November 23, 2012 Collaborative Production Run
Results - We have achieved an almost complete build of the Brick Press in 2 days with 8 people - down from 4 days in the first Collaborative Production Run. We had the first time where the CEB Press user (Barry Alexander, building contractor and entrepreneur, above) participated in our Collaborative Production Run. We built a machine almost completely in two days: grate, hopper, hopper supports, arms and legs, hopper seat, frame and covers, and drawer (needs 1 more hour of welding). We did not mount the cylinder, drawer, and compression chamber spacers. Electronics were prepared ahead of time. We pulled the main cylinder from an older machine and mounted a new abrasion resistant plate on it, and pulled the shaker assembly from an older machine. The solenoid valve and balance of hydraulics did not arrive in time. We welded the frame verticals from 1/2"x4"x6" angle - special order steel did not arrive in time. Keys to success were highel level of modularity: modular design of hopper supports, hopper, grate, sensor mounts, shaker, and valve mounts. See Future Directions for CEB Press Collaborative Production Run.
- 1 Preparation
- 2 Change Notes
- 3 Fabrication Diagrams
- 3.1 Master Fabrication PDF
- 3.2 Master Index
- 3.3 Fabrication Abstract
- 3.4 Optimization Notes
- 3.5 Production Run Notes
- 3.6 Hopper
- 3.7 Grate
- 3.8 Saddle
- 3.9 Main Cylinder Fabrication Diagram
- 3.10 Arms + Legs
- 3.11 Frame
- 3.12 Drawer + Drawer Rollers
- 3.13 Hopper Shaker
- 3.14 Hydraulics
- Dalton Hydraulics - ordered Hydraulic Solenoid Valve for CEB Press. File:Daltonceborder.pdf
- Ordered Annular Cutters
- Ordered 1" Bandsaw Blades - fine tooth
- Ordered 2 more Mag Drills Magnetic Drills
- Ordered CEB Cam Followers - 4 from IBT in Kansas City
- Ordered CEB Hydraulic Cylinder
- Ordered CEB IV Surplus Center Order - Surplus Center + Cylinder order took 1 hour including part replacement for missing items (secondary cylinder out of stock, selected new one)
- Sweiger Metal Order - File:Sweigernovceb.ods - note puncher dies are 1-1/16" for 1" holes, and 1-3/32 for the bottom half - needs clearance.
- Note: 3x6 u-channel is special order. Will use 4x6 angle and weld on another 1/2x3 flange. Accelerates cutting, but requires welding.
- Mokan fastener order - File:Mokannovcdb.ods
- Based on modular rear hopper supports, add quick attach to front hopper supports as well
- Shorten horizontal frame u-channels from 22" by 1.5" - to allow for the front hopper support to be mounted on the primary arms
- Simplify shaker shield to a single flat plate
- Add a more robust, modular holding mechanism for sensors
- Add safety disconnect for machine turn-off
- Can we get a better packing fraction on Part 24 of CEB IV Master Index?
- Shorten rail by 2" at the front of the machine, leave hanging 8" beyond drawer chamber at the rear.
- Use 1"x3" bar instead of 1/2"x3 (or 1/2"x5/8") and 1/2"x2"
- Lengthen hinges to 34" for the hopper and 24" for the grate supports
- Reduce bottom pin bushings from 1.8" to 1.5"
- Make bushing for bottom cylinder mount to frame the same as the end tube - 1.5"x2.5" DOM tubing - to reduce material list
- Remove bolt holes for back of hopper supports (shaker side) and clamp instead on top with 1/2"x6" flat.
Fabrication Drawing Corrections
- Fab Drawing (Part) #151: Correct spelling of Brake
- Part #153 & #154: change wall thickness from 1/2" to 1/4"
- Part #90: update to heavier hinge. Punching holes is preferred to drilling. Update length to not drill.
