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Article Title: GVCS Home List

The OSE printer is called D3D - for Distributive Enterprise 3D Printer. For Current Work see 3D Printer Genealogy.

Overview

3D Printers are a subset of CNC machines: they use stepper motors to move along X, Y, and Z axes according to gCode - essentially a text file with thousands of lines of coordinates and special commands (such as "return to origin" or "set nozzle temperature"). As motors on each axis moves the nozzle through 3D space, an additional motor feeds plastic filament through a heating element, very much like an automatic hot glue gun.

The software that turns a 3D model (such as an .stl or .obj) into instructions telling the printer how to move is called a "slicer" - it slices a model into layers that will stack up to make the finished object.

Many options exist for controlling the printer with your computer - nowadays several "slicers" can also connect to the printer directly, streamlining the printing process.. As a central backbone of Digital Fabrication, the end goal of 3D printers is to be able to print anything.

Genealogy

The Global Village Construction Set
Nickel-Iron Battery

The Global Village Construction Set
Nickel-Iron Battery

The Global Village Construction Set
Nickel-Iron Battery

See full genealogy at 3D Printer Genealogy

Details

Types of 3D Printers

Folgertech_Kit

Printing Process

(just adding a note here, please move where it fit better) To improve movement speed/accuracy of the printer head i was thought about a dual motor set (each axis) coupled with a differential gear-set so would be possible to reduce or multiply output turns with a digital controller that regulate the ratio of the two motors rotation. (not sure how to implement this and not sure it may be so effective, i just believe this may open for bigger volume printers (3m cube hypothesis). (adexmont 18/nov/2018)

Applications

http://www.instructables.com/id/3D-Printing-3D-Print-A-Solderless-Circuit-Board/

https://www.reddit.com/r/functionalprint

http://readwrite.com/2014/01/31/why-you-want-a-3d-printer-in-your-home

http://www.thingiverse.com/thing:113865

http://www.thingiverse.com/explore/newest/tools

http://www.treehugger.com/lawn-garden/garden-3d-10-things-you-can-3d-print-your-garden.html

http://3dprint.com/34873/3d-printed-lawn-mower/

https://www.pinterest.com/pin/412712753326603895/

https://www.pinterest.com/pin/412712753326427241/

https://www.pi-top.com/

https://i.materialise.com/blog/redesigning-the-bike-frame-james-novaks-experiment-with-3d-printing

http://design-milk.com/keystones-studio-minale-maeda/

http://www.instructables.com/id/Open-Source-3D-Printed-Water-Filter/

https://www.pinterest.com/pin/412712753325305467/

https://all3dp.com/3d-printed-laptop-case/

Product Ecology

Product Ecology
**3D Printer**
From	Uses	Creates	Enables
3D Scanner CAD Laser Cutter Bioplastic Extruder Components XYZ Table Motors Controller Spindle Extruder Feeder Tool Changer	Bioplastic	3D Prints	Metal Casting Digital Fabrication

Status

See past work related to Factor e Farm at RepRap Build.

Currently 3D printer designs are being researched, with the goal of full integration into the Product Ecology of GVCS technologies.

3D printer technology is currently undergoing a flourishing of innovation. As a relatively new technology (2003), many experimental designs and techniques are being explored by thousands of groups worldwide.

See D3D_Landing_Page for the most recent work on this machine

Overview

Kinect 3D Scanner

3D Scanners enable near-instantaneous input of spatial data into digital systems. The technology is currently undergoing a massive flourishing of innovation as the underlying hardware becomes ubiquitous. As a part of the GVCS 50, it enables a suite of powerful applications.

Applications

CAD
Rapid Prototyping
Workshop Control
Automation Programming
Robotic Systems
Training

Details

Product Ecology

Product Ecology
From	Uses	Creates	Enables
3D Printer CNC Circuit Mill Components Electric Motor Generator Case Camera Laser	Universal Power Supply Computer	CAD	3D Printer Sawmill Tractor Industrial Robot Digital Fabrication

Overview

The Aluminum Extractor extracts raw aluminum from alumina common clay (alumina silicate).

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Detail

Using a closed-loop cycle involving hydroflouric acid and a large amount of electricity, it is possible to extract raw aluminum directly from clay deposits. This is in contrast to the typical aluminum extraction technique from strategic bauxite mineral reserves.

There is posibility also to produce bauxite from very common feldspar mineral (sand) and carbon dioxide. This is natural process that produce clays, but it is posible to speed up usable level with increasing carbon dioxide partial pressure. Easy source for carbon dioxide are biogas reactors. Biogas cleaning produce large amounts pressurized carbon dioxide water solution. It is even posible to directly feed pressurized biogas through feldspar sand column and combine both process.

Alumium electrolyze process should be combined to localized power grid and its power consume should be tied to grid frequency after 50.5Hz or 60.5hz it should start itself and come full power until 51.0Hz or 61Hz so alumium making can be used to dump excess energy. Very useful combined with windpower.

Product Ecology

Product Ecology
From	Uses	Creates	Enables
Induction Furnace CNC Torch Table Components	Power	Aluminum	Induction Furnace

Components

Overview

The Backhoe is a piece of excavating equipment used for digging holes and trenches.

Versions

Backhoe 4

No real plans for Backhoe 4 as of Oct 2013. That's just a place to record ideas for a future version.

Backhoe 3

See Backhoe Prototype 3

Under active development as of Oct 2013

Backhoe 2

Plans and photos from the 6 in 60 campaign. See Cory Shenk Log for iterations of the design.

This is the most recent version of the backhoe that I have upon the end of 6 in 60: File:Backhoe deep dig.skp

We were never able to completely build it but we did complete sections and components. Check Leandra's Log and Luca's Log for any other information. We spent a decent chunk of time working on these together.

Bucket

Parts for the body of the bucket. I used three pieces that were 4 inches wide as you can see in the photo. Two should be replaced with an 8 inch wide piece of the same length. It reduces the amount of welding required and adds strength to the bucket.

You can see two pieces have already been welded. This should be cut out of one piece of steel.

I allowed myself extra room on the pieces that I cut for the sides of the bucket. This allowed some wiggle room when assembling the entire thing.

Step by Step in Photos

The connection points should be revisited for better attachment to the stick. See Stick Design.

There was often physical conflict where points attached that had square corners (in the case of the bucket and in other areas, usually cylinders). It might be a good practice to simply always notch them off or round the corners with the torch, or fabricate a rounded blade for the iron worker.
The teeth of the bucket are bolted on so that they can easily be removed. This seems unnecessary, especially in a final version.
I cannot determine how the shape of the bucket will affect its performance. This will need to looked into upon completion.

Stick

Although we never reached the point of assembling the entire Boom and Stick to the Pivot, my guess (based off of many experiences in that workshop) is that there would have been conflict with the bolts and cylinders within the range of motion.
To limit the amount of times that this occurs it would be beneficial to draw very exact models of bolts, washers, nuts, etc. Included with these should also be cylinders of various sizes, especially the sizes that would be used frequently.
One variable that would be tricky account for is the way that beams and plates fit together.
Is it possible to create warehouse pieces that include variables like these?

1
2
3
As you can see in photos 1, 2, and 3, the triangular design that allows greater range of motion for the bucket had to be made wide to clear the bolts. This resulted in a lot of side to side movement of these pieces which is not ideal, especially under load.
One possible solution would be to weld the two beams instead of bolting. This would allow the triangular component to rotate along the side of the stick, reducing the play.
4
If bolts are still used then the method of connecting the pieces needs to be addressed. We used threaded rod because we were in a rush and did not have the proper materials on hand. Threaded rod is decidedly weaker than a smooth rod. A tractor pin, or its equivalent, would be better, but it is still a great distance to span.
5
This design employs 4 points of rotation. I was attempting to mimic the designs that I found in most commercial backhoes.
6
7

Here are some photos that I referenced from a quick Google search:

Pivot

Cylinder - [5]

The greatest difficulty with the pivot (and every other component we tried to build) was that the holes did not line up which made assembly difficult. The pivot had many areas that required bolts to pass through along with two three inch pins. This exacerbated the problem.
We found that the best way to assemble was to build the pivot plates AROUND the pin and then bolt the plates to the corresponding tubing.
The collars cut for the pivot plate were slightly different in width. This caused an irregularity in plate width once they were welded in place.
The greatest challenge that we had with the pivot was coming up with a design to make the pivot move from side to side. Commercial backhoes have a cylinder that runs in between the top and bottom of the pivot and connects to a "C" shaped piece. Due to lack of time we were not able to come up with anything that would mimic this in design or functionality.

For the Future

make sure the holes align
build around the pin
streamline the pivot (it is very heavy)
Design with side to side motion in mind

Backhoe 1

Main page for the Backhoe 1.

Details

They are typically mounted on the back of a tractor or front loader, this one is mounted on a LifeTrac. It consists of a digging bucket on the end of a two-part articulated arm. The section of the arm closest to the vehicle is known as the boom, and the section which carries the bucket is known as the dipper or dipperstick (the terms "boom" and "dipper" having been used previously on steam shovels). The boom is attached to the vehicle through a pivot known as the kingpost, which allows the arm to slew left and right, usually through a total of around 200 degrees. Modern backhoes are powered by hydraulics.

The backhoe is one of the most basic dirt working tools and is a common attachment to many small tractor and skid-steer vehicles. It can be used for digging trenches for foundations, digging up material to make compressed earth blocks, digging waste pits, and many other common building/farming tasks. Furthermore, by attaching a chain to the bucket, the backhoe can be used to lift and transport heavy loads such as engine blocks, battery packs, long pieces of pipe, etc.

Commercially manufactured backhoes vary greatly in their size and capabilities and therefore vary significantly in price. A quick google search seems to indicate that relatively small, simple devices like the one we are considering range from 2 to 4 thousand dollars with more sophisticated attachments approaching 10 thousand dollars.

Product Ecology

Made with

Creates

Earth Moving

Videos

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Detail

A Baler is a piece of farm machinery used to compress a cut and raked crop (such as hay, cotton, straw, or silage) into compact bales that are easy to handle, transport and store. Several different types of balers are commonly used, each producing a different type of bales – rectangular or cylindrical, of various sizes, bound with twine, strapping, netting, or wire.

Product Ecology

Uses

Induction Furnace - Steel
CNC Torch Table - Parts

Works with

Tractor - Mounting
Power Cube - Power
Pelletizer - Pellets

Hay Rake
Hay Cutter

Creates

Bales

Components

Frame
Roller
Hydraulic Motor

Status

About to enter the prototyping phase as a part of the GVCS Rollout Plan, the Baler is soon to be reverse engineered and upgraded to meet OSE Spec.

Internal Links

External Links

The Wikipedia Page on Balers

The Global Village Construction Set
Habitat	CEB Press	Cement Mixer	Sawmill	Bulldozer	Backhoe
Agriculture	Tractor	Seeder	Hay Rake	Well-Drilling Rig
	Microtractor	Soil Pulverizer	Spader	Hay Cutter	Trencher
	Bakery Oven	Dairy Milker	Microcombine	Baler
Industry	Multimachine	Ironworker	Laser Cutter	Welder	Plasma Cutter
	CNC Torch Table	Metal Roller	Rod and Wire Mill	Press Forge	Universal Rotor
	3D Printer	3D Scanner	CNC Circuit Mill	Industrial Robot	Chipper Hammermill
	Drill Press	Induction Furnace
Energy	Power Cube	Gasifier Burner	Solar Concentrator	Electric Motor Generator	Hydraulic Motor
	Steam Engine	Heat Exchanger	Wind Turbine	Pelletizer	Universal Power Supply
	Nickel-Iron Battery
Materials	Aluminum Extractor	Bioplastic Extruder
Transportation	Car	Truck

Key	Design	Planning	Prototype	Almost done	Full Release

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Article Title: GVCS Home List

GVCS Home List
Home \| Research & Development \| Bill of Materials \| Manufacturing Instructions \| User's Manual \| User Reviews	78px

Overview

BioPlastic Extruder

The Bioplastic Extruder enables plastics production.

"Plastics extrusion is a high volume manufacturing process in which raw plastic material is melted and formed into a continuous profile. Extrusion produces items such as pipe/tubing, weather stripping, fence, deck railing, window frames, adhesive tape and wire insulation." - (wikipedia)

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Detailed Description

We aim to develop computer-controlled tools that can make plastic parts of any shape. 'Extrusion' means squeezing out a long shape; extruding a circle gives you a cylinder. Extruded plastic forms include sheets, tubes, and others. Greenhouse glazing made of polycarbonate, or UV-stabilized polyethylene, water pipes for plumbing and irrigation, plastic shapes and sheets are all doable with slight modifications of a basic extruder. The key may be a ram extruder (simple design) with inductive heating, to which various dies are adapted for profiles (extrusion), or molds for shapes (injection molding), or blowers and molds (blow molding).

With these tools, cheap feedstocks can produce very expensive products. For instance, polyethylene resin costs less than 15 cents/lb (at a density of 50 lb/cubic ft (800g/l)). When extruded into panes of Solexx glass, the end product costs $1/square foot ($10.76/m2). This makes the end product about 20 times more valuable than the feedstock. If an extruder is available - combined with the know-how - then localized production of such glazing could probably yield cost predictions of something marginally higher than material costs, under the DIY-flexible enterprise scenario.

The challenge is procuring the know-how for extruder fabrication and material extrusion. The material costs are expected to be around $5k for the machine - structure, hydraulic ram, inductive heating, and die.

Bioplastics

Bioplastics are the perfect addition to an integrated farm and forestry operation. An effective open-source method of producing bioplastics will allow communities to be self-sufficient in the raw materials for many modern comforts. Bioplastics promise to replace the many useful products we currently extract from oil. Combined with plastic extrusion and molding machines such as RepRap, bioplastics enable a local manufacturing process that starts with food waste or soil and creates computer and phone casings, car and machine parts, toys and tools, screws and sculptures.

Product Ecology

Product Ecology
**Bioplastic Extruder**
From	Uses	Creates	Enables
Induction Furnace CNC Torch Table Electric Motor Generator Components Ram Extruder Feeder Inductive heater Dies (extrusion) Molds (injection) Blowers (blow molding) Controller	Electricity	Plastic	3D Printer

OSE Project Status/Schedule

The bioplastic extruder project is currently in research phase. Subject matter experts are encouraged to contact us. See also the Open source bioplastic 2012 update

FreeCAD File Download

Finally, MicroTrac 2015 in FreeCAD - download File:Microtrac 2015.FCStd. To get involved in Design, see OSE FreeCAD Instructionals and download the part libraries at OSE Part Library. By Alec Higgins. Design Doc 1: edit Further Design Notes: edit Calculations: edit

Gallery

. MicroTrac as built in 2015.

