# 05FEB2024 ## TH Fab Car: 68 mi Time: 2 hr Hashed out details of arrangement, met guys Torque to turn while in ground: 120 in-lb # 07FEB2024 - 2.3 Set up SOLIDWORKS clock "IN" 15:33 clock "OUT" 17:52 target = 100 in-lbf (8.5 ft-lbf) PG71 = 16.6 ft-lbf / 75rpm ... ok so that's not so bad. builtin worm gearbox = 30:1 ratio shaft is a 5/8" shaft with a 1/2" long D-shaft stub: 1/2" diameter, 3/8" to the flat, with a cross-pin meant to capture a 1/4" (.266 actual) plate. The 5/8" section is 1" long. full range of spider angle is 120deg let's say 2 seconds to full completion that's 60deg/sec (10 rpm) times a 30:1 gear ratio is 300 rpm times a 2:1 gear ratio is 600 rpm which is NOT in range for a PG71; by about an order of magnitude The pg71 would take about 20 seconds to do a full changeover which is pretty long... how fast does a 5 deg adjustment need to take? ballpark 0.5s that's 10deg/s (1.6666666 rpm) times 30:1 times 2:1 is 100 rpm which *is* pretty similar to a pg71 Sent email to https://www.klaubergear.com/contact-us-kmg asking for a motor with 100RPM free and 30 ft-lbf stall ## HTD Pulley combo - Shaftloc [62T Pulley](https://shop.sdp-si.com/catalog/product/?id=A_6T25-H62DF1524) [19T Pulley](https://shop.sdp-si.com/catalog/product/?id=A_6T25-H19SF1520) ehhhh too small of diameters ## GT2 Pulleys - Metal https://shop.sdp-si.com/catalog/?cid=p217&filter=a0%3A2%3A5%20mm%20(GT2)&sort=undefined&view=table https://shop.sdp-si.com/catalog/?cid=p342&filter=a0%3A2%3ASingle%20Sided%3Ba16%3A2%3A5%20mm%20(GT2)%3Ba185%3A2%3A15.0&sort=undefined&view=table [56T - $32.35 / $25.15](https://shop.sdp-si.com/catalog/product/?id=A_6A55-056NF1516) [17T - $15.02 / $ 9.74](https://shop.sdp-si.com/catalog/product/?id=A_6A55-017NF1508) [120T- $31.81 / $19.88](https://shop.sdp-si.com/catalog/product/?id=A_6R55M120150) (also not in stock) Total: $79.18 / $54.77 ## #25 Chain (Hey, this would need a tensioner right? Maybe that's a good thing anyways though...) [15T - $14.90](https://www.mcmaster.com/2737T109/) [30T - $23.81](https://www.mcmaster.com/2737T223/) [2ft - $13.68](https://www.mcmaster.com/6261K171-6261K282/) Total: $52.39 [23T - $18.60](https://www.mcmaster.com/2737T154/) [45T - $36.67](https://www.mcmaster.com/2737T312/) [2ft - $13.68](https://www.mcmaster.com/6261K171-6261K282/) Total: $69.95 ## #35 Chain [15T - $18.21](https://www.mcmaster.com/6280k371/) [30T - $48.48](https://www.mcmaster.com/6236K231/) [2ft - $10.14](https://www.mcmaster.com/6261k172/) Total: $76.83 ... huh. Surprising that actually starts to get competitive with GT2 stuff. ## 25 or 35? #25: 140lbf working #35: 480lbf working 15T #25: 100 in*lbf / (0.250*15/pi)/2 = 167 lbf in chain which is a lot! 15T #35: 100 in*lbf / (0.375*15/pi)/2 = 112 lbf in chain which is well within working #35 is probably the way to go, especially for now. ## Final observations The drive shaft will need to be different. So you might as well put the drive mechanism on what is currently the nut side, so you don't have to worry