Yoonseo Log 10 2012
- 1 October 2012
- 1.1 31/10/2012
- 1.2 30/10/2012
- 1.3 29/10/2012
- 1.4 28/10/2012
- 1.5 27/10/2012
- 1.6 26/10/2012
- 1.7 25/10/2012
- 1.8 24/10/2012
- 1.9 23/10/2012
- 1.10 22/10/2012
- 1.11 21/10/2012
- 1.12 20/10/2012
- 1.13 19/10/2012
- 1.14 18/10/2012
- 1.15 17/10/2012
- 1.16 16/10/2012
- 1.17 15/10/2012
- 1.18 14/10/2012
- 1.19 13/10/2012
- 1.20 12/10/2012
- 1.21 Thu Oct 11, 2012
- 1.22 10/10/2012
- 1.23 9/10/2012
- 1.24 8/10/2012
- 1.25 7/10/2012
- 1.26 6/10/2012
- 1.27 5/10/2012
- 1.28 4/10/2012
- 1.29 3/10/2012
- 1.30 2/10/2012
Ordered fittings for water infrastructure, screws for CNC Torch Table
Cold Saw Test 3- clean cut, successful automated cooling, lots of vibration.
Kdenlive Codecs Troubleshooting -
Mpeg-4 Resolved. Installed the mp3 encoding library "lame" using synaptic package manager, then opened kdenlive and went settings>run config wizard, then was able to render in mpeg-4.
Installed libavcodec-extra-53 and reran kdenlive config wizard and further render options enabled.
Ordered 4 welding helmets from Harbor Freight- http://www.harborfreight.com/blue-flame-design-auto-darkening-welding-helmet-91214.html
Ordered from Mcmaster-carr:
T Slot Cutter: 8789A12
Reduced Shank Endmill: 8827A19
Roughing Endmill: 8817A52
Touch-Safe Terminal Block: 7618K618
Terminal Block: 7527K53
Organized Workshop - deployed more tables, mechanical assembly of cnc torch table almost complete - awaiting screws to be ordered.
Troubleshooted plasma cutter - it works! Changed control connector to more compatible interface.
Realized tripod is absolutely necessary to take video because 1 handed everything just doesn't work. For the same reasons, flashlight mount is crucial for nighttime work; headlights interfere too much with welding helmets and such.
Designed flashlight mount
OSE general topic meeting
Organized workshop, fitted flats in cnc torch table
Welding woes... TIG welder does not work even with the 2% lanthanated tungsten...
Designing Boxed Way
Fixed tractor hose leak.
Boxed Way Fabrication Preparation
Boxed Way Way-to-Base and antifrictionmaterial-to-saddle info acquired. Blocks - iron supplier and machined leadscrew supplier...
Finished up installation of stove. Review and modifications in progress- sealing all top gaps and replacing front door mechanism with hinge + latch.
Workshop Tools for hardware transparency and ease of analysis.
With Aaron: picked up Gabrielle from bus station, acquired some winter gear, acquired Fairshare Farm food.
Wood Stove Deployment Run, Day 7 with Aaron. Installation almost complete (flue pipe hole needs to get cobbed up some more). Tested with big fire in stove. Success - flue has no leaks. Near complete combustion. However... chain handle is dangerously close to front panel (<1") at 100 degrees celsius (water boiling point)- burn hazard. Front panel acting as door is difficult to open- non-ergonomic. Leaks in top panels and front panel causing great smoke especially during the fire startup process before a draft is created. Rebar damper gets too hot to touch- safer damper handle necessary; damper placement could be better, placed to the side of the stove instead of over the top panel. But... the fire burns, the thermal energy radiates. Warmth!
Analyzed inverter electronics - we are much closer to the universal power supply (any input, any output) than we previously thought.
Deployed more tables in workshop and organized tools for superb accessibility during production runs and open tech development.
