Vulcan Modules

Analysis for where modules can be reused between Vulcan systems. A part that can serve many purposes makes a case for a higher investment.

Motors

Brushed

The purist in me doesn't like this idea, but the reality is they're cheap and fairly powerful and require much less complex drivers. The major drawback is the brushes wear out, but the target audience consists of the best candidates to fix such an isue

Brushless

A module that combines a brushless motor and driver will be extremely valuable in many places. If this is feasible, it will probably be worth including several of them in the final design.

Something in the range of 150KV.

However this also goes back to building the motors.

Stepper

Also sort of bugs the purist because these compromise on both cost and power, but they're plentiful and provide great control.

I have a bit to learn, but the module should incorporate the stepper and a driver.

Induction

A 2.25 HP motor will use 15A@110V.

The module definition will include RPM under load. So for some motors, a gearbox may be required. The module should also be large enough to fit many different motors.

The idea is that for the larger machines, the motor can be moved quickly. So it should have handles that make it easy to carry, some key mechanism that makes it easy to seat in place and then a stronger locking mechanism to lock it down.

I think there should be a gear protruding from the module. This can seat inside something (like a pulley) or mesh with another gear. It means that the module can slide in horizontally without needing to attach belts or chains.

Control

Linear

Probably built off either the brushed or brushless motor, a standard linear drive will integrate into many cnc systems. It can also be helpful in systems that are not fully automated, for instance, positioning a stop on a miter saw.

PCBs

It may be possible to take multiple related circuits and merge them into one PCB. It's then feasible to make many prints of that one board.

For instance, I expect many of the low level electronics boards to be built around the ATMEGA328P TQFP. A design that makes it easy to add standard sensors and comms would allow for a single board to work in many different roles.

Handle

For many hand held devices, we will need a handle. It should have a trigger connected to a potentiometer, a thumbwheel connected to a rotary encoder and a 3 position switch. Either litium cells or AA battery clip.

There is a dedicated micro controller. When it boot it checks one bit to see if it should go into master or slave mode. In slave mode, it will listen as a I2C device and can run many programs. In master mode the switch chooses either the trigger or thumbwheel and the output varies based on that.

If the input voltage is zero, the output voltage comes from the internal supply. If a voltage is supplied, the handle only acts as a controller.

Case Studies

• Flash light
• circular saw
• drill
• hand vacuum

Gearbox

In different sizes (to fit the standard motor sizes) to manually switch gear ratios.

Casting/Templates

MDF

Useful for creating templates that can be followed with a router and molds for greensand.

For templates, we can create a dovetail or puzzle-piece lock for fillers or common shapes.

Steel

Only useful in the cases of the highest reproduction, but we can make a steel mold and then cast either aluminum or copper in it. Once the router is in place, this may be useful.

Hardware

Both easiest and most important. Choose standard sizes. I think it's worth using overkill sometimes to allow for reduced stock.

• threaded rod
• bolts/nuts/washers
• wood screws
• bearings
• hinges

Structural

Same progression as knex, 1, √2, 2, √8, 4, √32... with angle connectors at 45°. Plates are designed to go over these.

The idea is that we can make a number of these in various sizes and be able to assemble frames for many machines quickly.