AbeAnd Log

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HintLightbulb.png Status - Done: Reviewing and editing PC documentation To Do: Finalize all PC docs and generate cut files Blocks: Time

General links Critical Path Roadmap HR mediawiki formatting help Development Team Log Volunteer Timesheet OSE Hangout OSE Jitsi Meet

Abe's Links Abe's OSE Google Drive Folder Abe's OSE Google Calendar Abe's YouTube channel

Current Logs

Tues Jul 17, 2018

I re-constrained the tank panels to the tank fixed back.


Next examining constraining the plumbing in the tank and fittings welded to the tank into the frame module instead of the assembly to reduce complexity.


adding plumbing parts with constraints to simple version of frame file.

meeting prep.

Sun Jul 15, 2018

added symmetrical top notch to cube sides. edited side lengths to make cube 30" deep, which should give a little (~0.75") room for movement too.

I had some trouble with re-constraining the sides correctly so best to just delete most of the constraints and redo them.

I've also been thinking of constraining at least some of the plumbing parts into the frame; Especially, since the welded parts and the plumbing in the tank is technically part of the frame. It will also simplify plumbing constraints in the editable full assembly.


Tues Jul 10, 2018

Checking the engine-pump module in the frame shows quite a few needed changes. As expected the frame is to short vertically (~1") and in depth (~2"). The rubber feet in the base are currently 1" this increases the height once installed but at that point, the top being even with the frame isn't cause for concern. It is getting in the side of the frame that is difficult. The bottom mount plate is to small and the holes in the wrong position in general.



updated mount pattern to constrain engine module to for visuals of the next changes needed to the frame.


meeting prep.

As discussed in the meeting searching more I found a makerspace local to UCA in Conway. It appears funded by an organization called The Conductor that promotes entrepreneurship and is funded in turn by local businesses. Both could be good contacts for finding students and organizations interested in promoting learning through making hands-on and open source tools.


I also need to decide where to post a CAD rule about making sure parts are assembled from physical sub-parts such as those that are welded together.

In reviewing FreeCAD_101 and rewatching some of the videos I see some potentially out of date info, but they are all good tutorials. I think the last tutorial by Manolis uses the A2 WB to import all parts, which was later changed to mostly merging all, but a base part as in Roberto's tutorials. I thought Roberto's more recent tutorials on assembly workflow were included, but I don't see them there so I am adding them. I'm thinking of adding a final Tutorial section with guidelines as text and as a placeholder for potential future video update(s).

Mon Jul 9, 2018

reviewing engines module specs to look for flaws before finalizing to update other modules.

I found the mounting base was backward because the elongated holes are supposed to be close to the back not the front. Reconstraining this proved to difficult for the solver and editing the original sketch was to slow. So I simplified the base separate from the rest of the engine and constrained the simple parts and uploaded that and the final version.

I also noticed github doesn't show the descriptions, but an ellipse button in the history. I also wonder how searchable the descriptions are for finding versions of parts.

Started to assemble into pump module, but found the holes for the sleeve coupler is rotated out of alignment. So editing the sleeve is easiest to make sure holes are correct distances.

In editing the sleeve I looked at SAE bolt patterns and went back through logs and parts on the wiki. The engine pattern may be a SAE B 4 bolt, which is 90mm (~3.54331 in sq, I used 3.5") I think while the pump is SAE 2 bolt pattern and the pump CAD should be correct according to previous data found to create that CAD. I made the holes on the engine side 0.3" diameter instead of 0.25", the accuracy of the CNC may be uncertain anyway.

The way the CAD is done on the sleeve is simple enough to editable, but isn't done realistic parts as the would be welded together. The method used is probably quicker and simpler though. It will not give correct 2D patterns and measurements for nesting and CNC cutting as is because the inner hole size for the end plates needs to be the outer diameter of the pipe.

I think a CAD rule to add somewhere on a FreeCAD page would be to always draw actual sub-parts and then assemble. This should be discussed in the meeting tomorrow.






Tues Jul 3, 2018


on a trip the last week and can't make the meeting. I didn't get much done on CAD, but I have had a chance to listen to a lot of other educational media. Continued to learn a little python, and related info about tensorflow deep learning software tools. I noticed VRWorks tools for Android that allow measuring surroundings based on image processing (in cloud for mobile). I'm not sure how much of that software is based on open source, but the basic tools are open. I also reviewed info about Ethereum its contracts model and more. All useful open tools to learn to apply.

Tues Jun 26, 2018

checked extents on engine and looking at best way to add bolt pattern for pump. reviewing logs to make sure I'm not missing anything else.

meeting prep.

continued adjusting distances on the engine. The tank and filter/covers are a technically a bit short in depth (front to back), but with the current design, it looks ok to leave it as is. I finally got distances to add up to 14" with the shaft cut short by 2" (pics show 16" total depth), which makes sense given the 5" thick cover, 5.75" base, 1.25" back (with oil ports), and the 2" shaft. I will add a 0.25" bolt pattern next, which makes the total thickness of the back cover 1.5" as measured.

I added a ring with 1/4" bolt holes at 3.5" center to center.

Need to review, but I think it is ready to simplify. Using GitHub even though it versions files I think it will be easier to identify if I just use separate files with simple in the name like I do locally.

Mon Jun 25, 2018

reworking top compound of tank & air filter.


The distance of extents for the top tank and cover look ok they might be a little small now, but I don't see anything that obviously matters. Need to double check extents though. The last thing I can think of is to add a pattern for the bolt holes on the back side for the pump adapter mount. I might add a thin part instead of editing the existing clone if it makes sense distance wise.

Tues Jun 19, 2018

edited engine constraints to get distances more accurate and made measurements to figure out top/tank positioning. The tank+air filter compound needs to be redone since it is to narrow by ~1". Otherwise constraints are good. I also added a breather cap, but haven't got the pull cord handle right so it easy to constrain yet.

