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-% 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} |
