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workshops:public:led_pinwheels:start [2018/06/25 13:00]
Andrei Maberley 		workshops:public:led_pinwheels:start [2019/11/14 11:03]
pmusk [Summary]
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 This set of instructions details how to construct a pinwheel that uses a rubber band to drive a low-voltage generator. This set of instructions details how to construct a pinwheel that uses a rubber band to drive a low-voltage generator.
 When the current produced is passed through a Joule Thief circuit, the energy from a freely moving pinwheel spinner  When the current produced is passed through a Joule Thief circuit, the energy from a freely moving pinwheel spinner 
-is sufficient to make an LED glow.+is sufficient to make an LED glow (red, yellow and green LEDs require a lower voltage, and are more successful).
  
  ==== Materials ====  ==== Materials ====
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 ====Step 4: Joining the halves ==== ====Step 4: Joining the halves ====
-{{:prototypes:led_pinwheels:20151111_0045.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151111_0045.jpg?nolink&600 |}}
  
 Use a nail or sharp screw to make a 2mm hole where the perpendicular meets the baseline of each triangle.  Use a nail or sharp screw to make a 2mm hole where the perpendicular meets the baseline of each triangle. 
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-{{:prototypes:led_pinwheels:20151111_0048.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151111_0048.jpg?nolink&00 |}}
  
 Now do the same with the other triangle, so both halves have a hole in the centre of the baseline. Now do the same with the other triangle, so both halves have a hole in the centre of the baseline.
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 +{{ :prototypes:led_pinwheels:20151111_0055.jpg?nolink&600 |}}
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-\\ 
-{{:prototypes:led_pinwheels:20151111_0055.jpg?nolink&200 |}} 
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-{{:prototypes:led_pinwheels:20151111_0057.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151111_0057.jpg?nolink&600 |}}
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-{{:prototypes:led_pinwheels:20151111_0060.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151111_0060.jpg?nolink&600 |}}
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-{{:prototypes:led_pinwheels:20151111_0062.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151111_0062.jpg?nolink&600 |}}
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-{{:prototypes:led_pinwheels:20151111_0066.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151111_0066.jpg?nolink&600 |}}
  
 Use hot glue along the edge of the bottom piece to join the two halves together.  Use hot glue along the edge of the bottom piece to join the two halves together. 
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-====Step 5: Attachng the hubs ==== +====Step 5: Attaching the hubs ==== 
-{{:prototypes:led_pinwheels:20151111_0049.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151111_0049.jpg?nolink&600 |}}
  
 Use a craft knife to carefully cut the flanged end from the the centre of a T-shaped 4mm drip irrigation joiner. Use a craft knife to carefully cut the flanged end from the the centre of a T-shaped 4mm drip irrigation joiner.
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-{{:prototypes:led_pinwheels:20151112_0001.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0001.jpg?nolink&600 |}}
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-{{:prototypes:led_pinwheels:20151112_0006.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0006.jpg?nolink&600 |}}
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-Locate the two cardboard hubs, and on one hub highlight the engraved cirlce with a marker.+Locate the two cardboard hubs, and on one hub highlight the engraved circle with a marker.
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-{{:prototypes:led_pinwheels:20151112_0007.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0007.jpg?nolink&600 |}}
  
 Apply hot glue to the unmarked side of the hub, and glue them together with the marked circle on top. Make sure they are as evenly aligned as possible. Apply hot glue to the unmarked side of the hub, and glue them together with the marked circle on top. Make sure they are as evenly aligned as possible.
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 </WRAP> </WRAP>
  
-{{:prototypes:led_pinwheels:20151112_0009.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0009.jpg?nolink&600 |}}
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-{{:prototypes:led_pinwheels:20151112_0011.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0011.jpg?nolink&600 |}}
 \\ \\
 \\ Apply glue to the marked area, and glue the acrylic hub to the cardboard ones, lining up the edges with the marked circle. \\ Apply glue to the marked area, and glue the acrylic hub to the cardboard ones, lining up the edges with the marked circle.
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-{{:prototypes:led_pinwheels:20151112_0014.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0014.jpg?nolink&600 |}}
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-{{:prototypes:led_pinwheels:20151112_0017.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0017.jpg?nolink&600 |}}
  
