colour of the wires to be soldered are: blue (5V+), orange (GND), blue-white (Signal).'''
 
*'''Cover the exposed prong-solder-wire connections with the shrinkwrap and apply heat to the now-covered connections. The shrinkwrap should shrink, forming a tight isolating seal for each of the prong-to-wire connections.'''
 
*'''Insert the wired hall-effect sensor into the PVC tube leaving 3cm of space at the non-insertion end of the tube. Tape the insertion end of the tube as to produce a seal between the tube and the telephone cable.'''
 
*'''Mix the 2-part potting compound together then pour the mixture into the tube from the non-insertion end.'''
 
*'''Tape the tube to a surface such that the non-insertion end is pointing upwards. Wait for the potting compound to cure.'''
 
=Sensor Construction=


A four wire telephone cable is used to connect to the hall effects sensor.  Only three of the exposed wires are used; orange, blue/white, and blue.  These wires are soldered to the three prongs of the hall effects sensor in order from left to right when the hall effect sensor orientation includes visible text and the prongs pointing downwards: blue, orange, blue-white.  Small shrink wrap should be applied to the wires prior to soldering, and then slid into place to cover the leads to prevent short circuiting.
*Using the tin snips, cut the orange-white wire at both ends of the telephone wire.  


Slide the sensor into a small piece of pvc tube 3.5 inches long.  The pvc will be filled with a potting compound to encapsulate the sensor.  Tightly wrap electrical tape around the wire exiting the pvc tube, creating a seal to hold in the potting compound.  Clamp the pvc vertically with the wire protruding from the bottom and fill the inside of the pvc with the potting compound.
*Using the wire strippers, strip the bluewhite, blue, and orange wires of the telephone wire by 2cm at the 5cm end and by 1cm at the 20cm end. The stripping tolerance is 0.5cm.


<html>
*Insert 3cm shrinktubing into the 5cm blue, blue-white, and orange wires.
<iframe src="https://player.vimeo.com/video/29466230?title=0&amp;byline=0&amp;portrait=0" width="400" height="225" frameborder="0" webkitAllowFullScreen allowFullScreen></iframe>
</html>


# cut telephone cable 70" long
*Bend the sensor prongs and the exposed metal of the 5cm wires into hooks such that the 3 prong hooks can latch onto the 3 wire hooks to facilitate soldering. Use pliers to pinch the hook connections during the soldering process.
# strip shielding plastic 1.5" and 8" at either end
# solder hall effects sensor


[[Image:Cebpress-sensorunit-pourcompound.jpg|thumb]]
*Using the soldering set and the helping hand, solder the hall-effect sensor prongs to the 5cm wires. The orientation of the soldering connections is such that, when you can see the sensor text and its prongs pointing downward, from left to right the colour of the wires to be soldered are: bluewhite (for 5V+), blue (for GND), and orange (for Signal).  


*Using the heat gun, cover the soldered prong-to-wire connections with the shrinktubing then apply heat to the now-covered connections. The shrinktubing should shrink, forming a tight insulating seal for each of the prong-to-wire connections.


[[Image:sensorfab1.png|thumb|Step 1. Start with potting compound, 2 parts.]]
*Pour the silicone into the tube such that the tube is completely filled in.
[[Image:sensorfab2.png|Step 2. Take one Hall Effect sensor.]]


Fabricate the Sensors
*Insert the wired hall-effect sensor into the PVC tube leaving 2cm of space at the non-insertion end of the tube.


#Cut three 3’ sections of Underground Telephone Cable.
*Gently set the sensor unit on a flat surface and wait 24 hours for the silicone to cure.
#Strip about 3” of the outer covering off each end of the three sections
#Strip about ¼” off the orange, blue and blue-white wires at each end of each section.
#Tin the ends of the all of the wires on all of the sections
#Splice, with Solder, about 6” of the inner strands of some Cat-5 Cable (E17) to the wires at one end of each of the sections of Underground Telephone Cable
#Thread shrink-wrap (E28) to the three wires on the other end of each of the three sections of Underground Telephone Cable.
#Solder a Hall Effect Sensor (E20) to one endof the ther sections (pins numbered from left to right)
##Pin 1: Blue (5V)
##Pin 2:  Orange (GND)
##Pin 3: Blue-White (Signal)
#Shrink the Shrink-Wrap around each of the solder joints
#Cut three 3.5” sections of PVC Pipe (E15).
#Place a section of Pipe around each of the three hall effect sensors and encase them in Potting Compound (E29) with the Pipe Caps (E16) in place.

Revision as of 23:57, 15 December 2011

Tools

  • Compatible Set of Soldering Iron, Solder, Soldering Stand, and Wet Sponge or Wet Paper Towel
  • Straight Pattern Tin Snips
  • Wire Strippers Compatible With 22 Gauge Wire
  • Heat Gun
  • Pliers
  • Helping Hand
  • Measuring Tape
  • Wire Strippers Compatible With 8 Gauge Wire

Materials

  • Hall Effect Sensor
  • 1.5m of 4 Wire Underground Telephone Cable
  • Silicone
  • [3] 3cm lengths of Shrink Tubing
  • PVC Pipe with 2.5cm Outer Diameter, 1.5cm Inner Diameter, 9cm Length

Steps

  • Using the tin snips, cut the sleeve of the telephone wire by 5cm and 20cm at both ends. The cutting tolerance is 2cm.
  • Using the tin snips, cut the orange-white wire at both ends of the telephone wire.
  • Using the wire strippers, strip the bluewhite, blue, and orange wires of the telephone wire by 2cm at the 5cm end and by 1cm at the 20cm end. The stripping tolerance is 0.5cm.
  • Insert 3cm shrinktubing into the 5cm blue, blue-white, and orange wires.
  • Bend the sensor prongs and the exposed metal of the 5cm wires into hooks such that the 3 prong hooks can latch onto the 3 wire hooks to facilitate soldering. Use pliers to pinch the hook connections during the soldering process.
  • Using the soldering set and the helping hand, solder the hall-effect sensor prongs to the 5cm wires. The orientation of the soldering connections is such that, when you can see the sensor text and its prongs pointing downward, from left to right the colour of the wires to be soldered are: bluewhite (for 5V+), blue (for GND), and orange (for Signal).
  • Using the heat gun, cover the soldered prong-to-wire connections with the shrinktubing then apply heat to the now-covered connections. The shrinktubing should shrink, forming a tight insulating seal for each of the prong-to-wire connections.
  • Pour the silicone into the tube such that the tube is completely filled in.
  • Insert the wired hall-effect sensor into the PVC tube leaving 2cm of space at the non-insertion end of the tube.
  • Gently set the sensor unit on a flat surface and wait 24 hours for the silicone to cure.
Retrieved from "https://wiki.opensourceecology.org/index.php?title=CEB_Press/Manufacturing_Instructions/Sensor_Unit&oldid=48209"