Concept Design

2015 Build

Proof of Concept of MicroTrac Scalability - LifeTrac 7

The MicroTrac is overbuilt to 8000 lb of drive torque plus the ability to carry an extra 6000 lb of weight outside of its existing 2000 lb weight. With the structural Power Cube as the basis for other attachments, the MicroTrac can be scaled in size to build bulldozers by stacking 3 MictroTracs together for 24,000 lb of torque at the tracks. See initial testing of weight handling capacity, where the MicroTrac carries 6000 of dead weight, and is shown running in idle:

Hackaday Documentation

Go to Hackaday - [6]

Loader Arms

Here is a partial prototype of adding a Driver's Cab, second Power Cube, and loader arms to the base tracked platform consisting of tracks and power cube.

Proof of concept of bulldozer modules: tracks, stacked power cubes, cab, and arms.

Modules

edit

Development Template

The condition of satisfaction for torque was idle -

edit

Working Document

Overview

Bulldozer

The Bulldozer is a high-traction, earth-moving machine indispensible to building ponds, berms, or other earth-moving tasks such as building roads or clearing land. See Bulldozer Specification

Details

Most often, bulldozers are large and powerful tracked heavy equipment. The tracks give them excellent ground hold and mobility through very rough terrain. Wide tracks help distribute the bulldozer's weight over a large area (decreasing pressure), thus preventing it from sinking in sandy or muddy ground. Extra wide tracks are known as 'swamp tracks'. Bulldozers have excellent ground hold and a torque divider designed to convert the engine's power into improved dragging ability. The Caterpillar D9, for example, can easily tow tanks that weigh more than 70 tons. Because of these attributes, bulldozers are used to clear areas of obstacles, shrubbery, burnt vehicles, and remains of structures.

The GVCS variant is being pursued as a Tractor bladed retrofit with lower torque, and additional weight

Product Ecology

Made with

Induction Furnace - Steel
Tractor - Base
CNC Torch Table - Parts
Welder - Attachment
Power Cube - Power

Creates

Earth Moving

Components

Hydraulics
Blade
Blade Lift
Ripper
Cab
Tracks

Status

The Bulldozer is currently in the Research Phase of Product Development.

Videos

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OSE Links

LifeTrac Genealogy

The Global Village Construction Set
Habitat	CEB Press	Cement Mixer	Sawmill	Bulldozer	Backhoe
Agriculture	Tractor	Seeder	Hay Rake	Well-Drilling Rig
	Microtractor	Soil Pulverizer	Spader	Hay Cutter	Trencher
	Bakery Oven	Dairy Milker	Microcombine	Baler
Industry	Multimachine	Ironworker	Laser Cutter	Welder	Plasma Cutter
	CNC Torch Table	Metal Roller	Rod and Wire Mill	Press Forge	Universal Rotor
	3D Printer	3D Scanner	CNC Circuit Mill	Industrial Robot	Chipper Hammermill
	Drill Press	Induction Furnace
Energy	Power Cube	Gasifier Burner	Solar Concentrator	Electric Motor Generator	Hydraulic Motor
	Steam Engine	Heat Exchanger	Wind Turbine	Pelletizer	Universal Power Supply
	Nickel-Iron Battery
Materials	Aluminum Extractor	Bioplastic Extruder
Transportation	Car	Truck

Key	Design	Planning	Prototype	Almost done	Full Release

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GVCS Home List
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OSCar Concept

The Open Source Car is an automobile designed for transporting passengers.

Team Wikispeed

Joe Justice and Team Wikispeed are awesome and we're planning a formal partnership!

Team Wikispeed Collaboration

The instructions for copying Team Wikispeed's SGT01 car design are currently being built. You can find them here Wikispeed_SGT01

OSVehicle Tabby

The OSVehicle Tabby's chassis, suspension, ... can be ordered from their website (see also here). The vehicle can then be custom made by the person that ordered the parts.

Custom mini moke

A custom mini moke can be created for the purpose of creating a community of green mechanics which also organise races (on regular karting tracks). The mini moke design will form the "glue" to create this community due to the fact that unlike with regular karts, no trailer is needed to transport the racing vehicle (instead, the mini car can be driven itself to the track, and even also prove useful for day to day activities, meaning it isn't just an expense done for hobby purposes). The design would hence make the step towards engaging in this hobby smaller, and help convince more people into doing it.

Team Vélocar

Vélocar joined the OSE movement. Vélocar is now the official OSE microcar

Overview

The OS Car will be a lightweight and aerodynamic two passenger long range car that will be fueled with ethanol biodiesel. The current plan is for the car to have a reverse trike configuration: two front wheels and one rear wheel which is the only driven wheel. The two main benefits of the reverse trike design are lower cost and weight due to one less wheel, and lower wind drag due to the rain drop shape of the body. The construction of the car will be a steel space frame covered with non-structural polymer or composite panels. The proposed powertrain is a hybrid hydraulic system which includes a single cylinder engine that runs a hydraulic pump which directly powers a hydraulic wheel motor used to drive the car and which compresses a gas in an accumulator to store energy. Gas in the accumulator will also be compressed via regenerative braking when the hydraulic motor is run in reverse to slow the car down. Cost control and quick development will be maintained by using donor vehicle parts and off-the-shelf parts. Components that cannot be easily manufactured such as brake calipers, steering knuckles, and rims will be sourced from a donor vehicle and components such as instruments, wiring, and hydraulic components will be off-the-shelf components.

As the car design matures, some components from donor vehicles and off-the-shelf components can be replaced by scratch-built open source components. If desired, forks can be spawned from the original project for variants such a four or five passenger car, or perhaps a car with a hybrid electric powertrain.

Update - July, 2013 - See Yann Log

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UELVEs MBC

The UELVEs MBC is a libre-licensed 100kg 2-passenger concept vehicle currently in development, with off-the-shelf downhill mountainbike parts, twin Sur-Ron eBike motors, and using 3D-printed space-frame nodes and fibre-reinforced pipes, with the GABoats (Geodesic Aerolite Boats) technique and materials for its outer skin. Anticipated top speed if the expected drag coefficient can be achieved: over 100mph. Fuel efficiency (again dependent on the Cd): around 90mpg at 100mph, and over 200mpg at 55mph.

Product Ecology

Product Ecology
**Car**
From	Uses	Creates	Enables
Induction Furnace Industrial Robot Welder CNC Torch Table 3D Printer Multimachine Power Cube Hydraulic Motor Components Wheels Windows Frame Engine Drivetrain Suspension Controls Steering Column AC Brakes Lights	Power Cube Roads	Transportation

Status

The Open Source Car is currently in the Research Phase of product development.

The Open Source Car in the media

The Open Source Car has been covered in the following online media sources

Overview

CEB Press (aka "The Liberator"). See CEB_Press_6#Instructional_Files for detailed pictures of the latest machine build (v6), and for an exact picture of v6. Version shown is v3.

Bricks pressed on The Liberator

The Liberator is OSE's automatic, high throughput Compressed Earth Brick Press. It is named The Liberator because it is intended to free people from the single highest cost of living - housing. See Cost of Living.

The CEB is at product release status and is being actively manufactured at Factor e Farm. The presses was used heavily as a part of the Factor e Farm Infrastructure Buildout 2011. Builds using the OSE CEB ress continued with the Microhouse 1, Microhouse 2, Microhouse 3, and MicroHouse 4 built in 2014 - [7]. We have also built a utility room brick floor and an 8' wall section out of CEBs in the 2016 build of the Seed Eco-Home.

In 2020, we did a CEB Microhouse Build in Belize.

The bill of materials cost of the current, fully-automated machine is about $5000 US. See CEB Press#BOM.

The machine can also be made as a manually-controlled version with hydraulic valves. Other options are:

small or large hopper
with or without hopper shaker
automatic controller at 6-10 bricks per minute, depending on power unit

We are currently selling the full machine without power unit for $10k FOB Kansas City, lead time 2 months. Email info at opensourceecology dot org.

Price is FOB Kansas City, Missouri, USA, for a fully assembled machine, with quick couplers, ready to be plugged in to a power source. Price for other packing/crating options is extra.
Delivery time: machines are produced during scheduled production runs, with 8 weeks lead time from submission of payment.
Buyer is encouaraged to attend the build event - to learn how the machine is designed, built, and therefore, to learn about repair and modification. Basic instruction on using FreeCAD will be provided for viewing the CAD file. An operating and maintenance manual will be provided to the client. The buyer is encouraged to brind additional people to the build event to learn about the machine.

A tractor loader is used to provide approximately 2 cubic yards of soil per hour at at 6 block per minute pressing rate. A tractor loader is needed to keep up with the machine throughput. Approximately 3 people are required to keep up with the machine for stacking the block upon pallets. Approximately 30 people would be required to load the machine manually with shovels and buckets if no tractor loader were available. At the minimum, 4 people (1 tractor operator, 3 stackers) are required to produce palletized block on an all-day basis.

Specifications of the Standard Model

Block is plain block, not interlocking. Please see discussion on Interlocking_bricks
Version 17.08 is our most current model. See CEB Press Genealogy for past versions.
Open source hardware, controller, and software (CC-BY-SA 4.0, GPLv3)
Controller is fully automated for hands-off operation
Does NOT come with a power source - it is powered by a hydraulic power source, such as by our Power Cube or a tractor hydraulic take-off.
Full size bricks are 4"x6"x12", plain flat-faced bricks
Brick height is adjustable from 2"-4"
Brick dimensional variations: +/- 1/16". This assumes uniform soil. Soil uniformity will determine height uniformity of brick.
The standard model guarantees 6 full-sized bricks per minute at 12.5 gallon per minute hydraulic flow. See Brick Pressing Calculations. Brick pressing rate will increase with a higher hydraulic flow, up to the maximum rated flow of the hydraulic solenoid. Hydraulic solenoid valve is rated for a maximum of 10 gpm fluid flow at 3000PSI.
Cost of production for actual block ranges from 5 cents to 40 cents per block - depending on amount of cement used for stabilization (0-10%) and cost of labor (free to $25/hr). See Cost_of_CEB_Block
Fuel consumption with Power Cube running at 12.5 gpm fluid flow - about 1 gallon per hour
System hydraulic pressure - 2400 psi
Comes with hydraulic quick couplers ready to be connected to a power source
Weight - 1700 lb
Moving: brick press is moved with forks. Footprint (with legs in the inner position) allows machine to be placed in the bed of a 3/4 ton pickup. It has adjustable legs for uneven terrain. Machine can be moved around on a trailer (not included)
Material cost: $3000-$6500 depending on suppliers; manual machine (without hydraulic solenoid, machine costs $1000 less in materials. Production cost for a full kit: US$5000 above the bill of materials/supplies/consumables cost, paid by the buyer. Production currently occurs in Extreme Manufacturing Workshops - where the buyer is invited to the build so they understand how the machine is built - and is part of the buyer's Lifetime DIY Warranty. This warranty means that the user can maintain the machine for decades because they know how the machine is built, how it works, and how to source parts for the machine from local and online sources. This means that this is not a consumer machine, but a prosumer machine.
3'x6' grate for loading the machine with a tractor. Includes soil deflectors

Additional Power

The machine can be used to produce up to 10 blocks per minute with a larger power source. A larger secondary hydraulic cylinder must be used in that case. See CEB Press Log for developments.

BOM

See build BOM from 2017 at CEB_Press_v17.08#BOM

Versions

Hint: For full project version history, see CEB Press Genealogy and CEB Press Controller Genealogy

Details

The CEB Press takes earth/dirt/soil and compresses it tightly to make solid blocks useful for building. Compressed earth blocks have many advantages as a building material: by making the building materials from the readily available dirt on the building site, they eliminate the need to transport bricks from elsewhere, reducing financial cost and environmental impact. Compressed earth blocks are very strong and insulate well against both heat and sound, making for very energy-efficient building (especially combined with the energy savings from not needing to transport them from offsite). Best of all, the material they use is already on-site and does not need to be purchased -- quite literally, dirt-cheap! See the wiki page on Compressed Earth Blocks and the CEB category for more details on building using CEBs.

The Liberator has been fully designed and tested by the Open Source Ecology team. Because the Liberator is an open source technology, you can freely download instructions to build your own from materials you can obtain yourself, or contact opensourceecology[at]gmail[dot]com to buy a kit or a finished machine.

Building a machine yourself might seem intimidating, but every step of the process is fully documented and the OSE community is available on our discussion forums if you need help, advice, or a little hand-holding.

Using the CEB Press, two people can build a 6 foot high (1.83m) round wall, 20 feet (6.1m) in diameter, 1 foot (30cm) thick, in one 8 hour day, though construction time will vary somewhat depending on preparation time, what equipment is available (tractor to prepare the ground and move the blocks where they need to go), the quality of the soil, and other factors. The bigger the block size, the faster a wall can be erected, but at the cost of heavier blocks that are more of a strain to work with. Blocks from The Liberator average 25 pounds (11.3kg).

See CEB Design for more information.