Mon Jun 18, 2018

I assembled most of the engine fairly close, but some angles changed so I need to redraw the muffler part or just redo the constraints. I was concerned the tank and cover compound I froze might be to different in size to fit the new larger body, but it looks ok so far.

Need to adjust total height and add the breather cap that sticks up.


Tue Jun 12, 2018

editing engine CAD and meeting prep.

Sun Jun 10, 2018

Figuring out how to do re-assembly on the engine CAD. In order to make some symmetrical constraints I added hidden features just to use as constraint points. Still not quite enough, but getting closer.


Tues Jun 5, 2018

working on engine CAD and updating to github https://github.com/Witz0/OSE-Power-Cube/blob/master/Power%20Cube%20v17.08/Xp16hp.FCStd

meeting prep. copied current meeting doc

Sun Jun 3, 2018

created github repo for power cube https://github.com/Witz0/OSE-Power-Cube

I think I successfully separated some sketches in the engine file from faces by choosing to reorient them (Sketch--> reorient sketch...), but it still breaks most other features.

I'm not sure what best practices are for the github repo's are yet and I think there is a list of preferred licenses in the wiki somewhere, but a quick search didn't find that.

So I uploaded all the power cube folders I have including the engine file and some other files that maybe could be referenced from other repos depending on how they can be setup.


Sat Jun 2, 2018

I've been trying to edit the engine with some difficulty in finding the fastest way to make changes to the sub parts without breaking all the sketches and interdependencies. I've mostly given up and decided to break it down into simple components and reassemble them after redrawing the main body parts. This is an example of where I think the new Part WB in 0.17 will make editing easier. Sketches no longer map to faces and parts have more independent coordinate systems I think. Therefore it should make sub part merging and assembly easier.

The file is a mess though and I'm not sure the best way to clean it up perhaps parts will just need to be edited in the old version or redone if needed.

I'm also having trouble uploading it even though it is only ~500K. It is probably best to move it to github anyway.

Upload warning
It is recommended that files are no larger than 524288; this file is 540673.
A file with this name exists already, please check File:Xp16hp.FCStd if you are not sure if you want to change it. File:Xp16hp.FCStd

Tues May 29, 2018

checking history on the engine model I see Josh_Log#Fri_Aug_18.2C_2017 made a rough model on aug 18 and the photos are dated aug 19. So obviously they were not referenced as I thought. They are close, but not enough for CNC cutting parts.

Sun May 27, 2018

Looking for specs to redraw the quick disconnects to other sizes. 1/4" 1/2" and 3/4" are commonly needed.

The pump situation needs to be verified and BOM's updated.

Also modifying the engine CAD with fluid access points and pull cord.

Looking at OSE Pipe WB more I found I can generate the parts in FreeCAD 0.17 that glitch in 0.16, probably due to the part WB, but the design is still for PVC so I need to learn LibreCAD better. Getting the shapes shoud be possible with existing labels and code functions, but I'm not sure how much code reconfig might be required. I also think adapters like SAE-NPT could be done, but that clearly requires more coding and there are different ways to do it.

Added SAE -12 adapter. It would be nice to just generate these in a WB, but so far editing these is simpler. File:SAE 12 to 0.75in NPT adapter.fcstd

Added starter pull cord handle to engine in engine-pump module. File:PC v17.11 engine pump module.fcstd

A point to consider on the plumbing and BOM's it seems the demarcation point for parts to the PC versus the operating machine for plumbing may need to be the hoses simply because of hose length being dependent on installation to the machinery.

After further searching for an oil fill point besides the drains because I thought I understood there was one I found the stickers and tags show oil is filled through the drains as well. Tip it one way or the other after removing drains then level it and refill. Looks messy to service, but could be done while in the frame I think.

Further measurements in CAD and comparing to the photos shows there are likely some size discrepancies for the engine model. The base mount holes look close on depth (front to back), but short on the overall depth of the base as well as on the width of the mount holes. The whole model may be an ~1"+ short front to back. I thought I checked this before so I should review previous notes. It is disconcerting and makes me think the 3D photogrammetry method is needed to get sufficient accuracy for the CNC cutting.

Further measures and checking old logs show the breather cap still needs to be added and is ~18.75", which will require top notches in the frame as well. The engine is short almost 4" front to back. The mount holes are close at 3.5" from outer edges, but from photos could be 4.75". The width of the base is 10" total, but not quite 9" in photos. Looking closer the mount for the pump coupler look slike the distance between the 4 holes is ~3.5", but somehow I got ~5". I need to review because this looks like a mess of errors.

Fri May 25, 2018

I think I found the right pump https://www.surpluscenter.com/Brands/Dynamic/0-61-cu-in-Dynamic-GPF2010S9C-Hydraulic-Pump-9-7789-A.axd

It has Inlet Port SAE 12 and Outlet Port SAE 10. The size looks a little smaller so it should be ok, but the ports and fittings need to be changed in CAD.


Tues May 22, 2018

simplified File:SAE 10 to NPT 0.5in adapter.fcstd

The SAE 10 file is made is sections that should make it easy to edit it into many adapters including the SAE 16.

Fairly easy just sizes and renaming parts.

File:SAE 16 to 0.75in NPT adapter.fcstd

The difference in the way NPT versus SAE/JIC is measured relative to threads makes the sizes confusing and they look a little big and small relative to actual parts. Effectively SAE is including the threads while NPT is close to median because of the conical thread cut.

I have yet to try using the OSE pipe workbench much because these types of parts basically consist of three parts with the hex nut.

I also do not yet understand flamingo WB. There is clearly a learning curve to using to draw pipe between points.

meeting prep.


I'm not finding a 0.61 cu in pump on surplus center; I also see the SAE ports on the lower displacement pumps are smaller despite the main body section looking the same. The other factor is the SAE 2 bolt pattern can vary.

