Tues Apr 24, 2018
Progress on correcting the BOM
with the prior discussion on software tools integration websites etc. I was thinking of https://www.wevolver.com/projects again and it looks like the site is slow to progress, but I think the v2 with versioning is a new concept there. Wevolver essentially looks like an attempt to create a closed source web interface for online collaborative engineering. It is interesting to imagine what could be done with an open source version using all the open source software tools.
Mon Apr 23, 2018
Looking at what pipe fittings can be used to mount through the tank wall to clarify the BOM and fix the CAD. I was thinking about this differently before in tank plumbing to prevent air entrainment. The photos of prior builds show the elbows welded to the inside tank wall, which means nipples must thread through the wall into those. With 1/4" plate and ~3/4" of thread length question is will a 1/2" thread contact seal ok. Cheap black iron pipe can be used in the tank, but corrosion resistance is important outside.
https://www.zoro.com/zoro-select-nipple-34in-thrd-both-ends-2-12in-304-714-025sgr/i/G1832257/#specifications https://www.zoro.com/zoro-select-nipple-34in-thrd-both-ends-2-12in-304-714-025sgr/i/G1832257/#specifications https://www.surpluscenter.com/Hydraulics/Hydraulic-Adapters-Fittings/NPT-to-NPT/NPT-Male-to-NPT-Male---Hex-Nipple/3-4-NPT-Hex-Nipple-9-5404-12-12.axd
Fri Apr 20, 2018
I watched the Thurs meeting.
I'm prioritizing rectifying any difference in the PC v17.11 BOM (copied form v17.10) with the Power Cube Conceptual Design in order to make sure some of the final plumbing parts are correct before I draw/assemble them in CAD.
Sat Apr 14, 2018
A priority change I think could be better with the documentation is potentially eliminating or reducing the importance of the VBOM's by replacing them with more the accurate CAD diagrams and BOM's generated from those. The VBOM concept seems useful as scratch pads for developing layout and general interconnection of components but tends to lack detail and the files are harder to keep up with requiring more editing time. In general, it is another separate layer that needs to be updated frequently.
Potential tools like OpenPLM need to be reviewed again and if not up to standards new code development would be beneficial. Coding tools like Work Benches to reduce the overhead between design and documentation will result in more productive focus in the long term. Developing good tools now is important. Finding more developers interested in software should be easier than some of the other development team needs.
Getting the documentation methods streamlined will help speed development. There is a lot of instruction and text on the wiki and whether it is up to date or not it is so much it will always be difficult to follow guidelines for new and old developers.
I've just noticed the updates to FreeCAD. It looks like 0.17 is official now. I liked a lot of the new features I saw in 0.17 before and I hope the transition is smooth.
Another documentation file related issue is the Development Template Simple version is shorter, but still has many other sheets in the workbook this is making it slow to load. Lots of useful looking sheets, but if they aren't being utilized extensively they might as well be separated into other documents.
Figuring out changes to docs.
Updating the VBOM and BOM for PC v17.11 I'm not finding ideal cheaper solutions for cutting pipe nipples in half like https://fastfittings.com/products/1-inch-npt-lead-free-brass-nipples compared to the previous hydraulic nipples such as https://www.surpluscenter.com/Hydraulics/Hydraulic-Adapters-Fittings/NPT-to-NPT/NPT-Male-to-NPT-Male---Hex-Nipple/3-4-NPT-Hex-Nipple-9-5404-12-12.axdadded image
Tues Apr 10, 2018
Given likely slight changes in the BOM's etc. I think it easier just to make copies so they are ready to edit correctly. In fact, Iimportance'm thinking it will be better just make a copy of an entire "package". That being a google doc's folder and/or wiki pages template code etc. Unfortunately, even if an entire folder of gdoc's for a particular project can be copied and edited they still need to be published individually on the wiki.
When copying docs they also need to be labeled clearly as such somehow until edited differently from the previous version.
embedded new copies of docs to Power Cube v17.11
and to Power Cube v18.01
Sat Apr 7, 2018
Reviewing Development Template use for burndown charts. Currently, the burndown charts show work as mostly incomplete, which is not the case.
