Global Village Construction Set


We’re pleased to announce design completion of Prototype IV of the Compressed Earth Brick (CEB) Press.  The machine has come a long way since Prototype I. The main changes since Prototype III - part of our Christmas Gift to the World of 2011 -  includes redesign of the hopper, a stronger frame, the next iteration of the automation controller, and general  streamlining of the design for fabrication.

Below is a video history of the Liberator from 2007 until present :

The CEB Story 2012 from Open Source Ecology on Vimeo.

Below is a video illustrating the latest 3D CAD of the machine.


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The improvements are detailed as follows: (more…)

Categories: Global Village Construction Set, The Liberator

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Here is a historical perspective on LifeTrac since September 2008 – the completion of LifeTrac Prototype I.

The LifeTrac Story from Open Source Ecology on Vimeo.

Right now we are using the LifeTrac to trench water lines for Factor e Farm. LifeTrac now has a total of about 200 hours of operation. The modular Quick Attach Wheels are working well. They have a total of 4000 pounds of pushing force with 4 wheel drive. The bent loader arms improve balance.

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(more…)

Categories: LifeTrac, LifeTrac IV

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Hello World, it’s Brianna again, with the final update on Ironworker Prototype II. You can see former work on Prototype I from 2 years ago. See the wiki for more details.

The Completed Ironworker and me

The build of the Prototype II has been completed  with great success on some fronts, and failure on other fronts. The machine was successful in that it shears even more than I’d specified, and that it actually works. The failures were in how long the machine took to produce (see my initial build proposal), how much the materials cost, and that I didn’t finish the punch element.

The current state is that we have a functional prototype, but still don’t have CAD or full documentation on how to build it. My Sketchup model is not entirely up to date either; it needs to have the updated shear tables, updated clamps, the reinforcement plates on the back side, and parts of the vertical linkages which had to be torched away. If anyone is interested in building, I can tell you the changes I had to make. Just email me at brianna at kufadesigns dot com.

I do not have any plans for finishing the remaining documentation, as I have moved back to California and will be working full time in the fabrication industry. OSE is looking for a draftsman to finish the CAD and 2D fab drawings for the machine. See the summary of existing documentation.

Successes

First, for the successes: the machine has been tested and can cut up to 1”x10” flat steel, and 3/8”x4”x6” angle steel. It should cut up to 3/8”x6”x6” angle steel, but we didn’t have any on hand, so we didn’t test it. Here’s a video of the testing:


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The cuts were far closer to perfection than I’d hoped. What I’d been looking for in the cut was that there be no burr, and minimal deformation along the length of the cut. The cut was cleaner than any cuts of similar magnitude which I had seen on an industrial machine. The cleanliness of the cut is very difficult to achieve, as it requires the blades to be perfectly parallel, and to have a gap between .007” and .010”, which required very precise machining.

The 1"x10" cut

The 3/8"x4"x6" angle cut

The testing went smoother than expected, with only one failure. (more…)

Categories: Accomplishments, Ironworker Machine

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Hello everyone, sorry for the delay between blog posts lately. I’m Parker Bonnell, one of OSE’s newer staff members, working primarily with Marcin and Aaron on organizational development.

The last month has been a busy one at the Factor E Farm. Our population is now in the double digits, fluctuating at around 14 people on-site. This boom has been a doubled edged blade though. While it has led to greater progress on multiple fronts, (GVCS tools, agriculture, organizational development, and construction) it has also caused some issues with infrastructure breakdowns due to the rapid increase in population, and subsequent demand.

GVCS Tools

As some have seen from YouTube updates, Brianna (with CAD help from Emmanuel Carvajal and thanks to Roger Olson for fabricating a shear blade) has completed the Ironworker. It can shear up to 1”x10” steel flats with 100+ tons of force at the linkage, and roughly triple that for the angle shear. A more detailed blog post about it should be forthcoming.

Great strides have been made with the cold saw, which is nearly complete, and should be running by the end of the week. The torch table is also moving along nicely, and is slated to be finished within 3 weeks. Lastly, the sawmill while completed awhile back, has yet to be tested. This will hopefully change sometime in the next few weeks. We’ll keep you posted as things develop.

Agriculture

Gabi, our Agricultural Director, has been busy since she arrived last month. Working with other interested individuals on the farm, she has begun charting a long-term livestock/agricultural management and development plan that will navigate the farm as we move forward. In order to inform this process, land surveying has also begun.