I copied the text and highlighted the BOM issue on 17.10 and 17.11. The source and specs need to be verified and a link found. Also, need to know if parts are in stock or if these parts may change again in the next build. I wonder where in the process this info got lost; It would be good to minimize so inaccuracies don't creep into CAD. When using the CNC torch table to cut parts mistakes could become more difficult to correct manually in some cases.

Sun May 20, 2018

Looking up SAE charts to find pipe thread size for adapters on the pump etc. Most of the tables and charts are not clear or don't contain the specs needed. https://batamniagaperkasa.com/products/3/3-7/3-7-14/par14-8-2.html


Getting the O.D. and I.D.'s for all plumbing standards will help increase CAD accuracy.

Understanding the SAE JIC standards a little better I think. https://www.surpluscenter.com/images/techhelp/SAE.pdf

For the O-ring standard it looks like -10 is 7/8" O.D. with a no flare design such as here https://www.hydraulicsdirect.com/Fitting-Thread-Chart-s/1934.htm#SAE-STO-R

File:SAE 10 to NPT 0.5in adapter.fcstd

Wed May 16, 2018

corrected ball valve size and added to the PC. It took two tries to get it right, but it isn't too difficult once you recall the patterns to edit and I keep trying to improve labels.

File:Ball Valve 0.75in NPT

File:Powercube v17.11.fcstd

Tues May 15, 2018

fixing dimensions on parts like the ball valve so I can continue assembly on PCv17.11.

Meeting prep.

engine mount points need to be adjusted to the right ~1-2". details on engine for oil drains and fill need to be added. see engine photos from 17.08

I'm wondering if the engine rubber mounts might be too loose and enabling more shaking of the system than they inhibit because of their height or relative softness.

I installed flamingo workbench, but I don't quite see how to use it to make pipe joining parts.


edited frame, suction holes, engine mount and notch.

made more changes to the frame.

At first I thought the import wasn't going to work. It did glitch a bit, but it worked and all the constraints updated good every time. The slow downs with modularity are in the chain of complexity to make edits. Files saves have to be done in order to preserve editable files while updating the editable and simple files. The import function would work locally for more parts, but the simplification step interferes with that and the file links are local as well.

File:Powercube v17.11.fcstd

The ball valves are still wrong and the engine needs to be moved back a little for shaking, which means I can reduce & shift the notch again too.

Wed May 9, 2018

I've found the slowness and difficulty editing the PC is based in various issues in the file. Extra constraints not being removed automatically and occasional glitches where the sketches seem to get delinked from their pads. I had to delete and redo the constraints, clones, and pads. Then reproduce them from the sketches to get everything editable again. I've taken the opportunity to separate the frame into its own module. This creates problems of its own but reduces constraints in the full model. I think I'll try importing the frame with the A2 WB like I did the back tank wall then lock it so other constraints don't move the frame. The frame is close to done, but I see the engine mount hole pattern looks backward now. This way takes time to measure and transfer those between files, but at least I'm not sitting waiting for the solver to drive me crazy.


I uploaded a simple frame version though more changes may be needed.

I started adding new constraints between the frame the engine module and plumbing parts. I'm curious to see if using the frame as a locked imported part in the A2 WB will allow changes to it without disrupting constraints. Before this seemed to work only partially without errors.

File:Powercube v17.11.fcstd

Tues May 8, 2018

correcting the ball valves on PCv17.11. SAE parts need to be made next, but for simple plumbing parts that can be generated in the pipe workbench I will make spreadsheet CSV lists.

The engine fit through the frame is still a concern as well. Increasing the sides 1/4" and moving the top up will give a little. The question is how much of a puzzle will getting the engine through a side holes be. According to the CAD the engine height is over 16.5" and the holes now are 16". I think reduction of the bottom side widths from 2" to ~1-1.5" will fix the issue and the frame strength should be ok. The only significant weakness is in the monolithic nature of the tank-frame. If it takes a hard hit while on top of the back of the LT and the bending of the frame results in tank leaks that is a major loss or total rebuild.

meeting prep.

I uploaded an update for the meeting, but the ball valves are still wrong.

File:Powercube v17.11.fcstd

There are number of changes to make to the frame, so now I'm thinking separating the frame into its own module for simplification will make editing some things faster even if I have to edit the module more.

Sun May 6, 2018

I finally got freecad-legacy 0.16 installed functionally. I expected it to be faster to edit with, but it seems to be running the same. Slower than usual and crashing on basic functions. Maybe its some missed incompatibility with newer libs or the way I'm editing the chain of parts for the grate.

The slowdowns and bugs with the Assembly2 WB seem to be universal across systems so it must be the file itself.

I edited the grate for simplicity, but kept using the same methods then recalled I wanted to consider making the front holes more useful by cutting a pattern of rectangular strips drawn more simply in the sketcher without the multi-transform function, which may be overly complex and causing issues.

I need to move on to fixing the plumbing mistakes now though. I'm thinking about how to finalize the frame as a module, but plumbing parts that get welded to it make sense to include and positions still depend on many other external components so simplifying the frame separate seems problematic for editing. Despite the fact it may speed freecad work up.

I reworked the 1/2" NPT returns and re-constrained them and the 3/4" return. The A2 WB and other operations continue to be slower than before. There is a short period of no apparent activity before the app greys and takes several seconds or more to process the changes even when clicking certain things that without making changes.

File:Powercube v17.11.fcstd

Wed May 2, 2018

Finally got the frame grate for PCv17.11 ewdited in FreeCAD 0.16 using virtual box feels a little slower, but mostly the same interface issues and constraints behaving odd again.

File:Powercube v17.11.fcstd

Now looking at the hole pattern now it is a little excessive and should be reduced. To much of a CNC Torch table torture test. Instead of hex holes 2 to 4 columns of slots ~4" long several rows high would be less wasteful. In fact 1" square strips would be more useful as scraps.

