Sander van Vliet

Fabacademy2016
@Fablab Amsterdam


Applications and Implications

Week 17 (25 may - 1 june)


Lecture

This week Neil showed examples of Fablab projects which were grown into commercial products and businesses. He also showed us final projects of previous years to get inspiration from and explained about the implica ttions of the countless options we have for our final project.
See the overview of the lecture here.

Assignment

  • What will it do?
  • Who's done what beforehand?
  • What materials and components will be required?
  • Where will they come from?
  • How much will it cost?
  • What parts and systems will be made?
  • What processes will be used?
  • What tasks need to be completed?
  • What questions need to be answered?
  • What is the schedule?
  • How will it be evaluated?
  • Note that projects can be separate or joint, but need to show individual mastery of the skills covered.
    Where possible, you should make rather than buy the parts of your project.

    what will it do?

    It will help to maintain sufficient ventilation in my living room.
    When the CO2 level in the room is detected to be higher than a set maximum threshold, the window will be opened automatically. When it is lower than a certain minimum threshold, the window will close again automatically. (CO2 levels are a good indicator for ventilation)

    who's done what beforehand?

    I got the idea for this system when I saw a Netatmo weather station at a friend's house. It made me more aware of CO2 levels in a room and the effect of closed and open windows on its values. You can read more about this and see my initial final project ideas and sketches here.
    I did not find a similar project within the Fabacademy students sites. I found some which use a CO2 sensor, but not with a similar application.

    what materials and components will be required?

  • machinable wax, Vytaflex 30 urethane rubber, Smoothcast 305 polyurethane/plastic and demolding agent (wall side panel and mold)
  • waterproof multiplex (wall panel mold)
  • acryllic/pmma (panel rear plate)
  • fr1 copper plate + micro electronic smd components + soldering tin (all self fabricated boards)
  • 2x esp8266-12e WiFi module
  • mg811 CO2 sensor + breakout board
  • Liquid Crystal Display
  • 2 external power supplies (220V AC -> 5V/12V DC transformers)
  • 1 stepper motor
  • mdf/wood? (window side casing)
  • wires (all boards and motor)
  • software/arduino code

  • where will they come from?

    Most materials I used came from the Fablab Amsterdam inventory.
    The Fablab is buying the casting materials from FormX in Amsterdam and the Electronic components are ordered from either Farnell or Digikey. The acryllic is bought from Kunststofshop.nl.
    I bought the CO2 sensor from iPrototype.nl and Shirley gave me the Liquid Crystal Display.

    how much will it cost?

    Below is the BOM (bill of material)

    Components / material from amount price/unit $ total in $





    panel



    Vytaflex 30 FormX shop 0,65 € 25,17 € 16,36
    Smoothcast 305 FormX shop 0,50 € 24,75 € 12,38
    rear plate Fab inventory 0,00 € 31,90 € 0,06
    LCD Girlfriend 1,00 € 13,95 € 13,95
    CO2 sensor MG811 Dfrobot dfrobot 1,00 € 56,05 € 56,05
    fabkit Girlfriend 1,00 € 6,13 € 6,13





    wifi board 1



    esp8266-12e Fab inventory 1,00 € 7,50 € 7,50
    voltage regulator 3,3V 1A Fab inventory 1,00 € 0,34 € 0,34
    ftdi 6pin header Fab inventory 1,00 € 0,29 € 0,29
    tactile switch Fab inventory 1,00 € 0,74 € 0,74
    capacitor 1uF Fab inventory 1,00 € 0,12 € 0,12
    capacitor 10uF Fab inventory 1,00 € 0,18 € 0,18
    resistor 10KΩ Fab inventory 1,00 € 0,01 € 0,01
    Sparkfun level shifter Girlfriend 1,00 € 2,95 € 2,95
    power supply Fab inventory 1,00 € 7,50 € 7,50





    window hardware



    window frame dad's workshop 1,00 € 6,00 € 6,00
    acryllic sheet 3mm Fab inventory 0,08 € 99,00 € 7,92
    screws dad's workshop 16,00 € 0,15 € 2,40
    motor incl screw and nut Fab inventory 1,00 € 44,95 € 44,95
    3D printed motor mount Fab inventory 7,00 € 0,01 € 0,07
    3D printed bearing mount Fab inventory 7,00 € 0,01 € 0,07
    bearing Fab inventory 1,00 € 0,50 € 0,50
    mechanical part Fab inventory 0,04 € 35,00 € 1,40
    hinges Schmidt shop 2,00 € 2,10 € 4,20
    acryllic casing Fab inventory 0,07 € 31,90 € 2,23





