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Daniel Davis

About

I'm a Mechanical Engineer for a large UK Engineering Company with an interest in Product Design and Development, i've worked in this role for over 12 years and have gain valuable knowledge and experience in the Aerospace industry. I'm concerned about the environment and the impact the products I help develop have on the planet. I want to use my professional engineering skills to help develop ways that I can reduce my carbon footprint whilst making them available to the 3d printing community to maximise the benefit.

Skills

3d printing, Nx, PLM, adative layer manufacture, animation, concept, development, drafting, drawing, failure analysis, innovation, lean principles, manufacture, optimisation, product, solid modelling, solid works, test & measurement

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  • Ultimaker 2
    Utm2 small

    Ultimaker 2

    Daniel's 3D Printer

    I operate an unmodified Ultimaker 2.

Activity

Commented on MKII 5 Watt 3d printable Wind Turbine 5 days ago
Hello Andreas, i’ve just measured the nut at 7.95mm with digital callipers. Perhaps you could do a general upscale of the part in cura by 1.0-1.5%? Thanks Dan
Commented on MKII 5 Watt 3d printable Wind Turbine 8 days ago
Sounds good greg not used that material before but will look into it. I too use the gears on mine, I found a small wrap of PTFE tape on the Stepper shaft takes out any concentricity issue when you tighten down the grub screw.
Commented on MKII 5 Watt 3d printable Wind Turbine 8 days ago
Hi Sepio, my original design intent was 3:1 and this was easily achieved with the belts but the cogs just take up to much room and 2:1 was the best I can do in the space I had. I'd test the highest ratio possible, the higher ratio may mean you can run the turbine slower by trimming the PVP (adding more weights) and maintain Power output. Interested to know how you get on! Biggest problem I had with the pulleys was printing the sharp edges on the teeth profile, I spent an age on it and in the end opted for the cogs.
Commented on MKII 5 Watt 3d printable Wind Turbine 12 days ago
@Greg, I wonder if it was an issue with timing, did you try and install the nut the instant the print head moved away from the part? I was stood next to mine nut in hand and had it installed and printing again in 5 seconds flat :) just thought it might have cooled and shrank a little? Really good to hear your getting good feedback! Dan
Commented on MKII 5 Watt 3d printable Wind Turbine 12 days ago
Guys, the turbine was design for the fits and gaps of PLA shrinkage and not ABS, i've printed 11 blades throughout the process without any issue with the nut. If you let me know what size across flats you need for ABS shrinkage (haven't printed with ABS yet..) I can adjust the solid model and provide a STL model specifically for ABS? Let me know, cheers Dan
Commented on GT2 Belt Drive UPGRADE - MKII 5 Watt 3d printable Wind Turbine 14 days ago
Hi Abraham, sorry I don't understand the question? If your printing the Turbine I would absolutely recommend printing the MkII it has some very important features that you will need to make the wind turbine function at its maximum like the tail fin and the slip rings for the electronics. regarding the Belt drive this is an optional mod, you can use the cogs or belt both do the same job fundamentally. Does this answer your question? Thanks Dan
Contributed on Bearing Cover for MKII 5 Watt 3D printable Wind Turbine 20 days ago
Carousel thumb untitled
Printed on:
ultimaker 2
Result:
Perfect fit!
Contributed on Bearing Cover for MKII 5 Watt 3D printable Wind Turbine 20 days ago
Carousel thumb bearing cover
Printed on:
ultimaker 2
Result:
Perfect fit!
Commented on Bearing Cover for MKII 5 Watt 3D printable Wind Turbine 20 days ago
Thanks for the share, will do just the job!
Commented on MKII 5 Watt 3d printable Wind Turbine 21 days ago
Here are some pictures of the Slip ring install. https://drive.google.com/drive/folders/0B1OoBxMaa0WLWFdoX2lKYk5RRmc?usp=sharing
Commented on MKII 5 Watt 3d printable Wind Turbine 21 days ago
All, find link to optional Pulley and Belt drive for reduced noise! https://www.youmagine.com/designs/gt2-belt-drive-upgrade-mkii-5-watt-3d-printable-wind-turbine I've included the solid works models so you can modify to improve the fit if required. Cheers Dan
Contributed on GT2 Belt Drive UPGRADE - MKII 5 Watt 3d printable Wind Turbine 21 days ago
Carousel thumb img 0201
Printed on:
ultimaker 2
Result:
This is an example of the pulleys and belts in use x2.
Commented on MKII 5 Watt 3d printable Wind Turbine 21 days ago
Here is the MkII with GT2 Belt driven parts in place. The top pulley is 20 teeth, the bottom is 60 teeth and the belt is 158. This will maintain the 3:1 gear ratio. https://drive.google.com/file/d/0B1OoBxMaa0WLaTE4S1d6Tm5fRGM/view?usp=sharing
Commented on MKII 5 Watt 3d printable Wind Turbine 21 days ago
@ Sepio, I was toying with the idea of making some monster blades 50% bigger! I think the biggest issue would be as you increase the blade height you need more chord and with more chord at max pitching the blade would likely hit the tower and would need either a longer shaft or a spacer between the disc and shaft! As i broke 2 blades I might as well print some bigger ones :) Let me dig the GT2 stuff out now... its on a backup hard drive...
Commented on MKII 5 Watt 3d printable Wind Turbine 22 days ago
PS if your wondering what the hell is in the picture :)) its an Active Variable Pitch (AVP) variant that uses a raspberry Pi Zero to measure the shaft speed and then uses an NEMA11 to actively control the pitch of the blades to a given formula I wrote. With the Pi I was able to remote log in to the turbine to monitor its performance and also tweak any settings on the fly. Effectively this was the test machine that lead to the PVP design shared here.