Tues May 1, 2018

Reading the PartDesign Workbench User Manual is interesting, but not detailed enough. I am experimenting with basic examples in freecad and reviewing the functions individually. I'm also experimenting with the migration and its parameters to see how it affects the existing file.

While the new version of freecad is important to figure out I'm thinking of finishing the PC v17.11 CAD in FreeCAD 0.16 by running OSE Linux 4.3 so it done and it may be easier to start with a fresh project to learn 0.17 better. I still think migrating the old files to 0.17 is important, but the learning curve may take time and dedicating time to developing new tutorials on how to use 0.17 and migrate as needed may be a better use of time.

Meeting prep.

Considering the freecad and Assembly2 WB version situations it is a good time to discuss software dev version compatibility and how to develop most efficiently with the rest of the freecad and open source dev community.

Sun Apr 29, 2018

Testing migrating to the new part design WB is a bit confusing and appears to create chaos with the model most likely in constraints. I'm not sure A2 WB works at all after migration. I can see definite benefits to the new functions and methods, but it is a more significant learning curve than I expected.

Sat Apr 28, 2018

I'm looking into the FreeCAD file migration issue more. I think it is not a problem because a few people were using the 0.17 daily before and I have yet to notice any signifcant problems. For the record freecad daily 0.18 has not executed and loaded for me yet.

Assembly WB development https://forum.freecadweb.org/viewforum.php?f=20

Thurs Apr 26, 2018

more progress on BOM lately and now I'm attempting to update the CAD, but having some more issues with constraints and the way FreeCAD 0.17 is running seems to have changed. editing sketches and constraints feel slower and updates cause application pauses and hangs more. Other than that I find the interface changes ok and see some new functions to explore.

Waiting for the constraint solver is making me wonder if re-assembling all the parts again would help. It may also lead to a better process and method of organizing the tree view. Having more simple parts would also reduce the number and complexity of constraints, but this model is not that complex and I keep needing to edit the frame relative to other final parts.


Considering A2WB is technically no longer maintained and regardless of whether it can be made to work now, I think for long-term FreeCAD use a new workflow needs to be found before it is completely deprecated.

This makes me want to rethink prioritizing learning more internal aspects of FreeCAD and workbenches. FreeCAD is a critical app and we need to work with that community as the project moves forward.

Tips and recommendations for assembly and issues with 0.17 https://forum.freecadweb.org/viewtopic.php?t=16697

“part design next” WB is asking me to migrate my file to 0.17

Official FreeCAD Project for collaboration and PLM https://www.freecadweb.org/wiki/Resource_framework_project

File:Powercube v17.11.fcstd

got some parts updated, but need to migrate the file to 0.17 to use the new functions I need to modify the frame front. I see a new larger learning curve for 0.17 and I noticed other more advanced freecad tutorials with good info, but even they are out of date.

Tues Apr 24, 2018

Progress on correcting the BOM


Meeting prep.

with the prior discussion on software tools integration websites etc. I was thinking of https://www.wevolver.com/projects again and it looks like the site is slow to progress, but I think the v2 with versioning is a new concept there. Wevolver essentially looks like an attempt to create a closed source web interface for online collaborative engineering. It is interesting to imagine what could be done with an open source version using all the open source software tools.

Mon Apr 23, 2018

Looking at what pipe fittings can be used to mount through the tank wall to clarify the BOM and fix the CAD. I was thinking about this differently before in tank plumbing to prevent air entrainment. The photos of prior builds show the elbows welded to the inside tank wall, which means nipples must thread through the wall into those. With 1/4" plate and ~3/4" of thread length question is will a 1/2" thread contact seal ok. Cheap black iron pipe can be used in the tank, but corrosion resistance is important outside.

https://www.zoro.com/zoro-select-nipple-34in-thrd-both-ends-2-12in-304-714-025sgr/i/G1832257/#specifications https://www.zoro.com/zoro-select-nipple-34in-thrd-both-ends-2-12in-304-714-025sgr/i/G1832257/#specifications https://www.surpluscenter.com/Hydraulics/Hydraulic-Adapters-Fittings/NPT-to-NPT/NPT-Male-to-NPT-Male---Hex-Nipple/3-4-NPT-Hex-Nipple-9-5404-12-12.axd

Fri Apr 20, 2018

I watched the Thurs meeting.

I'm prioritizing rectifying any difference in the PC v17.11 BOM (copied form v17.10) with the Power Cube Conceptual Design in order to make sure some of the final plumbing parts are correct before I draw/assemble them in CAD.

Sat Apr 14, 2018

A priority change I think could be better with the documentation is potentially eliminating or reducing the importance of the VBOM's by replacing them with more the accurate CAD diagrams and BOM's generated from those. The VBOM concept seems useful as scratch pads for developing layout and general interconnection of components but tends to lack detail and the files are harder to keep up with requiring more editing time. In general, it is another separate layer that needs to be updated frequently.

Potential tools like OpenPLM need to be reviewed again and if not up to standards new code development would be beneficial. Coding tools like Work Benches to reduce the overhead between design and documentation will result in more productive focus in the long term. Developing good tools now is important. Finding more developers interested in software should be easier than some of the other development team needs.

Getting the documentation methods streamlined will help speed development. There is a lot of instruction and text on the wiki and whether it is up to date or not it is so much it will always be difficult to follow guidelines for new and old developers.

I've just noticed the updates to FreeCAD. It looks like 0.17 is official now. I liked a lot of the new features I saw in 0.17 before and I hope the transition is smooth.

Another documentation file related issue is the Development Template Simple version is shorter, but still has many other sheets in the workbook this is making it slow to load. Lots of useful looking sheets, but if they aren't being utilized extensively they might as well be separated into other documents.

Figuring out changes to docs.