Contour map of FeF

On the more material side of things, we have bee receiving a steady stream of raw milk (about two gallons a day) from our newly acquired bovine friend, aptly named “Good Cow.” We have also been using the excess milk, with progressively greater success, to make butter, with plans for cheese and yogurt. Our goal of meeting all dairy needs in-house is well on it’s way. Poultry-wise, less so. While we have ten or so laying hens, and more roosters than we need, they are laying few eggs in the heat of the summer. This should pick up by next Spring with our new generation of chickens—currently chicks that are still in their adorable stage of life.

Some garden beds have also started development, both behind the HabLab and alongside the old workshop. While it’s a bit late to plant much for harvest this year, we hope to enrich them for next Spring with compost and manure. We also have a newly constructed horto domi, built by Will Bratton and Samuel Bagot, which serves as a mini self-regulating greenhouse. We also just got some rabbits, which can  produce more than 100 lbs of meat per year.

Organizational Development

In this department, a number of balls are rolling in different directions, with the current focus on recruiting, flash mobs, team development, and documentation. In the last few months, Marcin stepped up recruiting to bring in the current group of folks now at the farm. A second round of recruiting is on its way, and we’ve been working to streamline the process, as well as reach a somewhat wider audience. In tandem with this, a database is being pieced together in order to organize applicants, and serve as a storehouse of contacts when we start utilizing the flash mob system on a regular basis.

Along with recruiting and flash mobs, everyone at FeF has also been working out how best to live together; what responsibilities everyone has and how to communicate most effectively when making group decisions and in general. This is an ongoing process, and if there’s interest from our readers, can be expanded upon as things progress.

In terms of documentation, we recently hired our first documenter, Tristan Smith. A talented videographer (formerly at WikiLeaks), Tristan has started by focusing on production of a short film that summarizes the essence of Open Source Ecology–slated for completion around late August. After that, he’ll be putting together high-caliber weekly updates about the goings-on of FeF, and other videos as needed.

Short video mood board proposal for OSE

Construction

On this front, the most notable developments consist of resumption of work on the HabLab, infrastructure/agricultural development plans, and completion of Vann’s hexayurt (which will be detailed in an upcoming post). While the HabLab is mostly complete, we’ve begun the final stage, consisting of finishing the four side-rooms on the east side of the house, wiring the unfinished outlets throughout the house, and stuccoing the unfinished walls. Once those are complete, all that will be left is setting up a heating system in time for winter. Moving forward from there, plans are being developed for a number of infrastructure and agricultural projects. Some notable potential projects include a cistern for rainwater catchment and well-water storage; burying water, power, and internet lines; a pond for additional water storage and irrigation; a possible secondary greenhouse, and keyline design with strategically placed berms and swales for efficient irrigation of crops.

Issues

As mentioned, our rapid population increase has caused some problems, which has slowed development in other areas as various folks work to troubleshoot the issues.  Water has been the primary trouble, as our well, dug 4 years ago with a submersible DC pump, hasn’t been able to produce enough water to meet demand. Our water storage tanks, exposed to sunlight, also began developing some algae, which led to two people getting sick. We have installed a reverse osmosis filter, but because of our water demand, not everyone was using it. It’s use has mostly remedied the potable water issue, and we plan on installing an ozonator or UV filter to further treat the water. As for supply, plans are in motion to dig another well – we  got Mark Finch to drill test holes and identified a 1 gallon per minute location. We will start rain catchment from the HabLab, and store water in an underground gravel cistern. Furthermore, we plan on linking up with the town water system, which will serve as an emergency backup.

Aside from water, there have also been some power and internet hiccups, but these are relatively minor problems, and will be detailed further another time. We are still electrically off-grid, and we are considering a biogas digester cooking gas/electrical system.
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That about sums up the recent progress at FeF. Stay tuned for more frequent updates. Part of my role is to produce a weekly blog post, since Marcin has less time for this due to his schedule. Things are settling down as we regroup and reorganize.

Categories: Community, Construction, Factor e Farm, Global Village Construction Set, Ironworker Machine, Open Source Ecology

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Hey all, Vann here. If you have a background in Power Electronics, and are interested in acting as a consultant, mentor, or remote developer of our Power Inverter project, please contact me at vann.miller@gmail.com.