Some of the old files like BOM's and VBOM's appear ok, but there could be small changes or less purchases for certain items if parts are replaced with other off the shelf or shop fabbed parts. Many of the additionally needed links to work in the development template will be to future work such as the CAM and cut lists. Others like software appear unnecessary.
Tues Apr 3, 2018
Looking at OSE pipe workbench OSE piping workbench. I see a few examples with more detail to the pipe fittings like the NPT style. It would be nice to differentiate visually in case a project contains both PVC with a smooth injection molded look or metal cast with thicker ends like NPT. I see some info about color so all PVC could be white unless some other color coding is desirable for assembly. I've been curious how the flamingo code draws the parts to some extent. I'm guessing it uses underlying FreeCAD code and is less similar to OPENSCAD in that it draws sub-parts and effectively assembles them into a compound.
Updated OSE Pipe WB and reviewed the files and structure. I see DXF's that look like they are being referenced for the base shapes and the CSV tables for dimensions and angles. Testing the create elbow dialog just seems to create Base->Sweep, Trajectory, and elbow_group folder.
Mon Apr 2, 2018
The elbows are designed with longer sweeps than standard parts such as on McMaster-Carr https://www.mcmaster.com/#44605k114/=1c5lahe There are different ways, possibly simpler to shape more accurate since the sweep was hard to work with. The loft tool may be easier, although positioning the end rings relative to one another via constraints seemed infeasible, but maybe hidden primitives could be used. Redoing these doesn't seem like a priority currently.
constrained in 1/2" elbows and pipes on return lines in the tank.
More significant prioritization needs to be given to the file management, documentation, wiki, and process so that the burndown and other data collection works correctly. The template and files really need to be done first and prioritized over getting work done so the order of work operations is correctly organized and processed for the burndown.
Tues Mar 27, 2018
resizing 3/4" elbow to 1/2" for the majority of returns into the tank.
Sun Mar 25, 2018
In order to do the plumbing inside the tank, I searched for CAD for elbows to use as a reference to create an editable FreeCAD version. The sweep util was giving me some trouble, but I think I have nearly solved it.
Assembled the 3/4" elbow and a pipe into the tank on the filter return.
Tues Mar 20, 2018
Looking at burndown chart situation. Definitely a need to add chart creation as the first task when starting a new project.
added template for LifeTrac v17.10
edited Power Cube Conceptual Design to add info on elbows and pipes inside the tank for return lines to prevent air entrainment.
The inner tank wall will probably need a little rework to make sure the elbows weld on the inside good and the pipe nipples thread through the tank wall into them easily.
Sun Mar 18, 2018
Busy lately with spring coming. Looking at the oil filter assembly position it seems to clear the frame sufficient to rotate 360 degrees so it can screw on over 3/4" without hitting the tank wall.
I adjusted constraints on the plumbing fittings to realistic estimates for threading depth and added a 3/4" pipe piece for the filter input.
Plumbing details are mainly what is left in the PC CAD itself. I think drawing and adding 1/4" FPT parts for the quick couplers on the case returns, the pump fittings and checking the cooler fittings are obvious next CAD steps.
Tues Mar 13, 2018
started to prepare for meeting and my internet went down. Checking current meeting docs.
Sun mar 11, 2018
editing the tank wall plumbing holes keeps altering the way the constraints work. Errors result after and resolving has tended to result in incorrect assembly. Redoing more constraints seems to have improved constraint function now though.
I reassembled most it with new constraints, edited the inner tank wall and added holes for the smaller case return lines. I also started using some different plumbing parts and sweeps representing hose to visualize arrangement.
It looks like the harder hose connection might be the suction line to the pump in the main PC, since it is short and needs to bend alot or loop around a bunch of other connections.
made tank filler and breather cap based on welding 2" NPT over 1.5" NPT with a screw cap on the 2".
