Yoonseo Log 2012

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November 2012

Testing new log strategy...

21/11/2012

Sweiger trip with Gabi (CEB Press, Caster, Light Screen)... done

CEB Press Electronics - Circuit Assembly... done

Terminal Case... that perfect tungsten end is really tough to get -_-

Ehow on Balling Tungsten

Miller TIG Tips

From WeldingTipsandTricks stuck with 2% thoriated for a long time. It worked great ... but on A/C the tip kind of got jacked up at high amperage. I tried 1.5% and 2% lanthanated and learned that both work fine but the 2% lanthanated works great and even better on A/C. And For TIG inverters like the Miller Dynasty 200dx or the Lincoln Invertec v205t, it is Da shizz.

It holds up really well at high frequencies like 120-150 HZ.It stays sharp on DC too.

The only drawback is that is does not break easily...you have to cut it with a grinder. Duly noted. Thought I was doing something wrong by having to grind-cut the lanthanted but guess that's standard practice.

20/11/2012

Hablab Cleaning! Jacob is coming.

Make Terminal Case... Needs argon gas refill, new ceramic cups. Make a light tack weld. Then, starting from 1 end (but give enough space for the other aluminum walls), get a junction puddle (between baseplate and wall) then travel along junction edge. Filler adding technique is to insert the filler rod at the junction edge coming from the opposing direction as the weld. Keep the weld small and tight. If for some reason the weld turns big, skip it and do the junction puddle + edge travel again. You can grind off the big part and reweld the gap later.

When balling the tungsten before welding, set material-to-tungsten electron % higher and the current lower instead of just increasing the current. This will keep the copper plate cooler while still heating-balling the tungsten correctly. Make sure that the end of the tungsten is a ball.

Make PCB Mount...

19/11/2012

Make Hall Effect Sensor Module x2... done

Test Hall Effect Sensor Module x2... done, both operational.

Make Solenoid Driver... done

Prepare for making Terminal Case... done

Organizing personal information at Yoonseo Kang...

Organizing development webpage at Open Source Technologies and adding material supplier links...

Coconut Oil Tests as Cutting Fluid

File:Cococutting.pdf

Coco Cutting Fluid, Forums

Ordering Coconut Oil... done Haha! This will be fun! You can eat it, you can machine with it!

Safety and health is incredibly important at the minor level because hazards that take off years off your life are actually cutting, say, 5 years of living in *the future*, at which point you can be doing things x10000%+ higher quality and faster than you are doing now. Furthermore, you would be missing out on 5 years of health and safety innovation in *the future* which could further extend longetivity and ability by orders of magnitude more. Critical stuff. Don't miss out. Safety and health gives you a lot more than you might realize, and you don't notice that you haven't been seriously injured so it doesn't enter your mind that much. Chronically underestimated factor of life...

Ordering earmuffs (we are darn low on these, and disposable earplugs aren't that great as a cluttery consummable)... done

18/11/2012

Deploying Magdrill x2... done

Design Boxed Way machined dimensions...

Order aluminum flat for Hall Effect Sensor Module x2... done

Prepare Terminal Case welding for CEB Press...

Organize Drill Bits...

Ordering Labels... done

17/11/2012

Hablab Ground Insulation Day

Documentation feedback for Chris Olah regarding www.implicitcad.org... done

16/11/2012

Upload Tooling Plate Documentation... done

Make Surface Grinder Video... done

Power Cube VII Electronics... awaiting someone to mount battery, solenoid and reveal 2AWG copper stranded wire

Upload Surface Grinder Video... done

Ordering Hall Effect Sensor... done

Stove sealing - Cement the gasket to the front top frame... done

Asking Andy about submersible pump wiring splice... done

Ask Josh about any available 120VAC/240VAC hydraulic power supplies... done

Website Setup Documentation

Get ImplicitCAD to Inkscape with Gcodetools for gcode toolchain working error-free... done

15/11/2012

Make Tooling Plate... done

Ordering Steppernug x6... done

Preventing Collet Slip

14/11/2012

Organize CEB Press Electronics Materials... done.

CNC Torch Table V2 Test 1... Y Axis jog test success. Needs 2 more steppernugs for complete control. y axis gear setscrew needs tightening.