 Thread the sandwich of hubs onto the wire assembly stand, with the double hub uppermost. Thread the sandwich of hubs onto the wire assembly stand, with the double hub uppermost.
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-{{:prototypes:led_pinwheels:20151112_0021.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0021.jpg?nolink&600 |}}
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-{{:prototypes:led_pinwheels:20151112_0022.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0022.jpg?nolink&600 |}}
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 ====Step 6: Folding the Pinwheel ==== ====Step 6: Folding the Pinwheel ====
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-{{:prototypes:led_pinwheels:20151112_0026.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0026.jpg?nolink&600 |}}
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-{{:prototypes:led_pinwheels:20151112_0028.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0028.jpg?nolink&600 |}}
 Glue the bottom of the spacer to the pinwheel. Glue the bottom of the spacer to the pinwheel.
 <WRAP center round alert 60%> <WRAP center round alert 60%>
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-{{:prototypes:led_pinwheels:20151112_0030.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0030.jpg?nolink&600 |}}
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 Locate the 10mm acrylic pinwheel cap (seen at left), slide it on to the assembly wire, and glue it on top of the spacer.  Locate the 10mm acrylic pinwheel cap (seen at left), slide it on to the assembly wire, and glue it on top of the spacer. 
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-{{:prototypes:led_pinwheels:20151112_0031.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0031.jpg?nolink&600 |}}
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-{{:prototypes:led_pinwheels:20151112_0033.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0033.jpg?nolink&600 |}}
  
 Find the corner of the lower half where you trimmed the overlying sheet.  Find the corner of the lower half where you trimmed the overlying sheet. 
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 </WRAP> </WRAP>
  
-{{:prototypes:led_pinwheels:20151112_0035.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0035.jpg?nolink&600 |}}
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-{{:prototypes:led_pinwheels:20151112_0036.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0036.jpg?nolink&600 |}}
  
 Check which side of the radial cut you have just glued to the cap (In the picture above, it was the right hand side)  Check which side of the radial cut you have just glued to the cap (In the picture above, it was the right hand side) 
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-{{:prototypes:led_pinwheels:20151112_0038.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0038.jpg?nolink&600 |}}
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-{{:prototypes:led_pinwheels:20151112_0042.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:20151112_0042.jpg?nolink&600 |}}
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 ====Step 1: Attaching the hubs ==== ====Step 1: Attaching the hubs ====
  
-{{:prototypes:led_pinwheels:poly:20160316_0002.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:poly:20160316_0002.jpg?nolink&600 |}}
  
-{{ :prototypes:led_pinwheels:chassis:20160407_0001_01.jpg?200|}}+{{ :prototypes:led_pinwheels:chassis:20160407_0001_01.jpg?600 |}}
  
  
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 ====Step 2 ==== ====Step 2 ====
  
-{{:prototypes:led_pinwheels:poly:20160316_0006.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:poly:20160316_0006.jpg?nolink&600 |}}
  
-{{ :prototypes:led_pinwheels:poly:spinner_for_comms.jpg?200|}}+{{ :prototypes:led_pinwheels:poly:spinner_for_comms.jpg?600 |}}
 Place the joined hubs onto the assembly stand with the double hub at the TOP,  Place the joined hubs onto the assembly stand with the double hub at the TOP, 
 and apply glue to the top surface. and apply glue to the top surface.
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 ====Step 3 : Folding the Spinner==== ====Step 3 : Folding the Spinner====
  
-{{:prototypes:led_pinwheels:chassis:20160323_0005.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:chassis:20160323_0005.jpg?nolink&600 |}}
  