Product Ecology

Construction Product Ecology

From

Uses

Creates

CEB Bricks

Enables

The CNC circuit mill took another turn in 2019 with the Open Source Microfactory STEAM Camp, where we built the D3D Universal 3D printer with a hole-drilling capacity for circuit boards.
D3D CNC Circuit Mill - built in 2018 with the Universal Axis.
We also built HydraFabber in 2014 - which used a low cost spindle. See John Log for pictures of the mill. This is prior to the Universal Axis, which was introduced in 2016. The spindle was built and run, but we did not mill any boards.
Yoonseo Kang built a circuit mill while at OSE in 2012. See Yoonseo Log - as a power user, Yoonseo developed a lot of useful proofs of concept, such as the Cold Saw and Tooling Plate, among others. Specifically - v1 was built, and v2 was not. These were pre-Universal Axis.
- CNCCM
- CNCCMV2

3D Model

You can rotate, zoom, and explode:

Hint: July 2018 - OSE Germany is working on a version of their MPPT Solar Charge Controller which can be milled with the OSE D3D CNC Circuit Mill - https://github.com/LibreSolar/MPPT-Charger_20A/issues/28

Publication

Published in Inventions, http://mdpi.com/2411-5134/3/3/64

Preprint - https://www.preprints.org/manuscript/201808.0233/v1

Build Instructions

Drill frame
Do Cut List below - rods, belt
Cut bed plate
Assemble electronics mounting plate
Assemble spindle in holder
Test electronics - motion
Test calibration code
Run a milling job

Cut List

(400, 350, and 300 lengths would work)

Belt - x - [2] 29"
Belt - y - [2] 33"
Belt - z - [2] 23"
Rods - x - [4] 14"- = 56"
Rods - y - [4] 16"- = 64"
Rods - z - [4] 11" = 44"
Frame if welded from flats - [24] 1/8"x1"x15" flats -
Electronics mounting panel - 1/10" plexiglass - 8"x16"

Rods if Using 6' Stock

Try 1

If use 6 foot stock- 72" - 4x11=44 + 28 = 72.
4x16 = 64 (8 left over). It's useful to rework design to allow for 8" rod on Z
2x14 = 28 (44 left over)
3 rods needed for 162" = 13.5'

Try 2

4x14 + 16 => perfect.
3x16 + 2x11 = 70 for 2" left over- great.
2x11 = 22 with 50 left over. Nice.

Continuing:

3x16= 2" left over from last one.
4x14 + 16 => perfect
1x16+4x11 = 60 - 12 left over.

Italic text

July 2017

Comparison to Industry Standards

Notes: precision is not defined here. If it is positioning accuracy, Othermill appears to be 0.003 (see D3D_CNC_Circuit_Mill#Industry Standards.

BOM

edit

Other Supplies

Single Sided Copper Clad Laminate PCB Circuit Board 4X3 (50pcs) Paramount CCL Link: http://a.co/3YcKSBe

Xuchuan 10Pcs PCB Print Circuit Board Carbide Micro Drill Bits 0.3-1.2mm Xuchuan Link: http://a.co/0KviIvf

JIUWU 1.0mm Tungsten Steel Carbide PCB CNC End Mill Engraving Bits Milling Machine Pack of 10 by JIUWU Link: http://a.co/1CL0H32

You can try these tools out - they are inexpensive and may yield good results for milling traces. But if you run into issues, the tools are likely chipping Autek 10x Titanium Coated Carbide PCB Engraving CNC Bit Router Tool 30 Degree 0.1mm Tip(J3.3001Tix10) by Autek Link: http://a.co/6UR8F9T

Instead it may be good to opt for higher quality milling tools. They should last a good long while:

	Universal Milling Tools
	100% Carbide universal milling tool for milling printed circuit board isolation tracks. V-shaped profile for variable milling width. 1.42" (36 mm) overall length.

https://www.lpkfusa.com/Store/pages/ProductDetail.aspx?cat=11%2f42&cid=42&pid=30

All Industrial Tool Supply TR72020 Dial Indicator (Magnetic Base and Point Precision Inspection Set), 1 Pack by All Industrial Tool Supply Link: http://a.co/5EgkHa0

Software: See this link - it has all of the software we used and then some: http://opencircuitinstitute.org/content/software

Additionally here is my web-based leveling utility: http://voltfolio.com/utilities/levelgcode.html

https://www.lpkfusa.com/Store/pages/ProductDetail.aspx?cat=11%2f38&cid=38&pid=76

Sorry I must make one amendment - I linked the incorrect milling tools from LPKF. Here are the correct ones:

https://www.lpkfusa.com/Store/pages/ProductDetail.aspx?cat=11%2f38&cid=38&pid=76

vBOM

Visual BOM:

edit

Calculations

edit

Sources

File:Backlash Pattern.odg - editable drawing of backlash pattern.

Electronics

edit

Source

Diagram in Libre Office - File:D3D Circuit Diagram.odg

Photo Album

On google photos - [8]

Videos

Mill Experiment - Backlash Compensation Stress Test - [9]
Leveled circuit - holder slides at the end - [10]
Mill Experiment - Large Leveled Circuit Take 2 - [11]
Auto Probing Experiment - [12]
Stepper driver breakout board - [13]

Workshop Preparation

edit

Development Template

edit

Burndown

Feb 2018 Update

September 2017 Update

Development Pictures

The disassembled axes required to convert the D3D printer to the circuit board mill

These are the required additional parts to transition from the 3D printer to the circuit board mill

The complete set of axes for the D3D circuit mill

Working Document

Design

edit

Data Collection

edit

CAD files

Assembly: File:D3D Circuit Mill.fcstd

Simplified Files

Assembly: File:D3D Circuit Mill.fcstd
D3D frame 16": File:D3D frame assembled 16 inch.FCStd
Single x axis: File:D3D Circuit Mill X Axis.fcstd
Single y axis: File:D3D Circuit Mill Y Axis.fcstd
Single z axis: File:D3D Circuit Mill Z Axis.fcstd
spindle motor: File:T-king spindlemotor.fcstd
Spindle Motor Mount: File:D3D Circuit Mill Motor Mount.fcstd
PCB holder: File:PCBholder simplified.FCStd

Accurate Files

3x End Stop interface: File:D3D End stop interface.fcstd
16x carriage piece: [[1]]
16x idler piece short: [[2]]
12x motor piece: [[3]]
2x Spindle Motor Mount: File:D3D Circuit Mill Motor Mount.fcstd
PCB holder: [[4]] and File:D3dcnccm PCB holder.stl

List of Files

Assembly: File:D3D Circuit Mill.fcstd
Frame 16" assembled: File:Full Frame 16in.FCStd
Single 16" frame: File:Single Frame 16in.fcstd
Single x axis: File:D3D Circuit Mill X Axis.fcstd
Single y axis: File:D3D Circuit Mill Y Axis.fcstd
Single z axis: File:D3D Circuit Mill Z Axis.fcstd
Spindle Motor: File:T-king spindlemotor.fcstd
Spindle Motor Mount: File:D3D Circuit Mill Motor Mount.fcstd. STL - File:D3D Circuit Mill Motor Mount.stl
PCB Holder: File:D3dcnccm PCB holder.stl File:PCBholder simplified.FCStd

Design Notes

Note on CAD Procedure and Organization:

Draw a frame piece, and create a complete frame made of 6 of these pieces.
Save file: File:D3D 13" Frame.fcstd
Begin the design by downloading the X axis - File:D3D 16 Sub-assembly X Axis.fcstd
Correct the length of the axis to 11" length (for 13" frame - 1" shorter on each side to accommodate mounting on the Y axes). Rotate the axis such that the orientation - when looking according to the Viewing Direction and XYZ axis orientation of Slide 1 in Working Document - is that the motor is on the left side of the axis (note that the orientation shown in First Slide in the Working Document has the motor on the right hand side, which is not correct).
Save the file as File:D3D Circuit Mill X Axis.fcstd once the length is 11" and orientation is correct. This will be the file you can use later for the x axis (2 of them) to merge into the final assembly - with the second x axis being a mirror image.
Now create the Y axis according to the orientation convention of the First Slide in the Working Document. This axis should be 13" long.
Save the y axis file as File:D3D Circuit Mill Y Axis.fcstd.
Now create the Z axis as in the working document. This axis can be 8" long - as we don't need a lot of z travel.
Save the Z axis file as File:D3D Circuit Mill Z Axis.fcstd.
Import the

Industry Standards

Toner Transfer gets reliable traces down to 0.15 mm, D3D CNC circuit mill works to 0.5 mm traces. [[14]. Disadvantage: a mill can do your holes and cut out your circuit board as well. Advantage - smaller features are possible.
Othermill - 0.003 mm positioning, with minimum mill bit of 0.25 mm - [15]. Positioning accuracy is not the limiting factor for features - but mill bit size. Minimum size is the same for D3D and Othermill (0.25 mm).
[The Ant PCB Maker]
Hackaday projects - [16]
Not open source - LilCNC - [17]. Uses Easel online 2D design software.

Existing Open Source Designs

Curriculum

Working doc - [18]

Useful Links

Tom's Guide 2018 discussing inferiority of mill conversions - [19]

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Article Title: GVCS Home List

Warning: Display title "CNC Torch Table" overrides earlier display title "".

Hint: Current work uses the Universal Axis as part of a precision motion ecocystem. See current work at D3D CNC Torch Table

CNC Torch Table Prototype I, used in 2011 Production Run

Overview

The CNC Torch Table (aka RepTab) is an enabling machine for any workshop. This machine enables creation of custom parts for fabrication or replacement of broken components. The CNC Torch/Plasma Table development is rebooting and building on some of the later versions, but starting with the replication of Koruza's Good Enough CNC Plasma Table. One the integrated designs is to go towards gas versus plasma, because of the dependencies of a plasma cutter and other devices that have not been fully open source. As well as the availability of gas production being a valuable option. The Version 3 iteration expects to build, source, and improve designs toward a 100% open source project and parts. The power supply, height controller, torch, and plasma cutter are items needing to be developed. In progress, the need for on-demand materials and supplies can be met with a functional and accurate CNC Torch/Plasma Table that will reduce manufacturing time and increase capacity. The Koruza Project does not a have table, therefore, building on previous versions maybe a possibility.

2019 Update

Working on CNC Torch Table Height Controller

2016 Update

During the course of 2014/2015 workshops of metal fabrication, the CNC Torch Table/Plasma Table is essential for future builds. The MicroTractor and the World's First Open Source Bulldozer can be built with general metal working toolings, however, the CNC Torch Table is a major manufacturing component of the GCVS. Tom Griffing and Jonathan Kocurek find it a useful effort to focus on the CNC Torch Table for PowerCube replications and parts manufacturing. Marcin's introduction with the Koruza project is a feasible option, however, Marcin's concerns are that some propriety parts exists that will need to be open source and developed. Such as the height controller and power supply. Tentative plans and efforts to grow the CNC Torch/Plasma Table Team are forming for 2016.

2014 Team Goals

Current team goals as of June 5 2014 for the end of June 2014.

Have the torch cutting steel, up to 1" thick, to a tolerance of 1/16" over 10 inches on all dimensions, and within 1/16 of a straight line re the waviness of the line. It is ok if it takes some manual intervention, or hand holding.
The machine should be reasonably durable and not finicky or prone to breakage, or absurdly high wear and tear. For example, the wiring is currently prone to breakage. Also the arduino on the z control would probably stop working pretty fast from the stuff splattering on it.

This entails meeting milestone 1 in the torch table prototype 2 requirements document (see dev board through dozuki, overall module, requirements document).

for the short term, make sure the documentation is at the point that someone can easily step in to Anthony's role in getting things working, and to operate the table for cutting.

record why we made the system the way we have so far, rather than some other way. This is important to avoid the need to go over the same ground too many times.

2016 Team Goals

Using 3D Printer Construction Set instance for xyz drive.
Off-shelf height controller tested, then replaced with open source version
Open source version - done by a design challenge, such as heroX or simple crowd platform

Versions

See CNC Torch Table Genealogy

Details

The CNC Torch Table allows workshops to create replacement parts on the fly for many of the components used in the GVCS. Additionally, the Torch Table gives workshops the ability to create many of the custom components used in the GVCS Machines. Many parts that make up the 50 GVCS Tools can be cut on the CNC Torch Table, making this machine valuable for replication.

Documentation

Much of the current documentation and raw data concerning

Product Ecology

General Fabrication Product Ecology

Made with

Multimachine - Precision Guides, bearings
Ironworker

Creates

Tractor - Plates, holes
CEB Press - Holes
QA Plates

See Product Ecologies for more information.

Status

The Dairy Milker is currently in the research phase.

Videos

Template:Video:GVCS Home List

Overview

Drill Press

A drill press (also known as pedestal drill, pillar drill, or bench drill) is a fixed style of drill that may be mounted on a stand or bolted to the floor or workbench. A drill press consists of a base, column (or pillar), table, spindle (or quill), and drill head, usually driven by an induction motor. The head has a set of handles (usually 3) radiating from a central hub that, when turned, move the spindle and chuck vertically, parallel to the axis of the column. The table can be adjusted vertically and is generally moved by a rack and pinion; however, some older models rely on the operator to lift and reclamp the table in position. The table may also be offset from the spindle's axis and in some cases rotated to a position perpendicular to the column.

Drill Press CAD. See Open Pario

Template:Video:GVCS Home List

Details

Status

The Drill Press is currently in the prototype phase of design.

QA Plate
Mounting Frame
Blades
Hinge

Study of Industry Standards

OSE hay cutter is studying the industry standards with this hydraulic-retrofit of a hay cutter:

An operating induction furnace usually emits a hum or whine (due to magnetostriction), the pitch of which can be used by operators to identify whether the furnace is operating correctly or at what power level.

Development Notes

Read a commercial description of an induction furnace from Voltamptransformers

Read about 3-phase electrical power at its wikipage

Read about 3-phase electrical standards in north America at control.com forums

Product Ecology

Uses

Universal Power Supply - Power

Creates

Steel - GVCS (pretty much every machine depends on this)

See Product Ecologies for more information.

Components

Induction Furnace Circuit
Heat Dissipation System
Coil
Melt Chamber
Feeder
Crucible

Status

The Induction Furnace is currently in the research phase of product development.

Internal Links

External Links

The Global Village Construction Set
Habitat	CEB Press	Cement Mixer	Sawmill	Bulldozer	Backhoe
Agriculture	Tractor	Seeder	Hay Rake	Well-Drilling Rig
	Microtractor	Soil Pulverizer	Spader	Hay Cutter	Trencher
	Bakery Oven	Dairy Milker	Microcombine	Baler
Industry	Multimachine	Ironworker	Laser Cutter	Welder	Plasma Cutter
	CNC Torch Table	Metal Roller	Rod and Wire Mill	Press Forge	Universal Rotor
	3D Printer	3D Scanner	CNC Circuit Mill	Industrial Robot	Chipper Hammermill
	Drill Press	Induction Furnace
Energy	Power Cube	Gasifier Burner	Solar Concentrator	Electric Motor Generator	Hydraulic Motor
	Steam Engine	Heat Exchanger	Wind Turbine	Pelletizer	Universal Power Supply
	Nickel-Iron Battery
Materials	Aluminum Extractor	Bioplastic Extruder
Transportation	Car	Truck

Key	Design	Planning	Prototype	Almost done	Full Release

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Article Title: GVCS Home List

GVCS Home List
Home \| Research & Development \| Bill of Materials \| Manufacturing Instructions \| User's Manual \| User Reviews	78px

Overview

Industrial Robot Arm

The industrial robot is an automated machine that perform a wide variety of functions, (including welding, assembly, and CAM, etc...), all depending on which tools its hand is equipped with.

