I had trouble printing the TPU sheaths, but I updated the model and printed a couple of usable ones. I also had to reprint a tang because the supports were stuck so badly that I could not remove them. The new sheath model had holes along the edges, but when I tested them, the sparking did not work.
The sparking was occurring inside the handle due to the TPU sheaths over-insulating. I cut away some plastic from the tang and sheaths to allow for a spark, but I realized I would have to update the internal components.
The sparking inside the handle was caused by two main issues: the internal nut's proximity to bare high-voltage wires and a significant gap between the aluminum blades. I can deal with the nuts by shortening the high-voltage wires and adding insulation. I redesigned the sheath and tang to include hemispherical divots where the electricity can jump, but also to avoid sharp corners.
I planned to print the latest version of the sheaths in PLA to save time, but the print failed due to a filament jam caused by an overheating print head. After clearing the jam and ordering a new cooling fan, I rounded the edges of the design to prevent potential scratches. Once I finished both prints, they lined up well, and I believe this revision was beneficial.
Despite the first round of frustrating Zener testing, I regulated a benchtop power supply from 2 to 4 volts. I used green LEDs as a load and watched the output remain capped at approximately 2.1 volts. The resistors heated up, so I ordered high-wattage components.
Chad P joined us to discuss Megamind (2010), where we enjoyed a relaxed episode with some distractions, noted the film's flaws, and its likely Caucasian-heavy writing team. We also spawned a running joke about kidnapping and cannibalism fitting for our first October show.
The rest of the summary posts have been arranged by date.
First time here?
Completed projects from year 1
Completed projects from year 2
Completed projects from year 3
Completed projects from year 4
Completed projects from year 5
Completed projects from year 6
Completed projects from year 7
Completed projects from year 8
Completed projects from year 9
Completed projects from year 10
Completed projects from year 11
Completed projects from year 12
Disclaimer for http://24hourengineer.blogspot.com and 24HourEngineer.com
This disclaimer must be intact and whole. This disclaimer must be included if a project is distributed.
All information on this blog, or linked by this blog, is not to be taken as advice or solicitation. Anyone attempting to replicate, in whole or in part, is responsible for the outcome and procedure. Any loss of functionality, money, property, or similar, is the responsibility of those involved in the replication.
All digital communication regarding the email address 24hourengineer@gmail.com becomes the intellectual property of Brian McEvoy. Any information contained within these messages may be distributed or retained at the discretion of Brian McEvoy. Any email sent to this address, or any email account owned by Brian McEvoy, cannot be used to claim property or assets.
Comments to the blog may be utilized or erased at the discretion of the owner. No one posting may claim property or assets based on their post.
This blog, including pictures and text, is copyright to Brian McEvoy.
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| Red TPU blade sheaths |
The sparking was occurring inside the handle due to the TPU sheaths over-insulating. I cut away some plastic from the tang and sheaths to allow for a spark, but I realized I would have to update the internal components.
 |
| Drilled gap |
The sparking inside the handle was caused by two main issues: the internal nut's proximity to bare high-voltage wires and a significant gap between the aluminum blades. I can deal with the nuts by shortening the high-voltage wires and adding insulation. I redesigned the sheath and tang to include hemispherical divots where the electricity can jump, but also to avoid sharp corners.
 |
| Hemispherical gaps in the sheath and tang |
I planned to print the latest version of the sheaths in PLA to save time, but the print failed due to a filament jam caused by an overheating print head. After clearing the jam and ordering a new cooling fan, I rounded the edges of the design to prevent potential scratches. Once I finished both prints, they lined up well, and I believe this revision was beneficial.
 |
| Three prints in the same color |
Despite the first round of frustrating Zener testing, I regulated a benchtop power supply from 2 to 4 volts. I used green LEDs as a load and watched the output remain capped at approximately 2.1 volts. The resistors heated up, so I ordered high-wattage components.
 |
| Getting a pretty consistent 2.1V from the regulator circuit |
Chad P joined us to discuss Megamind (2010), where we enjoyed a relaxed episode with some distractions, noted the film's flaws, and its likely Caucasian-heavy writing team. We also spawned a running joke about kidnapping and cannibalism fitting for our first October show.
Critical Affection: Megamind (1:07)
The rest of the summary posts have been arranged by date.
First time here?
Completed projects from year 1
Completed projects from year 2
Completed projects from year 3
Completed projects from year 4
Completed projects from year 5
Completed projects from year 6
Completed projects from year 7
Completed projects from year 8
Completed projects from year 9
Completed projects from year 10
Completed projects from year 11
Completed projects from year 12
Disclaimer for http://24hourengineer.blogspot.com and 24HourEngineer.com
This disclaimer must be intact and whole. This disclaimer must be included if a project is distributed.
All information on this blog, or linked by this blog, is not to be taken as advice or solicitation. Anyone attempting to replicate, in whole or in part, is responsible for the outcome and procedure. Any loss of functionality, money, property, or similar, is the responsibility of those involved in the replication.
All digital communication regarding the email address 24hourengineer@gmail.com becomes the intellectual property of Brian McEvoy. Any information contained within these messages may be distributed or retained at the discretion of Brian McEvoy. Any email sent to this address, or any email account owned by Brian McEvoy, cannot be used to claim property or assets.
Comments to the blog may be utilized or erased at the discretion of the owner. No one posting may claim property or assets based on their post.
This blog, including pictures and text, is copyright to Brian McEvoy.
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