Design C Clamp with linear interface for Hall Effect Sensor Module... done. Might end up better to just use off-shelf C-Clamps despite 2-piece assembly until C Clamp fabrication efficiency increases.

Contact Chris Olah about ImplicitCAD use instructions... done

Ordering Power Supply... done

Contacting Darren about Steppernug... done

Ordering Solderable Breadboard... done

Ordering LEDs and MOSFETs... done

Test ImplicitCAD... done

Test Gcodetools... Inkscape internal errors?!

Ordering small C Clamps... done

Designing Funnel...done

Ordering Aluminum Tube... done

Fixing Ubuntu Shutdown... no good File:Grubexamplefix.txt sudo shutdown -P now

Ordering Aluminum Sheet... done

Ordering Gasket for Stove... done

13/11/2012

CEB Press Electronics Coordination 1:30pm with Marcin... done

Power Cube VII Electronics... needs more touch safe terminal blocks

Laundry trip... done

Battery bank is too low for workshop use...

Organized Workshop with Drawers

Ordering touch safe Terminal Blocks... done

Ordering iron for Boxed Way... done

Ordering Flashlights...done

12/11/2012

Power Cube VII Production Run with Others Day 2...

CNC Electronics Wiring... done

Computer to Microcontroller troubleshooting...

http://code.google.com/p/processing/issues/detail?id=151

http://stackoverflow.com/questions/6459042/processing-how-to-write-to-the-serial-port

CNC troubleshooting... success.

Documentation spree.

Tooling Plate Fabrication Drawing

11/11/2012

Power Cube VII Production Run with others

CNC Electronics Mounting... done

Personal reminder that the Boxed Way module can be used as linear guides for Lathe

Ordering Annular Cutters... done

Began Computer Platform

CNC Electronics Wiring...

10/11/2012

Power Cube VII Materials Preparation with Tom and Marcin... done

Bandsaw blade replacing with Kavitha... done

Power Cube VII Production Run Preparation... done

Bandsaw blade replacement video... done

Use Gparted with a live cd or usb in order to repartition your computer's internal hard drive.

Began Adjustable Platform

Designing Caster... done

9/11/2012

Ordered Portable Light

CNC Electronics Wire to Terminal Tech... tinned wire vs fork connector resolved...

CNC Electronics Intra-connection Tech... male/female headers with twist connectors for now...

Analyzed on-site cordless chuck drills... no good. low torque and frustrating battery removal

Ordering Gloves... done

Documenting Extension Cord assembly... done

8/11/2012

Fabricate PCB Mount compressors... done

Install PCB Mount compressors... done

Deploying organizing drawer shipment... done

More drawers... ordered.

CNC Electronics Wiring Prep... heatsinks mounted, mounting holes drilled.

Ordering mcmaster-carr shipment (edge finders, iron for Tooling Plate, cable gland and rubber rod for Terminal Case)... done

7/11/2012

Ordering LIN steppers... done

Fabricating stove interface...done

Deploying (installing) stove door... done

Documenting stove door at Modular Stove Fabrication Procedure... done

Deploying extension cord shipment... done

Wrapping up hospital bill... itemization sheet on its way from hospital.

Ordering measuring tapes... done

Ordering wire... 18 gauge 500' red, 500' black ordered.

https://en.wikipedia.org/wiki/Nichrome

PCB Mount HDPE Plate cutting... done

Ordering hex to chuck converters... done

PCB Mount Mounting concept... done

Researching iron suppliers... mcmaster-carr is a supplier (http://www.mcmaster.com/#iron-sheets/=k2j66h)

http://www.wwgoa.com/articles/one-great-tip/do-i-really-need-an-impact-driver/

http://toolguyd.com/you-can-use-an-impact-driver-to-drill-holes-but-should-you/

http://www.familyhandyman.com/DIY-Tools---Tips/DIY-Tools/Power-Tools/choosing-the-best-impact-driver/View-All

http://www.candlepowerforums.com/vb/showthread.php?258999-NiMh-AA-Powered-LED-light-Current-Draw

http://batteryuniversity.com/learn/article/serial_and_parallel_battery_configurations

6/11/2012

240VAC Extension Cord... done

Food trip with Parker... done

TIG Welding Setup Video... done

CNC Torch Table mechanical assembly finishing... done

Ordering more winterwear... done

Ordering screwdrivers... done

Powercube Troubleshooting with Graham... fixed. The fuse was loose.

