Layout and building of the first MFRFP prototype started in earnest on November 30th 2006. All components were uncrated, dimensions verified and initial layout confirmed.
December 4th 2006 - First components mocked up in position
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The seed press will be on an elevated platform of plate steel and angle iron so the discharge of oil and seed cake will be manageable.
Identity of components: 4X4 I-beam frame, 3/8 inch decking except under motor where it is 1/2 inch, the components from right to left are: 2 ton seed press, 10kw generator, 120gpm pump, Lister style diesel engine, and C. S. Bell flour mill. The water purification system will be on the left end that is partially outside the area of the photo.
Week one showed the following progress as well as lessons learned:
The foundation was cut out of 4 inch mild steel I-beam. The motor, due to weight and potential vibration is mounted on ½ inch mild steel plate and the seed press and generator are on 3/8 inch mild steel plate. All seams between mounting plates are supported by further sections of 4 inch I-beam. The platform is somewhat over built compared to working examples in the field. However, none of the existing models we have encountered are designed to be moved as a single unit. One future design improvement that is clear even now is the need to build it on a single steel plate for the component mounting surface. All measurements are being input into a CAD program so the decking will be able to be reproduced on a plasma cutter with bolt holes already cut. About the CAD program, we are inputting all measurements and will be able to provide 3-D views of all items as well as routing paths of all power supplies, drive belts and components. The design is being built to allow all of the heaviest items to be located on one end. Six inch “C” channel is attached on the bottom of the frame to allow the MFRFP to be picked up by a fork lift and moved.
Once the foundation was established, square and welded it was moved for mock up of all components. At this early stage, getting the drive belt pathways was crucial so that the components could be run more than one at a time. My research has also shown that there are drive pulleys on current models in the field that are not readily available from all suppliers. Of principal interest are pulleys that tend to deal with flat, long belts and have been used in the examples in Mali. This style of drive we feel is more applicable to older industrial appliances that require older style of belts. Also, this belt style tends to come in longer lengths that might better suit field example we have seen photos of. Most field layouts seem to be in the area of 10 to 15 feet in length just considering the driven components and motor. Our design from the out set was intended to fit in an appropriate, shippable size if need be.
The Chinese manufactured seed press has a capacity of 2 tons per day and due to space and oil and seed waste discharge it is elevated approximately 36 inches off the ground. The frame has been made out of 2 inch mild steel angle iron with a ½ steel deck. The press is mounted by bolts with some left to right movement. This will allow preliminary adjustment as far as drive belt length is concerned.
It was fortuitous that the seed press needs to be elevated because once we located the 10kw generator between the press and the motor, it was apparent that the water pump would not be able to be mounted anywhere other than under the seed press platform. The design has, from day one, considered space a concern. Ideally, this design will be able to be reproduced and packed either 4 or 8 to a shipping container based on whether it is a 20 foot or 40 foot Connex box. While we are aware most platforms are built and sourced with local components, the ability to build and ship versions for use as teaching models or for field deployment was always part of the design.
Research is ongoing into constructing the cooling system. A small automotive radiator will need to be mounted to keep the engine at operating temperature. In the field this would be less of a concern as a convective cooling system can be used. However, the convective systems are meant to have 100 to 150 gallons in water capacity according to the engine supplier. Space will not allow this on the prototype.
At the end of week one, the MFRFP is moving steadily along. All major items are located and bolted down. A local supplier has been contacted and we are going to have drive pulleys for the water pump and grist mill by 12.13.06. Until we have the drive pulleys we cannot specify the length of the drive belts themselves, also final location of the grist mill will depend on belt alignment. Progress in this coming week will come in aligning the water pump drive as well as the grist mill. The wall for the water treatment components will be laid out and hopefully mounted as well. A belt tensioner system will also be mocked up using automotive tensioners.
