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Additional 5a Nano Polyfuses
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Description

We are going to need to include additional 5a nano polyfuses to the inside of the electronics case. We have received specific feedback that the tool kits will get lost/separated, and attached inside of the case is a better option.

We can always use some blue tape, but I feel there could be a more elegant solution with a printed part. @west any thoughts on how we could do this?

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@tutley are you saying that you would like @Shawn to print some test samples? If so, how many would work?

@david.hall no i was just going off your comment to let you know when it was in the cluster folder. so i was pointing you to the location of the stl's. I think they need to go through normal slice request procedure.

Gotcha! @EricNugent , please let me know when you want a test of these run. Thanks

@david.hall @tutley @west The slice requests have a gcode in the folder, I uploaded them before closing as wontfix. Per @cmerot I was under the impression we were not using a printed part solution for this.

Regardless I have some samples printed out if they need to be installed or tested on machines.

After thinking about this issue, I am going to completely reverse myself. Rather than be concerned about print cluster capacity, manufacturing will strive to find creative ways to use our printers to manufacture themselves and to solve problems, so let's implement the plastic parts. When we run out of printer capacity, we will use our printers to make more for ourselves. My apologies for not seeing this initially.
Christian

adam added subscribers: tomc, logan.Jul 11 2019, 12:35 PM

I have created the following part numbers for the fuse mount.
@logan which assembly should this go into?
@tomc please update the routing on the following parts for manufacturing in cluster and transport to where they are being installed.
[PP-GP0463] 5A Fuse Sleeve, Black
[PP-GP0464] 5A Fuse Mount, Black

@EricNugent has the test parts printed. @karrad do you want to see these parts first? How do we want to get this moving forward?

adam added a subscriber: Kazkade.Jul 11 2019, 1:03 PM

@david.hall I'm going to have Cluster run a couple pods of these parts and drop them off at @adam 's desk when they're done.

@david.hall If i am not available at mountain for a review, please give them to the project lead for review. If they are not available, anyone in PP should be able to handle the cosmetic approval. In this case, delivery to @adam should be good

Sounds great! we will get them done and over to @adam

adam added a comment.Jul 11 2019, 2:31 PM

These look great except they are the 5V labeled model version and not the 5A labeled version.
@EricNugent can you take a look at the slice to make sure it's the 5A version?

yea we definitely want 5A lol

@adam I am downloading the updated model and will slice using the same settings. The slice ticket was made and never updated with current rev for that model.

logan added a comment.Jul 12 2019, 8:13 AM

@adam This should be on AS-PR0162 Control Box Assembly. If we could get a strip of those fuses here in MER I can probably get a part from @EricNugent to take the OHAI photos today.

adam added a comment.Jul 12 2019, 8:17 AM

@tomc can you get @logan a strip of 5x EL-MS0235?
@EricNugent can you get me weights for the printed parts so I can get BOMs updated?

@adam sure thing, I will need the parts that you were given for cosmetic inspection. Otherwise it will be until I have more printed out.

adam added a comment.Jul 12 2019, 8:23 AM

@EricNugent can we get the 5A version printed in LB green?

@adam Fuse mount = 7.5g
fuse sleeve = 2.5g

@adam we have 21 of the 5amp version printing now in Cluster. We will print 21 of them in green as soon as they are finished.

adam added a comment.Jul 12 2019, 8:43 AM

added fuses, fuse mount, and fuse sleeve to AS-PR0162 OCA BOM and pushed to branch

logan moved this task from Beta to OHAI Content on the Redgum board.Jul 12 2019, 3:36 PM
logan claimed this task.

I will ensure this is of high priority for me next week to get it into the OHAI. Thanks all!

adam added a comment.Jul 15 2019, 9:53 AM

@EricNugent please make sure the proper slices for these are where they need to be for cluster. Those printed parts you showed me on Friday are good for use.
@Kazkade @david.hall have you started creating MOs and printing the printed parts?

@adam this should all be the same part number, so we will need to know whether we want to purge backstock, or keep using the "usable" parts and just roll this in.