Updating the VBOM and BOM for PC v17.11 I'm not finding ideal cheaper solutions for cutting pipe nipples in half like https://fastfittings.com/products/1-inch-npt-lead-free-brass-nipples compared to the previous hydraulic nipples such as https://www.surpluscenter.com/Hydraulics/Hydraulic-Adapters-Fittings/NPT-to-NPT/NPT-Male-to-NPT-Male---Hex-Nipple/3-4-NPT-Hex-Nipple-9-5404-12-12.axd

added image for Power Cube Library

Tues Apr 10, 2018

Given likely slight changes in the BOM's etc. I think it easier just to make copies so they are ready to edit correctly. In fact, Iimportance'm thinking it will be better just make a copy of an entire "package". That being a google doc's folder and/or wiki pages template code etc. Unfortunately, even if an entire folder of gdoc's for a particular project can be copied and edited they still need to be published individually on the wiki.


When copying docs they also need to be labeled clearly as such somehow until edited differently from the previous version.




embedded new copies of docs to Power Cube v17.11

and to Power Cube v18.01

Sat Apr 7, 2018

Reviewing Development Template use for burndown charts. Currently, the burndown charts show work as mostly incomplete, which is not the case.



Some of the old files like BOM's and VBOM's appear ok, but there could be small changes or less purchases for certain items if parts are replaced with other off the shelf or shop fabbed parts. Many of the additionally needed links to work in the development template will be to future work such as the CAM and cut lists. Others like software appear unnecessary.

Tues Apr 3, 2018

Looking at OSE pipe workbench OSE piping workbench. I see a few examples with more detail to the pipe fittings like the NPT style. It would be nice to differentiate visually in case a project contains both PVC with a smooth injection molded look or metal cast with thicker ends like NPT. I see some info about color so all PVC could be white unless some other color coding is desirable for assembly. I've been curious how the flamingo code draws the parts to some extent. I'm guessing it uses underlying FreeCAD code and is less similar to OPENSCAD in that it draws sub-parts and effectively assembles them into a compound.

meeting prep.

Updated OSE Pipe WB and reviewed the files and structure. I see DXF's that look like they are being referenced for the base shapes and the CSV tables for dimensions and angles. Testing the create elbow dialog just seems to create Base->Sweep, Trajectory, and elbow_group folder.

Mon Apr 2, 2018

File:0.5in NPT elbow.fcstd

The elbows are designed with longer sweeps than standard parts such as on McMaster-Carr https://www.mcmaster.com/#44605k114/=1c5lahe There are different ways, possibly simpler to shape more accurate since the sweep was hard to work with. The loft tool may be easier, although positioning the end rings relative to one another via constraints seemed infeasible, but maybe hidden primitives could be used. Redoing these doesn't seem like a priority currently.

File:Powercube v17.11.fcstd

constrained in 1/2" elbows and pipes on return lines in the tank.

More significant prioritization needs to be given to the file management, documentation, wiki, and process so that the burndown and other data collection works correctly. The template and files really need to be done first and prioritized over getting work done so the order of work operations is correctly organized and processed for the burndown.


Tues Mar 27, 2018

meeting prep.

resizing 3/4" elbow to 1/2" for the majority of returns into the tank.

Sun Mar 25, 2018

In order to do the plumbing inside the tank, I searched for CAD for elbows to use as a reference to create an editable FreeCAD version. The sweep util was giving me some trouble, but I think I have nearly solved it.

File:0.75in NPT elbow.fcstd

Assembled the 3/4" elbow and a pipe into the tank on the filter return.

File:Powercube v17.11.fcstd

Tues Mar 20, 2018

meeting prep.

Looking at burndown chart situation. Definitely a need to add chart creation as the first task when starting a new project.

added template for LifeTrac v17.10


edited Power Cube Conceptual Design to add info on elbows and pipes inside the tank for return lines to prevent air entrainment.

See photos of previous tank work https://photos.google.com/share/AF1QipM3mvI1hki8vMh9vrCPgQcvjZKkq2o2IfSWjqRuSwSdyFqUSMVOok-MkSQaUYGnbQ?key=SUVSSTl4WXpBV0lHWjMyQ2c5a1I4REZXMDlyV0d3

The inner tank wall will probably need a little rework to make sure the elbows weld on the inside good and the pipe nipples thread through the tank wall into them easily.

Sun Mar 18, 2018

Busy lately with spring coming. Looking at the oil filter assembly position it seems to clear the frame sufficient to rotate 360 degrees so it can screw on over 3/4" without hitting the tank wall.

File:Powercube v17.11.fcstd

I adjusted constraints on the plumbing fittings to realistic estimates for threading depth and added a 3/4" pipe piece for the filter input.

Plumbing details are mainly what is left in the PC CAD itself. I think drawing and adding 1/4" FPT parts for the quick couplers on the case returns, the pump fittings and checking the cooler fittings are obvious next CAD steps.

Tues Mar 13, 2018

started to prepare for meeting and my internet went down. Checking current meeting docs.

Sun mar 11, 2018

editing the tank wall plumbing holes keeps altering the way the constraints work. Errors result after and resolving has tended to result in incorrect assembly. Redoing more constraints seems to have improved constraint function now though.

I reassembled most it with new constraints, edited the inner tank wall and added holes for the smaller case return lines. I also started using some different plumbing parts and sweeps representing hose to visualize arrangement.

File:Powercube v17.11.fcstd

It looks like the harder hose connection might be the suction line to the pump in the main PC, since it is short and needs to bend alot or loop around a bunch of other connections.

made tank filler and breather cap based on welding 2" NPT over 1.5" NPT with a screw cap on the 2".

Need to consider angle of operation on slopes for spill over and fill level. Breather section of cap may need to be taller. I'm also thinking the filter will go in the 1.5" section below the breather part for smaller print and so it is closer to the tank, although this still doesn't seem to like it would allow for overfill visibility.

File:PC v17.11 Tank FIller Cap.fcstd

I added more plumbing fittings to the suction lines on the ball valves then added some sweeps for hose examples. I also added the 1/4" NPT pipe sections for case return lines and constrained those. I made and added the engine rubber feet as well. Everything seems to be constrained ok.