Need to consider angle of operation on slopes for spill over and fill level. Breather section of cap may need to be taller. I'm also thinking the filter will go in the 1.5" section below the breather part for smaller print and so it is closer to the tank, although this still doesn't seem to like it would allow for overfill visibility.
I added more plumbing fittings to the suction lines on the ball valves then added some sweeps for hose examples. I also added the 1/4" NPT pipe sections for case return lines and constrained those. I made and added the engine rubber feet as well. Everything seems to be constrained ok.
Reviewing Power Cube Conceptual Design to double check anything else easy I'm missing. There are still a few possible tweaks to frame size and assembly for ease of construction and plumbing.
The overall assembly and interconnection of cubes onto the LT will need more consideration as well.
Sat Mar 10, 2018
updated inner tank wall plumbing holes into a staggered pattern to test arranging plumbing.
editing the inner tank wall again mixed up the constraints on the PC differently this time. It insisted on deleting a main engine constraint and then solved the plumbing and hole constraints correctly, but pulled the frame apart strangely. I do not see the underlying causes of this behavior, but it is not entirely inconsistent.
Sun Mar 4, 2018
adding a burn down appears simple, but requires an admin login to OSEDev and the spreadsheet cell total ID from the URL's below.
I removed the extra crossbars from the bottom plates.
Editing the tank wall hole positions is proving a little harder with a more complex pattern needed. I think a redesign of that sketch is in order if possible. But, to contrain the plumbing the holes will just cause issues so constraining from the edges and just doing some math to position each part should work better.
Tue Feb 27,2018
Thinking about the power cube hooks and balance for lifting I'm wondering if a third hook point is needed or at least some consideration for weight.
Edited the ball valve for a 90 deg handle option to aid in more detailed plumbing arrangement.
Updated Small PC with latest version of single stage pump-engine module.
Sat Feb 24, 2018
redrawing PC top plate with hook points sill needs to include tank top.
I've had some issues getting that sketch to constrain that I'm not seeing immediately. There are many small parts and details yet to be done from the basic concepts, but after seeing how the plumbing fittings unconstrain to the holes everytime that is changed and how many edits I keep having to make to the frame I think prioritizing doing the plumbing by the numbers (maybe with constraints to edges instead of holes) will be the next best step since the plumbing could create a need to adjust the frame slightly.
I lost time on the top plate sketch due to stray components I didn't know were there. Finally, redrew it better and found them in the process.
I re-added the engine-pump module and put ball valve clones on the suction outlets. Clearly, the handles will be a complex alignment issue and it is hard to know ideal pattern without also knowing hose positions. Best guesses can be made and handles cut off, but clearances for getting vice lock pliers on to the handles would be needed anyway. It may help to make a closed version of the ball valve. The bottom plate also needs to be edited for strength and possible turning the handles downward below the cube.
Wed Feb 21, 2018
added shaft coupler into engine coupler pump module.
Tues Feb 20, 2018
detailing single stage hydraulic pump to update engine-pump module and to check more possible frame adjustments.
simplified the LT with the PC's for checking position options.
added ports to single stage pump File:Hydraulic Pump.fcstd
edited engine coupled to pump module.
edited coupler to add 1/4" key under set screw on 1" engine shaft end and reduced 9 spline pump shaft end to 5/8".
Mon Feb 19, 2018
reviewing needed changes and more models of ball valves.
created ball valve from references of with NPT size of 3/4". This should be easily scaled to 1" as well. File:Ball Valve 0.75in NPT
Not a perfectly editable workflow, but easily modified to 1".
added some hook points for hoisting auxiliary PC.
Thurs Feb 15, 2018
checking the pump-engine distances and simplifying the power cubes for checking stacking on the LT.
joined jitsi meet for call with Marcin about PC's and LT v17.10.
Lots of details to update. Vent Cap assembly, suction line 1" ball valves, add four 1/4" case drain returns, re-arrangement of all holes for lines, single stage pump is about 1" shorter, filter adapter needs clearance perpendicular to pipe (~4" diameter?).
Power Cubes do not fit well on LT. There is only 32" width between the LT frame. It would nice if the PC frame could be narrowed, but the cooler configuration currently prevents that.