Master Fabrication PDF
Build all parts from raw material. Team 1: hopper sheet metal cutting with 2 plasma cutters, hinge cutting to size with ironworker, punching of holes with hinge put in place on front and back hopper sheets. Team 2: does all cover plate sheet metal. Team 3: Ironworker team does pieces and holepunches them. grate fab after 1/4x2s and angle pieces are sheared on ironworker. Team 4: Cold cut team. Team 5: Bandsaw Team for 2.5"x3/16" tubing. Cuts metal for drawer at same time.
Hole puncher needs to have operability by 1 person with a well-positioned valve. 2 plasma cutters need to be in place. 4 welders need to be available. 2 acetylene torches should be available. CNC torch table will get hopper fab down to 1/2 hour for cutting. CNC torch table will optimize metal cutting for drawer and frame. Ironworker needs to be upgraded to handle 1/2"x4"x6" angle.
Production Run Notes
Record all notes on work flow, mistakes in fab drawings, procedure insights, challenges here. Mark time for each step under corresponding section below.
- Cut 4 sheets
- Cut hopper hinges to size
- Tack hinges
- Match punch hinge holes
- Assemble hopper, tack hinge to sides
- Finish weld
- Have second person or PD (Production Director) verify all hopper pattern
- Hinges are 34" and 24"
- Hinge tacked prior to match hole punching
- 3/4" punch
- Hinge begins 3" off corner, first hole 2" off edge
- 4 holes total per side on rear and front pieces, spaced at 10"
- Omit holes in middle of hopper piece
- Holes 1.5" off edge
- Sheet 1-4 labeled, Front and Back side of each piece Labeled
- Nuts welded on back side of front and back hopper pieces
- Hinge tacked only in place, welded fully on table
Time Estimates + Actual (Actual Work + Transition) - 2 People
Note: Write down time taken to do step + transition time and any optimization notes
- Setup - 30 min
- Marking - 30 min
- Cutting - 30 min
- Tacking hinges in place - 10 min
- Punching - 15 min
- Assemble hopper and tack - 30 min
- Finish Weld - 30 min
- Mark and tack hinge to side plates
- Match holepunch with 3/4" bit
- Weld nuts on the back of rear and front hopper sheets (88, 89 -> 88', 89')
- Assemble and clamp bolted on sheets - permanent weld to side sheets (87->87')
- Grind off tacks and bolt through
- Cut 4 frame members
- Cut sheet metal pieces- just long strips - just long ones so we make bend by welding
- Tack and match drill hinge supports
- Tack and match drill soil deflector strips, label soil deflectors
- Weld nuts on back - 3/4"
- Cut grate members
- Weld grate members
- Hole spacing for hinges is in middle of frame
- 20" hole spacing - hinges
- 27" hole spacing - vertical supports
- 2 vertical supports are cut - one is 3", and other is 6" wide
- Hole for vertical supports is 1.5" off top, 1" off edge
- Corners ground for safety
- Cut sides (1/4") and interface plate (1/2")
- Build interface plate first - weld 4 pieces
- Hole punch 4 holes
- Do not go further until the frame is complete
- Match drill 4 holes on top of frame
- Finish saddle: weld 4 nuts first, then weld sides
- Work with interface plate ONLY to match drill holes on top of frame while clamping interface plate on.
Main Cylinder Fabrication Diagram
Arms + Legs
- Cut arms to length - torch
- Weld on tube holders
- Holepunch (or mag drill) Primary Arms only
- Match torch all of secondary arms and connection to frame
- 6' length +/- 1/2"
- Grind corners for safety
- 27" off end and 10" space for main frame assembly
- 2&4" for secondary arm mount
- Grond holes for spatter
Drawer + Drawer Rollers
- Shear all metal on ironworker
-  1/2"x5"x6"
-  1/2"x3"x5"
-  1/2"x3"x3"...
- Begin welding belly-up: base (73) + press chamber (both of 76) + mid crosspiece (176) + outer crosspieces + at end do sides (72) + close with back (75) in that order for acccess to welding.
- Cap with 74
- Weld on rear 77, then eyes (78)
- Finish with rails