5/11/2012

Sweiger Trip for powercube/lathe accessories + stove metal. Done. Sweiger does not supply or have connections for iron.

Ordering more extension cords... 25ft x3, 50ft x2, 100ft x1 (Yellow Jacket from Amazon)... done

Ordering mass discrete component organizers... done

Wrapping up hospital bill... no response, message left.

Saw Blade Store response to order question... done. they were just confused with billing/shipping addresses

Septic system troubleshooting... fixed.

4/11/2012

Group clean Hablab!

Pictures for Light Screen, Trencher, Flashlight Mount

Light Screen from Josh missing a few parts - must search in Tristan's car...

CNC Torch Table Steppers' electronics interface wired up.

Set up camera tripod

Terminal Case interface with PCB mount...

Ordering HDPE plate for CNC electronics... done

3/11/2012

Tooling Plate fabrication preparation...

Terminal Case V3 welding... done - TIG welding aluminum isn't TOO hard...

We'll need to recharge our argon canister soon. Medium size canister is easier to transport, but must price check on medium and large refills.

Design, prototype, documentation Thermal Shield for TIG welding... done, done, and done

Preparing for next sweiger trip. Lathe/powercube accessories, iron for tooling plate, metal for stove door, pure argon gas refill... done

Must order edge finder (ex. from mcmaster-carr), but waiting on further items to optimize shipping.

Husking Walnuts!

http://www.cnccookbook.com/MTLatheCNCAccuracy.htm

http://www.gearsolutions.com/article/detail/5663/the-details-of-ductile-iron

Hinge redesign for stove

2/11/2012

New stove door design... mostly done.

Ordered aluminum bar for Terminal Case V3 construction (with welded seams for rigidity and waterproofing)

Tested and documented Trencher V1.5 with Aaron. It works pretty good!

Began TIG welding Terminal Case. Started using filler rod for the first time. The aluminum gets HOT. Don't touch it, even with gloves you will get burned. Cannot TIG weld continuously without heat shield. Must design heat shield for hand.

We need more 240VAC extension cords. Must order male and female plugs, as well as more large 3-strand wire.

Ordered 2 bandsaw blades

http://www.stepperworld.com/Tutorials/pgBipolarTutorial.htm

Stepper Motor considering: bipolar super torque steppers from Lin Engineering (http://www.linengineering.com/LinE/contents/stepmotors/5818.aspx)

Flexible shaft coupling considering: from http://www.mcmaster.com/#standard-shaft-couplings/=jzypil

Plan: organize drill bits

Plan: work on improving flashlight mount - magnetic mounting, adjustable angle

1/11/2012

TIG Welding tests... still no good. Grinded the aluminum and reduced the length of tungsten alloy tip sticking out to 1/8" but instead of puddling properly the aluminum totally melts underneath a film of oxide...

Bandsaw blade ordering [Emailed Parker and Marshall for previous bandsaw blade source]...

Thiel Fellowship monthly review... done

Thiel Fellowship annual update... done

Sweiger trip with Gabi for farmer's bank credit card form, powercube materials and TIG welding troubleshooting... success, success and success.

TIG welding aluminum test... success! Minor change was to mount the tungsten collet in the opposite direction. The major change was to ball the end of the tungsten by applying some high current 150-200A at ~50% AC balance to the tungsten tip but using copper plate.

Prototyped flashlight mount.


October 2012

31/10/2012

Workshop organizing.

Ordered fittings for water infrastructure, screws for CNC Torch Table

Cold Saw Test 3- clean cut, successful automated cooling, lots of vibration.

30/10/2012

Kdenlive Codecs Troubleshooting -

Mpeg-4 Resolved. Installed the mp3 encoding library "lame" using synaptic package manager, then opened kdenlive and went settings>run config wizard, then was able to render in mpeg-4.

Installed libavcodec-extra-53 and reran kdenlive config wizard and further render options enabled.

