From 8d1a9c1b47de1c8e9b6a441cd4909c913fd912e7 Mon Sep 17 00:00:00 2001
From: Blaise Thompson <blaise@untzag.com>
Date: Sun, 18 Apr 2021 19:25:00 -0500
Subject: first minimum viable assembly instructions

---
 assembly-instructions/wpr-assembly.tex | 240 ++++++++++++++++++++++-----------
 1 file changed, 162 insertions(+), 78 deletions(-)

(limited to 'assembly-instructions/wpr-assembly.tex')

diff --git a/assembly-instructions/wpr-assembly.tex b/assembly-instructions/wpr-assembly.tex
index 8a523b6..6b1c070 100644
--- a/assembly-instructions/wpr-assembly.tex
+++ b/assembly-instructions/wpr-assembly.tex
@@ -8,7 +8,6 @@
 \usepackage[utf8]{inputenc}
 \setlength\parindent{0pt}
 \setlength{\parskip}{1em}
-\usepackage{enumitem}
 \renewcommand{\familydefault}{\sfdefault}
 \newcommand{\RomanNumeral}[1]{\textrm{\uppercase\expandafter{\romannumeral #1\relax}}}
 
@@ -34,15 +33,21 @@
 \renewcommand\section{\clearpage\stdsection}
 
 % hyperref
-\usepackage{hyperref}
-\hypersetup{
-	colorlinks,
-	bookmarksopen,
-	bookmarksnumbered,
-	hidelinks,
-}
+\usepackage[colorlinks=true, linkcolor=black, urlcolor=blue, citecolor=black, anchorcolor=black]{hyperref}
 \usepackage[all]{hypcap}  % helps hyperref work properly
 
+
+
+\usepackage[shortlabels]{enumitem}
+\setlist[enumerate, 1]{nosep}
+\setlist[enumerate, 2]{nosep, topsep=-5ex}
+\setlist[enumerate, 3]{nosep, topsep=-5ex}
+\setlist[enumerate, 4]{nosep, topsep=-5ex}
+\setlist[itemize, 1]{nosep}
+\setlist[itemize, 2]{nosep, topsep=-5ex}
+\setlist[itemize, 3]{nosep, topsep=-5ex}
+\setlist[itemize, 4]{nosep, topsep=-5ex}
+
 % bibliography
 \usepackage[numbers]{natbib}
 
@@ -65,61 +70,87 @@
 
 \section{Introduction}
 
-Throughout this document we refer to an online repository containing source and design files.
-This repository appears at \url{https://github.com/uw-madison-chem-shops/wisconsin-photoreactor}.
-This repository contains everything including the source for this very document.
-
 The Wisconsin Photo-Reactor (WPR) is made to be easily assembled.
 This document is meant to help chemists accomplish this assembly.
 Each reactor has two major components requiring detailed custom assembly:
 
 \begin{itemize}
-  \item The 3D printed enclosure, described in section TODO
-  \item The drive electronics, described in section TODO
+  \item The 3D printed enclosure, described in \autoref{SEC:enclosure}
+  \item The drive electronics, described in \autoref{SEC:electronics}
 \end{itemize}
 
 With these two major components complete, assembly of the WPR is relatively straight-forward.
-Details of final assembly are described in section TODO.
+Details of final assembly are described in \autoref{SEC:assembly}.
 
-TODO: THIS IS A LIVING DOCUMENT, PLEASE CONTRIBUTE.
+Throughout this document we refer to an online repository containing source and design files.
+This repository appears at \url{https://github.com/uw-madison-chem-shops/wisconsin-photoreactor}.
+This repository contains everything including the source for this very document.
+
+A working WPR is made up of many separate commercially available parts.
+This guide assumes that you have already done the work of procuring those parts.
+The online repository contains several README files with detailed part numbers and suggested vendors.
 