Template:Video:GVCS Home List

This is the kind of thing you can do with a top-of-the-line industrial robot.

Detailed Description

The industrial robot is a rotating multi-axis machine that can hold various modules (called end-effectors) for performing different tasks such as welding and cutting. These tasks can be done in repetition (through proper "teaching") and with precision (based on the robot's repeatability, which is a measure of how far the robot deviates from a certain position when going there multiple times). The volume in which the robotic arm can travel is called the working envelope (rear of robot is typically restricted), and the axes of rotation are called degrees of freedom (6 or more for higher-end flexibility). A versatile industrial robot can significantly improve the accuracy, precision, and completion times of multiple production tasks while significantly reducing the need for operator involvement.

The industrial robot is task versatile, multi-way programmable, repeatably accurate, and modular with scalable reach and payload. The industrial robot serves a universal function mimicking a human arm, so can fill in (after being programmed) for any repetitive operation not better done by humans; other times, the industrial robot can be directly operator-controlled to act as a mega-arm machine where the high reach, payload, and working envelope are advantaged.

Product Ecology

Product Ecology
**Industrial Robot**
From	Uses	Creates	Enables
Induction Furnace Electric Motor Generator Welder Plasma Cutter Components	Welder Electricity	Welding Painting	Car Truck

Status

The Industrial Robot is currently entering the prototype phase of production.

Useful Links

The Global Village Construction Set
Habitat	CEB Press	Cement Mixer	Sawmill	Bulldozer	Backhoe
Agriculture	Tractor	Seeder	Hay Rake	Well-Drilling Rig
	Microtractor	Soil Pulverizer	Spader	Hay Cutter	Trencher
	Bakery Oven	Dairy Milker	Microcombine	Baler
Industry	Multimachine	Ironworker	Laser Cutter	Welder	Plasma Cutter
	CNC Torch Table	Metal Roller	Rod and Wire Mill	Press Forge	Universal Rotor
	3D Printer	3D Scanner	CNC Circuit Mill	Industrial Robot	Chipper Hammermill
	Drill Press	Induction Furnace
Energy	Power Cube	Gasifier Burner	Solar Concentrator	Electric Motor Generator	Hydraulic Motor
	Steam Engine	Heat Exchanger	Wind Turbine	Pelletizer	Universal Power Supply
	Nickel-Iron Battery
Materials	Aluminum Extractor	Bioplastic Extruder
Transportation	Car	Truck

Key	Design	Planning	Prototype	Almost done	Full Release

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Article Title: GVCS Home List

GVCS Home List
Home \| Research & Development \| Bill of Materials \| Manufacturing Instructions \| User's Manual \| User Reviews	78px

Ironworker hole puncher, built at OSE in 2010. See blog post.

Overview

Ironworker machines can shear, punch holes and notch in steel plates.

Versions

See Ironworker Genealogy.

Details

An Ironworker is a fundamental machine for working with many and is the backbone of many fabrication workshops. It generates tremendous force using hydraulic systems and mechanical leverage.

Product Ecology

Uses

Induction Furnace Steel
Welder parts

Creates

CEB Press arm holes
Tractor treads and plate holes

See Product Ecologies for more information.

The metal roller allows the operator to perform roll-bending operations with ease.

Product Ecology

Made with

Uses

Power Cube - Power
Induction Furnace - Steel

Creates

Rolled Steel

General Fabrication Product Ecology

See Product Ecology for more information.

Components

The principal elements of the metal roller include:

Frame: the ground-supported structure upon which the rest of the metal roller lies

Couplers: the mechanisms that convert rotary motion from the hydraulic motor to the cylinders

Hydraulic Circuit: the set of components that powers the hydraulic motor by sending pressurized fluid through its ports, hence producing rotary motion at the motor shaft

Adjusters: the mechanisms that allow cylinder movement for different placement configurations on the plane perpendicular to the axis of rotation

Cylinders: the components that make actual contact with the workpiece for roll-bending.

Status

The Metal Roller is currently in the research phase of development. Prototyping is planned for after product release of the Induction Furnace.

Overview

Agricultural Microcombine (Combine) - a combine is a complex device that cuts, threshes, and winnows grains and field crops of all sorts.

Template:Video:GVCS Home List

Details

Modern combines are huge devices today, and a smaller one is desirable for a small farm. This is not to say that this design should not be scaleable to larger size, as required to feed larger populations effectively. We propose a hybrid combine, with all parts driven by separate, infinitely speed controllable motors. This eliminates all pulleys and complexity of a single power source powering the entire modern combine. The key here is availability of cost-effective motors and controls, where today, motor controls are prohibitively expensive for such a proposition. OS changes this. With a microcombine under the control of the operator, expensive maintenance is avoided, and full food sufficiency becomes feasible on the tens-of-acres scale.

Product Ecology
**Microcombine**
From	Uses	Creates	Enables
Induction Furnace CNC Torch Table Multimachine Hydraulic Motor Components	Power Cube Tractor QA Plate	Grains	Bread

Status

Current work includes getting information from grain and bean farmers about their needs for a microcombine, the operation modes they'd like, etc. and surveying any commercial equipment available that is similar in scope/scale.

MicroTrac Geneaology

Working Model, 5/2013

April 17 2013

File:PtTRAC2.skp

Corners for structural tubing

Corner inserts are one possibility for the Power Cube and for connecting tubular steel members. They would make better use of space that is currently used with the "layering" of tubes in current designs.

Mention was made that adding corners would weaken the overall design, but this has not been proven. A structural analysis would be necessary to find out for sure.

Here is an image of a possible corner: File:PC7s-frame-with-corners.png

Here is the Sketchup drawing: File:PC7s-frame-with-corners.skp Frame with corners

Overview

MicroTrac is a small scale, walk/ride-behind version of LifeTrac suited for construction, agriculture, and general home and garden maintenance.

Template:Video:GVCS Home List

Product Ecology

Made with

Equips

Components

Status

The Microtractor is currently in the Prototype stage of Product Development. Later prototypes aim to integrate lessons learned from LifeTrac development.

See GVCS Rollout for more information.

Links

Material Suppliers

Introduction

Vertical milling machine. 1: milling cutter 2: spindle 3: top slide or overarm 4: column 5: table 6: Y-axis slide 7: knee 8: base

Horizontal milling machine. 1: base 2: column 3: knee 4 & 5: table (x-axis slide is integral) 6: overarm 7: arbor (attached to spindle)

CNC Bed Mill with ATC

Notice how the following commercial vertical machining center connects the Z axis support frame to the Y axis frame, as well as how the Y axis frame rests on the table.

Mechanical Assembly Concept

Precision Machine Design Tips

Product Ecology

Product Ecology
Template:CNC Machine
From	Uses	Creates	Enables
Components

Rotary Module

Spindle

Linear Guide

Boxed Way

Tooling Plate and Accessories

Tooling Plate

Board Mount

Electronics Assembly

CNC Electronics

Software Toolchain

CNC

EDA (Electronic Design Automation)

Old Info

V1 and Old V2 Prep

Internal Links

External Links

Open Source Machine Tools - spinoff of Multimachine website - [20]
5 ton CNC machine center with ATC- [21]
CNC Programming and Machining manual on Scribd - [22]
A Video by the YouTube Channel "Ivan Miranda" Titled "3D Printed CNC Knee Mill From Scratch
- The Design Files (20 USD but unclear on liscencing)

The Global Village Construction Set
Habitat	CEB Press	Cement Mixer	Sawmill	Bulldozer	Backhoe
Agriculture	Tractor	Seeder	Hay Rake	Well-Drilling Rig
	Microtractor	Soil Pulverizer	Spader	Hay Cutter	Trencher
	Bakery Oven	Dairy Milker	Microcombine	Baler
Industry	Multimachine	Ironworker	Laser Cutter	Welder	Plasma Cutter
	CNC Torch Table	Metal Roller	Rod and Wire Mill	Press Forge	Universal Rotor
	3D Printer	3D Scanner	CNC Circuit Mill	Industrial Robot	Chipper Hammermill
	Drill Press	Induction Furnace
Energy	Power Cube	Gasifier Burner	Solar Concentrator	Electric Motor Generator	Hydraulic Motor
	Steam Engine	Heat Exchanger	Wind Turbine	Pelletizer	Universal Power Supply
	Nickel-Iron Battery
Materials	Aluminum Extractor	Bioplastic Extruder
Transportation	Car	Truck

Key	Design	Planning	Prototype	Almost done	Full Release

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Article Title: GVCS Home List

Warning: Display title "" overrides earlier display title "CNC Machine".

GVCS Home List
Home \| Research & Development \| Bill of Materials \| Manufacturing Instructions \| User's Manual \| User Reviews	78px

Overview

Nickel Iron Battery

The Nickel Iron Battery is the only known lifetime design battery. These last 100 years, such as the Edison batteries unearthed after a century that work like new. Thus, it is the primary electrical energy storage device for the GVCS, outside of indirect sources such as Compressed Air Energy Storage, water Gravity Storage, and storage of energy via Hydrogen Production.

Advantages

Theoretically unlimited lifetime: Long lifetime of 8-10 years - when you don't throw out the battery - just replace the electrolyte. [23]
About X = $1000/kW - but unlimited life means that the full-cost accounted cost means that the cost is really X/N - where N is a number that you choose. Think of this - the core lives for ever - you replace the casing and electrolyte.
Open source design of electrodes
Cells can be made to any Ahr rating
Nickel and iron obtained from scrap stream, reprocessed via Induction Furnace
Completely closed loop material cycle ecology
Max discharge/charge = C/2. Optimal charge/discharge - C/4. [24]
Vidoe showing build of a simple cell - [25]
Discharge at 1C rate appears to get 70% of battery capacity? Not likely, it must be more like time - . Source - [26]

Disadvantages

The historical NiFe technology’s notable limitations include low specific energy,

low power, low charge retention and poor low temperature performance along with being high cost1 and is still in limited mass production throughout the world today for specific applications. NiFe battery chemistry is known for its robustness, extreme shelf and cycle life. The historical NiFe technology that was most robust to abuse also had limitations in being heavy, low power, low charge retention and poor low temperature performance along with being high cost. Thus, over the years, other nickel battery technologies (e.g., NiCd, NiMH, NiZn, and NiH2) have displaced NiFe in many applications. [27]. This paper discusses the 'improved' Encell cell with much shorter lifetime.

OSE Assessment:
- Low specific energy - still perfect for stationary applications of renewable energy
- Low power - in a renewable energy scenario, large loads are run from PV when the sun is shining. Battery storage is only carry-over through the night for essential activity such as computers and internet - not heating or cooling (high-priority overnight cooling needs, such as refrigeration, can still be met by Ni-Fe using devices with an inverter compressors). Thus, low power is not an issue.
- Low temperature performance - is an issue if batteries are outside in freezing temperatures.
- High cost - that is not an accurate assessment. They have a higher up-front cost, but their lifetime cost is significantly lower. Lead acid survives because it is a good car starter battery, but for power storage, it does not do well.
- C/2 max discharge rate.

The Latest

2012 - Ultra Nickel Iron Bats sighted in Nature - high performance nanotech batteries have been shown to be 1000x more powerful than Edison's originals and nearly 100% Coulombic Efficiency - in 2012 - [28]. Thus, the potential is there for a safe and durable battery - even in automotive applications.
2020 - Batolyzer - Combination battery and electrolyzer- has been demonstrated for producing hydrogen in addition to storing energy, thus killing 3 birds with one stone. Energy storage, hydrogen production, and SDG 7. See paper at [29]
2017 - High discharge, sintereed iron electrodes, 2017 - 3500 cycles at 100% depth of discharge. Potential for solving grid storage. [30]

Detailed Description

The nickel-iron battery (NiFe battery) or "edison cell" is a storage battery having a nickel oxide-hydroxide cathode and an iron anode, with an electrolyte of potassium hydroxide (lye can be used as a substitute).

The active materials are held in nickel-plated steel tubes or perforated pockets.

It is a very robust battery which is tolerant of abuse, (overcharge, overdischarge, and short-circuiting) and can have very long life even if so treated.

It is often used in backup situations where it can be continuously charged and can last for more than 20 years.

Nickel-iron batteries have ~50 year lifetimes, compared to a few-year lifetime of lead acid batteries. They are environmentally more benign, and lend themselves to local recycling and fabrication. They can have higher discharge rates and faster charge times than lead-acid batteries depending on mechanical design of the electrodes etc, so they lend themselves not only to off-grid power, but also to power electronics applications such as welding and heavy workshop power. In China a company by the name of changhong batteries makes a version of them for use in automotive starter batteries. Their energy density is half that of lead-acid batteries, but their long lifetime and deep discharge ability makes them highly relevant to the GVCS, including to electric farming equipment as the next generation of LifeTrac infrastructure.

The Edison Battery was developed and promoted primarily by Thomas A Edison.

Product Ecology

Product Ecology
**Battery**
From	Uses	Creates	Enables
3D Printer - Casing Controller Box - Power Rod and Wire Mill - Wires, Tubes Components		Electricity	Universal Power Supply - Stores energy Charge Controller Inverter

Components

Anode Compound

iron plate - low carbon, mild steel (demo)
iron graphite compounded (Edison)
iron oxide
- http://en.wikipedia.org/wiki/Iron(II,III)_oxide

node Construction

plain plate (demo)
pocket plate with mesh inserts (Edison)

Cathode Compounds

Nickel(III) oxide-hydroxide

nickel hydrate and pure nickel flake (Edison)

http://en.wikipedia.org/wiki/Nickel%28II%29_hydroxide

Nickel(II) carbonate can be combined with water to form Nickel(II) oxide, which can be used in cells. It generates Carbon Dioxide when mixed with water, which may affect Potassium Hydroxide in solution. Mix with water and allow to complete outgassing and dry before building the cell.

Nickel(III) hydroxide "Nickel Oxide Black" and Nickel(II) carbonate "Green" are used as clay/ceramic colorants and available cheaply from ceramic and pottery related websites ... and though the purity is considered lower, it is still usuable for experimentation at a much lower cost.

