Yes, summer is almost over and it’s been about the whole summer that I haven’t posted anything. That’s not to say that I haven’t been working on anything though. Here are a few of the things I’ve been working on.
This project hasn’t gone as quickly as I had hoped. I’ve been working mostly on the SONAR portion of it but frankly this summer has been very busy work-wise and thus I’ve been at a loss for getting stuff done. I’ve also been working on a viable, yet inexpensive depth sensor for the craft. For this I have to give a shout out to Farnell/Newark Canada who were kind enough to give me a sensor for the occasion. Visit them at http://canada.newark.com or http://element14.com
With this device I can easily keep an accurate depth reading up to my limit of 130ft. Yes the depth is arbitrary but that’s a good depth for most lakes around here. The idea first is to simply plunge the chassis down into the depths and record the images recorded from the main cabinet.
Well, there’s not much to her but perhaps I can get it dipped into a lake before the snow flies.
Yes, I’ve been working on games again. It’s a fun diversion for a while and it’s been a while since I’ve made anything substantial. Here’s a couple of screenshots
Anyways, aside from that I’m working on a basic design for a 2D stepper driven table for use with a stamping head but realistically I haven’t had the time to do anything with that.
It has been a long time since I wrote a game. This one just took me by surprise as I was playing Flappy Birds for the first time. Having heard that the author pulled it. I wanted to make my own version but different.
Pulling from Super Mario Bros. and Flappy, I came up with this. I started writing it at work today and am now finishing up the levels. Hell, I even made a little title graphic.
Well, it took me about a day to write the game but the levels are another thing. I will update the game as I finish the levels and hopefully someone, somewhere enjoys this game.
Some recent developments, whether they are fruitful or not, have got me thinking seriously about the design of 3D printers, their use and some of their current drawbacks.
Additive manufacturing has come a long way even in the last 15 years when it was just a novelty and not useful for much more than rough prototypes. While 3D printing will probably never supplant ‘subtractive’ methods such as turning and milling for most things, I believe it will be a real boon for strange, esoteric and one-off parts with limited mechanical demands.
This got me thinking about my own design and what I perceive to be some of the issues with current machines all the way up to commercial machines. A couple of those issues are of concern when making a upper-tier hobbyist grade machines for making prototype parts.
These two things are, the effects of gravity on the part when heated or produced, and the effects of uneven heating throughout the process of printing a given part. This will not only increase accuracy but reduce the need for support structures while printing.
Here is a rough pic of my idea for a 3D printer:
Having a heated suspension fluid eliminates the wow caused by uneven heating and the droop generated from gravity when the part is properly heated. By keeping the liquid level slightly lower than the workpiece you can still generate lattices without the fear of them filling in. The inflow and outflow should be computer controlled via electric pumps and valves, this way the fluid can remain hot without having to heat the whole enclosure. Draining from the bottom will partially help ensure that the cooler fluid is drained first. You could even add a filter to remove detritus.
For the fluid height sensor, I would probably try to tie it in with the nozzle height somehow without interfering with the work envelope. The level would need to be maintained very accurately in order to ensure maximum efficiency. For this sensor I would probably use my old design for a viscometer with the two Piezo discs, instead of measuring viscosity, I would just check for fluid contact, for this purpose it proved to be very accurate and resistant to fouling.
For the fluid, it should match the density of ABS fairly closely. Mineral oil or Propylene Glycol might be good candidates. The idea is to have a fluid that is non-toxic, non-flammable, somewhat viscous and chemically inert with plastics.
Fragile hollow objects with no holes (a ball) may become deformed due to fluid pressure. though this would require quite a bit of depth to achieve. Not to mention that the item would want to float.
Structure needs to be very rigid and acceleration and deceleration needs to be toned down as to not allow the fluid to slosh around which could shake the part loose during printing.
potentially messy with fluid being added to the mix.
mechanically more complicated and motion components need to be at least resistant to fluid being used.
Fluid would probably need to be changed with different materials. A fluid denser than the plastic being laid down may cause issues.
Stronger binding to the table is required especially with lattice heavy designs, floating will occur.
Anyways, that’s my idea, posted for posterity. Maybe someone will find it interesting or foolish.
