Máy ép nhựa và chân không dùng trong việc tạo hình và bảo quản các sản phẩm cỡ nhỏ. Một mẫu dùng trong các hộ sản xuất thủ công, quy mô nhỏ đáng được chế tạo và sử dụng. Một ý tưởng tuyệt vời. Với giá thành khá rẻ
VACUUM FORMING MACHINE PLANS TABLE OF CONTENTS DISCLAIMER GENERAL OVERVIEW LIST OF MATERIALS THE STRUCTURE TOTAL DIMENSIONS FOR THE BOXES CUTTING ALL THE PIECES BASE BOX PIECES HEATER BOX PIECES PLATEN PIECES 10 ALUMINUM 1” SQUARE TUBE PIECES 12 ALUMINUM 1” ANGLE PIECES 12 2020 ALUMINUM PROFILE PIECES 13 PVC TUBE PIECES 13 1.25” WOOD DOWEL PIECE 13 PUTTING ALL TOGETHER 14 THE BASE BOX 14 THE HEATER BOX 16 THE PLATEN 18 2020 PROFILE SUPPORTS 24 FRAME TUBE PIECES 24 ALUMINUM ANGLE FRAMES 26 BRACKETS 30 LIFT ARMS 30 HEATING COILS 36 3D PRINTED DETAILS 39 ELECTRIC DIAGRAM FOR 110V .40 ELECTRIC DIAGRAM FOR 220V .40 ELECTRONICS .422 SPECIAL INSTALLATIONS 42 COMPONENT PLACEMENT 43 CONNECTIONS 44 LABELING .44 VACUUM FORMING MACHINE PLANS DISCLAIMER READ THE FOLLOWING INFORMATION CAREFULLY BEFORE PROCEEDING The information and media found in Make & Tinker YouTube channel, project plans, documents and any other accounts/pages on the Internet related to Make & Tinker is intended for entertainment purposes only There are no warranties expressed or implied and your results may differ from ours The information provided by Make & Tinker has been compiled from personal experience and/or other sources deemed reliable and it is accurate to the best of our knowledge and belief; however, Make & Tinker and its owners cannot guarantee its accuracy, completeness and validity and cannot be held liable for any errors or omissions All information is provided “as is” and does not make any express or implied warranties, representations or endorsements whatsoever Working on “do it yourself” (DIY) projects may involve situations that can be hazardous to your health or even put your life at risk Those dangerous situations may include (but are not limited to): high pressure, high tension, dangerous voltage, poisonous and/or corrosive materials, sharp objects, high RPM motors, open flames or heating elements Always consult a professional before working on something dangerous Reader agrees to assume all risks resulting from the application of any of the information provided by Make & Tinker and its owners By using these plans, including any files, software and additional content accompanying it, the reader agrees that the use of this information is entirely at his/her own risk Each person is responsible for their own actions and decisions The construction and/or use of some projects may be restricted or prohibited in the area where you live, check with the local authorities before proceeding You should fully research, verify and confirm each technique and decide for yourself what is the safest possible work method, tools and materials for you We may not be experts or certified professionals and you should NOT rely solely upon the information and techniques presented and displayed on these plans and any other media included Changes to the information may be made periodically and at any time In NO event will Make & Tinker and its owners be liable for any type of loss, damage or injury arising from the use of the information contained in these plans, videos or elsewhere, as well as the use or download of any digital files, source code and extra materials The reader agrees to indemnify and hold harmless Make & Tinker and its owners from and against any personal type of injury, damages, costs and expenses, including any legal fees, potentially resulting from the application of any of the information and/or use of digital files provided No Resale or distribution The customer shall not resell or freely distribute the information or content, in whole or in part, contained within this plan and accompanying files Always use appropriate protection gear, common sense and follow all the recommended local laws and regulations Follow