Reviewing Power Cube Conceptual Design to double check anything else easy I'm missing. There are still a few possible tweaks to frame size and assembly for ease of construction and plumbing.

The overall assembly and interconnection of cubes onto the LT will need more consideration as well.

Sat Mar 10, 2018

updated inner tank wall plumbing holes into a staggered pattern to test arranging plumbing.

File:Powercube v17.11.fcstd

editing the inner tank wall again mixed up the constraints on the PC differently this time. It insisted on deleting a main engine constraint and then solved the plumbing and hole constraints correctly, but pulled the frame apart strangely. I do not see the underlying causes of this behavior, but it is not entirely inconsistent.

Sun Mar 4, 2018

adding a burn down appears simple, but requires an admin login to OSEDev and the spreadsheet cell total ID from the URL's below.




I removed the extra crossbars from the bottom plates.

File:Powercube v17.11.fcstd

File:PC17.11 auxiliary.fcstd

Editing the tank wall hole positions is proving a little harder with a more complex pattern needed. I think a redesign of that sketch is in order if possible. But, to contrain the plumbing the holes will just cause issues so constraining from the edges and just doing some math to position each part should work better.

Tue Feb 27,2018

Thinking about the power cube hooks and balance for lifting I'm wondering if a third hook point is needed or at least some consideration for weight.

Edited the ball valve for a 90 deg handle option to aid in more detailed plumbing arrangement.

File:Ball Valve 1in NPT.fcstd

Updated Small PC with latest version of single stage pump-engine module.

File:PC17.11 auxiliary.fcstd

meeting prep.

Sat Feb 24, 2018

redrawing PC top plate with hook points sill needs to include tank top.

File:Powercube v17.11.fcstd

I've had some issues getting that sketch to constrain that I'm not seeing immediately. There are many small parts and details yet to be done from the basic concepts, but after seeing how the plumbing fittings unconstrain to the holes everytime that is changed and how many edits I keep having to make to the frame I think prioritizing doing the plumbing by the numbers (maybe with constraints to edges instead of holes) will be the next best step since the plumbing could create a need to adjust the frame slightly.

I lost time on the top plate sketch due to stray components I didn't know were there. Finally, redrew it better and found them in the process.

I re-added the engine-pump module and put ball valve clones on the suction outlets. Clearly, the handles will be a complex alignment issue and it is hard to know ideal pattern without also knowing hose positions. Best guesses can be made and handles cut off, but clearances for getting vice lock pliers on to the handles would be needed anyway. It may help to make a closed version of the ball valve. The bottom plate also needs to be edited for strength and possible turning the handles downward below the cube.

Wed Feb 21, 2018

added shaft coupler into engine coupler pump module.

File:PC v17.11 engine pump module.fcstd

Tues Feb 20, 2018

detailing single stage hydraulic pump to update engine-pump module and to check more possible frame adjustments.


simplified the LT with the PC's for checking position options.

File:LT master cad.fcstd

added ports to single stage pump File:Hydraulic Pump.fcstd

edited engine coupled to pump module.

File:PC v17.11 engine pump module.fcstd

edited coupler to add 1/4" key under set screw on 1" engine shaft end and reduced 9 spline pump shaft end to 5/8".

File:PC 1708 coupler.fcstd

Mon Feb 19, 2018

reviewing needed changes and more models of ball valves.

created ball valve from references of with NPT size of 3/4". This should be easily scaled to 1" as well. File:Ball Valve 0.75in NPT

Not a perfectly editable workflow, but easily modified to 1".

File:Ball Valve 1in NPT.fcstd

added some hook points for hoisting auxiliary PC.

File:PC17.11 auxiliary.fcstd

Thurs Feb 15, 2018

checking the pump-engine distances and simplifying the power cubes for checking stacking on the LT.

joined jitsi meet for call with Marcin about PC's and LT v17.10.

Power Cube Conceptual Design

Lots of details to update. Vent Cap assembly, suction line 1" ball valves, add four 1/4" case drain returns, re-arrangement of all holes for lines, single stage pump is about 1" shorter, filter adapter needs clearance perpendicular to pipe (~4" diameter?).

Power Cubes do not fit well on LT. There is only 32" width between the LT frame. It would nice if the PC frame could be narrowed, but the cooler configuration currently prevents that.

Tues Feb 12, 2018

Still working on a few pipe fitting details such as making CAD for 3/4" NPT pipe section for hose suction lines. Overall the next details are related to ergonomics or logistics of use on the LT. Therefore I'm looking at connections and common accessibility needs such as fueling and engine control. A rail system or bracket structure for mounting on the LT may increase modular usability but adds complexity overall. How heavy are a main PC and a auxiliary? Can two strong humans lift the main cube up on top of the others without another machine to assist?

There are also still measurements needed to verify extents such as the engine-pump module height and length.

File:Powercube v17.11.fcstd

getting a bug constraining the red color-coded 3/4" NPT pipe sections

Planning to meet with Marcin on power cube stacking logistics for LifeTrac v17.10 on Thursday evening at 6pm CST.

http://opensourceecology.org/wiki/Power_Cube_v17.08#Other_Parts The pump in the current CAD is the two-stage log splitter pump, which was never used. The correct one is probably File:Hydraulic Pump.fcstd or something close enough it can be edited to match.

I also see a few errors in the vBOM's showing incorrect pump kits.

I created a section of 3/4" NPT pipe for the 1" suction hoses to attach to and added it to the Hydraulic Part Library (redirected to Hydraulic Fitting Library probably named so for less generality) File:0.75in x 1.5in NPT suction pipe.FCStd

updated File:3Quarter NPT Hex Nipple.fcstd to standard NPT dimenions and larger hex nut specs that appear more accurate.