@david.hall These are new parts not a change to an older one, we shouldn't have any of these in backstock right? Are you on the right ticket?

@adam I meant to put this one in the bezel CO, Sorry, too many things going on.
If we want to produce these, have we determined color? if so, we just need inventory to set up the requests and then we will print off of those. @Kazkade please see if this is active and ready for us to print or not.

adam added a subscriber: Heather.EditedJul 15 2019, 10:47 AM

@Heather @tomc we need routes set up for:
[PP-GP0463] 5A Fuse Sleeve, LulzBot Green, Flexible
[PP-GP0464] 5A Fuse Mount, Black

logan added a comment.EditedJul 15 2019, 10:48 AM

@adam @david.hall I thought we were doing black ABS mount and LB green ninjaflex sleeve

adam added a comment.Jul 15 2019, 10:48 AM

edited above sorry

Ok we're good then. Working on OHAI photos now

adam added a comment.Jul 15 2019, 10:49 AM

I copy/pasted from the comments above instead of from OCA where it is correct.

adam added a comment.Jul 15 2019, 10:50 AM

@david.hall we need to purge any black PP-GP0463 that we already printed. These need to be LB green.

@adam @david.hall do you think we should make filling the fuse holder and putting it together its own sub-assembly? That way it arrives to CB Assembly ready to install

adam added a comment.Jul 15 2019, 11:00 AM

I think that would be easier on CB assembly and shouldn't be too hard, but I will defer to @Kazkade and @david.hall on that.

I think that a sub assembly is the way to go. @EricNugent do you know if we have the files pushed to the Cluster folder and is the 463 part in green (in the part name)?

@david.hall Files are pushed into production folders.

@adam

@Heather @tomc we need routes set up for:
[PP-GP0463] 5A Fuse Sleeve, LulzBot Green, Flexible
[PP-GP0464] 5A Fuse Mount, Black"

These components have been updated with routes and reordering rules; they are ready to produce once the slicing is complete.

adam added a comment.Jul 15 2019, 1:00 PM

After discussing with @cmerot and @logan we are going to roll these into production as soon as we have parts printed. The amount of time necessary to rework these printers is significant and will reduce the number of printers we will be able to produce.
We can include the mount and fuses in the tool kit on the printers that don't get it installed.

i think having the mount and fuses in the tool kit but not installed may be received poorly by customers. Its like hey we didnt care to spend the time to install this, so its up to you now..

logan added a comment.EditedJul 15 2019, 1:52 PM

@adam Please create "Filled Fuse Holder" AS-PR number to include:
5x- EL-MS0235
1x- PP-GP0463
1x- PP-GP0464

logan added a comment.Jul 15 2019, 1:53 PM

@tutley So is your recommendation to just leave them out of those that didn't get them in the boxes?

adam added a comment.Jul 15 2019, 2:08 PM

@Heather we need routes set up for [AS-PR0169] 5A Fuse Mount Subassembly
@logan AS-PR0162 BOM updated with the assembly part and the components removed.

@tomc please note changes in BoM's on this and the new pars.

tomc removed a subscriber: tomc.Jul 15 2019, 2:10 PM
adam added a subscriber: tomc.Jul 15 2019, 2:12 PM

BOM updated and pushed to branch
@tomc @Heather I believe that the subassembly will be done in presub and delivered to electromech, but you might want to touch base with @david.hall and/or @Kazkade.

david.hall added a comment.EditedJul 15 2019, 2:36 PM

I want to build these in Elect/Mech, right before they are installed. But let me think about that and talk to elec/mech first.

@draubach and @guadalupe please look at the last couple of entries here and see if you think that it would be hard to put the fuse holder together with the fuses before you install the fuse holder in the chassis.

@logan how many units would need reworked?

its not that hard to pull the rambo off with all the wires still attached, slip the printed part on and reattach the rambo. I would be willing to come help rework these

logan added a comment.Jul 15 2019, 2:48 PM

@david.hall thats why we asked if these needed to be a sub-assembly. If they're just going to fill/assemble as they're installing them then we wouldn't need a sub-assembly. The idea behind the sub-assembly was to have it ready to go before it gets to CB assemblers. Otherwise you'd have to stock fuses and both printed parts at the stations and have them cut/fill/assemble the holder. I think it is better for assembly flow if this is done in pre-sub like we discussed.

