wiki:Fosscar

The FossCar project

"In essentials, unity; in non-essentials, liberty; in all things, charity. "

Goal

The goal of the FossCar project is to improve the state of available automotives (create cars, and car parts) using entirely Free or Open Source Tools.

Communication

We get together in #fosscar, on irc.oftc.net, or #fosscar on irc.freenode.org

Sub Projects

Free Hardware Licenses

Kansas

http://www.liftlaws.com/kansas_lift_laws.htm

Maryland

http://www.liftlaws.com/maryland_lift_laws.htm

  • Maryland has a bumper and frame height restriction of 20" for for Cars/SUVs, and a 28" limit for trucks.
  • No suspension modifacation laws or tire size restrictions
  • Maxmimum size is 102" wide, 13 feet 6" tall, and 45 feet long for one vehicle
  • All vehicles in the state must have brakes on all 4 wheels. They need to be able to stop the car within 25 feet at 20MPH
  • You also need a parking brake by law that is secondary
  • even though you don't need a windshield under the law, if you have a windshield you need wipers
  • Headlights and tailights, maximum limit of 4 front lights turned on while driving
  • you must have a muffler

Hot End

The hot end we have been working on consists of:

V5

  • A steel bolt, with a 3.1MM hole down the middle, softened, drilled and reamed, with a flange on the entry hole.
  • A cylindrical aluminium heating block, annodized. there should be a hole down the middle of it for the steel bolt, as well as holes drilled in the side for the thermistor, and the set screw.
  • A set screw, for holding the aluminium heating block in place.
  • Nichrome wire.
  • Zirconium Silicate paste.
  • High temperature gasket sealant outer coating.
  • Four small copper terminal wires for the heater core and thermistor hookups.
  • Thermistor.
  • A Chiller, which screws onto the shaft to cool the shaft directly.

V6

  • A steel bolt, with a 3.1MM hole down the middle, softened, drilled and reamed, with a flange on the entry hole, and a 'nipple' on the end to mate with the nozzle (0.01 inch thick and long).
  • A cylindrical aluminium heating block, annodized. there should be a hole down the middle of it for the steel bolt, as well as holes drilled in the side for the thermocouple, and the set screw.
  • A set screw, for holding the aluminium heating block in place.
  • Nichrome wire.
  • Zirconium Silicate paste.
  • bisque fired porcelain shell coating the outside.
  • Two thick copper terminal wires wrapped around the aluminium block, for the nichrome.
  • Type K Thermocouple, partially embedded in ceramic and a wrap of kapton tape (for strain relief).
  • A Chiller, which screws onto the shaft to cool the shaft directly.

V7

This is our current design, we are still building prototypes of:

  • A steel bolt, with a 3.1MM hole down the middle, softened, drilled and reamed, with a flange on the entry hole.
    • A cylindrical copper heating block. there should be a hole down the middle of it for the steel bolt(threaded), as well as three 90 degree opposing threaded holes drilled in the top and bottom of the sides for the thermocouple, a set screw (to secure to the shaft), and another set screw (to secure the thermocouple).
    • A set screw, for holding the aluminium heating block in place.
    • A set screw, for holding the thermocouple in place.
    • Nichrome wire.
    • Zirconium Silicate paste.
    • high temperature gasket sealant outer coating.
    • Terminal wires (2) for the nichrome. these terminal wires will be looped around the kapton tape, and twisted to themselves.
    • shielded (grounded) Thermocouple. this must not be electrically connected to its casing.
    • kapton tape for seperating the nichrome wire from the heating block.
  • A Chiller, which screws onto the shaft to cool the shaft directly.

Media

TODO

  • Re-document construction of prototype hot ends (v5, v6).
  • Complete hotend evaluation on the v6.
  • Use ImplicitCad? to design new hot end parts.
  • Construct new hot end (v7).
  • Obtain video of new hot end printing with ABS, PLA, and PC.

Competition

Head Controller

Responsibilities

  • Reporting the temperature of the hot end as accurately as possible.
  • Reporting sensor status.
  • Remembering the PID settings of the hot end.
  • Maintaining the temperature of the extruder motor(s).
  • Toggling power to Low Power Devices (LED(s))
  • Toggling power to High Power Devices (Hot end, extruder motor(s) fan(s), usb cameras)
  • distribution of USB connectivity to cameras.
  • Programmable via usb->5V serial adaptor.

