Power Cube Design Sprint

Sat Aug 19, 2017 - 12 to 4 PM

See PC 17.08 BOM + Last PC Design Sprint

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Main Goal: finish CAD + Master Assembly. Fit engine, pump, and filter into frame

Design Sprint Protocol

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1. Create FreeCAD files for different parts according to Work Assignment
1. Use BOM as reference for parts
2. If parts are already created, build upon them.
3. Upload your CAD to your log
2. Enter your CAD into Power Cube Part Library
3. Please update Master CAD checklist - with your work product link
4. Insert your part into Master CAD File as soon as you have finished using the “Import a Part” tool in Assembly2 Workbench. Please verify that your part has not been imported yet.

Work Breakdown

Structure

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2. Fan/Cooler Assy

Jose

Ayo

Jozef

Will/Michel

Abe

Antonio

Alejandro/Michel

Israel

Josh

Ahmed

Fan - 23”

Pump 1

1. Frame - includes engine mount + cooler mount + battery mount

Cooler - 1268

Coupler Parts

3. Engine Assembly

Salam

6. Filter

Cooler 1240

Engine

Fan 12”

Log Splitter Pump

Finished Coupler

Log Splitter Pump Mount

4. Pump Assembly

Engine Lovejoy Shaft Coupler

Pump Lovejoy Shaft Coupler

Battery

Hose Barb, Nip Quick Coupler

Engine 7/16”x2” Bolts

Battery Bolts

Cooler Mounting

Fan Mounting

3. Battery Assy

Battery Wires

Michel

https://photos.google.com/share/AF1QipMNKx0q8K3oWrlxlHi5A8qXvXVFdfrPtYv50ekm-UBXjsDltGRNf8OGkYdL5nwI2A?key=UU9mRlludWlfVkhUNVRFdTlOSGl0NEo5NW9zS3d3

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17.5 wide, 16” deep to end of shaft, by 18.5 tall.

Big Question: How to Divide Work?

By clear definition of what’s included in each assembly.

So let’s look at the vBOM and divide from there.

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1. Frame
2. Fan/Cooler

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Build Process

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FRAME

• Cut all frame members - 7 of them
• Weld frame
• Weld fittings into reservoir
• Leak Test.
• JB Weld epoxy any leaks in frame after leak testing or use a stop-leak formula

COOLER

• Put fittings on the cooler
• Attach the fan to the cooler

FILTER

• Attach return line to return filter (in the correct orientation).

ENGINE

• Mount engine to the frame
• Mount Lovejoy Coupler loosely on shaft

PUMP

• Mount the quick coupler of the pump to the hex nip
• Screw the hex nip to the pump
• Mount the Lovejoy Coupler to the Pump loosely

PUMP MOUNTING

• Mount the pump mount to the engine
• Mount the pump on the pump mount
• Connect 2 halves of Lovejoy Coupler and Tighten the Set Screws.
• Connect the suction line between the reservoir and pump, and hose clamp the connections

COOLER MOUNTING

• Mount the cooler to the vertical supports
• Weld the expanded metal mesh over the fan side.
• Attach the return filter to hydraulic tank and attach the return line to cooler

BATTERY

• Connect charger wires to the battery and the fan wires to the fan.

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vBOM

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• ISO 7241-1 Series A quick couplers - 28 gpm - 2500 PSI
• Hose Sizing

¾” welded nip

¾”x36” NPTM Hose

Return filter

Frame-Integrated Hydraulic Tank

Engine Shaft

1” NPT welded-in barb

1” NPTM barb pump inlet

14 ga wire from engine charger

1” Suction Hose 1.53” OD

½” NPTM to ¾” NPTF Swivel

(may need 90 degree swivel if hose routing is bad)

½” to ¾” NPT Nip

Filler Breather Cap

Hose

Clamp

Hose

Clamp

2.6” wide

1.5” wide

¾” Hex Nipple

Return Line ¾” Quick Coupler

Forward Line ¾” Quick Coupler

Cooler Mounting 1

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Procedure:

1. Attach at right side of power cube on vertical bars that are part of frame

2. Use holes for mounting cooler in right frame member on inside of frame

Right frame piece

Cooler Mounting 2

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Right frame piece

1-2. Put rubber blocks in the spaces in the cooler

3. Put threaded metal insert into rubber on the engine side

4. Use bolt (with washer and lock washer) to attach cooler from the outside. Bolt goes in through the rubber and threads into the threaded insert. When bolt clamps the rubber, the rubber expands holding the cooler against the rubber

5. Now the Cooler Assembly is mounted

Rubber blocks

1

2

3

Rubber blocks

Threaded Metal Insert

Fan Mounting

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Coo

l

er

1. To mount fan, use the Fan Mounting Hardware
2. Mount fan to cooler directly
3. Simply poke the hardware through the fan mounting hole, and right through the fins of the cooler

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• Attach the soft washer on the other side of the cooler
• Attach the ‘nut’ by sliding it onto the hardware. The nut can be

attached only once, so make sure you are attaching it in the right

location on the cooler.

