CEB Press Log

Thu Apr 29, 2021

Finalize the code for both low and high pressing operation - 6 or 10 block per minute.

• Known bugs: machine has currently been tested in multiple day production runs and is stable at 6 bricks per minute. For a higher flow rate, a different logic sequence is used.

• When solenoid valve runs with 2 Power Cubes at 28 gpm fluid flow, different control code needs to be used. The logic is based on a series valve with a series pressing sequence.
• Issue can be resolved also by using the same code, and a parallel solenoid valve instead of the series solenoid valve that is currently being used. This would require a closed center hydraulic system, however - so the hydraulic pump would have to be changed to make this work.
• Larger diesel engine which was used to power the brick press in 2010 at 30 gpm fluid flow used a simpler control code, which was written for series operation. A brick pressing rate of 10 full size block per minute was achieved in 2010. We switched to parallel logic, and are now returning to a more robust series logic.
• Control code optimization can happen to optimize power usage, saving a few percent on energy use.
• Log splitter hydraulic pumps can be used to allow for the use of a smaller engine. This has been begun, and completion remains as future work. The advantage of a log splitter pump is the possibility of much more efficient operation, perhaps up to 50% less fuel.

Wed May 11, 2016

Some tasks for CEB completion:

1. Complete the PDF of instructionals for the CEB press on a module-by-module basis. See the 18 module instructionals. These are 95% done - they need to be formatted better, some pictures need to be filled in, and assembled into one master PDF. The hard part may be the control system integration, which requires procedure for calibration, startup, and troubleshooting of the machine. To this, we have to comb through to quality control checkpoints - which are not documented well, and I would have to go over with you. There are critical points about alignment, finish grinding, etc - which need to be made explicit in the instructional so that even novices can check their own work quality. 4 weeks.

2. Complete 2D fabrication drawings for the CEB press using FreeCAD. 2 weeks.

3. Produce a complete video for each module build, about 2 minutes each, tightly edited like my 2 FreeCAD instructionals, using Kdenlive. This means that we are actually building the complete machine, with you taking video, including setting up a good time lapse. We have a good Canon camera and tripod. We would do a careful script for each module, such that you would work from the script to do the videos. I may want to narrate the videos for brand familiarity. We would post all our source video on youtube, so that new edits or updates could be made as needed, for which reason we also want to upload the Kdenlive files so others can build from them. 3 weeks

4. Generate detailed exploded part animations that show how each module goes together. These detailed animations would be included in the video - where the video includes exploded part animations, video of actual build, videos of me discussing the build procedure - on a module by module basis. 1 week.

5. Organize and clean the workshop, prepare work tables, lay out tools and materials. We are currently planning a CEB 1-day build workshop for August 27 - so you would be helping prepare this event, and help run it as an assistant. The workshop is currently a mess - we need to prepare it well. 2 weeks.

6. Generate DXF cutting files for the CEB press using FreeCAD Path Module, and generate Gcode files for the OSE CNC torch table (under development). Test the CNC torch table cutting. Document the workflow for this using FreeCAD. 2 weeks.

The idea is: the complete PDF, combined with 2D assembly drawings, and the video - provide the most exhaustive and complete documentation set that took us years to get to this point - and which will be released to the world as a 100% proven product. This is actually quite big for OSE - as this can become our first machine that gets widely replicated around the world because of its cost and performance advantage.