Cathode Construction

plain plate (demo)
pocket plate with mesh inserts (Edison)
generally nickel-plated rather than pure nickel

Nickel sponge
Sintered nickel powder
Nickel mesh/cloth

Electrolyte

aqueous potassium hydroxide

link
Water (121g per 100ml)

sodium hydroxide (alternate, lower voltage)
lithium (modern additive)

Cell Casing

nickel-plated steel box, rubber seals (Edison)
plastic box (modern commercial)
glass jars (demo projects)
pvc cylinders (Ed's Workshop)

Status

The Nickel-Iron Battery is currently in the research phase of development.

Off-the-Shelf

There's a number of suppliers of Ni-Fe batteries today.

Sichuan Changhong Battery Co., Ltd

It looks like most US companies selling Ni-Fe were white-label resellers of imported batteries manufactured by Sichuan Changhong Battery Co., Ltd (SCBC) in Mianyang, China. This is a huge manufacturer; I don't think you can buy direct from them.

Qualmega, Inc. is "the exclusive distributor of Sichuan Changhong Battery Co., Ltd (SCBC)". They have an excellent brochure that describes the manufacture of the batteries in great detail. For example, they describe the construction method for the electrodes and state the battery case is made from MBS or PP (exact dimensions given for each Ah).
Iron Edison was one of the most popular resellers of Changhong batteries^[2], but they went bankrupt during COVID (June 2023)
Zapp Works in Montana, USA (defunct)
Be Utility Free has been selling Ni-Fe batteries longer than Iron Edison

Seawill Technology Co., Ltd.

Another company (listed as both a manufacturer and a trader on alibaba) that sells Ni-Fe batteries in China is SeaWill. You *can* buy direct from them.

Cost

$4k for a 4.3kWhr usable capacity battery - see [31].
Note that if this is authentically 4.3kW and it lasts 30years - then this is 1/2 the cost of a 24kWhr $4k forklift battery. A forklift battery will last 5 years [32] - so this is 1/6 the length of the NiFe lifetime - or equivalent 4kW over the same time period. However, the beyondoilsolar.com link above says that electrolyte replacement at 30 years gets you another 30 years. If that is true, then we have 60 years life - and 1/2 the cost of lead acid batteries.
Disadvantage is slow discharge at C/2 rate max. For a 100A bat at 48V, that is 2400W. Plenty.
Summary - the up-front cost is steep - but lifetime considerations make this a very attractive offer.
Once open sourced, cost should go down 2x-5x still.
If we use Lead Acid for long life - 10% DoD - 2.4kW - for 20 year life - that is 3x more expensive than Nickel-Iron batteries over a 30 year life, and 6x more expensive over a 60 year life.

Links

Good technical description on construction, including patents - Edison Battery
Energy density is 13 Whr/lb. Compare to Li-Ion at 10x this.
Paper on reconditioning 85 year old batteries - [33]
Critique of Nickel Iron batteries - [34] - says that deep discharge destroys them.
Considerations for NiFe as starting batteries - Nickel-Iron SLI Battery
Nickel-Iron Battery/Prototype
Emails and communications - Battery Collaboration
See also Category:Nickel-Iron Battery Prototypes
Nickel-Iron Battery/Chemistry
Detailed construction of the battery is described in the book at Nickel-Iron_Battery/Manufacturing_Instructions - this is the best study of industry standards and taking off point for development. P. 14 in the PDF shows construction details of the battery.

The Global Village Construction Set
Habitat	CEB Press	Cement Mixer	Sawmill	Bulldozer	Backhoe
Agriculture	Tractor	Seeder	Hay Rake	Well-Drilling Rig
	Microtractor	Soil Pulverizer	Spader	Hay Cutter	Trencher
	Bakery Oven	Dairy Milker	Microcombine	Baler
Industry	Multimachine	Ironworker	Laser Cutter	Welder	Plasma Cutter
	CNC Torch Table	Metal Roller	Rod and Wire Mill	Press Forge	Universal Rotor
	3D Printer	3D Scanner	CNC Circuit Mill	Industrial Robot	Chipper Hammermill
	Drill Press	Induction Furnace
Energy	Power Cube	Gasifier Burner	Solar Concentrator	Electric Motor Generator	Hydraulic Motor
	Steam Engine	Heat Exchanger	Wind Turbine	Pelletizer	Universal Power Supply
	Nickel-Iron Battery
Materials	Aluminum Extractor	Bioplastic Extruder
Transportation	Car	Truck

Key	Design	Planning	Prototype	Almost done	Full Release

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Overview

The Pelletizer, also called pellet mill, creates fuel pellets out of biomass. It can make pellets from various raw materials, such as wood shavings, saw dust, crop straw, etc. There are pelletizer for small and large scale production.

Pelletizer was firstly invented for making feed pellets from animal cultication, late from 1970s, it began used for making fuel pellets because of the raising price of oil and gas.

Details

Biomass can be pellitized by first passing it through a Hammer Mill for uniformity, then feeding it to a press that has holes of uniform size. In this process, there is a marked increase in temperature, causing the lignin to plastify.

The pellets can be burned efficiently for energy.

Product Ecology

Product Ecology
**Pelletizer**
From	Uses	Creates	Enables
Induction Furnace Welder Multimachine Components Steel Hopper Die Roller Feeder Shaft Hydraulic Motor Outlet	Sawmill Baler Chipper Hammermill Power Cube Hay Kiln Sawdust	Pellets Animal Feed	Gasifier Burner

Industry Standards

$1100 from Aliexpress - [35]

Status

The Pelletizer is currently in the research phase of development.

There is a Pelletizer Log.

Useful Links

The Global Village Construction Set
Habitat	CEB Press	Cement Mixer	Sawmill	Bulldozer	Backhoe
Agriculture	Tractor	Seeder	Hay Rake	Well-Drilling Rig
	Microtractor	Soil Pulverizer	Spader	Hay Cutter	Trencher
	Bakery Oven	Dairy Milker	Microcombine	Baler
Industry	Multimachine	Ironworker	Laser Cutter	Welder	Plasma Cutter
	CNC Torch Table	Metal Roller	Rod and Wire Mill	Press Forge	Universal Rotor
	3D Printer	3D Scanner	CNC Circuit Mill	Industrial Robot	Chipper Hammermill
	Drill Press	Induction Furnace
Energy	Power Cube	Gasifier Burner	Solar Concentrator	Electric Motor Generator	Hydraulic Motor
	Steam Engine	Heat Exchanger	Wind Turbine	Pelletizer	Universal Power Supply
	Nickel-Iron Battery
Materials	Aluminum Extractor	Bioplastic Extruder
Transportation	Car	Truck

Key	Design	Planning	Prototype	Almost done	Full Release

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Overview

Plasma Cutter

A Plasma Cutter is used to cut metals and other materials. An inert gas or compressed air is exposed to an electrical arc and blown at high speed from a nozzle. Some of the gas ionizes to plasma form, which has a temperature high enough to melt metal. The plasma stream moves quickly enough to blow molten metal away from the points it is melting, creating cuts in material. See how a plasma cutter works.

Template:Video:GVCS Home List

Product Ecology

Created with

Induction Furnace - Casing
Bioplastic Extruder - Handle

Used by

CNC Torch Table

Uses

Universal Power Supply - Power
Compressed Air and/or Oxygen

Components

Status

The Plasma Cutter is currently in the Research Phase of product development

Internal Links

External Links

The Global Village Construction Set
Habitat	CEB Press	Cement Mixer	Sawmill	Bulldozer	Backhoe
Agriculture	Tractor	Seeder	Hay Rake	Well-Drilling Rig
	Microtractor	Soil Pulverizer	Spader	Hay Cutter	Trencher
	Bakery Oven	Dairy Milker	Microcombine	Baler
Industry	Multimachine	Ironworker	Laser Cutter	Welder	Plasma Cutter
	CNC Torch Table	Metal Roller	Rod and Wire Mill	Press Forge	Universal Rotor
	3D Printer	3D Scanner	CNC Circuit Mill	Industrial Robot	Chipper Hammermill
	Drill Press	Induction Furnace
Energy	Power Cube	Gasifier Burner	Solar Concentrator	Electric Motor Generator	Hydraulic Motor
	Steam Engine	Heat Exchanger	Wind Turbine	Pelletizer	Universal Power Supply
	Nickel-Iron Battery
Materials	Aluminum Extractor	Bioplastic Extruder
Transportation	Car	Truck

Key	Design	Planning	Prototype	Almost done	Full Release

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Powercube v7 Assembly. from Open Source Ecology on Vimeo.

The Powercube is a modular engine unit that powers all mechanical machines in the Global Village Construction Set.

This tutorial demonstrates how to assemble the Powercube v7 once all components have been sourced and fabricated. To see the full Powercube v7 designs, go to www.opensourceecology.org/wiki/Powercube_7

PowerCube II

Overview

Note: The current version as of June 2015 is Power Cube v15.6 as under Versions below.

The Power Cube is a modular, universal, self-contained power unit consisting of an engine coupled to a hydraulic pump, providing power from hydraulic fluid at high pressure through quick connect hoses. It is designed to function as a modular and interchangeable power supply for Global Village Construction Set (GVCS) technologies.

Details

The Power Cube was designed in accordance with OSE Specifications for maximum utility. The Power Cube features...

Modularity - String multiple power cubes together for increased hydraulic power.
Flexibility - Quick Connect hoses and Quick Attach Plate enable extreme flexibility to place power wherever it is needed.
Ease of Repair - All engine components are easily accessible and fast to replace/repair with off-the-shelf parts or locally produced equipment.

Versions

See Power Cube Genealogy

Product Ecology

Power Cube Product Ecology

The current iteration of the power cube is an off-the-shelf gasoline engine, but the design is intended to be as power source agnostic as possible so that the power production can be readily changed. There will likely be many variations on the power cube design, but all fitting inside a similar size profile so that one GVCS machine can readily swap out one Power Cube for another.

Product Ecology
**Power Cube**
From	Uses	Creates	Enables
Gasoline Biodiesel Steam Engine Steam Generator Gasifier Burner Pelletizer Components Frame Engine Coupler Metal Hydraulic Tank Gas Tank Hydraulic Pump Hydraulic Hoses	Biofuel Biomass Tractor QA Plate	Power Hydraulic	Tractor CEB Press Bulldozer Microtractor Car Truck Chipper Hammermill Drill Press Multimachine Welder Ironworker Sawmill Induction Furnace CNC Torch Table

Video (Older Power Cube Designs)

Introduction to the Power Cube Design (1 min 59 sec)
Power Cube Complete (5 min 6 sec)
Build Instructions (50 min 27 sec)

Development Status

Currently, the Power Cube is in development to product release, after numerous prototypes. See Status of Completion

Useful Links

A Wikipedia Page on Powerpack (Drivetrain) I just recently found this, it seems like a similar philosophy, although it doesn't use hydraulics I think. Still interesting though.

A Wikipedia Page on Power-Eggs Same as the powerpack but for aircraft.

Links

The Global Village Construction Set
Habitat	CEB Press	Cement Mixer	Sawmill	Bulldozer	Backhoe
Agriculture	Tractor	Seeder	Hay Rake	Well-Drilling Rig
	Microtractor	Soil Pulverizer	Spader	Hay Cutter	Trencher
	Bakery Oven	Dairy Milker	Microcombine	Baler
Industry	Multimachine	Ironworker	Laser Cutter	Welder	Plasma Cutter
	CNC Torch Table	Metal Roller	Rod and Wire Mill	Press Forge	Universal Rotor
	3D Printer	3D Scanner	CNC Circuit Mill	Industrial Robot	Chipper Hammermill
	Drill Press	Induction Furnace
Energy	Power Cube	Gasifier Burner	Solar Concentrator	Electric Motor Generator	Hydraulic Motor
	Steam Engine	Heat Exchanger	Wind Turbine	Pelletizer	Universal Power Supply
	Nickel-Iron Battery
Materials	Aluminum Extractor	Bioplastic Extruder
Transportation	Car	Truck

Key	Design	Planning	Prototype	Almost done	Full Release

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Press Forge

Press Forge Closeup

Overview

The Press Forge takes molten steel fresh from the Induction Furnace and presses it into useful forms.

Template:Video:GVCS Home List

Product Ecology

Uses

Induction Furnace - Steel
Hydraulic Motor - Press
Power Cube - Power

See Product Ecologies for more information.

Components

Press
Die
Feeder
Roller
Control Box

Status

Currently in the Research Phase of product development. Prototyping is dependent upon development of the Induction Furnace.

Overview

Rototiller

Soil pulverizing as part of soil preparation for Compressed Earth Block pressing - at the MicroHouse 3 Workshop, Friday, August 8, 2014.

A tractor implement that tills soil with blades via rotary action. It is a specialized form of Cultivator.

Template:Video:GVCS Home List

Field Use

During 2014 build of Faculty House:

Details

Cultivators stir and pulverize the soil, either before planting (to aerate the soil and prepare a smooth, loose seedbed) or after the crop has begun growing to kill weeds (controlled disturbance of the topsoil close to the crop plants kills the surrounding weeds by uprooting them, burying their leaves to disrupt their photosynthesis, or a combination of both). Cultivators are designed to disturb the soil in careful patterns, sparing the crop plants but disrupting the weeds.

Product Ecology

Uses

Induction Furnace - Steel
CNC Torch Table - Steel
Hydraulic Motor - Power
Power Cube - Power
Tractor - Mounting

Template:Video:GVCS Home List

The spader is set of mechanical shovels that prepare soil for planting without causing a hardpan typical of rototiller tilling. Also called a "rotary spader".

Template:Video:GVCS Home List

Details

Agricultural Spader - This is the most advanced, but least affordable, method of soil preparation for planting. The spader is the mechanized equivalent of several digging shovels. It is operated by the power take off (PTO) behind a tractor. It operates like a rototiller, but with reciprocating spades. It is a superior method of soil preparation for planting - because, unlike a rototiller, it leaves better soil structure without creating a hardpan underneath the tilling layer. Moreover, the spader is capable of deeper tilling. This is the state of art in soil preparation, but few farmers are privy to it because of high cost - $5k for used machines. Our version will be driven by tractor hydraulics, eliminating costly gearing. The fabrication is not straightforward like a rototiller, as the spader spades ride on cams that are offset from a rotating axle. Effective fabrication strategy must be developed. Overall, this would help improve farmers' efficiency. The spader (and rototiller) are a one step soil preparation method - unlike plowing - which is typically followed by multiple disking or disking and harrowing.

