Merge pull request #4 from plampkin/terminology

Updated terminology, add additional descriptions, updated graphics

21 files changed, 348 insertions, 0 deletions

diff --git a/fabrication-and-operation-instructions/3dp-coverat.jpg b/fabrication-and-operation-instructions/3dp-coverat.jpg
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diff --git a/fabrication-and-operation-instructions/bare-pcb.jpg b/fabrication-and-operation-instructions/bare-pcb.jpg
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diff --git a/fabrication-and-operation-instructions/barrels-tested.jpg b/fabrication-and-operation-instructions/barrels-tested.jpg
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diff --git a/fabrication-and-operation-instructions/cable-tie.jpg b/fabrication-and-operation-instructions/cable-tie.jpg
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diff --git a/fabrication-and-operation-instructions/connectors.jpg b/fabrication-and-operation-instructions/connectors.jpg
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diff --git a/fabrication-and-operation-instructions/digital-wired.jpg b/fabrication-and-operation-instructions/digital-wired.jpg
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diff --git a/fabrication-and-operation-instructions/driver-on-base.jpg b/fabrication-and-operation-instructions/driver-on-base.jpg
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diff --git a/fabrication-and-operation-instructions/electronics-coverart.jpg b/fabrication-and-operation-instructions/electronics-coverart.jpg
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diff --git a/fabrication-and-operation-instructions/heat-insert.jpg b/fabrication-and-operation-instructions/heat-insert.jpg
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diff --git a/fabrication-and-operation-instructions/led-and-heatsink.jpg b/fabrication-and-operation-instructions/led-and-heatsink.jpg
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diff --git a/fabrication-and-operation-instructions/pcb-driver.jpg b/fabrication-and-operation-instructions/pcb-driver.jpg
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diff --git a/fabrication-and-operation-instructions/redboard.jpg b/fabrication-and-operation-instructions/redboard.jpg
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diff --git a/fabrication-and-operation-instructions/reflector.jpg b/fabrication-and-operation-instructions/reflector.jpg
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diff --git a/fabrication-and-operation-instructions/soldered-led.jpg b/fabrication-and-operation-instructions/soldered-led.jpg
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diff --git a/fabrication-and-operation-instructions/surface-mount.jpg b/fabrication-and-operation-instructions/surface-mount.jpg
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diff --git a/fabrication-and-operation-instructions/wpr-assembly.pdf b/fabrication-and-operation-instructions/wpr-assembly.pdf
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diff --git a/fabrication-and-operation-instructions/wpr-assembly.tex b/fabrication-and-operation-instructions/wpr-assembly.tex
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+%% document
+\documentclass[11pt]{article}
+\usepackage[letterpaper, portrait, margin=0.75in]{geometry}
+\usepackage{setspace}
+\usepackage{color}
+
+% text
+\usepackage[utf8]{inputenc}
+\setlength\parindent{0pt}
+\setlength{\parskip}{1em}
+\renewcommand{\familydefault}{\sfdefault}
+\newcommand{\RomanNumeral}[1]{\textrm{\uppercase\expandafter{\romannumeral #1\relax}}}
+
+% math
+\usepackage{amssymb}
+\usepackage{amsmath}
+\usepackage[cm]{sfmath}
+\usepackage{commath}
+\usepackage{multirow}
+\DeclareMathAlphabet{\mathpzc}{OT1}{pzc}{m}{it}
+
+% graphics
+\usepackage{graphics}
+\usepackage{graphicx}
+\usepackage{epsfig}
+\usepackage{epstopdf}
+\usepackage{xpatch}
+\usepackage{pdfpages}
+\usepackage{float}
+
+% each section begins new page
+\let\stdsection\section
+\renewcommand\section{\clearpage\stdsection}
+
+% hyperref
+\usepackage[colorlinks=true, linkcolor=black, urlcolor=blue, citecolor=black, anchorcolor=black]{hyperref}
+\usepackage[all]{hypcap}  % helps hyperref work properly
+
+
+
+\usepackage[shortlabels]{enumitem}
+\setlist[enumerate, 1]{nosep}
+\setlist[enumerate, 2]{nosep, topsep=-5ex}
+\setlist[enumerate, 3]{nosep, topsep=-5ex}
+\setlist[enumerate, 4]{nosep, topsep=-5ex}
+\setlist[itemize, 1]{nosep}
+\setlist[itemize, 2]{nosep, topsep=-5ex}
+\setlist[itemize, 3]{nosep, topsep=-5ex}
+\setlist[itemize, 4]{nosep, topsep=-5ex}
+
+% bibliography
+\usepackage[numbers]{natbib}
+
+% title
+\title{Wisconsin Photoreactor \\ Assembly Instructions}
+\author{
+  Philip Lampkin \\
+  Blaise J. Thompson \\
+  Samuel H. Gellman
+  }
+\date{\today}
+
+\begin{document}
+
+\maketitle
+
+\includegraphics[width=\textwidth]{"../coverart.jpg"}
+
+\tableofcontents
+
+\section{Introduction}
+
+The Wisconsin Photo-Reactor (WPR) is made to be easily assembled.
