Saturday, September 17, 2016

IMTS 2016, Fusion 360 CAD/CAM, and plans to go play on the Safari Quest in British Columbia



So what is IMTS?  Irritable male tummy sensations?  

Nope.  It stands for International Manufacturing Technology Show, and it's the second largest manufacturing convention in the world (but I only found out about it through a very timely text from a friend who works at Cascade Designs in Seattle).  Its soooooo big and obnoxious that they only do it every two years, and it makes sense.  There are hundreds upon hundreds of millions of dollars of manufacturing robots, tools, and CNC machines displayed there, in addition to smaller vendors who supply measurement, software, and support systems for the manufacturing industry.  The logistics to hook up thousands of 3-phase robotic machines in 1-million+ square feet of convention center must be a pain, not to mention that these machines are being shipped here from all four corners of the earth.  

I went there because I'm pursuing employment in the manufacturing industry, and I figured it would be a good way to network and learn more about the industry....and I got all of that and more.  In the first of the two days I visited (it's huge: I literally could not see all the booths between 10am and 5pm) I met someone who has since assisted in scheduling one job interview, and on the second day I met in person with the North American Service Manager for the largest CNC machine producer in Japan (and they are one, if not the, biggest in the world) and discussed work in their maintenance/service department.  I'm really a nobody at this place, but I was surprised when later that same service manager walked up to me and addressed me by Danny, and gave me back a card he saw me drop on the floor while walking around the convention.  Pretty cool fella to remember one unimportant name in a sea of millionaire tool buyers.

Anywho, I learned TONS just seeing 5-axis mills, robotic part scanning and organizing systems, SLA production printers, high-pressure coolant systems, hall-effect positional sensors, 6-degree-of-freedom CAD controllers, large-scale 3D printers (think garages and structures), advanced cutting tools, and piles more stuff that I'm just plain forgetting about.  Plus meeting lots of people in the industry who were bored to death with their booths and were willing to share their personal stories and opinions on the manufacturing industry, global and local politics, and the elements that have (and continue to) effect our manufacturing economy.

Fun Fact: Hass Automation, a California-based, "Merican" company produced it's first 3-axis CNC vertical mill in 1988, and is today the largest CNC manufacturer in the United States.  


In other news, I've started using a Computer-Aided-Drafting and Computer-Aided-Manufacturing software (CAD/CAM for short) called Fusion 360 by AutoDesk.  It's rather revolutionary for me, in that it is free for non-commercial users (and only $300/year if you are commercial), has a seemingly well-developed CAD side, and a really cool CAM side that allows you too do cutting-operation simulations of your toolpaths.  This program essentially integrates two pieces of the machining "toolchain" into one software, and the developing team is looking to push the system even further.  I attended a post-IMTS "Fusion 360 Meetup, and tour" on Tuesday night at the Digital Manufacturing and Design Innovation Institute (DMDII), and it was very eye-opening.  I talked briefly with a youtube celebrity (John Saunders of NYC-CNC, a channel about learning CNC), and got to experience what it's like to have a bunch of CNC nerds all in one room, at one time.  It was great! 


In other news, I installed limit and homing switches on the Shapeoko2 at the makerspace, but I've hit a couple roadbumps and am working on debugging some issues with the control software/firmware, so that critter isn't quite ready for tool-changing just yet.  The goal is to have a machine that can return to the same zero (XY coordinates) position at the start of every cutting operation, or even mid-operation.  But without homing switches to tell it when the cutting head reaches said zero position, you'll be cutting the same pattern in slightly different places every time you start a cut.


In hobby world, I received my DPDT switches for the ROV and sucessfully tested them with 25' of Cat5 ethernet cable, and the results are encouraging. So far I've designed and printed a control switch enclosure on the Printrbot 3D printer, so now I just need to design a frame for the motors, decide on a bouyency system that is somewhat tune-able, and put it all together.


Job-wise, I have interviews next week at a commercial prop-shop that creates large-scale marketing/misc works, and a marketing company that designs and produces it's own product displays.  Lastly, I have hopes to hear back from a Chicago-based company called Inventables, who just happens to manufacture the Shapeoko2 (well, the ShapeOko 3 and other, newer products) CNC router that I've been working on for the past few weeks.  


Lastly, I agreed to fly out to Seattle to run a week-long trip as Captain on the 120' Safari Quest, as my sister Denee needed some time off and wasn't able to find anyone local to fill the position.  It's a bit of a bitter-sweet though, since choosing to run the trip means I'll be missing the Un-Cruise 20th anniversary shin-dig on the 30th, and seeing old friends.  Maybe I'll catch some of them on Saturday night or Sunday before I fly home?

Anywho, it's been a great week, and I'm excited for what is to come next!  

Friday, September 9, 2016

ROV's, Tugboat accessories, Makerspace Membership, and more!

This past week has been great!  Aimee had her first day of graduate school at Rush University on Thursday, I joined a sweet Chicago Maker/Hackerspace, and I have continued to apply and interview for cool manufacturing jobs here in the Windy City.

Accomplishments for this week:

1. Installed fenders around the deck of the tug boat, and made "bow pudding" on the...bow.  This is a new phrase to me, but apparently it is what is used to describe a bow fender that is made of line.  I had some spare twine of a scale size laying around, so I did a total hack job (certainly not a tallship-worthy) of knotting it together into a sort-of bow-pudding form.