-\section{3D Printed Enclosure}
+The WPR is a living project.
+We welcome and encourage duplication and modification of our designs and documentation.
+If you notice problems or omissions within this assembly document, please consider opening an issue or pull request.
+
+\section{3D Printed Enclosure} \label{SEC:enclosure}
 
 \includegraphics[width=\textwidth]{"./3dp-coverat.jpg"}
 
-The body of the WPR is made up of three main pieces.
+The body of the WPR is made up of three main pieces:
 
 \begin{itemize}
     \item Base, containing LEDs, fan, and drive electronics.
     \item Top plate accepting reaction vials.
-    \item Walls spacing the top plate at the appropriate distance away from the base.
+    \item Chamber walls spacing the top plate at the appropriate distance away from the base.
 \end{itemize}
 
 The WPR base is the same for all reactors.
-The top plate and wall height can be adjusted depending on the particular vials desired.
-Look within the repository in the subdirectory ``photoreactor-tops'' to find existing designs of (wall, top) for a number of different vial sizes.
-We encourage you to design your own (wall, top) if none of these suit your application.
+Look within the repository in the subdirectory ``photoreactor-base'' to find design and production files to produce the WPR base.
+You will also need to print a cable anchor, see files in that same directory.
+
+The top plate and chamber height must be specified for the particular reaction vessels used.
+Four examples for different vial sizes are pictured above.
+Look within the repository in the subdirectory ``photoreactor-tops'' to find existing designs.
+We encourage you to design your own if none of these suit your application.
 Consider adding your new designs to repository so that others may benefit from your design efforts.
-In addition to these three main components you should also print a cable-anchor for each of your WPR bases.
 
-TODO: SHARE DETAILS ABOUT CAD SOFTWARE.
-TODO: MAKE IT CLEAR THAT STL FILES ARE THE RELEVANT EXCHANGE FILE.
-TODO: RECOMMEND STL VIEWER.
-TODO: RECOMMEND SLICER.
+When interacting with the design files in our online repository you will see several different filetypes.
+We have designed the WPR enclosure using Fusion 360, and have included those f3d design files for those that wish to extend or modify the designs.
+Interacting with f3d files will require a Fusion 360 license.
+You will also find stl files in the online repository.
+These are common 3D-model exchange files which can be viewed using any 3D modeling program.
+In fact, GitHub itself has a built in stl viewer which you may use to inspect our designs.
 
 There are many options for getting your enclosures printed.
-TODO: DO WE WANT TO GIVE ANY ADVICE ABOUT MATERIAL CHOICE?
-TODO: RECOMMEND SPECIFIC MANUFACTURERS.
-Of course, you may wish to print multiple (wall, top) types to be used interchangeably with one base.
+We recommend white PLA as a material, although any white material should work---we have also used ABS.
+If you are printing yourself, follow the instructions provided by your printer to produce slices and program your printer.
+Note that you will need support material for the base.
+Any company or shop offering 3D printing as a service should be able to accept our stl files without further modification.
+
+We have succesfully printed using the following printers:
+
+\begin{itemize}
+  \item Ender 3
+  \item Stratasys uPrint SE Plus
+  \item Ultimaker 3
+\end{itemize}
 
 Once your parts are done you may need to remove extra bonding material with a razor blade or exacto-knife.
 The three pieces of your reactor should fit together snugly and securely.
 
-\includegraphics[width=0.5\textwidth]{"./heat-insert.jpg"}
+\clearpage
+
+\begin{center}
+  \includegraphics[width=0.5\textwidth]{"./heat-insert.jpg"}
+\end{center}
 
-7 heat inserts...
+Each WPR base contains seven threaded heat inserts.
+These allow components such as the drive circuit board to rigidly attach to the base via machine screws.
+Use a soldering iron to carefully heat these while pushing them into their cavities.
 
-\section{Electronics}
+\section{Electronics} \label{SEC:electronics}
 
 \includegraphics[width=\textwidth]{"./electronics-coverart.jpg"}
 
@@ -128,137 +159,190 @@ We refer to these small boards as ``drivers''.
 There are two types available: the ``analog-driver'' and ``digital-driver''.
 Refer to the associated directories in the online repository for design files for each of these.
 
+Both drivers are built around Mean Well's LDD-1000L LED driver module.
+This module delivers constant current up to one amp.
+The current delivered can be controlled electronically in several different ways.
+WPR users wishing to understand this design should refer to Mean Well's datasheet.
+
 The analog-driver circuit is made to be as simple as possible.
 The circuit accepts DC 12 V through a barrel jack.
 A small knob is used to adjust light intensity.
 Fan speed is not adjustable.
+Refer to \autoref{SEC:analog-driver} for analog-driver assembly instructions and further explanation.
 