about the locking mechanism. # 08FEB2024 - 0.5+0.2+3 Clock in: 10:21 12" long, 8" diameter $350 - $600-$700 sample not a very helpful call... except maybe that I need a very different motor maybe this is the right way to go: https://www.amazon.com/MOCW-Stabilizer-Replacement-K01285-C800-K01531-A800/dp/B09LM63RHY ## C800 motor - 12VDC - 7A - 53:1 gear ratio - 68 RPM - 50 in-lbf run torque clock out 10:53 clock in 10:58 clock out 11:18 clock in 15:27 Advised to visit CSH Incorporated; sure enough, they have the C800 motor: https://www.cshincorporated.com/k01531a800-replaces-k01285-c800-klauber-gear-motor/ clock out 18:09 I specced 8+3+3 = 14 hours for the design phase and I've burned 6 so far.. ok # 12FEB2024 clock in 1500 clock out # 16FEB2024 clock in 17:20 clock out 18:15 https://www.geartechnology.com/ext/resources/issues/0791x/errichello.pdf how fast are we going? 300*2*pi/60/s*40mm to ft/min = 247.4 ft/min 300*2*pi/60/s*40mm to m/s = 1.26 m/s https://khkgears.net/new/gear_knowledge/gear_technical_reference/lubrication-of-gears.html KHK seems to think that grease is appropriate. 10-30 C - 200-245 30-55 C - 350-510 # 23FEB2024 clock in 11:00 clock out 11:02 - :02 clock in 12:38 clock out 13:42 - 1:04 clock in 14:00 clock out 16:24 - 2:24 total: 3:30 ack. clock in 8:06 clock out 10:30 todo: - [x] finalize tensioner - [ ] finalize cover - [/] add hardware - [ ] make BOM bison EP18864-1 looks interesting ## pots https://www.digikey.com/en/products/detail/amphenol-piher-sensing-systems/MSC360-1A-C0007-ERA180-05K/13543612 billed # 22MAR2024 - 3.5hr # 25MAR2024 - 2.5hr clock in 9:48 clock out 10:48 clock in 11:00 clock out 12:30 Vishay 981he is a reputable option 981HE0B4WA1F16 MODEL: 981HE Features: 0 continuous rotation Linearity: A 1% (B 0.5%) Electrical Angle: 4 (360) Output type: W wires Output signal: A or B (Analog CW/CCW) Shaft type: 1F16 (1: 6.35, F: flatted, 16: length (16mm, standard)) $58: https://www.mouser.com/ProductDetail/Vishay-Spectrol/981HE0B4WA1F16?qs=IpR5h64PZJnosCtHP9bpXQ%3D%3D https://www.newark.com/vishay/981he0b4wa1f16/throttle-position-sensor/dp/15R3247 981HE0B4WA8H01 could work too, it's CCW, hollow D shaft: https://www.mouser.com/ProductDetail/Vishay-Spectrol/981HE0B4WA8H01?qs=xBCDPT02SF1aAq7obDlm8w%3D%3D https://www.digikey.com/en/products/detail/tt-electronics-bi/6127V1A360L-5FS/2620662?_gl=1*129k53o*_up*MQ..&gclid=Cj0KCQjwwYSwBhDcARIsAOyL0fjJ-HkKXQrTdVH6HHXJhOSrwul2iJfY-HebIL0XmgPecjzIoHLtjhEaAtmFEALw_wcB # ZF CU103602 Non-contact which is excellent https://www.digikey.com/en/products/detail/zf-electronics/CU103602/1642202 $59.74 CU103601 is 180deg instead of 360 https://www.digikey.com/en/products/detail/zf-electronics/CU103601/1642200 $59.74 https://www.sager.com/product/cu103601-zf-electronics/2449228 could also get the AS500106 magnet separately the AN820031 / 32 has 12" 18awg wire leads and 180degrees motion as opposed to the connector # I think this is the best option: AN820032 https://us.rs-online.com/product/zf-electronics/an820032/70386254/ - $28.54 AS500106 https://us.rs-online.com/product/zf-electronics/as500106/70386256/ - $8.41 - $36.95 - wire leads - 360 deg - non-contact YOU CAN USE THE AS1010 OR 709-21995 WITH IT TOO! - AS101001 is south - AS101002 is north - AS101003 is south with samarium RTP180LVxxA PST360 PST360G2-1A-C0000-ERA360-RE-K - 14mm rotor - simple analog - C0000 - 360 deg rotational angle - 7-15V - 200Hz PWM PST360G2-1S-C0000-ERA360-05K - 14mm rotor - SPI - C0000 - 360deg rotational angle - 5V https://www.newark.com/amphenol-piher-sensorscontrols/pst360g2-1s-c0000-era360-05k/magnetic-rotary-sensor-analog/dp/74AH3318?st=pst360g2 Ideal: PST360G2-1A-C0000-ERA360-05K # 28MAR2024 - 1 hr It works! Current characteristics: - 15A inrush current - 6-8A on unworked ground - 5-6A on worked ground - 4A in air Motor characteristics - 7 A running - 12 VDC - 68 RPM - 50 IN-LBF # 29MAR2024 - 5 hr clock in 08:15 clock out 09:45 clock in 09:50 clock out 11:18 clock in 12:00 clock out 14:00 Let's say 8A x 2 x 25 = 400 A 400 A * 12V = 4800 W 8A x 12V = 96W 96W x 12s = 1152 J -> 16F capacitor 15A x 12v x 0.01s = 1.8J -> 25 mF capacitor Hey... you know you were measuring the whole system current, not just the motor, right? Hmm. https://portal.agleader.com/community/s/article/2052?language=en_US https://portal.agleader.com/community/s/article/2420?language=en_US Oh man there's so much on agleader's site OK, but... an auxillary battery might be a better solution than a power unit. We are doing sporadic high current, not continuous lower current. 400A * 12s * 50 times / (3600 h/s) = 66 Ah = a car battery Wire fusing currents (lol): https://www.powerstream.com/wire-fusing-currents.htm Wire size: https://www.powerstream.com/Wire_Size.htm Pre-made 2AWG leads: https://www.amazon.com/ABIGAIL-Battery-Inverter-Automotive-Motorcycle/dp/B0BVB29FKR 2AWG running from the middle seems reasonable... northamerica@zf.com AN9 is same as AN8 but redundant output ANG-11HAW1 BILLED ## So many tasks! [ ] Get answers from ZF (worst case: we can't sell you that magnet, and there's nothing to be done about the other thingy... make one? eesh. 2x6mm magnets) [ ] Top sensor mount [ ] Lower sensor mount [ ] Cable routing [ ] Buy a bunch of electronics for prototyping [ ] Fix holes # 02APR2024 - 1hr clock in 1000 clock out 1100 # 03APR2024 - 2.5hr clock in 2100 clock out 2330 AutomationDirect 12mm inductive sensors PBM6-CP-1A - flush 2mm / PNP NC PBM6-AP-1A - flush 2mm / PNP NO PBM6-AN-1A - flush 2mm / NPN NO (limited stock) PBM6-AP-2A - proud 4mm / PNP NO 200mA lengths vary... for the IC side of things - LM2907 / LM2917 F->V converter - LM397 voltage comparator TONE DETECTION IS WHAT YOU ARE DOING! ## LM567 LM567CN is a DIP fo = 1 / (1.1 * R1 * C1) fo = 1 Hz ? R1 * C1 = 0.9 w 0.1 uF cap = 9 Mohm fo = 5 Hz solve 5 = 1/(1.1 * x * 0.1e-6) for x -> R1 = 2Mohm 100mA current sinking for output LM567CN + L7805CP + Or gate (drive signal at 12V) the 567 is high frequency = low low frequency = high so make the signal