• Do this for all 4 mounting holes of the fan. The fan rests on the

surface of the fins

4 Mounting Holes of the Fan

Updating Assemblies via Assembly 2 Workbench - 1

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Script (see Reference from Roberto&Emmanouil’s Script)

1. Say you are a developer and you want to contribute to machine design. Say you want to help on the Power Cube.
2. Go to the Power Cube Genealogy wiki page. All OSE machines in progress should have a Genealogy that lists the latest versions. Go to the latest version, here - Power Cube v17.08
3. First, find the Master Cad in the Part Library, along with its supporting files.
4. Scroll down to the Part Library, which is a gallery of part files and their representative image. The master cad should be on top. Whoever uploaded the Master CAD should have also uploaded the editable individual part files. Download the Master CAD and the parts that you want to edit. Say you want to edit the right frame side
5. Download the right side to your desktop.
6. Open the Master CAD file in FreeCAD 0.16.
7. Open the right frame side, and edit it, for example by putting a bolt hole in it. Edit the sketch of the face to add a hole.
8. Save your file.
9. Now you are ready to update the Master CAD.
10. ...From here show all your steps:
1. Changing directory settings of source files
2. How to identify which is the base object to which everything is constrained
3. Discuss how you know that the part you want to change is fully or properly constrained?
4. Discuss how to edit a constraint

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Updating Assemblies via Assembly 2 Workbench - 2

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Continued

• Discuss: how to remove and add constraints
• Discuss: what the import button does
• Discuss: what the Animate Degrees of Freedom does and what you learn from it? It shows if something is not fully constrained, identifying the remaining Degrees of Freedom(DoF) or how many possible moving options we have for the under constrained parts. We can animate these DoF to see those possible movements that we have to constraint. -roberto
• Do we ever use Solve Assembly constraints? Yes, if we move the constrained parts, with this tool all the parts return to their original position. -roberto
• Discuss Mux this tool can be used to create modules in the Master CAD, For ex: to avoid importing and constraining 4 times the parts for the legs in the CEB Press. With the Mux tool we can assemble only 1 leg and create 3 other modules (muxedAssembly objects) for the remaining legs. Another ex: in the Tractor Master CAD, the Power Cubes will be imported as modules (muxedAssembly objects). -roberto
• Discuss Check overlap
• Do we ever use Bolt Multiple Circular Edges?
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• Frame

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1. Has built-in reservoir
1. Reservoir has filler; suction fitting; return fitting
2. Engine mounting is part of bottom piece of the frame corresponding to engine bolt pattern
3. Cooler mounting is 2 vertical bars on right frame piece using cooler mounting hardware
• Rubber blocks of cooler mounting hardware attach to vertical bars
• Fan attaches to cooler
• Expanded metal mesh attaches to vertical bars
4. Battery mounting - a platform on the bottom frame piece

¾” welded nip return fitting

Frame-Integrated Hydraulic Tank

1” NPT welded-in barb suction fitting

Filler Breather Cap

2.6” wide

1.5” wide

2. Fan/Cooler Assy

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14 ga wire from engine charger

½” NPTM to ¾” NPTF Swivel

½” to ¾” NPT Nip

2.6” wide

1.5” wide

Return Line ¾” Quick Coupler

Includes:

• Cooler
• Cooler mounting to vertical bars (using Cooler Mounting Kit)
• Fan
• Fan mounting to cooler using fan mounting kit
• Swivel NPT fitting on return side
• Nip + Quick Coupler on entry side
• Expanded metal mesh

Cooler mounting kit

3. Engine Assembly

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Engine Shaft

Includes:

• Engine
• Coupler on engine shaft
• Pump mount
• Engine mounting bolts

HP16HP Engine FreeCAD File

4. Pump Assembly

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1” NPTM barb pump inlet

Hose

Clamp

¾” Hex Nipple

Forward Line ¾” Quick Coupler

Includes:

• Log Splitter Pump, PDF Nortrac, Manufacturer Deli PDF for CBDN 16/7 w/ Schematics & technical specs
• Hose barb fitting on pump (suction side)
• Hex nip fitting (pressure side)
• Quick coupler
• Lovejoy shaft coupler on pump
• Pump mounting bolts
• Pump mounting lock washers

SAE A 2 Bolt pattern

5. Battery

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Includes:

• Battery
• Battery wires
• Battery bolts