    wifi board 2



    esp8266-12e Fab inventory 1,00 € 7,50 € 7,50
    voltage regulator 3,3V 1A Fab inventory 1,00 € 0,34 € 0,34
    ftdi 6pin header Fab inventory 1,00 € 0,29 € 0,29
    tactile switch Fab inventory 1,00 € 0,74 € 0,74
    capacitor 1uF Fab inventory 1,00 € 0,08 € 0,08
    capacitor 10uF Fab inventory 1,00 € 0,10 € 0,10
    resistor 10KΩ Fab inventory 1,00 € 0,01 € 0,01





    voltage regulator board



    LM2940IMP 5V voltage reg. 1A Fab inventory 1,00 € 0,34 € 0,34
    capacitor 1uF Fab inventory 2,00 € 0,08 € 0,16
    capacitor 10uF Fab inventory 1,00 € 0,10 € 0,10
    through hole 90degr 4pin header Fab inventory 1,00 € 0,19 € 0,19





    attiny44 board



    attiny44 Fab inventory 2,00 € 1,18 € 2,36
    isp 6pin header Fab inventory 1,00 € 0,25 € 0,25
    through hole 90degr 4pin header Fab inventory 2,00 € 0,19 € 0,38
    resistor 10KΩ Fab inventory 1,00 € 0,01 € 0,01
    capacitor 1uF Fab inventory 1,00 € 0,08 € 0,08





    motor driver board



    A4950 Full-Bridge driver Fab inventory 2,00 € 3,11 € 6,22
    LM2940IMP 5V voltage reg. 1A Fab inventory 1,00 € 0,34 € 0,34
    capacitor 0,1uF Fab inventory 2,00 € 0,12 € 0,24
    capacitor 10uF Fab inventory 2,00 € 0,10 € 0,20
    capacitor 1uF Fab inventory 1,00 € 0,08 € 0,08
    through hole 90degr 6pin header Fab inventory 1,00 € 0,19 € 0,19
    power supply Fab inventory 1,00 € 7,50 € 7,50





    miscellaneous items Fab inventory 1,00 € 3,00 € 3,00









    € 225,00


    what parts and systems will be made?

  • wall mountable panel incl. rear plate
  • window mountable casing
  • cover for total of the window system
  • window frame model
  • mechanical part transfering motion of the motor
  • part for mounting the motor
  • part for mounting the screw bearing
  • 2 microcontroller boards
  • 2 WiFi boards
  • 1 motor driver board
  • 1 voltage regulator board
  • wiring for all external electronic connections
  • Arduino code

  • what processes will be used?

  • 2D modelling (Rhino) - wall panel rear part, casing for electronics, cover
  • 3D modelling (Rhino) - wall panel
  • laser cutter machining (BRM CO2 laser) - wall panel rear part, casing for electronics, cover
  • molding and casting (manual process) - wall panel
  • pcb design (CADsoft Eagle) - all fabricated boards
  • pcb fabrication (Roland Modela small milling machine) - all fabricated boards
  • mounting smd components (manual soldering) - all fabricated boards
  • programming (Brackets, help from local instructor Emma Pareschi, Lynda.com programming course, hours and hours and hours of internet research) - programs running on ATmega328p, ATtiny44 and esp8266-12e

  • what tasks need to be completed?

  • make window model to test with and show at the presentation
  • design and make mechanical part between motor and window
  • complete code for LCD, motor and communication between boards
  • design and make (3D print?) window mountable casing
  • design and make cover for the window side system
  • design and make microcontroller board for 'window side'
  • design and make a voltage regulator board

  • what questions need to be answered?

  • what type of mechanics will work well enough to operate the window
  • how will the communication routing be, via mqtt (internet) or between my microcontroller boards (locally) only

  • what is the schedule?

    I have two weeks left and will focus on the stepper motor control (code), mechanism (gears?) and window frame model first because I did not prove the concepts of these topics yet.
    Then I will continue with the code for the LCD and the communication between the boards which I have looked into a bit already and think I know (how) I can do it.
    Then I will design and make the window mountable casing and the microcontroller board. Then the motor mount part and the bearing mount part. Then the voltage regulator board and the cover.

    how will it be evaluated?

    The system should be able to respond to the fluctuating CO2 level by opening and closing the window when certain low and high thresholds are breached.