 Fold up the spinner arms on the side opposite to the hubs, inserting one half of a press stud through the hole from underneath.  Fold up the spinner arms on the side opposite to the hubs, inserting one half of a press stud through the hole from underneath. 
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 ====PART 3: Aligning the Spinner and Motor==== ====PART 3: Aligning the Spinner and Motor====
 ====Step 1: Mounting the motor ==== ====Step 1: Mounting the motor ====
-{{:prototypes:led_pinwheels:chassis:20160323_0007.jpg?200 |}}+{{ :prototypes:led_pinwheels:chassis:20160323_0007.jpg?600 |}}
  
  
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 ====Step 2 ==== ====Step 2 ====
  
-{{:prototypes:led_pinwheels:chassis:20160323_0001.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:chassis:20160323_0001.jpg?nolink&600 |}}
  
  
-{{ :prototypes:led_pinwheels:20151112_0054.jpg?nolink&200|}}+{{ :prototypes:led_pinwheels:20151112_0054.jpg?nolink&600 |}}
  
 Holding the wire axle with some pliers about 50mm from one end, bend it to a right angle. Holding the wire axle with some pliers about 50mm from one end, bend it to a right angle.
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 ====Step 3==== ====Step 3====
  
-{{:prototypes:led_pinwheels:chassis:20160323_0008.jpg?nolink&200 |}} +{{ :prototypes:led_pinwheels:chassis:20160323_0008.jpg?nolink&600 |}} 
  
 Glue the motor in the hole provided in the acrylic chassis with the shaft poking through (the motor should be on the left side, looking from the front). Glue the motor in the hole provided in the acrylic chassis with the shaft poking through (the motor should be on the left side, looking from the front).
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 When the zip-tie is tightened, the handle should still be able to be pushed up and down a bit for fine tuning later. When the zip-tie is tightened, the handle should still be able to be pushed up and down a bit for fine tuning later.
 ====Step 4 ==== ====Step 4 ====
-{{:prototypes:led_pinwheels:chassis:20160323_0003.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:chassis:20160323_0003.jpg?nolink&600 |}}
  
-{{ :prototypes:led_pinwheels:poly:20160316_0008.jpg?200|}}+{{ :prototypes:led_pinwheels:poly:20160316_0008.jpg?600 |}}
  
  
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-{{:prototypes:led_pinwheels:poly:20160316_0017.jpg?nolink&200 |}}+{{ :prototypes:led_pinwheels:poly:20160316_0017.jpg?nolink&600 |}}
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 ====Step 1: Winding the toroid ==== ====Step 1: Winding the toroid ====
  
-{{:prototypes:led_pinwheels:thief:20160323_0003.jpg?nolink&200 |}} +{{ :prototypes:led_pinwheels:thief:20160323_0003.jpg?nolink&600 |}} 
-{{ :prototypes:led_pinwheels:thief:wound_toroid_close_up.jpg?100|}}+{{ :prototypes:led_pinwheels:thief:wound_toroid_close_up.jpg?600 |}}
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-{{:prototypes:led_pinwheels:thief:wound_toroid_complete_close_up.jpg?200 |}}+{{ :prototypes:led_pinwheels:thief:wound_toroid_complete_close_up.jpg?600 |}}
  
-{{ :prototypes:led_pinwheels:thief:twisted_toroid_close_up.jpg?200|}}\\+{{ :prototypes:led_pinwheels:thief:twisted_toroid_close_up.jpg?600 |}}\\
 The toroid now has two pairs of wires emerging from either end of the winding.  The toroid now has two pairs of wires emerging from either end of the winding. 
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 ====Step 2: Assemble the Joule Thief circuit ==== ====Step 2: Assemble the Joule Thief circuit ====
  
-{{:prototypes:led_pinwheels:thief:parts_close_up.jpg?200 |}}\\+{{ :prototypes:led_pinwheels:thief:parts_close_up.jpg?600 |}}\\
 \\ \\
 The circuit requires a NPN transistor, a 1K resistor, the wound toroid and an LED. Red LEDs work best, but yellow or green will also suffice. The circuit requires a NPN transistor, a 1K resistor, the wound toroid and an LED. Red LEDs work best, but yellow or green will also suffice.
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 ====Step 3 ==== ====Step 3 ====
  