I resolved the FreeCAD constraint bug for the fittings. It was a pre-existing solver issue probably due to editing something like the tank wall holes. File:Powercube v17.11.fcstd

added and edited https://docs.google.com/spreadsheets/d/1Y3mnDo3gNi2-OrdrrmILmlIr6i0l6xJOi-jZsefcEu0/edit#gid=1 to Power Cube v18.01

I edited the File:Hydraulic Pump.fcstd to fix a glitch and check the measurements. The extents seem close, but the corresponding axis for the magnitudes listed were never clear until the 8" measurement. So I increased the body length to 5.125, the body width needs to be increased to 4.5 square. This will require a significant re-edit on the sketch, which currently doesn't appear to line up with that given the bolt pattern.

Sun Feb 11, 2018

Looking for more specific dimensions for fittings I'm finding it hard to find similar versions of the NPT to hose barb adapters on McMaster-Carr. They stock the more complex expensive types compared to the surplus center parts. Different types and materials may be close but have slightly different shapes and thicknesses. The most important dimension is the NPT end for the CNC hole cut, which should be an easy standard to work around. Also, the 3/4" pipe method is cheaper than buying adapters so I'm assuming the 3/4" NPT nominal OD pipe size + 1/8" is a good hole size.


1" NPT to barb https://www.mcmaster.com/#5363k73/=1bj2lm6

3/4" NPT to barb https://www.mcmaster.com/#5363k72/=1bj2p8x

1/2" NPT to barb https://www.mcmaster.com/#5363k71/=1bj2tdu

Sat Feb 10, 2018

corrected engine-pump module with updated coupling parts

File:PC v17.11 engine pump module.fcstd

File:Powercube v17.11.fcstd

File:PC17.11 auxiliary.fcstd

added shorter engine pump module to both versions of PC and corrected tank hole sizes on main PC. sizes should be close, but will further verify OD of 3/4in pipe for the 1" suction lines.

Tues Feb 6, 2018

catching up adjustments on PC CAD parts.

File:G22 Hydraulic Pump coupler sleeve.FCstd The flange patterns need further adjustment, but the current fits the CAD so it must be close.

File:PC 1708 coupler.fcstd shortened length to 2in as best guess given measurements of sleeve and shape of engine in CAD.

File:PC17.11 auxiliary.fcstd adjusted grate/mesh, cooler and mount holes.

adjusting PC v17.11 outlets and inlets/outlets. The VBOM's for 17.08 and 17.10 have some differences in nip and barb sizes and part links as well as 17.10 suggesting 1in instead of the 3/4in in 17.08.

Going with 0.5in for returns except the 3/4in needed for the filter.

The File:3Quarter NPT Hex Nipple.fcstd fitting CAD size is not actually 3/4in and requires editing.

File:Powercube v17.11.fcstd updated with 1/2in nips for ports except the 3/4in part redraw for the filter.

Wed Jan 31, 2018

Power Cube Genealogy can be updated with references to Solar Power Cube v17.10 and Power Cube v18.01

I got a little lost because PC v17.10 has no CAD file. I think some things got lost over the holidays and with the MC build. As I recall PC v17.10 was built around or after the MC build and a newer modified version of PC v17.08.

Tues Jan 30, 2018

meeting prep.

May need some good measurements and a better idea of PC interconnection on LT for adding finishing details to PC's.

Searching for CAD models for fittings before drawing from scratch...

Clarifying Auxiliary PC version as Power Cube v18.01

The engine-pump coupler needs to be adjusted to 3" long x 2.5" OD. I assume the shaft coupler also needs editing. The accuracy on this matters since it determines the total distance needed for the cube frame. Currently the gap between the tank and pump back end is narrow, this should help increase that or even allow the cube frame to be shortened ~3" wasting less metal.

Mon Jan 29, 2018

Reviewing plumbing parts on previous PC's CAD, BOM's, and Part Libraries in order to check what I'm should be adding into the holes in PC V17.11.

PC v17.08 uses File:Barb to nptm.stp But a Note says: Initial upload is 3/4" barb. We need 1" barb for Power Cube v17.08

So, I'm thinking a redraw is needed as I don't see a 1" barb. I'm thinking the STP's are from McMaster-Carr though...

1" seems necessary given the volume of flow and amount of hose needed (and therefore friction) with the modular design. BOM for 17.08 has 3/4 hex nip. I'm guessing these are what is easy to weld in.


Nope, 17.08 and 17.10 VBOM's suggest: 1” NPT welded-in barb http://www.surpluscenter.com/Hydraulics/Hydraulic-Adapters-Fittings/Hose-Barbs/Hosebarb-to-NPT-Male---Straight/1-HOSEBARB-TO-1-NPTM-ADAPTER-4404-16-16-9-4404-16-16.axd

https://en.wikipedia.org/wiki/National_pipe_thread effective thread diameter is about 1.25", but I'd guess for easy fit and weld that 1.3" is tight for the CNCed holes.

File:Powercube v17.11.fcstd

I'll have to review media for comments on sufficient size for return lines. As I recall one return through the filter is sufficient, so probably just multiple return holes for 3/4" fittings.

3/4" NPT OD is just over 1.001", so more return holes need added and all adjusted to ~1.1"

Sat Jan 27, 2018

working on adjustments moving the cooler to the front requires since it changes the engine position. There isn't a lot of clearance at the front or back of the engine-pump assembly, but I think that is ok. Optimal positioning of cooler in front of the engine is also not exactly clear, but minor adjustments can be made as needed. The bottom plate engine mount point has to be moved and that is a good time to add the bolt holes.


File:Powercube v17.11.fcstd

Continuing to add details to PC. There are many holes and to add for bolts and piping yet.

File:PC17.11 auxiliary.fcstd

added holes for bolts on the front of PCv17.11 and created an editable inner tank wall with holes arranged for plumbing.

