From b30f14749f90a8291ea95d48329efe20339dd66b Mon Sep 17 00:00:00 2001 From: Blaise Thompson Date: Sat, 24 Apr 2021 17:03:00 -0500 Subject: rough merge of content from operation instructions --- .../wpp-fabrication-operation.pdf | Bin 0 -> 57003665 bytes .../wpp-fabrication-operation.tex | 480 +++++++++++++++++++++ .../wpr-assembly.pdf | Bin 52642891 -> 0 bytes .../wpr-assembly.tex | 348 --------------- 4 files changed, 480 insertions(+), 348 deletions(-) create mode 100644 fabrication-and-operation-instructions/wpp-fabrication-operation.pdf create mode 100644 fabrication-and-operation-instructions/wpp-fabrication-operation.tex delete mode 100644 fabrication-and-operation-instructions/wpr-assembly.pdf delete mode 100644 fabrication-and-operation-instructions/wpr-assembly.tex (limited to 'fabrication-and-operation-instructions') diff --git a/fabrication-and-operation-instructions/wpp-fabrication-operation.pdf b/fabrication-and-operation-instructions/wpp-fabrication-operation.pdf new file mode 100644 index 0000000..af212e8 Binary files /dev/null and b/fabrication-and-operation-instructions/wpp-fabrication-operation.pdf differ diff --git a/fabrication-and-operation-instructions/wpp-fabrication-operation.tex b/fabrication-and-operation-instructions/wpp-fabrication-operation.tex new file mode 100644 index 0000000..f301d73 --- /dev/null +++ b/fabrication-and-operation-instructions/wpp-fabrication-operation.tex @@ -0,0 +1,480 @@ +%% 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 Platform\\Fabrication and Operation Guide} +\author{ + Philip Lampkin \\ + Blaise J. Thompson \\ + Samuel H. Gellman + } +\date{\today} + +\begin{document} + +\maketitle + +\includegraphics[width=\textwidth]{"../coverart.png"} + +\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. + +TODO: FIGURE 1 FROM OPERATION GUIDE + +A WPP device consists of a base, reaction module and reactor driver (Figure 1). +The base houses the photon source and cooling fan. +The reaction module is comprised of a reflective reaction chamber and rigid vessel holder. +A digital driver board, analog driver board or simple circuit integrating a commercial light emitting diode (LED) driver can be fitted to the base to drive the reactor. +Each component is highly versatile, and apparatus assembly is fully modular (Figure 1B). + +Through variation of each component, one can quickly produce bespoke WPP devices to meet specific research needs. +Configurational variations are easily documented for later reproduction. +Detailed below are instructions for configuration and documentation of each component in a WPP apparatus. + +\section{Fabrication} + +\subsection{Photon Source} \label{SEC:photon-source} + +TODO: FIGURE 2 FROM OPERATION GUIDE + +The WPP architecture utilizes industry standard 20 mm LED star circuit boards mounted with 3 high-intensity LEDs to deliver photons to photoreactions (Figure 2A). +These LED star boards are commercially available or can be easily fabricated (see fabrication guide). +The range of wavelengths provided by a LED star depends upon the emission profile of the mounted LEDs. +Through variation of the LED star integrated into a base (Figure 2B), the user can control the wavelengths of light delivered by the photon source to a reaction vessel. +See fabrication guide for LED star installation instructions. + +\subsection{3D Printed Enclosure} \label{SEC:enclosure} + +\includegraphics[width=\textwidth]{"./3dp-coverat.jpg"} + +A WPP reaction module consists of a reaction chamber and vessel holder. +By modifying chamber height and adjusting holder geometry, one can produce modules compatible with reaction vessels of various types and sizes. +Template reaction chamber and vessel holder CAD designs are provided in the project repository. +CAD designs and 3D-printable models for modules compatible with 1-, 4-, 8- and 24-mL vials are also provided in the repository (Figure 3A—B). + +A single reaction module can offer multiple layouts for reaction vessel placement. +For the provided modules, two vessel placement configurations exist. +First, the single reaction configuration, where one vessel is placed in the center of the module directly above the photon source (Figure 3C). +This configuration exposes one vessel to maximum light intensity. +Second, the multiple reaction configuration, where multiple vessels are placed in a circle around the photon source (Figure 3D). +This configuration exposes each vessel to less light relative to the single reaction configuration but provides equivalent exposure to each vessel. +Through variation of the reaction module, the user can configure the reaction vessel type, size and placement within a WPP apparatus. + +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. + +\subsection{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. + +A WPP device can be driven using a digital driver circuit board, an analog driver circuit board or a simple electronic circuit with a commercial LED driver (Figure 4). +Digital and analog driver board fabrication instructions are provided in the fabrication guide. +All provide power to the cooling fan and constant current to the LEDs. +All utilize 1000 mA forward current LED drivers. Each driver provides different configurational abilities. + +\clearpage +\subsubsection{Analog Driver} \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. + +Through use of the analog driver board, one can control WPP device light intensity. +This control is achieved through adjustment of the board-mounted potentiometer. +No software is required, and multiple WPP reactors can be connected in series to a single power source (Figure 6A). +However, fan speed isn’t adjustable and is maintained at maximum. +Relative light intensity can be determined using the analog driver board test points and a multimeter (Figure 6B-D). +The measured voltage can then be converted to relative light intensity using the values in Table 3. +These values are derived from the manufacturer’s datasheet for the analog board’s LED driver. +See the fabrication guide for more details. + +TODO: TABLE 3 FROM