precautions and instructions from tool, material and gear manufacturers as well VACUUM FORMING MACHINE PLANS GENERAL OVERVIEW WHAT IS VACUUM FORMING? “Vacuum forming is a simplified version of thermoforming, where a sheet of plastic is heated to a forming temperature, stretched onto a single-surface mold, and forced against the mold by a vacuum This process can be used to form plastic into permanent objects such as turnpike signs and protective covers Normally draft angles are present in the design of the mold (a recommended minimum of 3°) to ease removal of the formed plastic part from the mold Suitable materials for use in vacuum forming are conventionally thermoplastics The most common and easiest to use thermoplastic is high impact polystyrene sheeting (HIPS) This is molded around a wood, structural foam or cast or machined aluminum mold, and can form to almost any shape This high impact material is hygienic and capable of retaining heat and its shape when warm water is applied and is commonly used to package taste and odor sensitive products Vacuum forming is also appropriate for transparent materials such as acrylic, which are widely used in applications for aerospace such as passenger cabin window canopies for military fixed wing aircraft and compartments for rotary wing aircraft Vacuum forming is often used in low-level technology classes for an easy way to mold.” – Wikipedia, 2011 MACHINE SPECS Thermoplastic sheet size: 60 cm x 60 cm Max vacuum area: 54 cm x 54 cm Voltage AC: 110 V ~ 20A Voltages DC: 12 V ~ 1A / V ~ 1A Power: 1,500 W (750 W x 2) THE BUILDING PROCESS Start by building the structure of the vacuum forming machine, comprised of the following sections: 1) 2) 3) 4) 5) The base box The platen The heater box The frames The lift arms The electronics will be installed after the structure is all done VACUUM FORMING MACHINE PLANS LIST OF MATERIALS DESCRIPTION / TECHNICAL SPECS QTY WOOD mm (3/8") MDF 1.22 m x 2.44 m (4' x 8') sheet ALUMINUM 1" x 1" square tube, 1/16" (1.57mm) thickness 1" x 1" angle bar, 1/16" (1.57mm) thickness 1" flat bar, 1/8" (3.18 mm) thickness 2020 (20 mm x 20 mm) T-slotted aluminum extrusion, 1m long T slot L-shaped 90-degree bracket joint with setscrews INSULATION 1" thick mineral wool board, 24" x 48" m (13') m (16') m (40") WIRE AND MESH 16-gauge galvanized steel wire Galvanized wire mesh, 1/4" square openings 5m (16') m2 (40" x 40") HARDWARE Aluminum blind rivets 3/16 x 5/16 1/4-20 x 1.75" hex head bolt 1/4-20 x 2.5" hex head bolt 1/4-20 x 1.5" hex head bolt 1/4-20 x 3.5" hex head bolt 1/4-20 hex nut 1/4" x 5/8" flat washer M5 x 40mm Phillips pan head bolt M5 x 0.8 mm hex nut M5 x 10 mm x mm flat washer M2.5 x mm pan head machine screw M2.5 x 0.45 mm hex nut #10 x 2" pan head wood screw #10 x 1" pan head wood screw #10 x 1/2" flat washer #4 x 3/8" pan head screw Double V guide steel wheel (5mm x 24mm x 10mm) Continues… 36 16 2 30 46 12 2 25 4 VACUUM FORMING MACHINE PLANS DESCRIPTION / TECHNICAL SPECS (continued) ELECTRONICS Arduino Uno ATmega328P microcontroller board Relay module for Arduino, 5V / 125V 250V 10A, channel KY-016 RGB LED module 20x4 LCD display module MAX6675 thermocouple module K-type thermocouple temperature sensor 100k potentiometer 10k resistor 5V piezo buzzer SPDT roller lever micro switch, 1NO, 1NC 22 AWG cable (CAT5 cable can also be used, m) DC 2.1mm x 5.5mm power plug connector ELECTRIC Rocker toggle switch, pin, 125 – 250 VAC 20A Voltage Regulator (Dimmer) SCR, 110V – 220V 4000W Power supply, input: 110VAC or 220VAC output: 7.5, or 12 VDC * Heating Element Coil Wire, 110V 750W or 220V 800W * Way 30A ceramic terminal block Ceramic insulator bushing spacer with 13/32" I.D 18 AWG wire 12AWG THHN wire 12AWG MGT wire Nema 5-15P 15A 125V AC Plug * QTY 1 1 1 1 1 m (2 yd) 1 1 2 16 m (1 yd) m (5 yd) m (2 yd) PLUMBING 1.5" PVC SCH40 pipe 1.5" PVC SCH40 90-degree elbow m (40") MISCELLANEOUS Binder clips, large * IMPORTANT: Please use the one that