OSHW-OSE-Brick Press-Assembly

Video

Liberator CEB Press v4 Assembly. from Open Source Ecology on Vimeo.

Needs formatting.

Intro.

The Liberator is the worlds first, automated, open source compressed earth brick press. Using 20 tons of hydraulic pressure, this machine compresses construction-grade soil blocks suitable for building homes and other structures. This enables users to make cheap building materials on site, eliminating the need to buy and transport bricks, while lowering environmental impact.

The Liberator is built from of stock steel, hydraulic components and an optional automatic control unit – with a materials cost under $4000 for the fully-automated machine with hopper shaker. Steel materials require fabrication using standard tools found in any well equipped metal shop.

This video will demonstrate the correct assembly of all steel parts of the Liberator CEB Press once they have been acquired and fabricated. Hydraulic and automatic control unit assembly guides are not included in this video, but can be found on the Open Source Ecology wiki.

Disclaimer.

Before continuing, please be aware that the CEB Press is a large, heavy machine. Assembly should take place on a flat, stable surface, with constant attention paid to assembled pieces until they are secured. At least two people and a heavy duty hoist should be available to complete the assembly. If a hoist is unavailable, additional people will be required. Anyone involved in the assembly must wear a hard hat, eye prototection, and gloves to avoid personal injury.

Please exercise caution and common sense during the entire assembly process.

Parts.

First, ensure you have all parts ready for the assembly. (Introduce different parts)

Orientation

The Liberator has two ends that serve different functions. The loading side of the liberator is the end from which soil is loaded into the hopper. The ejection side is the end from which compressed soil bricks are ejected from the compression chamber. Sides of the Liberator will be referred to in this fashion throughout this assembly video.

It is recommended that an image of the assembled machine be available for reference throughout the assembly process to prevent errors.

Step 1: Main Frame Assembly.

Lay out the main frame assembly pieces on the ground. These should include:

•2 x vertical frame members. •1 x primary hydraulic cylinder •2 x cylinder mount plates. •2 x top frame plates. •2 x compression chamber cover plates •2 x compression chamber spacers

First, bolt the compression chamber spacers to the vertical frame members. Attach one cylinder mount plate and top frame plate to the vertical frame members and stand the frame up. Bolt on the second cylinder mount and top frame plates and insert the primary hydraulic cylinder with cylinder mount plate and secure with pin. Now attach the compression chamber cover plates.

This completes the main frame assembly.

Step 2: Base Assembly

Clear an open area and place the 4 legs in the 4 feet. Next insert the legs into the outer leg holders on the secondary arms for the loading side and ejection side of the machine. Note that placement of the secondary arm with the central welded tabs dictates the loading side of the machine.

Next, attach the primary arms to the secondary arms. Ensure the mid-way bolt holes on both primary arms align. Be aware that the position of these aligned mid-way bolt holes must be biased towards the ejection side of the base assembly.

Use a hoist to lower the main frame assembly between the primary arms. Ensure the main frame assembly is placed by the mid-way bolt holes on the primary arms, with its width parallel to the primary arms, so the base assembly can be raised around it.

(An alternate procedure is to attach only one primary arm to the secondary arms, raise the 3 arms to the required height, shuffle the frame assembly into place (this avoids the need to use a hoist in this step), and then attach the remaining arm around the frame.

Now raise the base assembly up the legs so the mid-way bolt holes on the primary arms rest just above the bolt holes on the compression chamber cover plates on the main frame assembly. It is important to tighten the bolts in the leg mounts firmly before proceeding.

Now pivot the main frame assembly so the bolt holes on the compression chamber cover plates align with the four mid-way bolt holes on the primary arms. Bolt these together securly.

Next, mount the drawer into the main frame assembly (such that the 1”x3” rail ('arm') is up). (Orientation to be added). Now attach the base of the secondary cylinder to the central welded tabs on the secondary arm on the loading side of the machine. Attach the piston of the secondary cylinder to the tabs on the drawer.

Now attach he 4 cam roller assemblies to the primary arms. Slide each of the 4 arms of the drawer onto a cam roller and secure (the cam roller assemblies) to the primary arms. (Note that you move the drawer into place, and then you place the cam roller assemblies under the arms of the drawer, and slide the roller assemblies as far as they go under the arms)

This completes the base assembly.

Step 3: Hopper Assembly

The main body of the hopper is assembled from four triangular pieces of steel plate fastened together with steel hinges. To assemble the hopper, lay the four pieces on the floor, and bolt them to the hinges as demonstrated. The flat rear of the hopper and angled front will be referred to as the 'rear' and 'front' of the hopper.

With the assembled hopper on standby, mount the hopper seat on top of the main frame assembly. Ensure the angled edge of the hopper seat is facing the ejection side of the machine, and bolt securely into place.

Next, mount the 4 hopper support holders to the primary arms. Of these supports, there are 2 rear support holders and 2 front support holders. Mount the 2 rear support holders so they are directly adjacent to the main frame assembly on the ejection side of the machine. Please note that the cam rollers on the ejection side should be mounted just after the rear support holders. The front support holders should be mounted on the loading side of the primary arms. Keep the four hopper supports on standby near the assembly.

Now we're ready to mount the hopper into the hopper seat. Using a hoist, raise the hopper and lower it into the hopper saddle, ensuring the angled side of the hopper is facing the loading side of the machine. While continuing to support the hopper in the hopper seat with a hoist or a dedicated person, mount the two longer rear hopper supports into the rear support holders, ensuring the welded bolts on the rear hopper supports are facing outwards. Bolt the rear hopper supports securely into the rear support holders, then bolt the rear hopper supports to the hopper. Once all bolts are securely tightened, the two shorter hopper supports can be mounted to the front support holders, ready to be connected later.

Step 4: Grate Assembly

The grate hinges attach the grate assembly to the top of the 4 hopper supports. Note the subtle differences between the grate hinges, and how their bolt holes align with bolt holes on the grate and hopper supports. Ensure the correct hinge is designated to each.

Mount the grate hinge designated to the rear hopper supports to the grate. Take the remaining grate hinge and secure it to the ends of the shorter two hopper supports, ready to be attached to the grate later. Now use a hoist to raise the grate above the hopper and bolt the rear hopper supports to the grate assembly via the grate hinge.

Now attach the front soil deflector to the loading side of the grate. This should be bolted securely between the grate and the remaining grate hinge. The four hopper supports should now all be supporting the grate. Now, bolt both side soil deflectors to the hopper.

Finally, mount the shaker assembly to the rear hopper supports.

Your Liberator CEB Press is now complete.