Serial(UART) Commands

  • Enable/Disable LED(s)
  • Enable/Disable/Display FAN(s)
  • Enable/Disable Camera(s)
  • Set Hotend Temperature
  • Get Hotend / Chiller / Controller / Motor temperature -- M105
  • Set Motor (maximum) Temperature - M144(?)
  • Set/Get? firmware values (M500-M503)
  • Set/tune PID values (M301, M303)
  • Get Location(not applicable)-- dump ADC states -- M114
  • Get Firmware Version and Capabilities -- M115

I2C Commands

  • Enable/Disable LED(s)
  • Enable/Disable FAN(s)
  • Enable/Disable Camera(s)
  • Set Hotend Temperature
  • Set Motor (maximum) Temperature
  • Get Hotend / Chiller / Controller / Motor Temperature
  • Extrude Material -- receives direction and amount over time of material extrusion, for thermal envelope calculations.

Components

  • AtMega48pa/AtMega32U4 or AtMega8535 -- control.
  • 74lvt14 -- inverter and 5V->3.3V voltage converter.
  • max31855 -- thermocouple reading.
  • PL2303 -- serial to USB conversion (if not atmega32u4).
  • Tip120 -- Hotend power delivery
  • ULN2003 -- power to cameras/high power LEDs?
  • GL850G USB hub (recommended by megal0maniac_afk)
  • SPI culomb counter?

DLC deposition

It is currently theorized that Diamond Like Carbon can be used on the outside of the heat pipe core as a high electrical resistance / low thermal resistance coating, allowing heat from the nichrome wire to conduct inward.

Media

Tools

Users of this project are encouraged to use GNU/Linux distributions.

In order to design machines consisting of hundreds of parts, it is important to use languages capable of defining interfaces between parts, and changing the shape of one part based on another.

  • Implicitcad -- functional programming language for designing parts.
  • Meshlab -- view the stl file created with Implicitcad's extopenscad command.

Software

All software images will be built atop the FAI CD available at cds.faikvm.com. this will allow us to integrate work done at multiple sites into our alpha site / servers.

  • Create a VM reproducing the software at http://www.implicitcad.org/ , getting the webGL frontend working again.
    • This is so we can make a cad application online in a distributed manner.
  • migrate to the new trac wiki at http://fosscar.faikvm.com/
  • create a mediagoblin VM image, for distributing videos / images / hardware designs.

Complete Vehicles

Competition

http://www.jaylenosgarage.com/extras/articles/jay-lenos-3d-printer-replaces-rusty-old-parts-1/

Bill Of Materials

for the large printer:

have:

  • 3 40mmx40mm extrusions, 5 Ft in length
  • 4 40mmx40mm extrusions, 2 Ft .5 in in length
  • 2 40mmx40mm extrusions, 22.5 in in length
  • 2 40mmx40mm extrusions, 19.5 in in length
  • 1 optical table, 50x98 inches, with tapped holes every 1 inch across the surface.
  • 3 powermax ][ motors, p21nsxc-lss-ns-07 , 57.5mm wide, square profile, dual shafted, 51.5mm deep, 1.2 mm tall ring 38mm wide , 29.8mm on the inside.

need:

  • openrail - unknown length -- openbuilds
  • 20mmx40mm extrusions - for mounting openrail to 40mmx40mm extrusions -- 8020?
  • 4 Dual V Wheel Kits for X axis (metal) -- openbuilds
  • 8 Dual V Wheel Kits for Y axis (metal) -- openbuilds
  • 2 mounting plates for Y axis -- openbuilds

for the extruder:

  • four 3.1MM rasps
  • four 3.1MM drill bits
  • copper stock (for the heat spreader, AND the chiller)
  • 10mm steel stock (for the shaft)
  • bucket o sand (for softening steel)
  • torch (for softening steel)
  • 1 WRX-31 thermocouple

for the lathe:

Last modified 5 years ago Last modified on 05/30/14 22:50:24