Happy March!

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Jeremiah's Knives
Good morning and can you believe it’s March already? Wow!¬†Now that Chinese New Year is past the last of the packaging materials for the IGBT Hybrid Driver kits have shipped. I’m now looking forward to getting it all packaged up. I have some fun and unique ideas for the packaging as well. ūüôā
Between ice and snow days, three kids with the flu, then me with it for a couple of days and throw some travel in there I’ve been working on the guide for the kit a bit more. It is coming together beautifully, and I enjoy working on it. But to be honest, I’m most excited to get back to work on finishing the main code. However since the drivers are a crucial part of the overall kit, this is time well spent.

Forging Ahead

On another note, while my brother Daniel is in the process of moving I let a friend, Jeremiah borrow the original induction heater. Jeremiah has been making knives for the better part of last year using stock blanks and handcrafting the handles from various materials. He wanted to get his feet wet forging his own blades from scratch but doesn’t have the area or set up for a flame forge. Maybe we’ll get some nice pictures or even a video or three. He is new to forging but has been studying the last few months, so he was ready for the IH!
Here is some of Jeremiah’s recent work. I believe he said these were Christmas presents this past year.¬†
 Jeremiah's Knives
I’ve met others with impressive talents in blade crafting like¬†Larry Fahnoe, check out his creations too! I am truly excited to see more people with access to induction heating and what they’ll do with it.

Power Progress – 240 Volt Quick Disconnect

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240V Quick Disconnect

In the photo below is my power test setup at home. Unfortunately, where my other shop is right now, I am unable to make changes like this. Here I explain what I did to get around that and make power progress!

DIY Induction Heater Power

Now that the ReactorForge is back on the bench it’s time to get it powered up!

This¬†setup isn’t necessarily something that an inspector would like to see. ¬†So don’t think this is my recommendation for a permanent solution. I’m just sharing what I did to make my current setup work. Keep in mind the breaker should always be OFF before connecting or disconnecting wires on the quick disconnect assembly.

To hook up 240 to the ReactorForge in this shop I have to run a temporary line. I don’t want to have to remove the breaker each time I do this, so I made an enclosure that mounts in a breaker slot. The assembly houses 3 Burndy splicers (PN: AMS2BAG2R). It does a few important things, it isolates them from each other, from the breaker box, and it snaps closed to prevent the lugs from sliding out (and attacking passer buys). On the side where the wires enter the assembly from the breaker, it is closed off except for holes just big enough for them, so it’s impossible for the splicers to slide out from that side. There are also ears on the front to keep the entire assembly from sliding all the way in the breaker box.

I printed a quick test in PLA, made a few changes and am ready to 3D¬†print the final version in nylon after Thanksgiving. I’m sharing all the files here in case anyone else finds it useful. Be smart, be safe.

Power progress photos:

New Shop Power Panel

My problem is that I do not want to open up the panel and remove the breaker and wires every time I need to remove the temp line.

Power progress

Fusion 360 power splice quick connect

So I drew a simple small enclosure to house some common splice blocks made by Burndy.

The prototype:

 

The slide lock action:

Technical Drawing:

240V Quick Disconnect Drawing v10.pdf

*Tip: I usualy try to make a technical drawing before I 3D print a part. It’s quick and easy in Fusion 360 and saves me wasted prints and time redrawing later. I always catch a lot more looking at the drawing with multiple views and mesurements than just looking at the drawing in the viewport.

You can view and download the CAD files over at Thingiverse –¬†204 Volt Quick Disconnect Splice Housing¬†