+This document is meant to help chemists accomplish this assembly.
+Each reactor has two major components requiring detailed custom assembly:
+
+\begin{itemize}
+  \item The 3D printed enclosure, described in \autoref{SEC:enclosure}
+  \item The drive electronics, described in \autoref{SEC:electronics}
+\end{itemize}
+
+With these two major components complete, assembly of the WPR is relatively straight-forward.
+Details of final assembly are described in \autoref{SEC:assembly}.
+
+Throughout this document we refer to an online repository containing source and design files.
+This repository appears at \url{https://github.com/uw-madison-chem-shops/wisconsin-photoreactor}.
+This repository contains everything including the source for this very document.
+
+A working WPR is made up of many separate commercially available parts.
+This guide assumes that you have already done the work of procuring those parts.
+The online repository contains several README files with detailed part numbers and suggested vendors.
+
+The WPR is a living project.
+We welcome and encourage duplication and modification of our designs and documentation.
+If you notice problems or omissions within this assembly document, please consider opening an issue or pull request.
+
+\section{3D Printed Enclosure} \label{SEC:enclosure}
+
+\includegraphics[width=\textwidth]{"./3dp-coverat.jpg"}
+
+The body of the WPR is made up of three main pieces:
+
+\begin{itemize}
+    \item Base, containing LEDs, fan, and drive electronics.
+    \item Top plate accepting reaction vials.
+    \item Chamber walls spacing the top plate at the appropriate distance away from the base.
+\end{itemize}
+
+The WPR base is the same for all reactors.
+Look within the repository in the subdirectory ``photoreactor-base'' to find design and production files to produce the WPR base.
+You will also need to print a cable anchor, see files in that same directory.
+
+The top plate and chamber height must be specified for the particular reaction vessels used.
+Four examples for different vial sizes are pictured above.
+Look within the repository in the subdirectory ``photoreactor-tops'' to find existing designs.
+We encourage you to design your own if none of these suit your application.
+Consider adding your new designs to repository so that others may benefit from your design efforts.
+
+When interacting with the design files in our online repository you will see several different filetypes.
+We have designed the WPR enclosure using Fusion 360, and have included those f3d design files for those that wish to extend or modify the designs.
+Interacting with f3d files will require a Fusion 360 license.
+You will also find stl files in the online repository.
+These are common 3D-model exchange files which can be viewed using any 3D modeling program.
+In fact, GitHub itself has a built in stl viewer which you may use to inspect our designs.
+
+There are many options for getting your enclosures printed.
+We recommend white PLA as a material, although any white material should work---we have also used ABS.
+If you are printing yourself, follow the instructions provided by your printer to produce slices and program your printer.
+Note that you will need support material for the base.
+Any company or shop offering 3D printing as a service should be able to accept our stl files without further modification.
+
+We have succesfully printed using the following printers:
+
+\begin{itemize}
+  \item Ender 3
+  \item Stratasys uPrint SE Plus
+  \item Ultimaker 3
+\end{itemize}
+
+Once your parts are done you may need to remove extra bonding material with a razor blade or exacto-knife.
+The three pieces of your reactor should fit together snugly and securely.
+
+\clearpage
+
+\begin{center}
+  \includegraphics[width=0.5\textwidth]{"./heat-insert.jpg"}
+\end{center}
+
+Each WPR base contains seven threaded heat inserts.