I just realized the front mesh grates may need to be halved for access to engine throttle etc. relative to ideal cooler placement. Bolt holes will need adjustment as well.

Tues Jan 23, 2018

Meeting prep. Measurements are likely needed to verify some details still. Next main details are plumbing. Verifying specific parts are accurate enough in CAD and adding to the hydraulic plumbing library will help overall.

Sun Jan 21, 2018

edited grate and added to File:Powercube v17.11.fcstd

Sat Jan 20, 2018

trying to edit details into power cubes. getting some FreeCAD crashes. Added Grate from PC v17.08 to auxiliary, but needs more editing.

File:PC17.11 auxiliary.fcstd

Still looking back through PC BOM's for rubber feet. PC v16.8 looks like the earliest version with a similar engine, but an order of rubber feet could have been for any previous engines as well.

Reworked grate to mesh and positioned it in the auxiliary CAD. The mesh is larger in data size and unnecessarily complex.

Wed Jan 17, 2018

Looking at previous PC CAD and BOM's to check for missing parts and the correct fittings for the tank and other plumbing.

Tues Jan 16, 2018

I'm still attempting to constrain engine pump module in auxiliary PCv17.11.

meeting prep.

I am concerned about FreeCAD methods and the easy editing of the files because the process has become more complex and likely not clear to others possibly including team members familiar with freecad. There are instructionals, but the process is not linear or straight forward and bugs are still an occasional problem. The logic to avoiding the bugs or correctly using the constraints is some complex decision tree I'm not sure is thoroughly documented enough anywhere other than maybe the underlying code. This is one reason I plan to start going through a Python course again soon.

Still many details to create for the PowerCubes engine feet, holes and fasteners, plumbing fittings, hose representations, cooler screen.

added Hydraulic Fitting Library and links between PC Library and specific versions.

Not seeing the rubber feet in any PC BOM's back to v16.8, but I found an editable grate/screen to adapt File:PC 1708 Grate.fcstd.

Mon Jan 15, 2018

updated File:PC v17.11 engine pump module.fcstd with simple and positionally correct version and constrained that into File:Powercube v17.11.fcstd.

Attempted to constrain the engine pump module into the Auxiliary PC as well, but I'm getting more bugs with it. I think it is not constrained as well as the main PC somehow. It also was not positionally correct due to the cube size difference, although the auxiliary is a derivative file of the main PC some changes or references in the copied data are causing issues. It would be good to understand what process mistake was made.

Fri Jan 12, 2018

In trying to edit the engine assembly and add the coupler sleeve I've found it is missing from assemblies all the way back to PC v17.08. This also highlights the need for clearly organized modules in the wiki PC Library. So, I think correcting the final assemblies and then separating the engine, shaft coupler, and sleeve coupler parts into a module would be ideal. It also begs the question if the CAD for the sleeve coupler is correct and how that worked out on the previous PC's. It does not appear in the PC v17.08 photos.

I keep running into bugs/crashes with the constraint solver attempting to assemble the sleeve coupler into the PC v17.08 master CAD file. Creating a separate module and reassembling later may work better.

File:PC v17.11 engine pump module.fcstd Note: module is positionally correct to File:PC1708 Master.fcstd since that was the last readily editable version.


Thurs Jan 11, 2018

I had an issue with Ubuntu after reboot likely due to a failed update. I followed iunstructions for the issue using a boot stick to run apt update and upgrade. Realizing my stick was probably out of date still I'm trying new versions of OSE Linux.

Corrected the cooler positions in PC. I moved it to the front bottom right for air flow off the fan in the pull start. I also noticed the File:G22 Hydraulic Pump coupler sleeve.FCstd was not included. I tried adding this for visualizing possible ducted fan designs using this part. However, further adjustments need to be made to the original engine pump coupling or length of the sleeve.

File:Powercube v17.11.fcstd

File:PC17.11 auxiliary.fcstd

Tues Jan 9, 2018

Reviewing Power Cubes, LT, wiki, and YT for meeting @2PM CST.


Reviewing old photos from 17.08 to try to see where exactly the air mover or fan is on the engine is to be used for cooling. https://photos.google.com/share/AF1QipMNKx0q8K3oWrlxlHi5A8qXvXVFdfrPtYv50ekm-UBXjsDltGRNf8OGkYdL5nwI2A?key=UU9mRlludWlfVkhUNVRFdTlOSGl0NEo5NW9zS3d3

From experience, I'm thinking there is an effective fan behind the pull start mechanism. It is however at the very front of the motor and I'm skeptical it is sufficient air flow, but mounting the 1240 cooler low and in the corner near the front shouldn't interfere with the pull start.

My only other thought is integrating some kinda of fan into the engine shaft to pump adapter, but that would increase the complexity of making that part and maybe cost of materials. Such a solution could, however, eliminate the need for stock off the shelf fans in general.

Tues Jan 2, 2018

Meeting Prep.

Catching up and refamiliarizing with PC.

Thurs Dec 14, 2017

cleaned log. For next year I think it will be more searchable to dump the monthly logs into one page of old logs.

adjusted some specs on pump for 17.10

I'm not sure this will be re-used for 17.11, but good to the correct for 17.10. Editing the tree on this part requires some rework, but it is simple enough. With further corrections changing the editing order or using simple component copiues with unions might be more efficient to edit in this case. Some inaccuracies in the extents, shaft, and general shape still exist since I can not find any detailed CAD diagrams from surpluscenter or Eaton.

File:Hydraulic pump Eaton 0.92 cu.fcstd

Wed Dec 13, 2017

Back from a trip that took longer than expected. Reviewing where I am with Primary and Auxiliary PC. Ready to finish the power cubes and move on to the next thing.

Sat Dec 2, 2017

Reviewing large PC and figuring out likely dimensions for the smaller cube.

Did a quick re-edit of the Main PC for the Auxiliary smaller cube.

File:PC17.11 auxiliary.fcstd

Old Logs