-{{:prototypes:led_pinwheels:thief:rans_res_close_up.jpg?200 |}} +{{ :prototypes:led_pinwheels:thief:rans_res_close_up.jpg?600 |}} 
-{{ :prototypes:led_pinwheels:thief:trnas_res_back_close_up.jpg?200|}}+{{ :prototypes:led_pinwheels:thief:trnas_res_back_close_up.jpg?600 |}}
  
 First insert the transistor through the holes in the template. It is important to orient the transistor correctly, so follow the diagram carefully. First insert the transistor through the holes in the template. It is important to orient the transistor correctly, so follow the diagram carefully.
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 ====Step 4 ==== ====Step 4 ====
  
-{{:prototypes:led_pinwheels:thief:led_close_up.jpg?200 |}} +{{ :prototypes:led_pinwheels:thief:led_close_up.jpg?600 |}} 
-{{ :prototypes:led_pinwheels:thief:led_back_close_up.jpg?200|}}+{{ :prototypes:led_pinwheels:thief:led_back_close_up.jpg?600 |}}
  
 Attach the LED, taking care to put the longer leg on the right side. Twist together with the transistor on the back of the template. Attach the LED, taking care to put the longer leg on the right side. Twist together with the transistor on the back of the template.
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 ====Step 5 ==== ====Step 5 ====
  
-{{:prototypes:led_pinwheels:thief:toroid_close_up.jpg?200 |}} +{{ :prototypes:led_pinwheels:thief:toroid_close_up.jpg?600 |}} 
-{{ :prototypes:led_pinwheels:thief:toroid_back_close_up.jpg?200|}}+{{ :prototypes:led_pinwheels:thief:toroid_back_close_up.jpg?600 |}}
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 ====Step 6==== ====Step 6====
  
-{{:prototypes:led_pinwheels:chassis:20160323_0009.jpg?200 |}} +{{ :prototypes:led_pinwheels:chassis:20160323_0009.jpg?600 |}} 
-{{ :prototypes:led_pinwheels:chassis:20160323_0010.jpg?200|}}+{{ :prototypes:led_pinwheels:chassis:20160323_0010.jpg?600 |}}
 Now attach the motor wires as indicated: black wire to the transistor + LED, and red wire to the joined toroid wires. Now attach the motor wires as indicated: black wire to the transistor + LED, and red wire to the joined toroid wires.
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 ====Step 1: Attaching the Joule Thief circuit==== ====Step 1: Attaching the Joule Thief circuit====
  
-{{:prototypes:led_pinwheels:chassis:20160323_0011.jpg?200 |}}+{{ :prototypes:led_pinwheels:chassis:20160323_0011.jpg?600 |}}
  
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-{{:prototypes:led_pinwheels:chassis:20160323_0012.jpg?nolink&200  |}} +{{ :prototypes:led_pinwheels:chassis:20160323_0012.jpg?nolink&600  |}} 
-{{ :prototypes:led_pinwheels:chassis:20160323_0015.jpg?nolink&200|}}+{{ :prototypes:led_pinwheels:chassis:20160323_0015.jpg?nolink&600 |}}
  
 First, fold the enclosure along the scored line.  First, fold the enclosure along the scored line. 
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 ====Step 3: Attaching the spinner ==== ====Step 3: Attaching the spinner ====
  
-{{:prototypes:led_pinwheels:chassis:20160323_0017.jpg?200  |}} +{{ :prototypes:led_pinwheels:chassis:20160323_0017.jpg?600  |}} 
-{{ :prototypes:led_pinwheels:chassis:20160323_0018.jpg?200|}}+{{ :prototypes:led_pinwheels:chassis:20160323_0018.jpg?600 |}}
  
 Take the rubber band, and loop it over the hubs so that it sits in the groove made by the acrylic hub. Now slide the 10mm spacer on to the axle, and then the spinner with the double hubs closest to the chassis.  Take the rubber band, and loop it over the hubs so that it sits in the groove made by the acrylic hub. Now slide the 10mm spacer on to the axle, and then the spinner with the double hubs closest to the chassis. 

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