OSE Shop 2011

Main > Housing and construction

---

A 12 cell (16'x16') workshop for prototyping and production runs of open source ecology machines

Design Model

Sketchup model: [[1]]

Embed:

Design feedback from a Production/Floor designer

Outline extracted from a conversation between David Ihnen (design proposer) and David Dalton of Kansas City, a professional production floor layout contact.

• Shop Design:
  • likes the roof angles
  • Chlerestory brings lots of light in, that is good
  • Gantry is good
• Biggest problem: Headspace.
  • low cieling feels claustrophobic, is not so nice to work in.
  • extra cieling space can be used to hang racks and store materials
  • too little overhead space and you can't do anything about it
  • Gantry system needs space for hoist - it would lucky to be able to lift a lifetrac off the ground at its current height of 9 feet at top.
• Storage space
• A nearby building - suggest the gantry extends to a shed to the north, where production materials will be stored. Gantry allows easy retrieval without ground level improvements (concrete).
• Compressed Air.
  • Compressed air is critically important for cleanup, blowing bits out of crevasses better than about anything.
  • Compressed air tools are bulletproof - electric ones wear out quickly,compressed air tools do not.
  • Compressed air tools are powerful and buffered - no matter how slowly compression is generated, maximal power is available at the moment it is needed.
  • Compressed air does not require electricity - either directly off of wind power (good idea!) or steam, or gas engine, or lister - whatever.
  • Take the time to distribute your compressed air around the shop
  • keep your requirement for flexi-hoses short, 4 inner columns good location for them
• Gantry.
  • Excellent materials handling solution
• makes moving heavy things, lifting them up, etc far easier - when dealing with heavy things, that hoist can make a world of difference.
  • Transport from storage to production floor is easy and smooth
• Tiger STop
  • Any sort of production needs a length-measuring table with adustable stops for efficiency
  • tiger stop style table will accelerate production massively - 30-40% easily.
  • fully automatic tiger stop style table will accelerate parts cutting even more
  • is a single-axis cnc - not difficult to arduino and construct ourselves!
  • consider a double ended table, one end bandsaw, one end mitre saw
  • HIGH USE TOOL - as the most frequently useful tools in the shop, it should be centrally located
  • Can also be equipped with a drill press for automating positioning of materials to be drilled!
• The Robots.
  • Put robots in range of equipment
  • consider flexibility - hard-mounted robot gets in the way when not being used
  • robots are useful only when actively programmed.
  • board mill->robot->rack->robot->cnc->robot->rack workflow could automatically create wooden parts
  • robot combined with tiger stop type table could automate much workflow of creating metal parts too
• Table Saw
  • You ABSOLUTELY DO want a table saw if you're doing wood fabrication
  • a large one - or don't bother
  • can double as workbench with blade retracted
• Dust Collection
  • Install a dust collection system if you're going to be routing and/or cutting much wood. Recycle the chips for fuel, and the fine sawdust is even more useful.
  • use a two stage filtration chamber to separate - easy to build
• Curtains
  • Put BLACK curtains around the welding areas.
  • Welding flash causes eye damage, even indirectly
  • Welding exposure is bright UV, impacts more than merely the eyes of those around, radiation burns too.

Construction Plan Mindmap

Full size here:[[2]]

Actual Mindmap file here (created with freemind) [[3]]

Cost Estimates

Component	Materials	# of units	Unit	cost/unit	Materials cost
CEB columns 2.5' X 2.5' on 3'X3'X3' pad [20 units]	Stone fill	20	yd3	?	#VALUE!
	Concrete	3.5	yd3	?	#VALUE!
	CEB	6480			$0.00
	Slurry				$0.00
Floor	"Stone [6"" layer]"	59	yd3	?	#VALUE!
Roof 50.5' x 66.5' plus 3' overhang	lumber	228	"2""x10""x16'"	$12.22	"$2	786.16"
	barn roof panels	88	"17' x 39"" "	$56.00	"$4	928.00"
	screws	2	pails	$136.00	$272.00
	glue	4	cases (12)	$40.00	$160.00
	gutter	148	lin. Ft.	?	#VALUE!
	gutter downspouts	4		?	#VALUE!
	gutter nails			?	#VALUE!
	gutter fittings			?	#VALUE!
	lumber			?	#VALUE!
	Calk			?	#VALUE!
	flashing			?	#VALUE!
Power Requirements  ??	30 amp outlet unit
	20 amp outlet unit
	lighting control units
	light units
	30 amp wiring
	20 amp wiring
	light wiring
	staples/brackets
	conduit