... accidentally erased the latter half of the stove pictures in the camera... darn...
Ordered sheet metal power shear
Contacted Gilman USA about way-base adhesion
Updated boxed way diagram
Wood Stove Deployment Run, Day 6 with Aaron. Flue fabrication complete. Installation in progress.
Plastic welder test. Success.
Inverter Control Waveform Diagrams
Ordered Copper Clad Board
Wood Stove Deployment Run, Day 5 with Aaron. Got all the materials from Sweiger, established full design, completed long assembly.
Inverter documentation with Aaron.
Workshop organization. Deploying lots of tables.
Ordered aluminum rods, tubes, bars.
Ordered bench grinder.
Discussed budget creation process with Aaron Budget Creation Process
Laundry and food trip.
Ordered various fulcrum hand tools.
Wood Stove Deployment Run Day 4 with Aaron. Took lots of pictures and videos. 400MB+!. Spent lots of time designing and preparing fabrication and looking for tools that we didn't find after all. Time for technological saturation. Quality tools will always save the day. Bad tools, no matter low prices, are super-expensive in practice... but not having tools is worse.
Time to order some more tools and materials... Metal protractors. Bronze rod.
Received C Clamps and Tables
Replacing back wall of chicken coop with Parker
Wood Stove Production/Deployment Run Day 3
Received and deployed digital camera
Ordered AA Battery Holders
Fablab Tool Organization
Searching for a leadscrew and leadscrew nut supplier that provides end machining services
Tested Geiger Counter
Sent torch table pictures to Chuck Harrison - Internet connection timed out, resending in multiple emails... Success,
Ordered more tables. Extremely useful.
Researching animation software...
Responded to Kevin Harrington (Kevin Harrington at Neuron Robotics)
Received batch of shipments
Wood Stove Production Run Day 2
Trying to install screencastor... Success. How about also XVidCap?-Marcin --- screencastor is just a screencapture GUI for ffmpeg and ffmpeg is much stronger (more configurable, more codec support, higher max video quality) than xvidcap-Yoonseo
Researching shaft coupling type between leadscrew and stepper motor. Flexible couplings (helical slit type) used to accommodate slightly misaligned shafts.
Requested 5618L-54P stepper motor quote from Lin Engineering
Learning with Aaron about plasma cutting- Everlast PowerPro 256
Setting up FFmpeg as screen capture for video recording of desktop
Pre-Production Run Preparation for Wood Stove with On-site Team
Wood Stove Production Run - Learned how to plasma cut!
Ordered welding magnets
Installed Cinelerra and Kdenlive
Starting Google Sketchup
Ordered self-adjusting clamps and pipe clamps
Troubleshooting internet - testing wired connection to router.
Mechanical diagrams for CNC Circuit Mill
Ordered plastic welder
Contacted flexsoundproofing for free welding screen sample.
Acquired food and cast iron kitchenware with Aaron and Parker
Discussed OSE Specifications with Aaron
Called Everlast for TIG Welder troubleshooting - pure tungsten is not compatible with inverter welders' square waves and must be replaced by lanthanated or ceriated tungsten
Ordered 2% Lanthanated tungsten 3/32" x 7"
Tested TIG welding steel to some success with pure tungsten.
Ordered wire brushes x3
Ordered tables x2
Internet soooooo slowwwww... Efficiency at <10%...
When getting any portable, data-focused electronics (meaning you need energy storage and data storage), consider the following 3 factors to be the most important:
- Uses common replaceable batteries. Ex. AA batteries. Necessary for ease of continuous use (otherwise it will sit collecting dust, you never having the time or money to spend on getting another proprietary battery; also makes charging/having extra charged batteries much less of a hassle).
- Uses common data storage cards. Ex. SD cards. Necessary for ease of compatible use. Last thing you want is to be unable to transfer your pictures and videos to your computer.
- Is rugged! Expect falls and pressure, immersion in water, extreme temperatures, and more.