@tutley I have no idea how many have been produced.

logan added a comment.Jul 15 2019, 2:51 PM

@tutley With the location of the fasteners that mount the RAMBo I'm inclined to disagree with you. I don't see that being an easy rework at all. You run great risk of losing fasteners inside the case/power supply this way (from experience). Plus there's the copper tape to deal with, which is a pain itself with the harnesses installed.

adam added a comment.Jul 15 2019, 2:54 PM

@tutley right now I think we are sitting at 52 control boxes/printers to rework. 33 in production and 19 as control boxes.

adam added a comment.Jul 15 2019, 2:56 PM

at 15 min per swap we are looking at 13 hours of work.

so we are pushing off that difficult installation onto the customer who just bought a $3k machine..
In my mind, if it is that difficult then that is even more of a reason for us to take the time to install them

the copper tape would likely need pulled off and completely replaced

@logan I will take a look at this and see what direction we want to go. I am trying to manage people, so that I can keep up with the needs of production. I will definitely keep your ideas in mind. Thanks

logan added a comment.Jul 15 2019, 3:04 PM

I'm working on getting the installation into the OHAI. It isn't up to me how labor is spent. Either we let this roll in, or we eat the high cost of rework & lost time.
There's nothing at all requiring customers to install the mount into the case, the point would be that they have them.

For the record, I do not condone the idea of attempting this rework with the box resting vertically, it is risky and sounds incredibly difficult.

logan reassigned this task from logan to david.hall.Jul 15 2019, 3:14 PM

@david.hall if you decide to change this from what we decided earlier in creating the sub-assembly part number, let me know and all I have to do is move that workstep from one project to the other and remove the AS-PR number from it. Right now it resides in general sub-assemblies and the AS-PR part is called out in the CB assembly.

@logan, sounds good. I do still think Presub will be a better way, just trying to make it all work!

logan added a comment.Jul 15 2019, 3:21 PM

@david.hall Understood. I think it is important to keep as much of an assembly line flow to CB assembly as possible and in my mind having this produced in presub would help accomplish that. Let me know if you need anything else.

logan moved this task from OHAI Content to Beta on the Redgum board.Jul 15 2019, 3:53 PM

PP-GP0464, PP-GP0465 and AS-PR0169 have all been updated in light of this information.

Correction:
Per request by @cmerot, these parts (PP-GP0463, PP-GP0464) will be routed from Cluster to ElectroMech, and AS-PR0169 will be assembled and installed there.

adam added a comment.Jul 16 2019, 7:25 AM

I have updated the AS-PR0162 BOM to remove AS-PR0169 and added the raw parts (PP-GP0463, PP-GP0464, and EL-MS0235)

@adam
Should we go ahead and shut down and archive AS-PR0169? There's a significant chance that the ElectroMech team will build these in large sets at a time and have them sitting so it may be prudent to leave the assembly intact.

adam added a comment.Jul 16 2019, 7:38 AM

@Heather my understanding from my conversation with @david.hall was that since these were going directly in the control box that we wouldn't need the subassembly. I think @david.hall has the final call here. If he wants the subassembly so his people can build ahead I can switch the BOM back.

@adam
Okay, that doesn't answer the question I asked though. Shall we go ahead and archive this assembly?

adam added a comment.Jul 16 2019, 7:46 AM

We need to leave it for now. David is going to the other building to confer with Lupe and Dylan on the actual physical process for this. Once he gets back to me we will know for sure if we need this subassembly. If we do not need the subassembly, we will archive it.