They do not leave a "hardpan" due to the somewhat random action of the spades. Spaders are very expensive in north America as they are all made in Italy/Holland etc. (see links below). Inventing an open source spader would be a great achievment. They are a one pass type of implement, allowing easy working in of cover crops into the soil. Towing the spader behind LifeTrac would be easy as spaders are not a real load on the tractor/machine. All that is needed is a slow hydrostatic drive, but we have that covered.

Research

The embedded video, showing a Celli spader with "shovels", is from a University of Vermont DVD (available here).

Spader setup and operation - note 3rd pic down: it's the soil "pulverizer" after the spades. Spades dig first, "pulverizer" breaks up the clods and makes seed bed. Imants use a roller with curved tines instead. Does it all in one operation. Looks almost exactly like your tines on soil pulverizer.

"Product Review: Spaders - These must-have machines help preserve soil structure". At the bottom of that page a reader suggests Imants spaders from Holland: "Imants produces a spader that achieves the same results based on a different mechanical approach". The Imants use circular "arms". They supposedly will leave a hardpan like a tiller (eventually). I'm sure they run smoother/longer though.

Good spader video, shows the Imants final roller with tines. He discusses the mechanism up close.

Another Imant in action.

Product Ecology

Uses

Induction Furnace - Steel
CNC Torch Table - Structure

Works with

Tractor - Mounting
Power Cube - Power

Spader Product Ecology

See Product Ecologies for more information.

It can be used to power devices such as steam engines and steam turbines. Both of these machines convert expanding steam into rotational power, power that can be used to drive other GVCS tools or generate electric power. Excess or vented steam can also be used to heat a home or greenhouse.

Steam Generator Pages

Product Ecology

Product Ecology
**Steam Generator**
From	Uses	Creates	Enables
Induction Furnace Steel Components Tubes Turbine	Water	Steam	Steam Engine Power Cube Solar Turbine Greenhouse

Status

The Steam Generator is currently the Research Phase of Product Development.

Overview

LifeTrac is a low-cost, multipurpose open source tractor. It serves as a workhorse backbone for many of GVCS technologies. Prototype III stage has been completed, and field testing determined the need for Prototype IV prior to product release.

Featuring a modular design and detachable PowerCube units, it has the ability to rapidly switch between a variety of GVCS machines and/or Commercial Of-The-Shelf tools via the QA Plate. The machine is overbuilt with a focus on lifetime design and ease of repair.

Four hydraulic motors provide skid steer power to the wheels, and a chain tread system enables navigation of extreme terrain.

Join discussion at Hacker News - tractor discussion got the longest thread on Hacker News so far.

Details

Latest version of LifeTrac as of Jan. 2013 is LifeTrac IV - with Quick Connect Wheels and Bent Loader Arms, where III had straight arms and non-detachable wheel units.

Versions

See LifeTrac Genealogy

Remote Repository

Lifetrac Github Repository

Distributed Collaboration

Distributed Collaboration is a way to manage the digital files that describe the machine in such a way that people all over the world can work together through the internet. The process is made up of three steps: definitions, projects and reports.

LifeTrac III Definitions The definitions are any files that specify what the pieces of the machine are. An experience fabricator would be able to make all the pieces from just these files.

LifeTrac III Projects The project(s) is a database that turns the definitions into steps which, if all accomplished, will result in a finished machine. At the moment, we're just using an existing project management program.

LifeTrac III Reports The report(s) is a polished document that compiles all the definitions and project steps together in a way that is easy to follow. Additionally, the report includes background, context and any other piece of information that is relevant to the machine but is not strictly related to making it.

Product Evolution

Use the Product Evolution tree below to learn about the different versions of the LifeTrac and how far they got in product development (shown in italics). Follow the arrows to see where branching occurs. The dashed outlined represents the most complete documented version to date and tested at FeF.

Major Design Style
Articulated Design
	LifeTrac I Prototype 1		LifeTrac 5	LifeTrac 6

Skid Steer Design
	LifeTrac II Prototype 1	LifeTrac III Documentation	LifeTrac IV Retrofit


		LifeCat 1.0 R&D

Safety Concerns

No structural engineering analysis has been performed on the LifeTrac III or IV. If you choose to replicate this product you are doing so at your own risk and with this understanding. We will be performing analysis soon and will post those results as we get them.

There is also an email to OSE Europe mailing list describing some concerns about LifeTrac safety of use, and points out possible issues with: Frame, Steering, Brakes and Roll-Over Protection.

Product Ecology

Product Ecology
From	Uses	Creates	Enables
Power Cube Hydraulic Motor Induction Furnace Steel Components	Power Cube		CEB Press Rototiller Backhoe Universal Rotor Well-Drilling Rig Trencher Baler Seeder Spader Rototiller Hay Rake Hay Cutter

Videos

The Global Village Construction Set
Habitat	CEB Press	Cement Mixer	Sawmill	Bulldozer	Backhoe
Agriculture	Tractor	Seeder	Hay Rake	Well-Drilling Rig
	Microtractor	Soil Pulverizer	Spader	Hay Cutter	Trencher
	Bakery Oven	Dairy Milker	Microcombine	Baler
Industry	Multimachine	Ironworker	Laser Cutter	Welder	Plasma Cutter
	CNC Torch Table	Metal Roller	Rod and Wire Mill	Press Forge	Universal Rotor
	3D Printer	3D Scanner	CNC Circuit Mill	Industrial Robot	Chipper Hammermill
	Drill Press	Induction Furnace
Energy	Power Cube	Gasifier Burner	Solar Concentrator	Electric Motor Generator	Hydraulic Motor
	Steam Engine	Heat Exchanger	Wind Turbine	Pelletizer	Universal Power Supply
	Nickel-Iron Battery
Materials	Aluminum Extractor	Bioplastic Extruder
Transportation	Car	Truck

Key	Design	Planning	Prototype	Almost done	Full Release

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Warning: Display title "" overrides earlier display title "LifeTrac".

GVCS Home List
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2013 Prototype

2013 Development page at Dozuki - http://opensourceecology.dozuki.com/c/Trencher_-_Modules
3D CAD - [36]
YouTube playlist - [37]
Images on Trovebox - [38]
Test Video -

2012, Prototype I

A trencher is a piece of construction equipment used to dig trenches, typically for laying pipes or cables, or for drainage.

Think a chainsaw, but one that cuts into the earth.

Off-shelf Trencher

Hydraulic trencher design

Prototype I

Open Source Trencher. from Open Source Ecology on Vimeo.

Trencher Prototype I

Product Ecology

Created With

Induction Furnace Steel
CNC Torch Table Cutouts
Welder

Used with

Tractor - Mounting

Creates

Trenches

See Product Ecologies for more information.

Components

Motor
Blade
Teeth
Housing

Status

The Trencher is currently in the Research Phase of Product Development

See GVCS Rollout Plan

See Trencher Log

Videos

Template:Video:GVCS Home List

Example of a ripper with pipe laying attachment

Links

Trencher Rentals

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Intro

1 Overview
2 Genealogy
- 2.1 Details
- 2.2 Product Ecology
- 2.3 Status
- 2.4 See Also
- 2.5 Further reading
- 2.6 Overview
- 2.7 Details
- 2.8 Product Ecology
3 See Also
4 Overview
5 Detail
6 Product Ecology
7 Components
8 See Also
9 Overview
10 Versions
- 10.1 Backhoe 4
- 10.2 Backhoe 3
- 10.3 Backhoe 2
- 10.4 Backhoe 1
11 Details
12 Product Ecology
13 Videos
14 See Also
- 14.1 Overview
- 14.2 Detailed Description
- 14.3 Solution Statement
- 14.4 Status
- 14.5 See Also
15 Overview
- 15.1 Detail
- 15.2 Product Ecology
- 15.3 Components
- 15.4 Status
16 Internal Links
17 External Links
- 17.1 Overview
- 17.2 Detailed Description
  - 17.2.1 Bioplastics
- 17.3 Product Ecology
- 17.4 OSE Project Status/Schedule
- 17.5 See Also
18 FreeCAD File Download
19 Gallery
20 Concept Design
21 2015 Build
22 Proof of Concept of MicroTrac Scalability - LifeTrac 7
23 Hackaday Documentation
24 Loader Arms
25 Modules
26 Development Template
27 Working Document
28 Overview
29 Details
30 Product Ecology
31 Components
32 Status
33 Videos
34 See Also
35 OSE Links
36 Team Wikispeed
37 OSVehicle Tabby
38 Custom mini moke
39 Team Vélocar
- 39.1 Overview
40 UELVEs MBC
41 Product Ecology
- 41.1 Status
- 41.2 The Open Source Car in the media
- 41.3 See Also
42 Overview
- 42.1 Specifications of the Standard Model
43 Additional Power
44 BOM
45 Versions
46 Details
47 Product Ecology
48 See Also
- 48.1 Overview
- 48.2 Detailed Description
- 48.3 Product Ecology
- 48.4 OSE Project Status/Schedule
- 48.5 See Also
- 48.6 Links
- 48.7 Overview
- 48.8 Details
- 48.9 Product Ecology
- 48.10 Components
- 48.11 Status
- 48.12 See Also
49 Basics
50 Genealogy
51 3D Model
52 Publication
53 Build Instructions
54 Cut List
- 54.1 Rods if Using 6' Stock
  - 54.1.1 Try 1
  - 54.1.2 Try 2
55 July 2017
56 Comparison to Industry Standards
57 BOM
- 57.1 Other Supplies
58 vBOM
59 Calculations
- 59.1 Sources
60 Electronics
- 60.1 Source
61 Photo Album
62 Videos
63 Workshop Preparation
64 Development Template
65 Burndown
66 Feb 2018 Update
67 September 2017 Update
68 Development Pictures
69 Working Document
- 69.1 Design
- 69.2 Data Collection
70 CAD files
- 70.1 Simplified Files
- 70.2 Accurate Files
- 70.3 List of Files
- 70.4 Design Notes
71 Industry Standards
72 Existing Open Source Designs
73 Curriculum
74 See Also
75 Useful Links
76 Overview
77 2019 Update
78 2016 Update
79 2014 Team Goals
80 2016 Team Goals
81 Versions
82 Details
- 82.1 Documentation
83 Product Ecology
84 See Also
- 84.1 Overview
- 84.2 Detailed Description
- 84.3 Solution Statement
- 84.4 Product Ecology
- 84.5 Components
85 Status
86 Videos
87 See Also
88 Overview
- 88.1 Details
89 Status
90 See Also
- 90.1 Overview
- 90.2 Detailed Description
- 90.3 Product Ecology
- 90.4 Status
- 90.5 See Also
- 90.6 Overview
- 90.7 Details
- 90.8 Product Ecology
- 90.9 Status
- 90.10 See Also
91 Overview
92 Details
93 Product Ecology
94 Components
95 Study of Industry Standards
96 See Also
- 96.1 Overview
- 96.2 Details
- 96.3 Product Ecology
- 96.4 Components
- 96.5 Status
- 96.6 See Also
- 96.7 Overview
- 96.8 Detailed Description
- 96.9 Product Ecology
- 96.10 Status
97 See Also
98 Overview
99 Requirements
100 Details
101 Development Notes
102 Product Ecology
103 Components
104 Status
105 Internal Links
106 External Links
- 106.1 Overview
- 106.2 Detailed Description
- 106.3 Product Ecology
- 106.4 Status
- 106.5 See Also
- 106.6 Useful Links
107 Overview
108 Versions
109 Details
110 Product Ecology
111 See Also
- 111.1 Overview
- 111.2 Details
- 111.3 Product Ecology
- 111.4 Components
- 111.5 Status
- 111.6 Videos
- 111.7 See Also
- 111.8 Usefull Links
- 111.9 Overview
112 Description
113 Description
- 113.1 Solution Statement
- 113.2 Product Ecology
- 113.3 Components
- 113.4 Status
114 See Also
115 Overview
- 115.1 Details
- 115.2 Status
116 See Also
117 MicroTrac Geneaology
- 117.1 Working Model, 5/2013
- 117.2 Corners for structural tubing
- 117.3 Overview
- 117.4 Product Ecology
- 117.5 Components
- 117.6 Status
- 117.7 See Also
118 Links
119 Introduction
120 Mechanical Assembly Concept
121 Product Ecology
122 Rotary Module
123 Linear Guide
124 Tooling Plate and Accessories
125 Electronics Assembly
126 Software Toolchain
127 EDA (Electronic Design Automation)
128 Old Info
129 Internal Links
130 External Links
131 Overview
- 131.1 Advantages
- 131.2 Disadvantages
132 The Latest
133 Detailed Description
134 Product Ecology
135 Components
- 135.1 Anode Compound
- 135.2 node Construction
- 135.3 Cathode Compounds
- 135.4 Cathode Construction
- 135.5 Electrolyte
- 135.6 Cell Casing
136 Status
137 See Also
- 137.1 Other Communities
138 Off-the-Shelf
- 138.1 Sichuan Changhong Battery Co., Ltd
- 138.2 Seawill Technology Co., Ltd.
- 138.3 Cost
139 Links
140 Overview
141 Details
- 141.1 Product Ecology
142 Industry Standards
143 Status
144 Other Videos
145 See Also
146 Useful Links
- 146.1 Overview
- 146.2 Product Ecology
- 146.3 Components
- 146.4 Status
- 146.5 Internal Links
- 146.6 External Links
147 Overview
148 Details
149 Versions
150 Product Ecology
151 Video (Older Power Cube Designs)
152 Development Status
- 152.1 See Also
153 Useful Links
154 Links
- 154.1 Overview
- 154.2 Product Ecology
- 154.3 Components
- 154.4 Status
155 See Also
- 155.1 Overview
- 155.2 Details
- 155.3 Product Ecology
- 155.4 Components
- 155.5 Status
156 See Also
157 Overview
158 Field Use
159 Details
160 Product Ecology
161 See Also
- 161.1 Overview
- 161.2 Detailed Description
- 161.3 Product Ecology
- 161.4 Status
- 161.5 Videos
- 161.6 See Also
- 161.7 Links
  - 161.7.1 Theo's Github Repository
- 161.8 Overview
- 161.9 Details
- 161.10 Product Ecology
- 161.11 Components
- 161.12 Status
162 Videos
163 See Also
- 163.1 Overview
- 163.2 Details
- 163.3 Product Ecology
- 163.4 Components
- 163.5 Status
- 163.6 See Also (OSE Wiki)
- 163.7 External Links
164 Overview
- 164.1 Details
- 164.2 Research
- 164.3 Product Ecology
165 See Also
- 165.1 Overview
- 165.2 Details
- 165.3 Product Ecology
- 165.4 Status
- 165.5 See Also
166 Overview
- 166.1 Details
- 166.2 Product Ecology
- 166.3 Status
- 166.4 See Also
167 Overview
- 167.1 Details
- 167.2 Versions
168 Remote Repository
169 Distributed Collaboration
170 Product Evolution
171 Safety Concerns
172 Product Ecology
173 Videos
174 2013 Prototype
175 2012, Prototype I
- 175.1 Prototype I
- 175.2 Product Ecology
- 175.3 Components
- 175.4 Status
- 175.5 Videos
- 175.6 See Also
176 Links
177 Intro
178 Documentation
179 Alternative Body Styles
180 Concepts
181 More Concepts
182 Concepta
183 Maintenance Concept Text
184 Maintenance Concept Videos
185 More Concepts 3
186 More Concepts 3
187 text
- 187.1 Overview
- 187.2 Detailed Description
- 187.3 Product Ecology
- 187.4 Status
- 187.5 See Also
188 Overview
189 Updates
190 Definition/Concept
- 190.1 Rectifiers
- 190.2 Voltage Converters
- 190.3 Inverters
191 Product Ecology
192 Status
193 See Also
194 Development
195 Overview
196 Build
197 Details
198 Product Ecology
199 Status
200 Links
201 Overview
- 201.1 Details
- 201.2 Product Ecology
- 201.3 Components
- 201.4 Status
- 201.5 See Also
- 201.6 Overview
- 201.7 Description
- 201.8 Product Ecology
- 201.9 Components
- 201.10 Status
202 Internal Links
203 External Links
204 Overview
- 204.1 Details
- 204.2 Product Ecology
- 204.3 Status
- 204.4 OS Projects
- 204.5 See also
  - 204.5.1 Wikipedia
- 204.6 External links

A truck is a transportation machine that you can drive in order to move yourself, others, and stuff to wherever you can get with wheels. The difference between a truck and car is that trucks are stronger and have more dedicated space for stuff on the vehicle.