Ordered 4 welding helmets from Harbor Freight- http://www.harborfreight.com/blue-flame-design-auto-darkening-welding-helmet-91214.html

Ordered from Mcmaster-carr:

T Slot Cutter: 8789A12

Reduced Shank Endmill: 8827A19

Roughing Endmill: 8817A52

Touch-Safe Terminal Block: 7618K618

Terminal Block: 7527K53

Organized Workshop - deployed more tables, mechanical assembly of cnc torch table almost complete - awaiting screws to be ordered.

https://en.wikipedia.org/wiki/Gender_of_connectors_and_fasteners

29/10/2012

Ordered supplies

Troubleshooted plasma cutter - it works! Changed control connector to more compatible interface.

Video'd

Realized tripod is absolutely necessary to take video because 1 handed everything just doesn't work. For the same reasons, flashlight mount is crucial for nighttime work; headlights interfere too much with welding helmets and such.

Ordered tripod

Designed flashlight mount

28/10/2012

OSE general topic meeting

Organized workshop, fitted flats in cnc torch table

27/10/2012

Welding woes... TIG welder does not work even with the 2% lanthanated tungsten...

Organized workshop.

Designing Boxed Way

26/10/2012

Workshop Tools

Fixed tractor hose leak.

Organized workshop.

Boxed Way Fabrication Preparation

25/10/2012

Boxed Way Way-to-Base and antifrictionmaterial-to-saddle info acquired. Blocks - iron supplier and machined leadscrew supplier...

Finished up installation of stove. Review and modifications in progress- sealing all top gaps and replacing front door mechanism with hinge + latch.

Workshop Tools for hardware transparency and ease of analysis.

24/10/2012

With Aaron: picked up Gabrielle from bus station, acquired some winter gear, acquired Fairshare Farm food.

Wood Stove Deployment Run, Day 7 with Aaron. Installation almost complete (flue pipe hole needs to get cobbed up some more). Tested with big fire in stove. Success - flue has no leaks. Near complete combustion. However... chain handle is dangerously close to front panel (<1") at 100 degrees celsius (water boiling point)- burn hazard. Front panel acting as door is difficult to open- non-ergonomic. Leaks in top panels and front panel causing great smoke especially during the fire startup process before a draft is created. Rebar damper gets too hot to touch- safer damper handle necessary; damper placement could be better, placed to the side of the stove instead of over the top panel. But... the fire burns, the thermal energy radiates. Warmth!

Analyzed inverter electronics - we are much closer to the universal power supply (any input, any output) than we previously thought.

Deployed more tables in workshop and organized tools for superb accessibility during production runs and open tech development.

... accidentally erased the latter half of the stove pictures in the camera... darn...

File:Stovepics.zip

Ordered sheet metal power shear

Contacted Gilman USA about way-base adhesion

Updated boxed way diagram

23/10/2012

Wood Stove Deployment Run, Day 6 with Aaron. Flue fabrication complete. Installation in progress.

Plastic welder test. Success.

Grounding Case Study

Grounding Tips from Solacity

Inverter Control Waveform Diagrams

Ordered Copper Clad Board

22/10/2012

Wood Stove Deployment Run, Day 5 with Aaron. Got all the materials from Sweiger, established full design, completed long assembly.

Inverter documentation with Aaron.

Workshop organization. Deploying lots of tables.

Ordered aluminum rods, tubes, bars.

Ordered bench grinder.

21/10/2012

Forging Types

Caster

Discussed budget creation process with Aaron Budget Creation Process

Organized Workshop

Laundry and food trip.

Ordered various fulcrum hand tools.

20/10/2012

Wood Stove Deployment Run Day 4 with Aaron. Took lots of pictures and videos. 400MB+!. Spent lots of time designing and preparing fabrication and looking for tools that we didn't find after all. Time for technological saturation. Quality tools will always save the day. Bad tools, no matter low prices, are super-expensive in practice... but not having tools is worse.

Time to order some more tools and materials... Metal protractors. Bronze rod.

Oxyacetylene Torch vs Plasma Cutting

19/10/2012

Heli-cal Shaft Couplings

File:Helicalcouplings.pdf

Mcmaster-Carr Helical Beam Couplings

Machining a Ballscrew Video

Received C Clamps and Tables

Replacing back wall of chicken coop with Parker

Wood Stove Production/Deployment Run Day 3

Received and deployed digital camera

Ordered AA Battery Holders

Fablab Tool Organization

Searching for a leadscrew and leadscrew nut supplier that provides end machining services

Tested Geiger Counter

Sent torch table pictures to Chuck Harrison - Internet connection timed out, resending in multiple emails... Success,

Ordered more tables. Extremely useful.