low frequency = high so OR gate (74LS32) # 04APR2024 clock IN 0845 clock OUT 1130 clock IN 1400 clock OUT 1600 DTP10-4P DT15-4P DTP10-4P DTP15-4P AMPHENOL, YOOOO https://www.digikey.com/en/products/filter/rectangular-connectors/headers-male-pins/314?s=N4IgjCBcoBw1oDGUBmBDANgZwKYBoQB7KAbRACYAGAZjADYB2EAXQIAcAXKEAZQ4CcAlgDsA5iAC%2BBALQAWBCGSR02fCABuw1JlwFikMgxpgArC3ZdIISRIlA littelfuse 55505 and ZF GS101201/02 are interchangeable I kinda like their package better # 11APR2024 clock IN 0830 clock OUT 1100 clock IN 0200 clock OUT 0400 got CAN working # 12APR2024 clock IN 0700 clock OUT 0800 clock IN 1515 clock OUT 1853 clock IN 1949 clock OUT 2049 ## Stalling C800 motor I get 300mV on my oscope at 10 mV/A -> 30A (multimeter seems to confirm this) Boy, it's a torquey motor! 3in ^2 * pi/4 * 120 psi to lbf = 283 lbf airbag fully extended 7.75-8" long. pivot point distance 3.75". AN820032 ANG-11HAW1 55300-00-02-A !!! PS2P-ARC is cool PS2P-CON is usable PS2P-CON-CE-1A0-C0000-ERA360-05 is $50 and would just work https://us.rs-online.com/product/piher-amphenol/ps2p-con-ce-1a0-c0000-era360-05 https://www.mouser.com/ProductDetail/Amphenol-Piher/PS2P-CON-CE-1A0-C0000-ERA360-05?qs=wnTfsH77Xs6wFhE4CvwJ8Q%3D%3D PIHER's PSCI series seems too good to be true (they are) AS5600... man... it's cheap and tiny. Is it robust? # 13APR2024 clock IN 0800 clock OUT 1050 shear strength of grade 8 = 91ksi shear force for 5/16" bolt: 91000 psi * (0.3125in)^2 * pi/4 = 6980 lbf torque on shaft = 6980 lbf * 1.25 in = 8725 in-lbf pitch diameter of worm about 3.11 in force on worm = 5610 lbf pin diameter = .156 in = 292600 psi (91000 psi * (0.3125in)^2 * pi/4 * 1.25 in / (3.11 in /2)) / ((.15625in)^2*pi/4) # 14APR2024 clock IN 1345 clock OUT 1438 LM567C is not the right path 4*12 mph / (18*pi inches) to 1/s -> 15 Hz 4*1 mph / (18*pi inches) to 1/s -> 1.25 Hz # 16APR2024 clock IN 1230 clock OUT 1630 clock IN 2034 clock OUT 2200 tested CAN bus over 30 feet CAT5 got LCDs working (you can do custom characters with them too) tested inductive prox over 30 feet CAT5 continued developing messaging protocol got encoders working (with buttons... not as encoders. need to spec them) https://www.digikey.com/en/products/detail/pei-genesis/IPM12-A8F-PC-3/13143998 https://www.digikey.com/en/products/detail/amphenol-ltw/M12A-08PFFS-SF8001/5253167 ehhhh: https://www.amazon.com/Aviation-Connector-Lonlonty-Flange-Waterproof/dp/B0BBQN6NVR/ref=sr_1_4?crid=1RM3U3RJ342YG&dib=eyJ2IjoiMSJ9.bL04l_yAqfeArHfLlg9T5d5RPh52acgbzRwVCM8-fxsUksWOMbU8Gxn0KOUqjmJOjqCmgdsAOUl3yodYaxWHqw3ek3NAk0B4xYAcwzmHugxA3Gevigw_hjoXH8bgcT-ZmjiQhQy4_IkIEj5AzJZY55B4aQdJbO_sbNiGkLnrS0G7ITY4Or9OsrQZ0MgtwAEX6cZvOvkUeU7mNrrGzB2jXsS-DcmJUiF3Rs0-NCncIcw.EDwEZQ4hL5bwr5xqx8iOiIJiWp6Ss7g1c_4wkJBdQZA&dib_tag=se&keywords=m12+8+pin+bulkhead&qid=1713325429&sprefix=m12-8+bulkhead%2Caps%2C433&sr=8-4 box: https://www.amazon.com/Otdorpatio-Waterproof-Electrical-Electronic-200x120x75/dp/B09B6QHQDQ https://www.digikey.com/en/products/detail/bud-industries/CU-3283/428968 