Documentation

If you're new to mechanical things, check out Mechanical Intro

Alternative Body Styles

Depending on the function of the truck, it could have a smaller body style. (Unless, it is intended for hauling large amounts of agricultural goods.) If a light duty vehicle is all that would be necessary in many situations, then a more efficient size might be better.

There are a couple examples of small body styles that are common to the rest of the world but not in North America. First is the coupé utility (basically the same as the Chevrolet El Camino), known as the Ute in Australia and New Zealand. Second the minitruck from Japan, as known as the Kei truck, which are being imported to the United States as light duty off-road vehicles in some rural areas. In both Australia and Japan, vehicles are right-hand-drive. Though, it might be legal to operate a RHD vehicle on US roadways, there is the issue of practicality.

https://en.wikipedia.org/wiki/Ute_(vehicle)

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

A small modular design with standardized parts is probably more cost effective and still allows for vehicle type options.

Concepts

More Concepts

Concepta

Maintenance Concept Text

Pneumatic

Tire Air Pressure

Hydraulic

Engine Oil

Coolant

Transmission Fluid

Brake Fluid

Windshield Washer Fluid

Mechanical

Tires

Brake Pads

Windshield Wipers

http://www.carbibles.com/maintenancetips.html

Engines have a lot of moving parts that rub against each other and create friction. The friction generates a lot of heat. When plastics get hotter and hotter, they get softer and eventually melt. When metals get hot, they get softer, which accelerates wear, and if hot enough, metals melt too. So cooling the engine is important. The engine is essentially a complex hulk of metal, so pumping water through it will cool it down. But water boils and freezes too easily- if the water turns into a gas, then it loses a lot of cooling ability- in other cases, a lot of pressure (from gaseous expansion or ice formation) will crack and break the solid parts of the cooling system (and the engine). So adding substances (like antifreeze) keeps the coolant system working in hot and cold conditions.

Another way to solve the heat problem is to stop friction in the first place. Lubricants are substances that have very low coefficients of friction so they generate very little thermal energy when rubbed together. By applying lubricants to the moving parts of an engine, less heat will be generated.

Car Maintenance - Scotty Kilmer's Youtube Channel

Maintenance Concept Videos

Vehicle Fluid Maintenance

More Concepts 3

Gear Dimensions and Terminology File:Geardimterm.pdf

Gear Types from Engineer's Edge

More Concepts 3

text

4 Wheel Drive

4 Wheel Drive Explanation at Wikipedia

Leaf Suspension vs Coil Spring

Leaf vs Coil Comparison at JP Magazine

Leaf vs Coil Comparison at eHow

Cargo Bed Size and Payload

Towing Interface and Capacity

Manual vs Automatic Transmission

Ground Clearance

Fuel Efficiency

http://en.wikipedia.org/wiki/Auto_maintenance

Fuel for regular operation

Engine oil for lubricating

Oil Filter Replacement

Coolant for cooling

Filling Radiator Fluid, Video at Youtube

Coolant Filter Replacement

Brake Pad Replacement

Tire Replacement

Overview

http://opensourceecology.org/wiki/Truck/Research_Development

The Open Source Truck is a heavy off-road vehicle capable of equipping many pieces of equipment used on the Tractor, and transporting heavy loads long distance. The Open Source Truck project is currently in the research phase.

Template:Video:GVCS Home List

Detailed Description

Goal specifications

Open Source Truck Concept - similar to Mercedes Unimog:

Top speed of 60 mph
Equipped with suspension
Capable of handling extreme off-road conditions
Equipped with front and rear power take-off, hydraulic take-off, and quick attach mounting plate for hydraulic heavy and rotary equipment such as backhoe, loader, power generator, hammermill, pelletizer, and any agricultural, utility, and construction equipment that is already avialable for the Tractor or Microtractor
Dual utility for agricultural and transportation uses
Hydraulic drive
Quick attach Power Cube
27-270 hp models
Eventually powered with Modern Steam Engine

Product Ecology

Product Ecology
**Truck**
From	Uses	Creates	Enables
3D Printer Induction Furnace Rod and Wire Mill Multimachine Hydraulic Motor Industrial Robot Welder Components Steel Frame Axles Wheels Plastic Inserts Engine Winch QA Plate	Power Cube Biodiseal Steam Engine	Transportation

Status

The Open Source Truck is currently in the Research phase of product development.

Overview

A Universal Power Supply forms the backbone of an off-grid electrical system for powering machines and power electronic devices such as the induction furnace.

Updates

See Universal_Power_Supply Requirement for 2019 version.
Initial prototypes:

Template:Video:GVCS Home List

Definition/Concept

This is a combination inverter, converter, pulse-width modulation current controller, and high frequency power supply for applications from off-grid power, charge controllers, to power supplies for welders, induction furnaces, and plasma cutters.

A large range of power electronic devices is desirable within the infrastructure of communities. Having an individual power supply for each is redundant and expensive. A modular UPS construction kit is desirable as an analogue to the 'industrial-strength Lego' that we have already demonstrated for heavy mechanical hardware infrastructures.

Rectifiers

Rectifier power dissipation as a function of current

Rectification is the conversion of AC to DC. A universal power supply would require one or two rectifying stages: one at the AC input to provide DC for the voltage converter, and another if the voltage converter is a proper Active PFC converter, which produces PWM shaped output.

Rectifiers can be either passive schottky diode bridges, or active (IC-controlled) MOSFET H-bridges. Passive ones are cheaper, and ultimately more efficient for very high currents, while active ones are superior for low-medium-and-maybe-high currents yet more expensive. This design choice affects price, producability and simplicity.

In either case a rectifier stage requires power packaged components and a heat sink. The size of the heat sink is a function of the current, which is higher at low voltages for a given output power. Questions for the specification is how much power the device should be able to deliver from a 12V source (first rectifier in the case of voltage up-conversion) and to a load at 12V DC output (second rectifier if present).

Voltage Converters

Inverters

An inverter is an electrical device that converts DC voltage from batteries to AC voltage for off-shelf electrical tools and appliances.

Off-the-shelf inverters have about a 2 year lifetime, and 5-10 year lifetime for higher quality models. Lifetime design inverters with plug-in replacement components are required for sustainable communities which use battery storage as a component of their electricity infrastructure. One of the few other feasible, non-battery, non-fuel energy storage may be via heat storage coupled to thermoelectric generators, or possibly thermal storage via phase-change salts and heat engines.

Product Ecology

Product Ecology
**Universal Power Supply**
From	Uses	Creates	Enables
CNC Circuit Mill 3D Printer Rod and Wire Mill Components Wires Casing Circuits	Battery Power Cube	Electricity	Electric Motor Generator Welder Induction Furnace Plasma Cutter Industrial Robot

Status

OSE is recruiting subject matter experts with experience in inverter design. Those with relevant experience are encouraged to Contact Us

Adjustable Power Supply v18.08 is in development

Development

Development Template
	Description	Link to Work Product	%
	DESIGN
1	Requirements + Value Proposition	Universal Rotor Requirements + Value Proposition	0
2	Industry_Standards	Universal Rotor Industry Standards	0
3	Conceptual Design	Universal Rotor Conceptual Design	0
4	Module Breakdown	Universal Rotor Module Breakdown	0
5	Design Guide	Universal Rotor Design Guide	0
	TECHNICAL DESIGN
6	3D CAD	Universal Rotor 3D CAD	0
7	Calculations	Universal Rotor Calculations	0
8	Electronics Design	Universal Rotor Electronics Design	0
9	Wiring and Plumbing	Universal Rotor Wiring and Plumbing	0
10	Software	Universal Rotor Software	0
	BILL OF MATERIALS
11	BOM	Universal Rotor BOM	0
12	vBOM	Universal Rotor vBOM	0
13	CAM Files	Universal Rotor CAM Files	0
14	Cut List	Universal Rotor Cut List	0
	BUILD
15	Build Instructions	Universal Rotor Build Instructions	0
16	Fabrication Drawings	Universal Rotor Fabrication Drawings	0
17	Exploded Part Diagram	Universal Rotor Exploded Part Diagram	0
18	Production Engineering	Universal Rotor Production Engineering	0
	LIFECYCLE DESIGN
19	Build Pictures and Video	Universal Rotor Build Pictures and Video	0
20	Data Collection	Universal Rotor Data Collection	0
21	Future Work	Universal Rotor Future Work	0
22	Troubleshooting and Repair	Universal Rotor Troubleshooting and Repair	0

Overview

Universal Rotor

The Universal Rotor(UR) is a standardized, heavy duty, modular, scalable rotor for utility, construction, and manufacturing purposes. The current iteration inolves a triple interface mount that allows for various tasks (work) to be accomplished by harnessing the high rotational torque and speeds generated by a hydraulic motor (or electric motor, etc). This is a fundamental component for any GVCS machine that uses a motor. It provides modularity, redundancy, scalability and represents a significant cost reduction by being able to use only one motor to power many machines. Examples are: Attaching the wheels to Lifetrac and powering them; a mower, auger or slurry mixer for Lifetrac; the saw blades on the Saw Mill. Attaching a lathe chuck and adding the 2" Universal Axis with Universal Controller turns it into a CNC lathe. It can be used to drive heavy slow rotors, such as a plastic shredder, pelletizer, or with geardown - a rock grinder. It connected to rollers, this can drive metal rolling equipment.

See Universal Rotor Genealogy

Build

Details

This triple interface that allows the UR to harness motor power has 3 interfaces which each have 2 sides to it. The following are the three interfaces with the 2 sides of each interface in parenthesis:

1) Anchor Interface: (Receiver & Attachment)

Is the stationary side of the interface and serves to 'anchor' the UR to a solid object. This is done by connecting/inserting the Attachment on the UR to the Receiver on the solid object.

-Allows the shaft(tool) to be mounted at multiple angles in relation to the machine. This makes the UR useful for vertical shaft applications like an earth auger or mower and horizontal shaft applications like a wheel trencher or wheel drive that powers the LifeTrac. This can be accomplished with a single square tube which is rotated 90 degrees and reattached.

-Another axis of rotation can be accomplished by adding multiple tubes to either the receiver side of the interface at angles to the primary one. It could also be accomplished by using an angle adapter tube.

2) Power Interface: (Motor & Mounting Plate)

Mounts the motor to the mounting plate which is part of the UR's structure. In addition to how the motor attaches, this interface also considers the space that various motors would need and ensures that the rest of the UR structure nor the machine it is attached to doesn't interfere with the space need for motors. Additionally, space for motor removal and the connection and protection of hydraulic lines needs consideration. There are four common motor mount styles: Face, Wheel Motor(body) Tail, Base. The focus of the UR will be face and wheel motor mounting for hydraulic motors. For face mounting the UR will utilize SAE hydraulic motor mounting dimensions since the GVCS hydraulic motor will likely adopt these and SAE motors are currently being used by OSE and readily available. Wheel Motor Mounting dimensions are less standardized. In either case by starting with one of the largest SAE face mounting patterns, adapter plates can be bolted to that pattern to accommodate smaller face mount and wheel motors.

3)Tool Interface: (shaft connection & tool connection)

Connects the rotating shaft of the motor to the tool to be rotated. There might be adapters for different applications. For example a tire rim on the LifeTrac might bolt to the same mount as an 8' diameter wheel trencher. But that might be to large mount for an auger or a 16” cold saw blade. The primary mount needs to be sufficient to handle the forces for all applications, and then smaller adapter mount attached to it. The primary mount should be as compact as possible but still quickly attachable, perfectly concentric and have zero slop. If a wheel style mount is used, there are two types, hub concentric(w/flat lug nuts) and stud centric(with tapered/cone lug nuts)

1,2&3) All three interfaces must individually be:

-Scalable in thickness or dimension for applications with higher forces

The Universal Rotor as a whole must be:

-Withstand extreme radial, axial and twisting(in relation to the motor shaft) generated by all the applications for which it will be used for.

-Light as possible to be managed by hand

-Compact

Other Considerations:

1) Accomodating for gearing and multiple motors

Because there may be a limit to the amount of power or speed that available motors produce, gearing or the use of multiple motors may be needed when the tool requires more power or speed. For gearing with a single motor this can be accomplished by breaking the direct connection between the motor shaft and the tool and routing the power flow thru a gear reduction (chain & sprockets) first. Or additional motors could be added by keeping a direct connection between the tool and motor but mounting a 2nd motor and connecting its shaft to the shaft of the primary motor via chain. However, if the speed and power of the motor is suitable for the application it is best to have a straight connection to the tool.