Researching animation software...

Sintel- Blender-animated Short Film

Pencil Basics

Researching Vises...

Responded to Kevin Harrington (Kevin Harrington at Neuron Robotics)

18/10/2012

Received batch of shipments

ffmpeg guide

Boxed Way

Spindle

CNC Circuit Mill

FFmpeg GUI for screen capture: Screencastor

Screencastor Installation Guide

Wood Stove Production Run Day 2

Trying to install screencastor... Success. How about also XVidCap?-Marcin --- screencastor is just a screencapture GUI for ffmpeg and ffmpeg is much stronger (more configurable, more codec support, higher max video quality) than xvidcap-Yoonseo

How to Fix Broken Packages

Screencastor Main Thread

How to Remove Repositories in Ubuntu

Researching shaft coupling type between leadscrew and stepper motor. Flexible couplings (helical slit type) used to accommodate slightly misaligned shafts.

Shaft Couplings

File:Rigidshaftcouplings.pdf

File:Servocouplingguide.pdf

Requested 5618L-54P stepper motor quote from Lin Engineering

Tooling Plate

17/10/2012

Learning with Aaron about plasma cutting- Everlast PowerPro 256

Setting up FFmpeg as screen capture for video recording of desktop

FFmpeg Noise Reduction

FFmpeg Video/Audio Separation

Pre-Production Run Preparation for Wood Stove with On-site Team

Wood Stove Production Run - Learned how to plasma cut!

Ordered welding magnets

Installed Cinelerra and Kdenlive

Starting Google Sketchup

Starting with Google Sketchup

16/10/2012

Ordered self-adjusting clamps and pipe clamps

Troubleshooting internet - testing wired connection to router.

Mechanical diagrams for CNC Circuit Mill

Plastic Welding

Ordered plastic welder

Work Screen Distributor

Contacted flexsoundproofing for free welding screen sample.

Acquired food and cast iron kitchenware with Aaron and Parker

Discussed OSE Specifications with Aaron

Called Everlast for TIG Welder troubleshooting - pure tungsten is not compatible with inverter welders' square waves and must be replaced by lanthanated or ceriated tungsten

TIG Welding Tungsten Electrode Current Test

Ordered 2% Lanthanated tungsten 3/32" x 7"

Tested TIG welding steel to some success with pure tungsten.

Ordered wire brushes x3

Ordered tables x2

Internet soooooo slowwwww... Efficiency at <10%...

Point and Shoot Camera Buying Guide

Outdoor Rugged Digital Camera Guide

When getting any portable, data-focused electronics (meaning you need energy storage and data storage), consider the following 3 factors to be the most important:

  • Uses common replaceable batteries. Ex. AA batteries. Necessary for ease of continuous use (otherwise it will sit collecting dust, you never having the time or money to spend on getting another proprietary battery; also makes charging/having extra charged batteries much less of a hassle).
  • Uses common data storage cards. Ex. SD cards. Necessary for ease of compatible use. Last thing you want is to be unable to transfer your pictures and videos to your computer.
  • Is rugged! Expect falls and pressure, immersion in water, extreme temperatures, and more.

Ordered SDHC card 16gb

Ordered Camera

Ordered many AA and AAA batteries Enerloop Batteries

Ordered Smart Battery Charger

15/10/2012

TIG Welding Advanced Settings

TIG Welding Advanced Settings 2

TIG Welding Advanced Settings 3

TIG Welding Advanced Settings 4

TIG Welding - Getting a Puddle

TIG Welding Aluminum Basics

TIG Welding Basics

TIG Welding Residue Troubleshooting

TIG Welding Troubleshooting

TIG Current Calculator

Completed Thiel Fellowship review session

Ordered wire strippers, welding gloves, work gloves

14/10/2012

Heidendan Vertical Machining Center

Feeler Taiwan Vertical Machining Center

Moriseiki VMC

Mechanical diagrams for CNC Circuit Mill

File:Vmcex.pdf

Benefits of Linear Ways

File:Vmcex2.pdf

Shaft Collars and Rigid Couplings

How to connect two shafts together - use shaft couplings. A shaft coupling has 3 main considerations: how does it connect to one shaft, how does it connect to the other shaft, and how does the coupling connect in the middle? Shaft connection-wise, unless a weld is made (molecular bond between the coupling and shaft), either setscrews are used to tension down on the shaft, OR, a screw is tightened on the wall of the coupling to clamp the coupling on the shaft.