https://www.digikey.com/en/products/detail/bud-industries/PN-1324-DG/387043 1092D1-12V-ND 1092D5-12V-ND PEC11R-4220K-S0024 adafruit 5529, 2056 https://www.digikey.com/en/products/detail/bourns-inc/PEC11R-4220K-S0024/6164059 https://www.digikey.com/en/products/detail/cliff-electronic-components-ltd/FC7252/21406836 COM-10002 is best # 18APR2024 clock IN downforce 1343 clock OUT 1355 clock IN RHP 1718 clock OUT RHP 1932 clock IN SSACT 2008 clock OUT SSACT 2230 IPM12-<# contacts>- (-3 for front mount) IPM12-A8M-SC-3 is for socket cup IPM12-A8M-PC-3 is for PCB mount ********F is for female looks like flying leads aren't available lol # 19APR2024 clock IN 1500 clock OUT 1700 clock IN 2030 clock OUT 2400 breakers relay: https://www.digikey.com/en/products/filter/power-relays-over-2-amps/188?s=N4IgjCBcoOwExVAYygMwIYBsDOBTANCAPZQDaIccAnGACwCsIhDMAHDAGxMW1X2uNCcXvy4BdQgAcALlBABlaQCcAlgDsA5iAC%2BhOgAYqiECkgYcBYmRC199KhyMSQMuYtWade2mH3HT5niEJJDkcPoABACC3ADMkTHOrpAgAKpqKtIA8qgAsrjo2ACuSrheIAC0CNAmUMpFliHkjGLabUA J107F1CS205VDC.45 should work: https://www.digikey.com/en/products/detail/cit-relay-and-switch/J107F1CS205VDC-45/14000915 - 90mA coil current - 20A running current NOTE: AT15-P-BM03 is the board mount you want, when you go to design a PCB https://www.digikey.com/en/products/detail/cit-relay-and-switch/A161CS12VDC-64/12503232 is also good # 09MAY2024 clock IN 0800 (SS) clock OUT 1300 (SS) clock IN 1315 (RHP) clock OUT 1415 (RHP) clock IN 1415 (SS) Spider actuator works. Reasonably tuned. Here's a list of things that can/should be done: - Try the Piher sensor - Build a wiring harness - Mount sensors to cover - Space out the actuator - Put a USB port on the control box - Put SD card logging in the control box - Design mount for the center sensor - Put cigarette lighter adapter on M12 cable for RHP - Potentiometers for dimming #29MAY2024 testing started kP 100 kD 75 sample len 25 runs 1 & 2 changed to kP 75 kD 50 sample len 18 changed sample len 12 kP 70 kD 40 len 15 kP 80 kD 50 #31MAY2024 refining CAD replaced THF-W210 with simply THF-2091 modified THF-2091 THF-2071 THF-2045 THF-2057 THF-2079 THF-2078 THF-2061 created THF-2091-GASKET CENTER PIVOT SENSOR BRACKET removed THF-W210 (replaced with THF-2091) # 01JUN2024 what MCU to use? - R4 Minima - Mega Embed - Nano # 07SEP2024 let center be positive cw, so it's positive when the rear is tilted left let angle be positive throwing in let front and rear be positive cw if (center > 0) front = + angle + center rear = - angle - center else front = - angle + center rear = + angle - center if (row == 0 and center > 0) rear = - center if (row == 0 and center <= 0) front = + center if (row == LAST and center > 0) front = + center if (row == LAST and center <= 0) rear = - center - OR - if (center > 0) front = + angle rear = - angle else front = - angle rear = + angle if (row == 0 and center > 0) rear = 0 if (row == 0 and center <= 0) front = 0 if (row == LAST and center > 0) front = 0 if (row == LAST and center <= 0) rear = 0