Tues Feb 12, 2018
Still working on a few pipe fitting details such as making CAD for 3/4" NPT pipe section for hose suction lines. Overall the next details are related to ergonomics or logistics of use on the LT. Therefore I'm looking at connections and common accessibility needs such as fueling and engine control. A rail system or bracket structure for mounting on the LT may increase modular usability but adds complexity overall. How heavy is a main PC and a auxiliary? Can two strong humans lift the main cube up on top of the others without another machine to assist?
There are also still measurements needed to verify extents such as the engine-pump module height and length.
getting a bug constraining the red color-coded 3/4" NPT pipe sections
Planning to meet with Marcin on power cube stacking logistics for LifeTrac v17.10 on Thursday evening at 6pm CST.
http://opensourceecology.org/wiki/Power_Cube_v17.08#Other_Parts The pump in the current CAD is the two-stage log splitter pump, which was never used. The correct one is probably File:Hydraulic Pump.fcstd or something close enough it can be edited to match.
I also see a few errors in the vBOM's showing incorrect pump kits.
I created a section of 3/4" NPT pipe for the 1" suction hoses to attach to and added it to the Hydraulic Part Library (redirected to Hydraulic Fitting Library probably named so for less generality) File:0.75in x 1.5in NPT suction pipe.FCStd
updated File:3Quarter NPT Hex Nipple.fcstd to standard NPT dimenions and larger hex nut specs that appear more accurate.
I resolved the FreeCAD constraint bug for the fittings. It was a pre-existing solver issue probably due to editing something like the tank wall holes. File:Powercube v17.11.fcstd
I edited the File:Hydraulic Pump.fcstd to fix a glitch and check the measurements. The extents seem close, but the corresponding axis for the magnitudes listed were never clear until the 8" measurement. So I increased the body length to 5.125, the body width needs to be increased to 4.5 square. This will require a significant re-edit on the sketch, which currently doesn't appear to line up with that given the bolt pattern.
Sun Feb 11, 2018
Looking for more specific dimensions for fittings I'm finding it hard to find similar versions of the NPT to hose barb adapters on McMaster-Carr. They stock the more complex expensive types compared to the surplus center parts. Different types and materials may be close but have slightly different shapes and thicknesses. The most important dimension is the NPT end for the CNC hole cut, which should be an easy standard to work around. Also, the 3/4" pipe method is cheaper than buying adapters so I'm assuming the 3/4" NPT nominal OD pipe size + 1/8" is a good hole size.
1" NPT to barb https://www.mcmaster.com/#5363k73/=1bj2lm6
3/4" NPT to barb https://www.mcmaster.com/#5363k72/=1bj2p8x
1/2" NPT to barb https://www.mcmaster.com/#5363k71/=1bj2tdu
Sat Feb 10, 2018
corrected engine-pump module with updated coupling parts
added shorter engine pump module to both versions of PC and corrected tank hole sizes on main PC. sizes should be close, but will further verify OD of 3/4in pipe for the 1" suction lines.
Tues Feb 6, 2018
catching up adjustments on PC CAD parts.
File:G22 Hydraulic Pump coupler sleeve.FCstd The flange patterns need further adjustment, but the current fits the CAD so it must be close.
File:PC 1708 coupler.fcstd shortened length to 2in as best guess given measurements of sleeve and shape of engine in CAD.
File:PC17.11 auxiliary.fcstd adjusted grate/mesh, cooler and mount holes.
adjusting PC v17.11 outlets and inlets/outlets. The VBOM's for 17.08 and 17.10 have some differences in nip and barb sizes and part links as well as 17.10 suggesting 1in instead of the 3/4in in 17.08.
Going with 0.5in for returns except the 3/4in needed for the filter.
The File:3Quarter NPT Hex Nipple.fcstd fitting CAD size is not actually 3/4in and requires editing.
File:Powercube v17.11.fcstd updated with 1/2in nips for ports except the 3/4in part redraw for the filter.
