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| -rw-r--r-- | assembly-instructions/wpr-assembly.pdf | bin | 4248307 -> 10618577 bytes | |||
| -rw-r--r-- | assembly-instructions/wpr-assembly.tex | 106 |
2 files changed, 96 insertions, 10 deletions
diff --git a/assembly-instructions/wpr-assembly.pdf b/assembly-instructions/wpr-assembly.pdf Binary files differindex 2a1f19a..1376830 100644 --- a/assembly-instructions/wpr-assembly.pdf +++ b/assembly-instructions/wpr-assembly.pdf diff --git a/assembly-instructions/wpr-assembly.tex b/assembly-instructions/wpr-assembly.tex index d146cf9..f41885d 100644 --- a/assembly-instructions/wpr-assembly.tex +++ b/assembly-instructions/wpr-assembly.tex @@ -69,16 +69,93 @@ Throughout this document we refer to an online repository containing source and 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. +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 section TODO + \item The drive electronics, described in section TODO +\end{itemize} + +With these two major components complete, assembly of the WPR is relatively straight-forward. +Details of final assembly are described in section TODO. + +TODO: THIS IS A LIVING DOCUMENT, PLEASE CONTRIBUTE. + \section{3D Printed 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 Walls spacing the top plate at the appropriate distance away from the base. +\end{itemize} + +The WPR base is the same for all reactors. +The top plate and wall height can be adjusted depending on the particular vials desired. +Look within the repository in the subdirectory ``photoreactor-tops'' to find existing designs of (wall, top) for a number of different vial sizes. +We encourage you to design your own (wall, top) if none of these suit your application. +Consider adding your new designs to repository so that others may benefit from your design efforts. +In addition to these three main components you should also print a cable-anchor for each of your WPR bases. + +TODO: SHARE DETAILS ABOUT CAD SOFTWARE. +TODO: MAKE IT CLEAR THAT STL FILES ARE THE RELEVANT EXCHANGE FILE. +TODO: RECOMMEND STL VIEWER. +TODO: RECOMMEND SLICER. + +There are many options for getting your enclosures printed. +TODO: DO WE WANT TO GIVE ANY ADVICE ABOUT MATERIAL CHOICE? +TODO: RECOMMEND SPECIFIC MANUFACTURERS. +Of course, you may wish to print multiple (wall, top) types to be used interchangeably with one base. + +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. + +\includegraphics[width=0.5\textwidth]{"./heat-insert.jpg"} + +7 heat inserts... + \section{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. + +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. + +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. +More details about this digital control system are in TODO: LINK TO SECTION. + +\clearpage \subsection{Analog} +TODO: PICTURE OF PCB AS DELIVERED BY MANUFACTURER + +TODO: ADD SURFACE MOUNT +Recommend thin solder, e.g. 0.015''. +Small green line on LED towards ground (left). + +TODO: ADD CONNECTORS, TRIMPOT +Recommend standard solder, e.g. 0.031''. + +TODO: ADD BARREL JACKS, TEST POINTS + +TODO: TEST +150 mA to 3 V + +TODO: ADD DRIVER + \includepdf[landscape=true]{"../analog-driver/driver.pdf"} \subsection{Digital} @@ -96,22 +173,22 @@ Consistent with Adafruit, Sparkfun, Seeed... \includegraphics[width=\textwidth]{"./assembly-coverart.jpg"} - 0.5'' standoff: RAF 4505-440-AL \subsection{Base} -\subsubsection{LED and Heatsink} +TODO: ASSEMBLE LED +In this case LED Supply 07007-PL000-F +May be a challenge---heat sinking will fight you +Add lead-based solder to make easier TODO: LED PCB part number TODO: heatsink part number -\begin{figure}[H] - \centering +\begin{center} \includegraphics[width=\textwidth/2]{"./tap-heatsink.jpg"} - \caption{Two of the innermost holes on the extruded heatsink must be 4-40 tapped.} -\end{figure} +\end{center} Tap the heatsink. We used thread-forming tap: OSG 1400105300. @@ -120,11 +197,9 @@ TODO: heatsink compoud Install with wires facing towards printed hole -Use 4-40 1/4''. - -\subsubsection{Fan} +Use 4-40 1/4''. Fastenal 0146455 -TODO: fan part number +TODO: MOUNT FAN Noctua NF-A12x15 PWM @@ -135,4 +210,15 @@ black: ground Use 4-40 3/4'' into captured nuts +TODO: cable tie + +\subsubsection{Reflector} + +\begin{center} + \includegraphics[width=\textwidth/2]{"./reflector.jpg"} +\end{center} + +TODO: part number + + \end{document} |