Decisions:

1) Wheel Motors(bearings built in) or Jack Shaft(with auxiliary bearing support structure)?

Due to the wide range of applications, the UR needs to handle high axial and radial forces. Wheel motors have larger bearings then standard hydraulic motors to resist these much higher forces. Wheel motors are available commercially that will handle the radial and axial loads of all current GVCS applications. However wheel motors are low speed. High speed motors don't usually have such large bearings. While generally you don't need large bearings while doing high speed operations, an accident, such as hitting a tree stump with a high speed mower blade may damage a motor with smaller bearings. Adding a separate shaft(jack shaft) that is supported by separate bearings between the motor shaft and tool effectively isolates the motor shaft and bearings from any radial forces, as well as axial forces if properly designed. This is the design currently being used on LifeTrac III and the MultiAuger. The current design on the LifeTrac is excessive in length and has some proven and suspected issues. A much shorter and simpler jack shaft setup should be possible that is more comparable to a wheel motor in size. If a jack shaft setup is chosen as the primary UR setup, it should be designed so that only wheel motor can be used instead with minimal variation(or none) for replicators who choose to do so.

The current quick connect wheel assembly with the jack shaft and auxilary bearings was a necessary component when the LifeTrac was powered by the original weaker drive motors. However during the redesign, new 15,000 Inch Pound Motors were purchased which are actually wheel motors that have a much higher carrying capicity which means the whole jack shaft assembly might not even be necessary as the motor is designed to handle up to 11,000 of radial load per the specs provided by the manufacturer. It has already been proposed by Marcin that the wheel connect be redesigned to address several issues, but in reality, it can actually be completely ommited without having to purchase additional motors.

Comparison:

Wheel Motor UR Advantages:

-Much more compact, lightweight, cheaper and very quick to build

-Sealed & lubricated bearings

-Industry Proven

-Less parts to break or wear out

Auxiliary Bearing UR Advantages:

-Can remove the motor with out disconnecting the tool(or the tire when used as wheel drive)

-More motor choices (especially rpm)

-Can use a gear reduction or multiple motors much easier

2) Tapered or Roller Bearings?

If a jack shaft with auxiliary bearings are to be used, will it use tapered bearings to resist axial thrust or just thrust washers? Thrust washers are not good, especially if the tool is hanging, being pushed on(ie. Auger) or anything with constant side loading. The only reason not to use tapered bearings is because they are harder to make and mount out of raw steel and if a suitable off-the-shelf setup might not be found in the mean time They also require preloading of the two opposed tapered bearings against each other by means of a threaded shaft or a press fit. One source might be preassembled “4x4 truck hubs” as found on ebay. A tapered bearing solution will almost always be more compact and robust.

Before spending much time on one particular design, it will help to imagine that design being used in each of the applications that the UR is to be used in.

Applications with the LifeTrac for the UR:

Other GVCS machines with UR applications:

Product Ecology

Auger Attachment

Uses

Induction Furnace - Steel
CNC Torch Table - Parts
Tractor - Mounting
Power Cube - Power
Hydraulic Motor - Power

Mounts

String Trimmer,
Tree Planting auger,
Lathe,
drill press,
soil line cutting rotor,
honey extractor.
Trencher

Status

The Universal Rotor is currently in the prototyping phase of product development.

The hydraulic motor is interchangeable, and so far, a 32 cu in and a 6 cu in motors have been used which have a quick mounting plate with 2 3/4" bolts for hold-down. The assembly can be mounted either horizontally or vertically by bolting to a back plate accordingly.

Future prototype designs aim to improve structural integrity, increased ease of mounting for LifeTrac, and improved interchangeability of motors.

Actions are logged in Universal Rotor Log.

Links

Universal Rotor Construction Set
Universal Rotor 2 - Modular Wheel Units - are one implementation of the Universal Rotor. Also used in track drive.
Deka-kW VAWT Wind Turbine - another implementation of the Universal Rotor
Blog Post
CAD
Institution of Engineering and Technology

The Global Village Construction Set
Habitat	CEB Press	Cement Mixer	Sawmill	Bulldozer	Backhoe
Agriculture	Tractor	Seeder	Hay Rake	Well-Drilling Rig
	Microtractor	Soil Pulverizer	Spader	Hay Cutter	Trencher
	Bakery Oven	Dairy Milker	Microcombine	Baler
Industry	Multimachine	Ironworker	Laser Cutter	Welder	Plasma Cutter
	CNC Torch Table	Metal Roller	Rod and Wire Mill	Press Forge	Universal Rotor
	3D Printer	3D Scanner	CNC Circuit Mill	Industrial Robot	Chipper Hammermill
	Drill Press	Induction Furnace
Energy	Power Cube	Gasifier Burner	Solar Concentrator	Electric Motor Generator	Hydraulic Motor
	Steam Engine	Heat Exchanger	Wind Turbine	Pelletizer	Universal Power Supply
	Nickel-Iron Battery
Materials	Aluminum Extractor	Bioplastic Extruder
Transportation	Car	Truck

Key	Design	Planning	Prototype	Almost done	Full Release

EN
AR
BG
BN
CS
DE
EL
EO
ES
FR
HE
HI
HU
HR
IT
JA
LT
NL
NO
PA
PL
PT
RO
RU
SV
TH
TR
UK
VI
ZH-HANS
Article Title: GVCS Home List

GVCS Home List
Home \| Research & Development \| Bill of Materials \| Manufacturing Instructions \| User's Manual \| User Reviews	78px

Overview

Welder

The Welder enables all the wonders of welding, a fabrication process that joins metal pieces together.

Template:Video:GVCS Home List

Details

Welding is often done by melting the workpieces and adding a filler material to form a pool of molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld. This is in contrast with soldering and brazing, which involve melting a lower-melting-point material between the workpieces to form a bond between them, without melting the workpieces.

Product Ecology

Welder Product Ecology

Uses

Universal Power Supply - Power
Rod and Wire Mill - Welding Wire

Used by

Industrial Robot

See Product Ecologies for more information.

Components

Wire Feed
Spooler
Tensioner
Transformer
Welding Wire
Control Box
Handle
Nozzle
Sleeve
Case

Status

The Welder project is currently in the Research Phase of product development.

Overview

Well-Drilling Rig

The Well Drilling Rig enables the construction of water wells. Water is crucial for human and animal consumption, washing, irrigation, and industrial processes. Access to clean drinking water is one of the key challenges facing many countries today. Addressing this need with the GVCS has the potential for far reaching impact.

If this machine plans are changed little to "General Drilling Rig" it can be used also mining purposes, to drill & blast caves, make bolt holes, drill water and geothermal wells etc. There can be two changeable drill heads. One for bigger holes (compressed air driven) and second hydraulic driven (fast) for smaller holes. And modified LifeTrac may carry them. Modified Backhoe offer enough movement for drill head tool.

Template:Video:GVCS Home List

Description

Well drilling can be broken down into three basic phases:

breaking up the rock/soil in the well column
removing the cuttings from the well column
stabilising the well column and preparing it for production.

Breaking Breaking of rock/soil to produce cuttings is achieved by a cutting tool, either a rotating drill bit or a raised and dropped 'chisel-like' device; for the GVCS well drilling rig we will likely employ the rotating bit design as it is a much more common method of well preparation. The bit is rotated by attaching it to the end of a long series of pipes connected together called the drill string, turning the drill string turns the cutting bit.

Pumping Once the bit has cut up the rock/dirt it needs to be lifted up out of the well. The most common way of doing this is to pump water/mud down the center of the piping that makes up the drill string, and letting it flow out the end of the bit. By continuously pumping more drilling mud into the well, it eventually fills up and the only place left for the mud to go is to be pushed up to the top of the well and spill over the side, carrying the cuttings along with it. This flow of mud and broken up rock spills over the top of the well and is sent to a small settling pond where the rocks and sand settle out of it. After some time in the settling pond the mud is recycled by the mud pump and pushed back down the well again to pick up and remove more cuttings allowing the well to be contiuously drilled deeper and deeper, stopping only to add new sections of drill string.

Stabilizing After the well is drilled to the desired depth it must be finished and put into production. The drill string is withrawn from the well, but the well is left full of water/drilling mud to prevent the sides from caving in until the well is finished. After the drill string is out the casing pipe is slid into the well to prevent caving in of the sides. Once this is done, the drilling mud is removed from the well column leaving it empty. At this point a water bucket or temporary well pump is placed in the well and as much water as possible is drawn up for a test period of 1 to 3 days to clean out any remaining drilling mud and stabilize the aquifer for production. Also during this time the water extraction rate is measured to verify that it is worth continuing to finish the well (poor producing wells may have the casing withdrawn and be re-drilled at a more favorable location). Once the well is shown to be a producing well it is capped with a cement cap, and the water pump is installed making the well operational.

Product Ecology

Made with

Induction Furnace - Steel
CNC Torch Table - Parts
Power Cube - Power
Hydraulic Motor - Drill, Ram, Vacuum Pump

Uses

Hydraulic Motor - Pump
Power Cube - Power
Cement Mixer - Cement Cap

Creates

Water Wells

Components

Steel
Drill
Pipe Casing
Drill String
Hoses
Mud Pump
Vacuum

Status

The Well Drilling Rig is currently in the research phase of product development

Internal Links

External Links

The Global Village Construction Set
Habitat	CEB Press	Cement Mixer	Sawmill	Bulldozer	Backhoe
Agriculture	Tractor	Seeder	Hay Rake	Well-Drilling Rig
	Microtractor	Soil Pulverizer	Spader	Hay Cutter	Trencher
	Bakery Oven	Dairy Milker	Microcombine	Baler
Industry	Multimachine	Ironworker	Laser Cutter	Welder	Plasma Cutter
	CNC Torch Table	Metal Roller	Rod and Wire Mill	Press Forge	Universal Rotor
	3D Printer	3D Scanner	CNC Circuit Mill	Industrial Robot	Chipper Hammermill
	Drill Press	Induction Furnace
Energy	Power Cube	Gasifier Burner	Solar Concentrator	Electric Motor Generator	Hydraulic Motor
	Steam Engine	Heat Exchanger	Wind Turbine	Pelletizer	Universal Power Supply
	Nickel-Iron Battery
Materials	Aluminum Extractor	Bioplastic Extruder
Transportation	Car	Truck

Key	Design	Planning	Prototype	Almost done	Full Release

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Article Title: GVCS Home List

GVCS Home List
Home \| Research & Development \| Bill of Materials \| Manufacturing Instructions \| User's Manual \| User Reviews	78px

Overview

Wind Turbine

The Wind Turbine is a machine that converts mechanical kinetic energy of the wind into electrical energy. As a part of the GVCS it enables the generation of clean, renewable power.

Template:Video:GVCS Home List

Details

Small wind turbines are currently the main class being considered as a community-scale solution for power. These turbines may be as small as a fifty watt generator for boat, caravan, or miniature refrigeration unit. Small units often have direct drive generators, direct current output, aeroelastic blades, lifetime bearings and use a vane to point into the wind.

Product Ecology

Product Ecology
**Wind Turbine**
From	Uses	Creates	Enables
Induction Furnace Multimachine Electric Motor Generator Battery Components Blades Tail Hub DC generator Battery Diode Sensors Mount Wires Tower Base Pole Guy-wires Bearings	Wind	Electricity

Status

Open Source Ecology Europe and -Germany are working on a prototype VAWT design: Germany/Wind_Turbine. Research and development is currently concentrated at TiVA, a tiny wind turbine prototyping platform. With this very small turbine, we can easily change parts, try out new ideas and increase the quality of the design on a small scale in a fast and inexpensive way.

The wind turbine is currently in the Research phase of product development.

There are a wide number of Open Hardware turbines, that are currently under consideration for adoption/consideration as a part of the GVCS.

portable wind turbine that can fit in a tube; wind lens.

OS Projects

AirEnergy 3D [39]- A 3D printed, opensource, mobile wind turbine.
SolarFlower [40]
Zoetrope [41]

External links

Onawi

The Global Village Construction Set
Habitat	CEB Press	Cement Mixer	Sawmill	Bulldozer	Backhoe
Agriculture	Tractor	Seeder	Hay Rake	Well-Drilling Rig
	Microtractor	Soil Pulverizer	Spader	Hay Cutter	Trencher
	Bakery Oven	Dairy Milker	Microcombine	Baler
Industry	Multimachine	Ironworker	Laser Cutter	Welder	Plasma Cutter
	CNC Torch Table	Metal Roller	Rod and Wire Mill	Press Forge	Universal Rotor
	3D Printer	3D Scanner	CNC Circuit Mill	Industrial Robot	Chipper Hammermill
	Drill Press	Induction Furnace
Energy	Power Cube	Gasifier Burner	Solar Concentrator	Electric Motor Generator	Hydraulic Motor
	Steam Engine	Heat Exchanger	Wind Turbine	Pelletizer	Universal Power Supply
	Nickel-Iron Battery
Materials	Aluminum Extractor	Bioplastic Extruder
Transportation	Car	Truck

Key	Design	Planning	Prototype	Almost done	Full Release

Main > Energy > Wind energy

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[2] ttps://www.terravolt.net/iron-edison

[1]

[2]

GVCS Home List

Overview

Genealogy

Details

Types of 3D Printers

Printing Process

Applications

Product Ecology

Status

See Also

Further reading

Overview

Details

Product Ecology

See Also

Overview

Detail

Product Ecology

Components

See Also

Overview

Versions

Backhoe 4

Backhoe 3

Backhoe 2

Bucket

Stick

Pivot

For the Future

Backhoe 1

Details

Product Ecology

Videos

See Also

Overview

Detailed Description

Solution Statement

Status

See Also

Overview

Detail

Product Ecology

Components

Status

Internal Links

External Links

Overview

Detailed Description

Bioplastics

Product Ecology

OSE Project Status/Schedule

See Also

FreeCAD File Download

Gallery

Concept Design

2015 Build

Proof of Concept of MicroTrac Scalability - LifeTrac 7

Hackaday Documentation

Loader Arms

Modules

Development Template

Working Document

Overview

Details

Product Ecology

Components

Status

Videos

See Also

OSE Links

Team Wikispeed

OSVehicle Tabby

Custom mini moke

Team Vélocar

Overview

UELVEs MBC

Product Ecology

Status

The Open Source Car in the media

See Also