Difference between revisions of "Frame: Vacuum Formed Scale: A Plastic/Aluminum Hybrid"

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(Vacuum Formed Frame Fabrication and Development)
 
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'''OVERVIEW:'''<br>
 
'''OVERVIEW:'''<br>
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The vacuum formed scale utilizes a rectangular plastic hive rail with a reinforced aluminum undercarriage.  The general concept behind this scale was to produce an affordable light-weight scale that was able to accommodate both ten frame and eight frame Langstroth beehives.  An additional aluminum undercarriage was added as extra reinforcement was needed to support the weight of the cantilevered load cells.   
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The vacuum formed frame utilizes a rectangular plastic hive rail with a reinforced aluminum undercarriage.  The general concept behind this scale was to produce an affordable light-weight scale that was able to accommodate both ten frame and eight frame Langstroth beehives.  An additional aluminum undercarriage was added as extra reinforcement was needed to support the weight of the cantilevered load cells.   
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'''PRODUCTION:'''<br>
 
'''PRODUCTION:'''<br>
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'''DEVELOPMENT AND FABRICATION PHOTOS:'''<br>
 
<gallery>
 
<gallery>
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File:Scale1.JPG|Stainless Steel Scale with Load Cells|alt=alt language
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File:ScaleMoldTesting2.JPG|Test drilling for wooden mold creation|alt=alt language
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File:Scale1.2.JPG|Testing the Scale with Weights|alt=alt language
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File:ScaleMold1.JPG|Creation and drilling of wooden mold|alt=alt language
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File:Scale2.JPG|Leveling and Installation of the Scale|alt=alt language
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File:VacuumFormDuplicates.JPG|Plastic vacuum formed hive rails arrive|alt=alt language
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File:Scale2.2.JPG|Rough Installation of Components|alt=alt language
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File:VacuumForm1.JPG|Plastic vacuum formed hive rail|alt=alt language
  
 
</gallery>
 
</gallery>
 
<gallery>
 
<gallery>
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File:Scale2.3.JPG|Connection to the Internet Accomplished|alt=alt language
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File:VacuumForm2.JPG|Removal of excess/unneeded plastic|alt=alt language
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File:Scale3.JPG|HawaUbee Hive Langstroth 10-Frame|alt=alt language
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File:VacuumFormBars1.JPG|Creation of aluminum undercarriage bars|alt=alt language
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File:Scale4.JPG|Inside the Container|alt=alt language
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File:VacuumFormBars1.5.JPG|Aluminum undercarriage bars complete|alt=alt language
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File:Scale5.JPG|HawaUbee(NASA #TX01)is Complete|alt=alt language
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File:VacuumFormBars3.JPG|Installation of aluminum bars and load cells|alt=alt language
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</gallery><br>
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'''HiveTool Scale: HawaUbee02'''
 
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<gallery>
 
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File:Scale2-1.JPG|Stainless Steel Scale with load cells|alt=alt language
 
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File:Scale2-2.JPG|HiveTool Development Board Components|alt=alt language
 
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File:Scale2-3.JPG|Soldering Components|alt=alt language
 
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File:Scale2-4.JPG|HawaUbee02 powered by battery|alt=alt language
 
 
</gallery>
 
</gallery>
 
<gallery>
 
<gallery>
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File:Scale2-5.JPG|Preparing to install the scale|alt=alt language
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File:VacuumFormFinish1.JPG|Picture of the finished product - Undercarriage|alt=alt language
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File:Scale2-6.JPG|Installing HawaUbee02 Computer|alt=alt language
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File:VacuumFormFinish2.JPG|Picture of the finished product - Topside|alt=alt language
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File:Scale2-7.jpg|Construction of Light Sensor|alt=alt language
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File:VacuumFormTesting1.JPG|Testing of load application - Distributed|alt=alt language
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File:Scale2-8.JPG|Final Installation of HawaUbee02 Under a Flow Hive|alt=alt language
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File:VacuumFormTesting2.JPG|Testing of load application - Focused|alt=alt language
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</gallery><br>
 