Wed Jan 31, 2018
I got a little lost because PC v17.10 has no CAD file. I think some things got lost over the holidays and with the MC build. As I recall PC v17.10 was built around or after the MC build and a newer modified version of PC v17.08.
Tues Jan 30, 2018
May need some good measurements and a better idea of PC interconnection on LT for adding finishing details to PC's.
Searching for CAD models for fittings before drawing from scratch...
Clarifying Auxiliary PC version as Power Cube v18.01
The engine-pump coupler needs to be adjusted to 3" long x 2.5" OD. I assume the shaft coupler also needs editing. The accuracy on this matters since it determines the total distance needed for the cube frame. Currently the gap between the tank and pump back end is narrow, this should help increase that or even allow the cube frame to be shortened ~3" wasting less metal.
Mon Jan 29, 2018
Reviewing plumbing parts on previous PC's CAD, BOM's, and Part Libraries in order to check what I'm should be adding into the holes in PC V17.11.
PC v17.08 uses File:Barb to nptm.stp But a Note says: Initial upload is 3/4" barb. We need 1" barb for Power Cube v17.08
So, I'm thinking a redraw is needed as I don't see a 1" barb. I'm thinking the STP's are from McMaster-Carr though...
1" seems necessary given the volume of flow and amount of hose needed (and therefore friction) with the modular design. BOM for 17.08 has 3/4 hex nip. I'm guessing these are what is easy to weld in.
Nope, 17.08 and 17.10 VBOM's suggest: 1” NPT welded-in barb http://www.surpluscenter.com/Hydraulics/Hydraulic-Adapters-Fittings/Hose-Barbs/Hosebarb-to-NPT-Male---Straight/1-HOSEBARB-TO-1-NPTM-ADAPTER-4404-16-16-9-4404-16-16.axd
https://en.wikipedia.org/wiki/National_pipe_thread effective thread diameter is about 1.25", but I'd guess for easy fit and weld that 1.3" is tight for the CNCed holes.
I'll have to review media for comments on sufficient size for return lines. As I recall one return through the filter is sufficient, so probably just multiple return holes for 3/4" fittings.
3/4" NPT OD is just over 1.001", so more return holes need added and all adjusted to ~1.1"
Sat Jan 27, 2018
working on adjustments moving the cooler to the front requires since it changes the engine position. There isn't a lot of clearance at the front or back of the engine-pump assembly, but I think that is ok. Optimal positioning of cooler in front of the engine is also not exactly clear, but minor adjustments can be made as needed. The bottom plate engine mount point has to be moved and that is a good time to add the bolt holes.
Continuing to add details to PC. There are many holes and to add for bolts and piping yet.
added holes for bolts on the front of PCv17.11 and created an editable inner tank wall with holes arranged for plumbing.
I just realized the front mesh grates may need to be halved for access to engine throttle etc. relative to ideal cooler placement. Bolt holes will need adjustment as well.
Tues Jan 23, 2018
Meeting prep. Measurements are likely needed to verify some details still. Next main details are plumbing. Verifying specific parts are accurate enough in CAD and adding to the hydraulic plumbing library will help overall.
Sun Jan 21, 2018
edited grate and added to File:Powercube v17.11.fcstd
Sat Jan 20, 2018
trying to edit details into power cubes. getting some FreeCAD crashes. Added Grate from PC v17.08 to auxiliary, but needs more editing.
Still looking back through PC BOM's for rubber feet. PC v16.8 looks like the earliest version with a similar engine, but an order of rubber feet could have been for any previous engines as well.
Reworked grate to mesh and positioned it in the auxiliary CAD. The mesh is larger in data size and unnecessarily complex.
Wed Jan 17, 2018
Looking at previous PC CAD and BOM's to check for missing parts and the correct fittings for the tank and other plumbing.
Tues Jan 16, 2018
I'm still attempting to constrain engine pump module in auxiliary PCv17.11.