Make Project Article with nice stepper motor to ballscrew pictures

Based on everything I've learned so far about precision machine design: Precision Machine Design Tips

Preparing for Thiel Fellowship review

13/10/2012

Recoveredering from minor sickness

Troubleshooting internet slowdowns - Tomato Wikibook - Success!

Winterizing, organizing, cleaning Hablab with others. Great results.

TIG welder argon flowing! Solution was to use hose clamps on the regulator barb and machine barb.

Huge C Clamp order.

12/10/2012

Successfully troubleshooted hablab internet system

Oscilloscope on Arduino with Direct Digital Synthesis

Acquired tungsten rods and foods

Prototyped and documented Light Screen

Continued setting up TIG welder - argon not flowing?! - ah read the manual File:TIGTorchmanual.pdf and should try adjusting the knob of the regulator with a wrench.

Advanced TIG Welding Setup

Ordered 3/4"MPT to 3/4"FPT Lead-Free Brass Elbow

Ordered Geiger Counter after thoriated tungsten spook

Thu Oct 11, 2012

Inverter Development - Extent of Arduino's Functions

Successful materials for Light Screen from Sweiger Shop with Gabi

Setting up TIG welder

How to Set Up a TIG Welder

How to TIG Weld

Pure tungsten is appropriate for AC TIG welding (ex. 99.5%+ tungsten)

TIG Welding: Tungsten Electrode Guide

10/10/2012

Inverter Development - Further topology development at Inverter Log and learnings from Buck Boost Converter at Wikipedia

Discussion with Alexander Kiselev

CNC Circuit Mill Electronics Sourcing Research - Stepper Motors

Dynamics of Hybrid Stepper Motors

Winterizing items

9/10/2012

Organized Inverter development documentation

Produced and documented Terminal Block x2

Journey Inside the Cell: Information to Proteins

How Cells Obtain Energy

Perspective

8/10/2012

Ordered more power strips and a light for the hablab

Fix for Ubuntu 12.04 Stuck at Shutdown

Successful food acquisition trip with Gabi, Graham, and David

Successfully uploaded GRBL to Arduino Uno R3 using Ubuntu 12.04 - followed documentation from before, adding ruby and avrdude installation steps

Successful troubleshooting of Powercube V6 with Graham - faulty relay, temporary fix with connector-to-connector switching solution

Successfully started coordination of Inverter development, with the Inverter Log with Aaron

7/10/2012

Preparation for winterizing and organizing personals.

Civ5 and starcraft LAN party. Great mental exercise- lots of information processing.

6/10/2012

Mainly group construction work- sealing up gaps to winterize the hablab and organizing the backroom for better tool accessibility

Ordered various electronics parts for CNC Circuit Mill V2

5/10/2012

Specifying and hyperlinking mechanical/electronics/software for CNC Circuit Mill V2

Minor revisions to documentation presentation for the electronics projects in Open Source Technologies

Research into motor selection for spindle designs at Electronics Design Info

4/10/2012

The way to prevent premature latching on the CEB Press is to keep the hall effect sensors mounted parallel to the magnets' moving plane. This resolved all premature latching issues. CEB Press 4.0 fully operational. Optimized CEB Press Testing and Operation Code: CEB Test and Operation Code

Restocked food inventory.

Performed first aid and health operations on hurt/sick members of on-site team. Arrythmia and pre-hypertension concerns.

Improved documentation for the CEB Press

Ordered more aluminum flat bar, mainly for Terminal Block production

3/10/2012

Installed Hall Effect Sensor Module x2 on CEB Press V4.0 with bent pieces of aluminum flat bar and small C-Clamps.

Resolved a broken inverter issue with Marcin by connecting the workshop grid to one of the remaining inverters. Reliability is definitely a significant design principle.

Discussed short-term implementation of forums/stack overflow-like software to help development process. 2 major factors for the success of such software identified as access and action relevance. Access made easier with invites, action relevance made easier by the right questions to prompt the right answers.