OPERATION GUIDE + +\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-board/driver.pdf"} + +\subsubsection{Digital Driver} \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} + +Through use of the digital driver board, one can control WPP device light intensity and fan speed. +This control is achieved by connecting a control unit, like an Arduino Uno, to the digital driver board using custom software. +Multiple WPP devices with digital driver boards can be connected to a single control unit and power supply (Figure 5). +Open-source software for interfacing digital driver boards and Arduino Uno control units is provided in the project repository. +Instructions for implementing this software and controlling WPP devices using it are in the fabrication guide. +Other I2C peripherals can be connected to digital driver boards to expand functionality, but software must be produced to interface with them. + +\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-board/driver.pdf"} + +\subsubsection{Simple Driver} \label{SEC:simple-driver} + +TODO: FIGURE 7 FROM OPERATION GUIDE + +The LED driver circuit shown in Figure 6 is the simplest way to drive a WPP apparatus. +Neither light intensity nor fan speed can be configured when using the simple LED driver circuit. +Both are maintained at maximum power. +However, no circuit board fabrication is required, and any commercial 1000 mA LED driver can be used. + +\subsection{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 +\subsubsection{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 +\subsubsection{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. + +\section{Operation} + +Once a WPP apparatus is configured with the desired photon source, reaction module and reactor driver, it can be used to drive photoreactions. + +TODO: FIGURE 8 FROM OPERATION GUIDE + +To conduct a photoreaction using a WPP device, an assembled apparatus should be placed on a lab stir plate, to provide reaction mixture stirring, and reaction vessels should be inserted into the apparatus in the desired layout (Figure 8). +The 130 by 130 mm footprint of the WPP architecture is compatible with typical stir plates. +A standard 12 V power supply can then be plugged into the reactor driver to turn on the device and start reaction. +A single 12V 2 A power supply is sufficient to drive 2 WPP devices simultaneously. +A switch can be installed between the WPP apparatus and power supply to provide power switching. + +Reaction and photon source cooling is provided by the computer fan integrated into the base. +Additional cooling can be achieved through placement of fans above the WPP apparatus or by placing a WPP device on a stir plate within in a refrigerator or cold room. + +Once finished, the WPP apparatus can be switched off by simply unplugging it and disassembled for storage. + +\section{Documentation} + +Users should report the following for each photon source used: + + (1) Max emission wavelength for LEDs. + (2) Manufacturer and part number for LEDs. + (3) Supplier and part number for LED star (if commercial). + +This information enables precise reproduction of WPP photon sources. Characterization of a photon source’s emission profile using a spectrometer is recommended but not required for reproduction. Emission profiles for commercial LEDs are supplied in part datasheets provided by manufacturers. A list of WPP-compatible LED stars exhibiting emission profiles across the visible range is provided in the project repository. + +Users should provide and report the following for each module used: + + (1) Original CAD designs for both module parts. + (2) 3D-printable models for both module parts. + (3) Photos of each reaction vessel placement configuration. + (4) Manufacturer and part number for reaction vessel. + +These provisions enable precise reproduction of reaction modules. Documenting the height a vessel is held above the photon source is recommended but not required for reaction module reproduction. All reaction modules provided in the project repository hold vessels a standardized 7 mm above the photon source. + +Users should report the following when an analog driver board is used: + + (1) Measured test point voltage. + (2) Relative intensity at which LEDs are driven (0 to 100%). + +These provisions enable precise reproduction of reaction conditions for transformations carried out using WPP devices fitted with analog driver boards. + +Users should provide and document the following when a digital driver board is used: + + (1) Software used to operate the digital driver board, control unit and any other peripherals. + (2) Relative intensity at which LEDs are driven (0 to 100%). + (3) Relative fan speed (0 to 100%). + +These provisions enable precise reproduction of reaction conditions for transformations carried out using WPP devices fitted with digital driver boards + +Users should report the following when a simple LED driver circuit is used: + + (1) Manufacturer and part number for LED driver. + +This information enables reproduction WPP devices fitted with the simple LED driver circuit. + +\section{Safety} + +WPP reactors utilize high-intensity light emitting diodes (LED) that can cause eye damage if proper safety precautions are not observed. +Light-filtering safety glasses should be worn whenever a WPP apparatus photon source is powered. +Care must be taken to use safety glasses protective against the specific emission wavelengths of the photon source. + +\end{document} diff --git a/fabrication-and-operation-instructions/wpr-assembly.pdf b/fabrication-and-operation-instructions/wpr-assembly.pdf deleted file mode 100644 index df4123c..0000000 Binary files a/fabrication-and-operation-instructions/wpr-assembly.pdf and /dev/null differ diff --git a/fabrication-and-operation-instructions/wpr-assembly.tex b/fabrication-and-operation-instructions/wpr-assembly.tex deleted file mode 100644 index 6b1c070..0000000 --- a/fabrication-and-operation-instructions/wpr-assembly.tex +++ /dev/null @@ -1,348 +0,0 @@ -%% 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} -- cgit v1.2.3