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<hr>
 
  
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'''Parts List'''<br>
 
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Below is a list of parts that will produce a system that is very close to what is at the HawaUbee Apiary.  Keep in mind that this system is way above and beyond a typical system it is also completely off the wired grid, utilizing solar power and a hotspot for wireless internet connection.  This cost does not include tools, labor, Hivetool Development Kit, and actual scale construction.  The hotspot is a 5GB/month plan and roughly costs $50 per month.  To see a breakdown click on the PartsList - HawaUbee.xlsx link that is below this image.<br>
 
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[[File:HawaUbee-PartsList.JPEG|800px]]<br>
 
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[[File:PartsList - HawaUbee.xlsx]]
 
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<hr>
 
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'''Soldering/Construction Manual''' <br>
 
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If you have decided to assemble your own board below is a manual to aide in the assembly of your HiveTool v0.3 board. <br>
 
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[[File:Manual.jpg]]<br>
 
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[[File:HiveToolV0.3Board - Construction.pdf]]
 
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<hr>
 
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'''EZ Connector for the DHT22 (Temperature) Sensor'''<br>
 
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Soldering the DHT22 is not an easy thing to do, even for the savvy solder-er utilizing a high-end iron and a convenient clamp.  I have found a connector/cable combo that will take the headache out of making/repairing/replacing your temperature sensors. The wire leads off the connector are much easier to solder, I even accomplished this in-field with relative ease.  This cable can be purchased at Amazon.com for around $6.00 for a quantity of ten. <br>
 
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Search: "'TronicsPros RGB LED Light Strips Female Connector RGB LED Strip Connector Cable"  I am going to call the connector the DHT-EZ for the descriptors below. 
 
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<gallery>
 
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File:DHT22-1.JPG|Picture of the DHT-EZ|alt=alt language
 
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File:DHT22-2.JPG|DHT22 sensor is inserted into the DHT-EZ|alt=alt language
 
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File:DHT22-3.JPG|Shrink Tubing Securely attaches the DHT22 to the DHT22-EZ|alt=alt language
 
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File:DHT22-4.JPG|Leads off the DHT-22EZ are soldered and insulated|alt=alt language
 
 
</gallery>
 
</gallery>
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<hr>
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<br>
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'''Lightbulb Lux Sensor'''<br>
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'''PARTS LIST:'''<br>
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This is a creative play off of the ping pong ball setup of the Sensi of Sensors, Adrian Ogden.  This model utilizes a carefully disassembled 60W Sylvania LED light bulb.  I probably should have included a desiccant in the construction of this which should be considered in future models.  Take note of the clear piece of plastic that I added between the back of the sensor and the metal piece on the light bulb (pictured below). 
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Due to the complexity and specialized techniques utilized in the creation of this scale a parts list is not available for this design.
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<gallery>
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File:LUX-1.JPG|Sylvania 60W LED Bulbs|alt=alt language
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File:LUX-2.JPG|Bulb and Lux Sensor|alt=alt language
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'''PROS/CONS/AVAILABILITY:'''<br>
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File:LUX-3.JPG|Dome removed from bulb base (wear gloves)|alt=alt language
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The vacuum formed plastic scale is currently undergoing testing for weather durability and accuracy as it is light weight and seemingly sturdy.  Initially the vacuum formed scale was an option for mass production however, due to the size of the scale shipping costs may negate any cost cutting use of plastic over other light weight options with a smaller footprint.
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File:LUX-4.JPG|Removal of LEDs,*Installation of Plastic Insulator* and Notch bulb body for wire|alt=alt language
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</gallery>
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<gallery>
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'''CREATION CREDIT:'''<br>
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File:LUX-5.JPG|Solder wires to Lux Sensor|alt=alt language
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Ken Hill - [http://www.khill.com K-Hill Inc.]<br>
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File:LUX-6.JPG|Secure Lux Sensor to bulb base|alt=alt language
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David Hawa[http://hivetool.org/w/index.php?title=User:David - HiveTool]
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File:LUX-7.JPG|Use electrical tape to reattach dome to bulb body|alt=alt language
 