matches the voltage in your location (either 110V or 220v) VACUUM FORMING MACHINE PLANS THE STRUCTURE TOTAL DIMENSIONS FOR THE BOXES CUTTING ALL THE PIECES Base box total dimensions: Width (front): 61 cm Depth (side): 60 cm Height: 15.9 cm Heater box total dimensions: Width (front): 61 cm Depth (side): 60 cm Height: 12 cm Platen total dimensions: Width (front): 54 cm Depth (side): 54 cm Height: 4.9 cm VACUUM FORMING MACHINE PLANS CUTTING ALL THE PIECES BASE BOX PIECES VACUUM FORMING MACHINE PLANS VACUUM FORMING MACHINE PLANS HEATER BOX PIECES VACUUM FORMING MACHINE PLANS 33 STEP 44 On the left lift arm assembly, draw a line in the tube between the bracket and the end of the tube with a pencil or marker, running along the middle of the tube Place the switch trigger 3D printed piece (file: Trigger.stl) with the large rounded corners towards the bolt on the brackets, making sure the holes are centered on top of the line you drew and mark the center of the holes on the tube Drill the holes and then screw the trigger into the tube with two #4 x 3/8” screws Press the lid (file: TriggerLid Stl) in place to finish the switch trigger installation STEP 45 On the short lift arm tube, place the switch box 3D printed piece (file: SwitchBox.stl) centered on the tube and at 35 mm from the apex of the rounded end Mark all the holes on the tube Drill all the holes into the tube Insert two M2.5 nuts in the bottom of the switch box and then screw it into the tube with two #4 x 3/8” screws in the corners VACUUM FORMING MACHINE PLANS 34 STEP 46 Feed the cable for the switch through the 6mm hole in the corner of the switch box and guide it inside the tube until it comes out of the far end Solder the wires on the switch, tuck the cable in and screw the switch with two M2.5 x mm screws into the nuts placed on the previous step Close the switch box with the lid (file: SwitchBoxLid.stl) to finish the installation Check that the switch is being pressed by the trigger when fully extended STEP 47 On each of the 39.2 cm square tubes drill through a 1/4” hole, centered vertically and horizontally Insert a 3.5” 1/4” bolt with a washer from the inside of the base box From the outside insert the square tube on the bolt followed by a washer and a nut Repeat on the other side VACUUM FORMING MACHINE PLANS 35 STEP 48 Place a nut and a washer in the axis bolt of the top frame Place a second nut on the bolt in the base box Inserting the long bracket and the short tube from the lift arm into the bolts from the frame and the base box respectively Followed by a washer and a nut in both cases Repeat on the other side STEP 49 Screw the handle wood rod into the lift arms, placing a washer on each side of the square tube Use wood glue on the hole of the handle and don’t fully tighten the #10 x 2” screws, so the handle can rotate freely VACUUM FORMING MACHINE PLANS 36 STEP 50 As stops for the rollers, slide a T-slot L shape joint bracket in the slot of the four 2020 profiles, and tighten them in place, making contact with the rollers where they rest when the frame is pulled down and the bottom edge of the top frame is even with, or up to mm below, the platen’s surface Place one under each roller Alternatively, drill a 1/4“ hole and insert a 2” long bolt with nuts to stop the rollers HEATING COILS STEP 51 Wrap a piece of wire about 30 cm long around each of the porcelain insulators, leaving 7-8 cm of wire sticking up as shown below Insert the wires of the 16 insulators through the mineral wool until the insulators almost contact the wool Bend the ends that come through the other side over the wire mesh to keep them in place VACUUM FORMING MACHINE PLANS 37 STEP 52 Thread the heating coils through the porcelain insulators, until you have them in a shape like shown below Pull or press the loops of the coils make it longer or shorter, but try to keep the spacing between the loops as even as possible Warning: never cut the wire to shorten the coils, as this