We’re just starting and thus still defining our design parameters (in accordance to OSE Specifications), but the initial goal is to develop an inverter capable of taking up to 72V DC and outputting 120v AC, say up to 5000W. Eventually we’d like one with three phase power, perhaps expandable via modules. And we’d like to do all this using a (so-called) modern, high frequency design, to help keep component costs low. (more…)

Categories: Global Village Construction Set, Open Source Inverters, Open Source Technology

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Global Village Construction Set development  is scaling. There are currently 9 projects under active development and 3 full time developers besides me – Aaron Makaruk, Brianna Kufa, and Yoonseo Kang, two of which are currently off-site. The active projects include: the Ironworker Machine (build started), open source Tractor (modification field testing), CNC Circuit Mill (build almost complete), CNC Torch Table (build started), Dimensional Sawmill (build to be resumed next week), Heat Exchanger (prototype 1 coil done), Gasifier Burner (complete design, rationale, CAD, cam files- details in next blog post), Modern Steam Engine (parts kit arriving next week), and Backhoe (design challenge is up at GrabCAD). You can download a linked map by Aaron that shows the scope of some of the activity in the USA.

Most intriguing to me is two of high school engineers from Pasadena- who are replicating LifeTrac independently – with a goal to donate it to South Central Farmers in Los Angeles. See their work and the LifeTrac t-shirts in their fund-raising effort.

Development priorities for this year have been outlined in the OSE Enterprise Plan video – which we are passing on to potential investors. More current priorities for the next few months are outlined in (more…)

Categories: Accomplishments, Global Village Construction Set

[7] Comments

Last week I said I’d have the complete OSE proposal and Sketchup done for the ironworker by Friday. I didn’t get it done by then, but I am prepared to start building next week. I finished the majority of the OSE Proposal, see it here. I’ll be posting my engineering calculations onto the proposal when I get them scanned in. I also generated a Bill of Materials with most of the costs listed.  I’m waiting on the quotes for the steel; these should come in Monday morning. I plan on having all materials purchased by Tuesday, and begin building as soon as I get materials to work on.


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Categories: Ironworker Machine, Open Source Ecology, Production

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Hello world,

This is an update for the Ironworker prototype 2.

By next Friday, Feb. 3, I will have completed the remainder of the sketchup design, and the official OSE Proposal, and will be posting both in another blog post. This will include my calculations for the machine sizing, a design rationale, an overall project plan, a bill of materials and a budget. I’ve been designing the ironworker for months now, and the design stage is finally nearing completion. See the latest sketchup model. The design is not quite finished, but will be within the next week. Major things which are missing from the design are the frame to suspend the machine, and a clamp for the flat shear. Everything else is pretty much done, except that a few bolts and holes, as well as the pins need to be fixed.

(more…)

Categories: Ironworker Machine

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The Ironworker shear assembly challenge is now live at GrabCAD. See my prior post here, and note that we are funded to get this done. We are escalating the pace, and exploring the use of open source crowd engineering in the process. This is our second entry at GrabCAD, the first entry being the tractor. Let any engineer friends know!

Categories: Collaboration Platform, Crowd Engineering, Ironworker Machine

[2] Comments

Recently, the CEB Press electronics improved to the third major iteration, replacing Generation 2 electronics from September of this year. Generation 3 electronics consist of a revised solenoid driver board that eliminates the need for the Arduino breakout board.

Generation 3 is now under evaluation at Factor e Farm and at Creation FlameGeneration 1 electronics included 2 solenoid driver boards borrowed from the RepRap project, and is robust but not recommended due to unnecessary complexity. Generation 2 included consolidation of the 2 driver boards into one, in surface mount format, and is proven in field testing with over 100 hours of brick pressing. Generation 1 and 2 included the breakout board, and the Generation 3 redesign eliminates the need for the breakout board by including sensor connections right on the driver board. This reduces controller complexity and cost significantly over Generation 2.

Furthermore, the organization of the controller box has been streamlined, the materials required for the sensor unit have been reduced, and the electro-hydraulic integration now assembles more intuitively.

We aim to reduce the complexity of the CEB controller to the point that a novice could build it in a few hours from available parts. (more…)

Categories: CEB Press Controller, CNC Circuit Mill, Compressed Earth Block Press

[2] Comments

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