Ordered SDHC card 16gb
Ordered many AA and AAA batteries Enerloop Batteries
Ordered Smart Battery Charger
Completed Thiel Fellowship review session
Ordered wire strippers, welding gloves, work gloves
Mechanical diagrams for CNC Circuit Mill
How to connect two shafts together - use shaft couplings. A shaft coupling has 3 main considerations: how does it connect to one shaft, how does it connect to the other shaft, and how does the coupling connect in the middle? Shaft connection-wise, unless a weld is made (molecular bond between the coupling and shaft), either setscrews are used to tension down on the shaft, OR, a screw is tightened on the wall of the coupling to clamp the coupling on the shaft.
Based on everything I've learned so far about precision machine design: Precision Machine Design Tips
Preparing for Thiel Fellowship review
Recoveredering from minor sickness
Troubleshooting internet slowdowns - Tomato Wikibook - Success!
Winterizing, organizing, cleaning Hablab with others. Great results.
TIG welder argon flowing! Solution was to use hose clamps on the regulator barb and machine barb.
Huge C Clamp order.
Successfully troubleshooted hablab internet system
Oscilloscope on Arduino with Direct Digital Synthesis
Acquired tungsten rods and foods
Prototyped and documented Light Screen
Continued setting up TIG welder - argon not flowing?! - ah read the manual File:TIGTorchmanual.pdf and should try adjusting the knob of the regulator with a wrench.
Ordered 3/4"MPT to 3/4"FPT Lead-Free Brass Elbow
Ordered Geiger Counter after thoriated tungsten spook
Thu Oct 11, 2012
Inverter Development - Extent of Arduino's Functions
Successful materials for Light Screen from Sweiger Shop with Gabi
Setting up TIG welder
Pure tungsten is appropriate for AC TIG welding (ex. 99.5%+ tungsten)
Discussion with Alexander Kiselev
CNC Circuit Mill Electronics Sourcing Research - Stepper Motors
Organized Inverter development documentation
Produced and documented Terminal Block x2
Ordered more power strips and a light for the hablab
Successful food acquisition trip with Gabi, Graham, and David
Successfully uploaded GRBL to Arduino Uno R3 using Ubuntu 12.04 - followed documentation from before, adding ruby and avrdude installation steps
Successful troubleshooting of Powercube V6 with Graham - faulty relay, temporary fix with connector-to-connector switching solution
Preparation for winterizing and organizing personals.
Civ5 and starcraft LAN party. Great mental exercise- lots of information processing.
Mainly group construction work- sealing up gaps to winterize the hablab and organizing the backroom for better tool accessibility
Ordered various electronics parts for CNC Circuit Mill V2
Specifying and hyperlinking mechanical/electronics/software for CNC Circuit Mill V2
Minor revisions to documentation presentation for the electronics projects in Open Source Technologies
Research into motor selection for spindle designs at Electronics Design Info
The way to prevent premature latching on the CEB Press is to keep the hall effect sensors mounted parallel to the magnets' moving plane. This resolved all premature latching issues. CEB Press 4.0 fully operational. Optimized CEB Press Testing and Operation Code: CEB Test and Operation Code
Restocked food inventory.
Performed first aid and health operations on hurt/sick members of on-site team. Arrythmia and pre-hypertension concerns.
Improved documentation for the CEB Press
Ordered more aluminum flat bar, mainly for Terminal Block production
Resolved a broken inverter issue with Marcin by connecting the workshop grid to one of the remaining inverters. Reliability is definitely a significant design principle.
Discussed short-term implementation of forums/stack overflow-like software to help development process. 2 major factors for the success of such software identified as access and action relevance. Access made easier with invites, action relevance made easier by the right questions to prompt the right answers.