After reviewing all of the information with Lupe, I think we will go ahead and us the sub assembly number, so that she can build ahead (est. 50) Then when the chassis is being assembled the parts can just be installed. This appears to be the way to go presently. I will re-visit this with @cmerot to see if he would like this to stay or change. Could we please set this up so that all parts are delivered to Cables at the Rockies bldg. They will make the sub assembly. Also @Heather could you check the el-ms0235, as it says that they have 40 at the Rockies, but they currently have 4. That way we can start on the installation of these in our chassis. Thank you

adam added a comment.Jul 16 2019, 11:55 AM

@Heather the AS-PR0162 bom has been updated to use the subassembly based on the post above. We need to make sure that AS-PR0169 is set up correctly to be built in electromech and used in electromech.

adam added a comment.Jul 16 2019, 12:02 PM

pushed current OCA BOM to branch

@david.hall
@adam
Okay, reordering rules have been reinstated for the AS-PR0169 and 300pcs have been procured and have an MR available.

@Heather did you check on the EL-MS0235 ? Or do I need to ask Tom?

You could ask Tom, or you could look it up yourself. Looks like 100pcs were delivered

I will back out of the subassembly issue for now and leave that implementation decision to @logan @david.hall @guadalupe . Everyone is working hard to implement the going forward solution by incorporating the fuses assembly into the chassis. I will however participate in the decision to retrofit stock build before implementation into the chassis. Logan is going to install the fuses assembly into a MER Redgum, identify potential risks of damage, measure time from start to finish, create an outline of steps and report on any potential difficulties. I have been told we are adding this feature for the military who don't follow our instructions and blow fuses by cleaning the nozzle with a wire brush. I believe it is unusual for the typical customer to blow a fuse. I believe the decision to retrofit existing machines is a decision that belongs jointly to product planning, sales, tech support and manufacturing. I will call a meeting with Adam, Dani, Lisa and Galadriel and we will make a decision on retrofitting or not.
Sound okay?

logan added a comment.Jul 16 2019, 1:44 PM

@cmerot I was able to alleviate much of the risk involved with gravity by laying the machine on the right side of the frame atop a piece of cardboard for cushion.
Steps:

  1. Lay machine up on the right side of the frame
  2. Remove 14 cover fasteners
  3. Use tweezers and exacto knife to remove copper tape from RAMBo USB
  4. Use ball tipped 2mm driver to unthread RAMBo mount fasteners
  5. lift RAMBo and try to keep the mounting fasteners in the holes
  6. place fuse holder on RAMBo standoffs
  7. Carefully lower RAMBo back into place without any of the fasteners falling out of the holes into the case.
  8. tighten RAMBo mount fasteners
  9. cut new strip of copper tape and re-apply using tweezers and ruler
  10. put cover back on
  11. reinstall 14 cover fasteners

Time to complete 1: 9 minutes (8 minutes 47 seconds measured)
Cost estimate: $100-200+ depending on total QTY and wage of individual(s) completing rework
Damage potential: Minimal - this rework must be performed in an area where ESD protection measures can be utilized (wrist-straps). Assembler must be careful not to knock the machine over as it rests on the right side of the frame. Any fasteners that fall under the RAMBo will be difficult to retrieve. Dropped tools could result in damage to board or board mounted components.
Potential difficulties: Fasteners falling out of RAMBo mount holes and having to retrieve them from inside the case. I had to use a combination of an exacto knife, tweezers, and ruler to remove and replace the copper tape on the RAMBo USB; knife to peel up enough to grab with tweezers, tweezers and end of ruler used to adhere new copper strip and press it flat.

Excellent work @logan . Thank you, Christian

we have installed the AS-PR0169 into the 15 Workhorse chassis here at Rockies they will have 2 yellow tags to indentify them saying they have fuses when they come to Mountain and now we are waiting for Fuses to be able to proceed with this change.Thank you all for the team work this change went really smooth.

adam moved this task from Beta to Needs Review on the Redgum board.Jul 17 2019, 7:27 AM
adam reassigned this task from david.hall to Steven.

Please merge to master - already being rolled out on the line.

@adam @logan the gcode file still has TEST in the file name, am I good correct that?

We are already printing these and installing them on printers. We should have the "test" removed.

Steven closed this task as Resolved.Jul 17 2019, 3:22 PM

This is now merged into master. @adam I don't think there is anything else to do here so closing out but please reopen if needed.