Power Cube VII

Assembly Video:

Powercube v7 Assembly. from Open Source Ecology on Vimeo.

Introduction

The purpose of Power Cube is to supply hydraulic fluid power for other machines. While the Power Cube designs are meant to be scalable, this design uses a 28 HP engine and hydraulic components that have proven to work well with OSE machines.

Power Cube VII marks the next level of modularity in the power cube with quick-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 equipment in the Global Village Construction Set.

Development

The Power Cube has gone through a series of updates and this page reflects the current designs of Version 7 of the Power Cube.

This design has proven to work well and has had few updates lately. Here are the latest updates:

Oct 2014: Added a pressure relief valve and associated plumbing - TLG.
Oct 2014: Changed sight gauge to shorter model and moved above the suction strainer for greater visibility - TLG.

Files for Power Cube VII

Sketchup

please upload new version by clicking on existing version - the wiki has file versioning

• Latest file (see revision history for versions) - File:Power Cube VII.skp
• July 4, 2014 - File:Power Cube VII July.skp
• June 2014: File:Power Cube VII June.skp
• May 2014: File:Power Cube VII.skp

Bill Of Materials (BOM)

• Latest BOM: File:Power Cube VII BOM.pdf
• Latest BOM: http://opensourceecology.org/wiki/Power_Cube_VII/Bill_of_Materials
• Power Cube 6 BOM: http://opensourceecology.org/wiki/Power_Cube_6/Bill_of_Materials
• Power Cube VII Surplus Center Order
• Power Cube VII Steel Order
• 27_hp_Briggs_and_Stratton_Engine

Module Drawings

• Control Panel File:Control Panel.skp
• Control Panel Assembly File:Control Panel Assy.skp
• Oil Cooler File:Oil Cooler.skp
• Frame File:Frame.skp
• Fuel Tank File:Fuel Tank Assy.skp
• Hydraulic Reservoir File:Hydraulic Reservoir.skp
• Wiring Harness File:Frame.skp

Fabrication Steps

Power Cube fabrication is organized into modules, finishing with integration of the modules. Please view the fabrication overview for general steps and the following for details for each module:

Overview: File:PCVII Fabrication.pdf

Modules

• Fuel Tank Module: File:Fuel tank.pdf, File:Fuel tank assy.pdf
• Hydraulic Reservoir Module: File:Hyd reservoir.pdf, File:Reservoir.pdf
• Hydraulic Reservoir Module: File:Reservoir.pdf, File:Reservoir assy.pdf
• Engine Module: File:Engine.pdf
• Hydraulic Pump Module: File:Pump.pdf, File:Pump assy.pdf
• Oil Cooler Module: File:Oil cooler.pdf
• Control Panel Module: File:Control panel.pdf, File:Control panel assy.pdf
• Frame Module: File:PCVII frame.pdf
• Solenoid Module: File:Solenoid.pdf
• Wiring Harness: File:Wiringharness.pdf, File:Wiringharness.dia

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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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.

• 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.

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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• Verification of wiring from Tom - Metal tab / plastic / Connection
  • C / M / Magneto
  • S / S / starter
  • " " / B / Battery
  • G / G / Ground
  • L / L / Lights

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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Finishing the July Workshop Build

1. Fuel Tank: Weld bolts in place
2. Hydraulic Reservoir: Finish plumbing
3. Drill/torch holes in 2” tank brackets, bolt in place
4. Drill/trorch holes in expanded steel (make plate if necessary), bolt in place
5. Mount tanks
6. Drill 4 holes in pump plate and mount across tanks
7. Cut 1/2” from engine shaft, mount engine plate to engine
8. Mount cooler
9. Finish plumbing
10. Finish Wiring Harness

Research

• Mechanical shaft quick coupling patent - [2]

July 2014 - Structural Power Cube

The frame of the Structural Power Cube is designed for stacking of multiple power cubes. This documents is about the angle iron frame Power Cube for applications where only one or two Power Cubes are required. Here is the link to the Structural Power Cube:

Link: Structural Power Cube