+These allow components such as the drive circuit board to rigidly attach to the base via machine screws.
+Use a soldering iron to carefully heat these while pushing them into their cavities.
+
+\section{Electronics} \label{SEC:electronics}
+
+\includegraphics[width=\textwidth]{"./electronics-coverart.jpg"}
+
+The WPR incorporates small circuit boards controlling the incorporated LED and fan.
+We refer to these small boards as ``drivers''.
+There are two types available: the ``analog-driver'' and ``digital-driver''.
+Refer to the associated directories in the online repository for design files for each of these.
+
+Both drivers are built around Mean Well's LDD-1000L LED driver module.
+This module delivers constant current up to one amp.
+The current delivered can be controlled electronically in several different ways.
+WPR users wishing to understand this design should refer to Mean Well's datasheet.
+
+The analog-driver circuit is made to be as simple as possible.
+The circuit accepts DC 12 V through a barrel jack.
+A small knob is used to adjust light intensity.
+Fan speed is not adjustable.
+Refer to \autoref{SEC:analog-driver} for analog-driver assembly instructions and further explanation.
+
+The digital-driver circuit is made to be incorporated into an I$^2$C-based digital control system.
+In addition to power, these boards have 4-pin connectors to carry the I$^2$C serial data.
+The digital-driver is pictured above, without any connectors attached.
+Refer to \autoref{SEC:digital-driver} for digital-driver assembly instructions and further explanation.
+
+When interacting with the design files in our online repository you will see several different filetypes.
+These circuit boards were designed using KiCad, a free and open source electronics CAD software.
+All KiCad files are contained within the ``kicad'' subdirectories.
+You may modify and extend these designs however you like.
+
+Those wishing to reproduce our designs should refer to the gerber subdirectory.
+Within the gerber directory you will find zip files for each separate version of the PCB.
+You may upload these zip files to PCB manufacturers when ordering copies of our designs.
+
+\clearpage
+\subsection{Analog} \label{SEC:analog-driver}
+
+The analog driver circuit is meant to be as simple as possible while still allowing for reproducible LED intensity control.
+To this end, the number of components has been minimized as much as possible.
+A full schematic of the analog circuit appears at the end of this section.
+A bill of materials appears within the README of the online repository.
+
+\begin{center}
+  \includegraphics[width=\textwidth/2]{"./bare-pcb.jpg"}
+\end{center}
+
+Your PCB manufacturer will send you a bare board, as seen above.
+
+\begin{center}
+  \includegraphics[width=\textwidth/2]{"./surface-mount.jpg"}
+\end{center}
+
+Begin by adding the surface mount components.
+Recommend thin solder, e.g. 0.015''.
+The LED does have a polarity---ensure that the small green line points towards ground (left).
+Once done your board should look like the above.
+
+\begin{center}
+  \includegraphics[width=\textwidth/2]{"./connectors.jpg"}
+\end{center}
+
+Next, add the connectors and the potentiometer knob.
+From now on we recommend standard gage solder, e.g. 0.031''.
+Once done your board should look like the above.
+
+\begin{center}
+  \includegraphics[width=\textwidth/2]{"./barrels-tested.jpg"}
+\end{center}
+
+Next, add the barrel jacks and the test points.
+With these added you may plug in your board for the first time.
+You should see your power indicator LED illuminate.
+You should also be able to adjust the DC control voltage relative to ground by turning the knob, as shown above.
+
+\begin{center}
+  \includegraphics[width=\textwidth/2]{"./pcb-driver.jpg"}
+\end{center}
+
+Finally, add the Mean Well LED driver.
+Note that this component goes on the back of the PCB, as shown above.
+
+\includepdf[landscape=true]{"../analog-driver/driver.pdf"}
+
+\subsection{Digital} \label{SEC:digital-driver}
+
+The digital driver circuit can be controlled from a computer or some other digital device.
+We built our driver to work over I2C, consistent with an emerging standard for many ``maker'' products.
+While the physical connectors may be different, our digital circuit is compatible with the following systems.