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File:LUX-8.JPG|Secure using electrical tape to 3/4' PVC pipe|alt=alt language
 
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</gallery>
 
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<hr>
 
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<br>
 
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'''Solution to Overheating Hot Spot'''<br>
 
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If you are in areas of extreme heat during the summertime, you may have problems with your equipment overheating.  Fortunately the only gadget I was having problems with was the AT&T Velocity Hotspot.  After tossing around a few ideas, inclusive of using a super mini refrigerator I decided on using a CPU air cooler as a viable option.  You will undoubtedly have to have an exterior container to take advantage of this option. I also had to make a wooden mount to hold the air-cooler upright. <br>
 
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<gallery>
 
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File:FAN-1.JPG|Type of CPU Air Cooler I used|alt=alt language
 
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File:FAN-2.JPG|Remove back plate exposing the battery pack|alt=alt language
 
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File:FAN-3.JPG|Fasten the Hotspot to the cooler with zip-ties|alt=alt language
 
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File:FAN-4.JPG|The cooler in the enclosure, I have a second fan to move air also|alt=alt language
 
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</gallery>
 
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<hr>
 
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<br>
 
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'''Super Affordable Scale Option'''<br>
 
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Current Project
 

Latest revision as of 00:18, 16 March 2017

OVERVIEW:
The vacuum formed frame utilizes a rectangular plastic hive rail with a reinforced aluminum undercarriage. The general concept behind this scale was to produce an affordable light-weight scale that was able to accommodate both ten frame and eight frame Langstroth beehives. An additional aluminum undercarriage was added as extra reinforcement was needed to support the weight of the cantilevered load cells.


PRODUCTION:
Production of this scale started out by creating a very accurate wooden mold that was able to be used in a commercial vacuum forming machine. The plastic used was 1/4" thick and possesses UV resistant properties that could handle the exposure to weather elements. After the plastic form was produced additional work was done to remove the unneeded flashings. Holes were drilled and aluminum bars were cut to size and added to properly secure the load cells.


DEVELOPMENT AND FABRICATION PHOTOS:

  • Error creating thumbnail: File missing

    Test drilling for wooden mold creation

  • Error creating thumbnail: File missing

    Creation and drilling of wooden mold

  • Error creating thumbnail: File missing

    Plastic vacuum formed hive rails arrive

  • Error creating thumbnail: File missing

    Plastic vacuum formed hive rail

  • Error creating thumbnail: File missing

    Removal of excess/unneeded plastic

  • Error creating thumbnail: File missing

    Creation of aluminum undercarriage bars

  • Error creating thumbnail: File missing

    Aluminum undercarriage bars complete

  • Error creating thumbnail: File missing

    Installation of aluminum bars and load cells

  • Error creating thumbnail: File missing

    Picture of the finished product - Undercarriage

  • Error creating thumbnail: File missing

    Picture of the finished product - Topside

  • Error creating thumbnail: File missing

    Testing of load application - Distributed

  • Error creating thumbnail: File missing

    Testing of load application - Focused


PARTS LIST:
Due to the complexity and specialized techniques utilized in the creation of this scale a parts list is not available for this design.


PROS/CONS/AVAILABILITY:
The vacuum formed plastic scale is currently undergoing testing for weather durability and accuracy as it is light weight and seemingly sturdy. Initially the vacuum formed scale was an option for mass production however, due to the size of the scale shipping costs may negate any cost cutting use of plastic over other light weight options with a smaller footprint.


CREATION CREDIT:
Ken Hill - K-Hill Inc.
David Hawa- HiveTool

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