Well, After some time thinking about it, it’s time to take things into my own hands and design what I want, the way I want it. Since it’s shortly after my 34th birthday I’ve realized that time is getting short and I have to forge ahead.
Hence, the VariGage. I’ll change the name later but it suits it just fine for now.
This device will allow for a multitude of gaging options with full communication between the anvils and expansibility. Gagemaker makes something quite similar however, mine differs in a number of ways in both design and use.
Affordability, the average machinist should be able to afford a unit to fit in their repetoire. While it’ll be a very expensive tool, it’d be nowhere near the 12,000 bucks or so of the GageMaker device.
Anvil communication. The device will communicate with the anvils allowing for future use of anvils that weren’t available upon first creation of the device. also this allows for cheaper calibration of anvils rather than the device itself.
The device is motorized. It will position itself to the desired location and hunt when the user is pressing and calibrating a gage on the device. The final version will involve a clutch to allow rapid hand positioning
Light weight with modular display design.
These are a few of the differences. The market is completely different from what GageMaker sells. I’m not even completely sure it’s sell able but I simply have to build it. I have a few other ideas and designs I have to get done but this is the first in the line and I think it’ll be very interesting when done. Heck, it’ll be nice to have if I go to another shop even, who knows. 🙂
Well, It’s been three years at Rejent (plus a week). Since I haven’t updated in a while I figured I’d go through some of my Solidworks files and post a few of the things I’ve worked on during my time here. After looking through the files I am quite amazed at how freakin’ many parts I’ve worked on over the time I’ve been here. Hundreds of different things!
Anyways, here are some pics of a few things I’ve worked on during my time here, albeit a very limited selection of them.
That was just a few of them that I randomly found, nothing too crazy since some of I couldn’t really show. Well, let’s see what the next few years brings.
I have just finished the project that has taken up the last 3 months. Delivered to the customer and they are very happy with it.
I’m so glad to be done this project. While it wasn’t a terribly long project, I’m glad it all went off without any real problems. It measures better than they’d hoped and it’s a pretty attractive little package, for what it is. Next iterations will be significantly smaller and I will look at new encoders to use.
Also, as an aside I have set up my new office. It’s nice to get out of the basement. I now have a lot of free room now so it’s nice to spread out and be able to sort through all my shit and set it up as efficiently (for me) as possible.
This device is almost complete. Yes, It’s missing its buttons but the device seems to work well and nice and smooth. The real anvils are almost done and the device will ship to our customer fairly soon and I’m glad to see these guys be done!
There are still some tweaks to make especially in the realm of overall rigidity but overall it’ll be a neat device to attempt to bring to market in different ways.
Well, it’s coming along with some speed. I am now going to build the final version complete with internal battery charging, better logic and a severe reduction in mass. Hopefully this will go down well with the customer.
Anyways, this post was for posterity. As always I hope it turns out well. 🙂
Something I haven’t worked on in a while but is coming up is my new electrolytic deburring machine. I figured I’d post a couple of pictures for posterity.
In it’s current state, it does work to a degree. I need to work on the chemistry of the fluid. Right now it seems to just pit the material. Perhaps the voltage is too low or too high but I suspect it’s purely a lack of conductivity or the incorrect chemistry for this type application.
Eventually we should be able to deburr cutters and various other items. Just thought I’d share.
It’s been a while since I’ve posted and that’s primarily because I’ve been working on a project. I have to keep some of the details to myself but I will show some pictures of the prototype that has taken me a couple of weeks to design and build.
The device uses the AT715 from Mitutoyo and what an interesting device it is. With a resolution of .0005mm and an RS485 interface, it is an ideal device for measurement and for use on machines. The device, which uses magnetic induction, uses 30ma whereas a lot of other glass scales use up to 250ma @ 5v. This is a pretty cool device.
Well, I can’t get into a great deal of detail because the product I have in mind may compete with other gaging companies like Gagemaker with a universal, handheld, high precision, digital gage that has active, rugged and dynamic probes. The images shown are that of a rough prototype, I’m not normally secretive but once one is built in a few weeks I can post some images of the more refined version.