Building - Arms Pt. 2

With all the bearings epoxied into the arms, I could start with assembling them into the 4 individual groups.

I started by measuring the width of the arms put together, after having been glued together, sanded, and painted I couldn't be sure of exactly how thick the arms actually were.

Once I knew the thickness of each joint I could cut the rod to the approximate length. For all the joining rods and drive axles, I used 5/16" steel welding rods. 5/16" is 7.9375 mm, the inner diameter of the bearing is 8mm so it works out pretty perfectly.

The blue residue is from the hacksaw blade.

Then I ground the cut end with a bench grinder.

Measure and grind until it's the right length. Having the caliper was super useful during this whole process but especially when trying to get these joining rods all the same length.

Once all the joining rods were ground to the correct length I sanded them lightly to try and smooth out the slightly rounded end.

Then gave them several coats of black spraypaint.

I did pretty much all the joints one at a time, I really didn't want to mess something up and have to remake an entire set of arms.

I used a scrap piece of the 1/8" plywood to ensure the space between and the arms is the same.

All the joints completed. This was super time-consuming but at the end, everything lined up.

Comments

Designing - The Cells

A distinction I should make before going any further is the difference between solar cells and solar panels. When I am talking about the solar cells I am talking about the individual square parts inside of the panel. The panel being the housing for the cells, some sort of stiff material for the back and a sheet of glass over the front. The cells produce power and the panel houses and protects the fragile cells. The first step of designing the solar panels was to get the actual solar cells I'd be using since literally, everything was dependent on their size. I was able to find some panels for fairly cheap on eBay, so I officially began the project with the purchase of 10 A Grade 4.8W 19.6% 156mm Mono Silicon Cells. Here's what that means: A Grade - Panels are completely intact. B, C, or D Grade will have increasingly large chips missing from the cells. Read more here. 4.8W - This is the power output. 19.6% - This is the claimed efficiency of the cells. ...

Update - Drive System

Right, so my suspicions about the bond between the drive arm and drive arm were correct. When I tried to extend the panels using a pair of pliers the epoxy joints cracked and the axle broke loose. The panels did not extend at all. I've drilled a hole through the drive arm and axle, I epoxied a nail into the hole and it seems to be holding. I can now extend the panel with pliers. It takes quite a bit of force to do it. I kinda doubt a servo will be able to handle it.

Building - Arms Pt. 1

Building the arms was by far the most time-consuming task. If only I had a cnc.... The rim of wood around the bearing was needed but I didn't like the really thick arm, I drew this up in Fusion, printed out the drawing, and stuck it down with a glue stick. The slot in the middle was an idea to make the arms lighter and look cooler. I tried it with one arm and then ditched the idea, it really didn't work and was a lot of work. All cut-out, at this point I didn't have access to a scroll saw so this was all done with a regular handsaw and files. It's pretty rough but I cleaned it up as best I could. Already looking much better. The next step was mass production, I needed 20 arms total. For this, I bought a used Craftsman Scroll saw. It was very, very useful. All cut and drilled out. Removing the paper was annoying, I used the top edge of a file to scrape it off. Since I put it on with a glue stick it wasn't very difficult to scrap...

Martens Solar

Search This Blog