2. Researched ROV (tethered submarine) designs in hope of building a functional RC dive barge with an ROV that has a video feed and a grabber arm.  I learned that many hobby ROV's use un-protected, "wet" motors for thrust, that voltage drop is a big problem on tethers of any real length, and that the build complexity on these things can range wildly.  I've purchased a handful (literally) of small dc motors to use as thrusters, and ordered some DPDT momentary toggle switches to handle the topside motor-reversing commands of my first (likely bathtub-only) ROV.  Ethernet-tethered Arduino's with motorshields, or Pixhawk ArduSub systems will likely be in later versions.  The object of the computer-controlled units is to allow for serial/ethernet/I2C communication with the surface, which will allow for proportional motor control (not just "On" or "Off" at full power) and also keep my options open for adding sensors for depth, attitude, voltage, etc.  Just for kicks, Aimee and I watched the pilot episode of "SeaQuest DSV" on NetFlix....only to realize that Jaws was a far better endeavor for Roy Scheider (R.I.P.).



3. Joined the Maker/Hacker Space "Pumping Station: One" in Chicago.  PS1 (because pumping is just a little too.....pumpy...for me) is a freaking awesome workspace collective housed in an old two-story building to the North of downtown Chicago, about a 18 minutes from our house (at 2am....more like 30 minutes during normal hours).  I've been working on getting one of their CNC routers up and running, a ShapeOko2 (pictured below, after receiving some love).  Their tool inventory includes a huge CNC laser, a small CNC laser, a 4x8' Shopbot CNC router, a small CNC Carvy (small, enclosed RTR router/engraver), every wood tool imaginable, TIG/MIG/STICK/Plasma hot-metals area, a 3D printer area, textiles shop, electronics space (with billions of tiny components, and piles of hackable/discarded electronic assemblies), test equipment galore, and all sorts of groups of people who use all these things.  Membership is $40/month for 24/7 keycode access to the space and ALL of it's toys.  Oh, and I forgot to mention the full manual-machining shop with lathes, mills, presses, shears, brakes, etc.  Totally freaking awesome.


4. Had some excellent Thrift-store finds:  I found a really cool stainless-finish arc lamp ($20), an infant bathtub stool for cradling my RC sailboats ($5), and a Craftsman workbench ($5).  I'm pretty stoked about all of these purchases, as they all help to make our home that much more fitting.


Lastly, Aimee started school this week, and there was a moment that happened this morning that put the biggest smile of the week on my face...   I had made my coffee, fed Charlie, and walked with him to the dog park to play some fetch.  A few minutes after 8am, I was sitting on a bench sifting through job postings when I spot a pretty lady walking by the dog park on her way to the El train (pictured below).  Both Charlie and I jumped up and rushed over to take her picture and give her a kiss.  It was great.  : )


Friday, September 2, 2016

RC Tugboat Modifications: Deck Winch Build, Bridge Camera Tuning, Reduction Gear Repair


It has been nearly three years since my last posting, but I'm not here to apologize.  Today is about starting anew and putting down fresh tracks.  So here goes:

This morning I woke up with a headache, a stuffed-up nose, and a bathtub full of cold water (and I couldn't be happier).

I'm stoked for a number of reasons:

1. I have a dedicated bath tub for my RC watercraft. Yes, our new home has TWO full bathrooms, which means I can keep one of them full of water for "sea trials."

2. Yesterday I finished up a lot of work on my 1/36th-scale RC tugboat.  The PMG (Port Main Gear) output shaft was slipping on the nylon input gear, causing the vessel to only produce about 50% thrust.  The FPV (First Person View) camera in the wheelhouse had a poorly-oriented linear-polarized VTx (video transmitter) antenna, causing the signal to fade at certain headings.  Lastly, the deck-winch did not exist, and I find that to be a problem for a tugboat.  So I removed the slipping gear, used an engraver to "machine" splines into the SS shaft, and applied a bit of epoxy to the splines and re-assembled the gearbox.  Then I  re-oriented the antenna (of which 1/2 is now protruding through the top of the wheelhouse, much like a radio whip antenna), and got to work designing the deck winch.  The "winch" is an old bait-casting reel I bought at 2nd Base in Seattle's University District for $10, specifically for it's "level-wind" mechanism (it evenly feeds line onto the the spool, moving the feed point from side-to-side).  I then modeled 3D parts in Sketchup, "sliced" (used a toolpath-generator/CAM software) them in Cura, and printed them on my Printrbot Simple Metal FDM 3D printer.  I used a continuous-rotation servo from an old kite-camera panning mechanism, and tied that into the main control Rx (radio receiver) to have wireless control of the tow line while underway (for transitioning from long-haul to short-tow conditions).



3. This morning I tested it all, and I can claim 100% success! Stall torque is acceptable, and I have two speed settings programmed for scale operation and stupid-fast.  See video here:



Next: Stainless Steel wire rope for winch, panning for bridge camera, and adding a second (selectable) aft-facing workdeck camera.  None of these are critical, so they may never happen, but I like having a list of to-do's just in case.  : )

I hope to make more short/small posts like this, and hopefully not every three years!

Cheers,

Danny