I am concerned about FreeCAD methods and the easy editing of the files because the process has become more complex and likely not clear to others possibly including team members familiar with freecad. There are instructionals, but the process is not linear or straight forward and bugs are still an occasional problem. The logic to avoiding the bugs or correctly using the constraints is some complex decision tree I'm not sure is thoroughly documented enough anywhere other than maybe the underlying code. This is one reason I plan to start going through a Python course again soon.
Still many details to create for the PowerCubes engine feet, holes and fasteners, plumbing fittings, hose representations, cooler screen.
added Hydraulic Fitting Library and links between PC Library and specific versions.
Not seeing the rubber feet in any PC BOM's back to v16.8, but I found an editable grate/screen to adapt File:PC 1708 Grate.fcstd.
Mon Jan 15, 2018
Attempted to constrain the engine pump module into the Auxiliary PC as well, but I'm getting more bugs with it. I think it is not constrained as well as the main PC somehow. It also was not positionally correct due to the cube size difference, although the auxiliary is a derivative file of the main PC some changes or references in the copied data are causing issues. It would be good to understand what process mistake was made.
Fri Jan 12, 2018
In trying to edit the engine assembly and add the coupler sleeve I've found it is missing from assemblies all the way back to PC v17.08. This also highlights the need for clearly organized modules in the wiki PC Library. So, I think correcting the final assemblies and then separating the engine, shaft coupler, and sleeve coupler parts into a module would be ideal. It also begs the question if the CAD for the sleeve coupler is correct and how that worked out on the previous PC's. It does not appear in the PC v17.08 photos.
I keep running into bugs/crashes with the constraint solver attempting to assemble the sleeve coupler into the PC v17.08 master CAD file. Creating a separate module and reassembling later may work better.
Thurs Jan 11, 2018
I had an issue with Ubuntu after reboot likely due to a failed update. I followed iunstructions for the issue using a boot stick to run apt update and upgrade. Realizing my stick was probably out of date still I'm trying new versions of OSE Linux.
Corrected the cooler positions in PC. I moved it to the front bottom right for air flow off the fan in the pull start. I also noticed the File:G22 Hydraulic Pump coupler sleeve.FCstd was not included. I tried adding this for visualizing possible ducted fan designs using this part. However, further adjustments need to be made to the original engine pump coupling or length of the sleeve.
Tues Jan 9, 2018
Reviewing Power Cubes, LT, wiki, and YT for meeting @2PM CST.
Reviewing old photos from 17.08 to try to see where exactly the air mover or fan is on the engine is to be used for cooling. https://photos.google.com/share/AF1QipMNKx0q8K3oWrlxlHi5A8qXvXVFdfrPtYv50ekm-UBXjsDltGRNf8OGkYdL5nwI2A?key=UU9mRlludWlfVkhUNVRFdTlOSGl0NEo5NW9zS3d3
From experience, I'm thinking there is an effective fan behind the pull start mechanism. It is however at the very front of the motor and I'm skeptical it is sufficient air flow, but mounting the 1240 cooler low and in the corner near the front shouldn't interfere with the pull start.
My only other thought is integrating some kinda of fan into the engine shaft to pump adapter, but that would increase the complexity of making that part and maybe cost of materials. Such a solution could, however, eliminate the need for stock off the shelf fans in general.
Tues Jan 2, 2018
Catching up and refamiliarizing with PC.
Thurs Dec 14, 2017
cleaned log. For next year I think it will be more searchable to dump the monthly logs into one page of old logs.
adjusted some specs on pump for 17.10
I'm not sure this will be re-used for 17.11, but good to the correct for 17.10. Editing the tree on this part requires some rework, but it is simple enough. With further corrections changing the editing order or using simple component copiues with unions might be more efficient to edit in this case. Some inaccuracies in the extents, shaft, and general shape still exist since I can not find any detailed CAD diagrams from surpluscenter or Eaton.
Wed Dec 13, 2017
Back from a trip that took longer than expected. Reviewing where I am with Primary and Auxiliary PC. Ready to finish the power cubes and move on to the next thing.
Sat Dec 2, 2017
Reviewing large PC and figuring out likely dimensions for the smaller cube.
Did a quick re-edit of the Main PC for the Auxiliary smaller cube.
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