will lower its resistance value and can result in fire, electrical damages or accidents STEP 53 Insert the end of each heating coil into a ceramic or porcelain block and tighten the screws to hold them Secure the blocks in place with a piece of wire that goes through the center of the block and the mineral wool and bend the ends on the other side VACUUM FORMING MACHINE PLANS 38 STEP 54 With a screwdriver dig a hole through the mineral wool at the center Feed the thermocouple wires through until the nut is even with the surface Run the wires along the flat aluminum bar on the other side of the heater box to the back, securing them with zip-ties STEP 55 On the back side of the heater box, screw the Max6657 module 3D printed box (file: MaxBox.stl) close to the hole for the heater coil wires and from where the thermocouple wires hang Pass the thermocouple terminals through the opening on the top of the box and the data cables through the bottom opening and make all the connections in the module Fix the module board in place by screwing it to the center hole of the box Once finished close the box with the lid (file: MaxBoxLid.stl) VACUUM FORMING MACHINE PLANS 3D PRINTED DETAILS STEP 56 Close the openings of the lift arm tubes with de 3D printed caps (file: TubeCap.stl) For the left lift arm that has the cable from the switch coming out of it, use the cap with a hole (file: TubeCapHole.stl) STEP 57 Place a 3D printed gromet (file: Grommet.stl) on all the 5/8” holes in the base and heater boxes 39 VACUUM FORMING MACHINE PLANS ELECTRIC DIAGRAM FOR 110V 60Hz 40 VACUUM FORMING MACHINE PLANS ELECTRIC DIAGRAM FOR 220V 50Hz 41 VACUUM FORMING MACHINE PLANS 42 ELECTRONICS SPECIAL INSTALLATIONS POWER CORD Leave at least m of 12 AWG cord to connect the machine to a wall outlet Install a NEMA 5-15P plug on the end of the cord Warning: It’s not recommended to use extension cords but if you must use one, make sure that it is at least 12 AWG to reduce the chance of failure and fire or shock hazards VOLTAGE REGULATOR Unscrew and open the voltage regulator’s (dimmer) enclosure Unsolder the potentiometer from the PCB board Pass three 18 AWG wires (approximately 30 cm long each) through the round opening in the enclosure and solder them back to the potentiometer and their respective terminals on the PCB Place the enclosure cover back on and screw it closed POWER SWITCH Insert the power rocker switch through the front of the 3D printed protector (file: SwitchProtector.stl) and then insert it into the opening on the front of the base box VACUUM FORMING MACHINE PLANS 43 COMPONENT PLACEMENT 10 Voltage regulator (Dimmer) SCR, 110VAC (or 220VAC) 4000W Voltage regulator’s potentiometer (extended with wires to the front panel) 20x4 LCD display module KY-016 RGB LED module 100k potentiometer (for display module) 5V piezo buzzer – mounted on 3D printed holder (file: BuzzerHolder.stl) Rocker switch, pin, 110VAC / 250VAC 20A Arduino Uno ATmega328P microcontroller board Relay module for Arduino, 5V DC / 110VAC – 250VAC, channel Power supply – 110Vac or 220VAC either 7.5, or 12 VDC Use #4 x 3/8” screws to hold components in place to the base box Hot glue can also be used to secure small components (like the RGB LED module) in place SETTING UP THE ARDUINO Upload the accompanying sketch VacuumFormer.ino to the Arduino board Instructions on how to this can be found here: https://www.arduino.cc/en/Guide/ArduinoUno VACUUM FORMING MACHINE PLANS CONNECTIONS 44 VACUUM FORMING MACHINE PLANS 45 VACUUM FORMING MACHINE PLANS 46 VACUUM FORMING MACHINE PLANS 47 LABELING OPTIONAL LABELS Labels can be placed in several parts of the vacuum former to warn users of hazardous points while operating the machine The images are included in the accompanying document named Labels.pdf and it can be printed on self-adhesive label paper Their suggested positions are as follows: Thank you for purchasing the plans! 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