 The digital-driver circuit is made to be incorporated into an I$^2$C-based digital control system.
 In addition to power, these boards have 4-pin connectors to carry the I$^2$C serial data.
-More details about this digital control system are in TODO: LINK TO SECTION.
+The digital-driver is pictured above, without any connectors attached.
+Refer to \autoref{SEC:digital-driver} for digital-driver assembly instructions and further explanation.
+
+When interacting with the design files in our online repository you will see several different filetypes.
+These circuit boards were designed using KiCad, a free and open source electronics CAD software.
+All KiCad files are contained within the ``kicad'' subdirectories.
+You may modify and extend these designs however you like.
+
+Those wishing to reproduce our designs should refer to the gerber subdirectory.
+Within the gerber directory you will find zip files for each separate version of the PCB.
+You may upload these zip files to PCB manufacturers when ordering copies of our designs.
 
 \clearpage
-\subsection{Analog}
+\subsection{Analog} \label{SEC:analog-driver}
+
+The analog driver circuit is meant to be as simple as possible while still allowing for reproducible LED intensity control.
+To this end, the number of components has been minimized as much as possible.
+A full schematic of the analog circuit appears at the end of this section.
+A bill of materials appears within the README of the online repository.
 
 \begin{center}
   \includegraphics[width=\textwidth/2]{"./bare-pcb.jpg"}
 \end{center}
 
+Your PCB manufacturer will send you a bare board, as seen above.
+
 \begin{center}
   \includegraphics[width=\textwidth/2]{"./surface-mount.jpg"}
 \end{center}
 
+Begin by adding the surface mount components.
 Recommend thin solder, e.g. 0.015''.
-Small green line on LED towards ground (left).
+The LED does have a polarity---ensure that the small green line points towards ground (left).
+Once done your board should look like the above.
 
 \begin{center}
   \includegraphics[width=\textwidth/2]{"./connectors.jpg"}
 \end{center}
 
-Recommend standard solder, e.g. 0.031''.
-
-\begin{center}
-  \includegraphics[width=\textwidth/2]{"./connectors.jpg"}
-\end{center}
+Next, add the connectors and the potentiometer knob.
+From now on we recommend standard gage solder, e.g. 0.031''.
+Once done your board should look like the above.
 
 \begin{center}
   \includegraphics[width=\textwidth/2]{"./barrels-tested.jpg"}
 \end{center}
 
+Next, add the barrel jacks and the test points.
+With these added you may plug in your board for the first time.
+You should see your power indicator LED illuminate.
+You should also be able to adjust the DC control voltage relative to ground by turning the knob, as shown above.
+
 \begin{center}
   \includegraphics[width=\textwidth/2]{"./pcb-driver.jpg"}
 \end{center}
 
-150 mA to 3 V
+Finally, add the Mean Well LED driver.
+Note that this component goes on the back of the PCB, as shown above.
 
 \includepdf[landscape=true]{"../analog-driver/driver.pdf"}
 
-\subsection{Digital}
+\subsection{Digital} \label{SEC:digital-driver}
 
-TODO: document I2C connection choice.
-Consistent with Adafruit, Sparkfun, Seeed...
+The digital driver circuit can be controlled from a computer or some other digital device.
+We built our driver to work over I2C, consistent with an emerging standard for many ``maker'' products.
+While the physical connectors may be different, our digital circuit is compatible with the following systems.
 
-\subsubsection{Driver}
+\begin{itemize}
+  \item \href{https://learn.adafruit.com/introducing-adafruit-stemma-qt}{Adafruit STEMMA}
+  \item \href{https://www.sparkfun.com/qwiic}{Sparkfun Qwiic}
+  \item \href{https://www.seeedstudio.com/category/Grove-c-1003.html}{Seeed Grove}
+\end{itemize}
 
-\includepdf[landscape=true]{"../digital-driver/driver.pdf"}
+\begin{center}
+  \includegraphics[width=\textwidth/2]{"./digital-wired.jpg"}
+\end{center}
+
+Each digital driver is based around an ATtiny85 microcontroller acting as an I2C peripheral.
+Multiple digital driver boards may be ``networked'' together onto one I2C bus by simply daisy-chaining the boards together, as shown above.
+In such a use-case you must choose a unique I2C address for each ATtiny85 peripheral.
+
+\begin{center}
+  \includegraphics[width=\textwidth/2]{"./redboard.jpg"}
+\end{center}
 
-\subsubsection{Controller}
+There are many ways to interface with the I2C bus.
+We have used a SparkFun RedBoard, pictured above.
+You may find an example within the online repository that dynamically controls both the LED intensity and fan speed.
 