Tested the CEB Press with manual control. Teamed up with Marcin to fix some issues. Troubleshooted total non-movement by increasing up the hydraulic pressure from the powercube. Troubleshooted primary cylinder non-movement by loosening front support plate, but discovered that the real problem was a loose quick connector connection from the primary solenoid valve. Full manual control success. Back to solo work.
Tested the CEB Press with test code. Troubleshooted weird sensor-triggered movement by examining sensor analog values. So! The hall effect sensors switch and latch on and off, but electrical noise and in-circuit imperfections cause fluctuating output signals. To add to the problem, the magnetic field of the magnets interact with the sensitivity of the sensors as to cause multiple latching events when the sensor passes a single magnet!
How to make the sensors work properly?
1. Take multiple sample readings and average them into a moderated value; this will diminish the effect of short-lived extreme fluctated signals. Increasing the number of samples per averaged reading and decreasing the delay time after each sample helps, but will be limited by the processing speed of the electronics.
2. Use separate upper and lower trigger values for the microcontroller to determine when the sensor has passed a magnet. This ensures that fluctuations that pass a trigger value can be safely ignored to an extent by the microcontroller. 2 values that help determine the upper and lower trigger values are: minimum value in the high-latched sensor state and maximum value in the low-latched sensor state. If possible, have the lower triggger lower than the aforementioned minimum value and the higher trigger higher than the aforementioned maximum value.
3. Use post-latch delays. That can be as simple as putting a fixed delay after each latch-switch. This helps minimize the effect of sensor sensitivity to strong irregular magnetic fields but limits the operating speed of the sensor-controlled movement (ex. if the delay is 1 second, then the magnets need to be at least 1 second apart for the microcontroller to have enough time to pick up on the next latch point as it passes the second magnet). CORRECTION: Forget this, the sensor still latches and it's just the microcontroller that doesn't respond until after the delay. No good. We don't want the sensor to prematurely latch in the first place.
Made significant revisions to the testing code for extreme troubleshooting ease. CEB Press Test Code
Tested the new test code to success after implementing all of the make-sensors-work-properly changes. Started to revise the operation code for continuous brick pressing.
Contacted Star Simpson about inverter design topologies.
Using arduino IDE 64-bit on ubuntu 12.04 - Guide to Arduino make sure you open arduino as power user with sudo ./arduino when in the correct folder! Otherwise the serial port will be greyed out.
Hall Effect Sensor Module V2 x2 complete
- Research for choosing between rod, dovetail, or boxed way for linear guide (whoa there's V-ways and half-round ways too!) Gah I need a free download of the book "Foundations of Mechanical Accuracy"
You are not under the impression that the dovetail cutter needs to be the full width of the female dovetail are you?The cutter only needs to be as tall as the dovetail.Your remark about not having large dovetail cutters prompts my question.
Dovetails only need 1 gib
Actually the dovetail is the simpler mechanism. It is simpler to make and simpler to adjust in use. The one gib at 45 or 60 degrees takes up slack both sideways and vertically. One adjustment and you are done.
I was afraid of the results before I made my first dovetail, but it is a piece of cake if you plan it properly. The setup is the same for both male and female parts. As mentioned above, you do not use a cutter that is the full width of the female dovetail. You use a standard milling cutter to rough out the center, usually to a depth slightly greater than the actual dovetail. then you cut each side individually. The cutter only needs to be tall enough to cut the whole angle at one time.
I used a CAD drawing and placed even sized circles tangent to both the angled sides and the flat top/bottom surfaces to give me a way of measuring the width of the dovetail. You can read the distance between them off the drawing to three or four places and them use drills or ground, round stock of the same size to measure your work. Just mike between them on the female dovetail and across them on the male. Real quick way of checking your work on the mill. Of course, with a gib, you don't need extreme accuracy.
Boxed way more rigid than dovetail
Boxed way conventionally steel with turcite for anti-friction contact surface OR cast iron with oiling OR metal with high-pressure oil (hydrostatic)
Boxed way conventionally ground then scraped