Tested the CEB Press with manual control. Teamed up with Marcin to fix some issues. Troubleshooted total non-movement by increasing up the hydraulic pressure from the powercube. Troubleshooted primary cylinder non-movement by loosening front support plate, but discovered that the real problem was a loose quick connector connection from the primary solenoid valve. Full manual control success. Back to solo work.

Tested the CEB Press with test code. Troubleshooted weird sensor-triggered movement by examining sensor analog values. So! The hall effect sensors switch and latch on and off, but electrical noise and in-circuit imperfections cause fluctuating output signals. To add to the problem, the magnetic field of the magnets interact with the sensitivity of the sensors as to cause multiple latching events when the sensor passes a single magnet!

How to make the sensors work properly?

1. Take multiple sample readings and average them into a moderated value; this will diminish the effect of short-lived extreme fluctated signals. Increasing the number of samples per averaged reading and decreasing the delay time after each sample helps, but will be limited by the processing speed of the electronics.

2. Use separate upper and lower trigger values for the microcontroller to determine when the sensor has passed a magnet. This ensures that fluctuations that pass a trigger value can be safely ignored to an extent by the microcontroller. 2 values that help determine the upper and lower trigger values are: minimum value in the high-latched sensor state and maximum value in the low-latched sensor state. If possible, have the lower triggger lower than the aforementioned minimum value and the higher trigger higher than the aforementioned maximum value.

3. Use post-latch delays. That can be as simple as putting a fixed delay after each latch-switch. This helps minimize the effect of sensor sensitivity to strong irregular magnetic fields but limits the operating speed of the sensor-controlled movement (ex. if the delay is 1 second, then the magnets need to be at least 1 second apart for the microcontroller to have enough time to pick up on the next latch point as it passes the second magnet). CORRECTION: Forget this, the sensor still latches and it's just the microcontroller that doesn't respond until after the delay. No good. We don't want the sensor to prematurely latch in the first place.

Made significant revisions to the testing code for extreme troubleshooting ease. CEB Press Test Code

Tested the new test code to success after implementing all of the make-sensors-work-properly changes. Started to revise the operation code for continuous brick pressing.

Contacted Star Simpson about inverter design topologies.

Scraping in a Dovetail - Detailed

File:Hardenedboxwayslides.pdf

File:Dovetailslides.pdf

File:Linearwayslides.pdf

File:Cartridgeblockspindles.pdf

2/10/2012

Using arduino IDE 64-bit on ubuntu 12.04 - Guide to Arduino make sure you open arduino as power user with sudo ./arduino when in the correct folder! Otherwise the serial port will be greyed out.

Hall Effect Sensor Module V2 x2 complete

  • Research for choosing between rod, dovetail, or boxed way for linear guide (whoa there's V-ways and half-round ways too!) Gah I need a free download of the book "Foundations of Mechanical Accuracy"

Dovetail

You are not under the impression that the dovetail cutter needs to be the full width of the female dovetail are you?The cutter only needs to be as tall as the dovetail.Your remark about not having large dovetail cutters prompts my question.

Dovetails only need 1 gib

Actually the dovetail is the simpler mechanism. It is simpler to make and simpler to adjust in use. The one gib at 45 or 60 degrees takes up slack both sideways and vertically. One adjustment and you are done.

I was afraid of the results before I made my first dovetail, but it is a piece of cake if you plan it properly. The setup is the same for both male and female parts. As mentioned above, you do not use a cutter that is the full width of the female dovetail. You use a standard milling cutter to rough out the center, usually to a depth slightly greater than the actual dovetail. then you cut each side individually. The cutter only needs to be tall enough to cut the whole angle at one time.

I used a CAD drawing and placed even sized circles tangent to both the angled sides and the flat top/bottom surfaces to give me a way of measuring the width of the dovetail. You can read the distance between them off the drawing to three or four places and them use drills or ground, round stock of the same size to measure your work. Just mike between them on the female dovetail and across them on the male. Real quick way of checking your work on the mill. Of course, with a gib, you don't need extreme accuracy.

Box

Boxed way more rigid than dovetail

Boxed way conventionally steel with turcite for anti-friction contact surface OR cast iron with oiling OR metal with high-pressure oil (hydrostatic)

Boxed way conventionally ground then scraped