-\section{Assembly}
+\includepdf[landscape=true]{"../digital-driver/driver.pdf"}
+
+\section{Assembly} \label{SEC:assembly}
 
 \includegraphics[width=\textwidth]{"./assembly-coverart.jpg"}
 
+Once 3D printing is done and PCBs have been filled, WPR assembly is fairly straight-forward.
+The various electronic components must be installed into the base (pictured above), as described in \autoref{SEC:base}.
+Reflective coating must be added to the chamber walls, as described in \autoref{SEC:top}.
+After these final steps, your WPR is ready for synthesis!
 
 \clearpage
-\subsection{Base}
+\subsection{Base} \label{SEC:base}
 
 \begin{center}
   \includegraphics[width=\textwidth/2]{"./bare-led.jpg"}
 \end{center}
 
+If possible, it's best to order your LEDs pre-attached to an ``LED star'' heat sink.
+Otherwise you may order bare LED stars and discrete LEDs.
+Either way, you will have a filled LED star as pictured above.
+In this example we are using LED Supply part number 07007-PL000-F.
+
 \begin{center}
   \includegraphics[width=\textwidth/2]{"./soldered-led.jpg"}
 \end{center}
 
-In this case LED Supply 07007-PL000-F
-May be a challenge---heat sinking will fight you
-Add lead-based solder to make easier
-
-TODO: LED PCB part number
+Start by soldering leads onto your LED star, using the red positive black negative convention.
+Soldering here may be challenging, as the LED star itself will resist your efforts to heat it.
+Adding some lead-based solder may help, due to the lower melting point.
 
 \begin{center}
   \includegraphics[width=\textwidth/2]{"./tap-heatsink.jpg"}
 \end{center}
 
-Tap the heatsink.
-We used thread-forming tap: OSG 1400105300.
-
-Install with wires facing towards printed hole.
+The aluminum heatsinks arrive preformed but without any tapping.
+Tap the heatsink for imperial 4-40 machine screws.
+We used thread-forming tap: OSG 1400105300 with a pneumatic ``air-tapper'' (pictured above), but you may do this by hand if you wish.
+You will need to tap just two of the innermost holes.
 
 \begin{center}
   \includegraphics[width=\textwidth/2]{"./led-and-heatsink.jpg"}
 \end{center}
 
-Use 4-40 1/4''.   Fastenal 0146455
+Install the LED star and heatsink with wires facing towards printed hole.
+Use 1/4'' screws.
 
 \begin{center}
   \includegraphics[width=\textwidth/2]{"./mounted-fan.jpg"}
 \end{center}
 
-Noctua NF-A12x15 PWM
-
-Use 4-40 3/4'' into captured nuts TODO: Fastenal part number
+Install the fan.
+Pay special attention to the orientation of the fan, including the location of the cord.
+Use 3/4'' screws here.
 
 \begin{center}
   \includegraphics[width=\textwidth/2]{"./cable-tie.jpg"}
 \end{center}
 
+Install the cable anchor using a 1/4'' screw.
+Use a zip tie to capture the fan cord, as shown above.
 
-TODO: cable tie
+\clearpage
 
 \begin{center}
   \includegraphics[width=\textwidth/2]{"./driver-on-base.jpg"}
 \end{center}
 
+Install the driver board using the threaded standoffs.
+Plug the LED and fan into the board.
+Pay special attention to the orientation of the fan connector.
+You should now be ready to test your base---remember to use proper eye protection!
 
-pins:
-blue: PWM (5 V)
-yellow: +12 V
-black: ground
-
-
-0.5'' standoff: RAF 4505-440-AL
-
-TODO: LED PINS SOLUTION
-
-\subsection{Top}
-
-Language: top and chamber.
+\clearpage
+\subsection{Top} \label{SEC:top}
 
 \begin{center}
   \includegraphics[width=\textwidth/2]{"./reflector.jpg"}
 \end{center}
 
-TODO: part number
+Simply cut the reflective material to line the chamber.
+It's good to leave overlap around the interior, as shown.
+Remove the backing and stick the material to the chamber walls.
 
 \end{document}
-- 
cgit v1.2.3