+
+\begin{itemize}
+  \item \href{https://learn.adafruit.com/introducing-adafruit-stemma-qt}{Adafruit STEMMA}
+  \item \href{https://www.sparkfun.com/qwiic}{Sparkfun Qwiic}
+  \item \href{https://www.seeedstudio.com/category/Grove-c-1003.html}{Seeed Grove}
+\end{itemize}
+
+\begin{center}
+  \includegraphics[width=\textwidth/2]{"./digital-wired.jpg"}
+\end{center}
+
+Each digital driver is based around an ATtiny85 microcontroller acting as an I2C peripheral.
+Multiple digital driver boards may be ``networked'' together onto one I2C bus by simply daisy-chaining the boards together, as shown above.
+In such a use-case you must choose a unique I2C address for each ATtiny85 peripheral.
+
+\begin{center}
+  \includegraphics[width=\textwidth/2]{"./redboard.jpg"}
+\end{center}
+
+There are many ways to interface with the I2C bus.
+We have used a SparkFun RedBoard, pictured above.
+You may find an example within the online repository that dynamically controls both the LED intensity and fan speed.
+
+\includepdf[landscape=true]{"../digital-driver/driver.pdf"}
+
+\section{Assembly} \label{SEC:assembly}
+
+\includegraphics[width=\textwidth]{"./assembly-coverart.jpg"}
+
+Once 3D printing is done and PCBs have been filled, WPR assembly is fairly straight-forward.
+The various electronic components must be installed into the base (pictured above), as described in \autoref{SEC:base}.
+Reflective coating must be added to the chamber walls, as described in \autoref{SEC:top}.
+After these final steps, your WPR is ready for synthesis!
+
+\clearpage
+\subsection{Base} \label{SEC:base}
+
+\begin{center}
+  \includegraphics[width=\textwidth/2]{"./bare-led.jpg"}
+\end{center}
+
+If possible, it's best to order your LEDs pre-attached to an ``LED star'' heat sink.
+Otherwise you may order bare LED stars and discrete LEDs.
+Either way, you will have a filled LED star as pictured above.
+In this example we are using LED Supply part number 07007-PL000-F.
+
+\begin{center}
+  \includegraphics[width=\textwidth/2]{"./soldered-led.jpg"}
+\end{center}
+
+Start by soldering leads onto your LED star, using the red positive black negative convention.
+Soldering here may be challenging, as the LED star itself will resist your efforts to heat it.
+Adding some lead-based solder may help, due to the lower melting point.
+
+\begin{center}
+  \includegraphics[width=\textwidth/2]{"./tap-heatsink.jpg"}
+\end{center}
+
+The aluminum heatsinks arrive preformed but without any tapping.
+Tap the heatsink for imperial 4-40 machine screws.
+We used thread-forming tap: OSG 1400105300 with a pneumatic ``air-tapper'' (pictured above), but you may do this by hand if you wish.
+You will need to tap just two of the innermost holes.
+
+\begin{center}
+  \includegraphics[width=\textwidth/2]{"./led-and-heatsink.jpg"}
+\end{center}
+
+Install the LED star and heatsink with wires facing towards printed hole.
+Use 1/4'' screws.
+
+\begin{center}
+  \includegraphics[width=\textwidth/2]{"./mounted-fan.jpg"}
+\end{center}
+
+Install the fan.
+Pay special attention to the orientation of the fan, including the location of the cord.
+Use 3/4'' screws here.
+
+\begin{center}
+  \includegraphics[width=\textwidth/2]{"./cable-tie.jpg"}
+\end{center}
+
+Install the cable anchor using a 1/4'' screw.
+Use a zip tie to capture the fan cord, as shown above.
+
+\clearpage
+
+\begin{center}
+  \includegraphics[width=\textwidth/2]{"./driver-on-base.jpg"}
+\end{center}
+
+Install the driver board using the threaded standoffs.
+Plug the LED and fan into the board.
+Pay special attention to the orientation of the fan connector.
+You should now be ready to test your base---remember to use proper eye protection!
+
+\clearpage
+\subsection{Top} \label{SEC:top}
+
+\begin{center}
+  \includegraphics[width=\textwidth/2]{"./reflector.jpg"}
+\end{center}
+
+Simply cut the reflective material to line the chamber.
+It's good to leave overlap around the interior, as shown.
+Remove the backing and stick the material to the chamber walls.
+
+\end{document}