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Chapter 02

A Quick-look at steps involved in development of POVPD

Page 1

A Bird's eye view
Using the all inclusive POVPD kit

STEP  1 : Take a wooden board, with wooden frame or an Acrylic sheet
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Cut a hole of Φ=11cm This will be the chassis or the main body which holds all parts
 
STEP  2 : Take a cabinet fan 12cm X 12cm size
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Company: NMB 4715KL-04W-B50-E00 12 V, 1A, RPM: 3600 Noise 50 dB
  It has Ball Bearings so its good
STEP  3 : Cut the blades of the fan
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Cut all the blades/fins with a cutter smoothen the rough cuts with file/sandpaper
 
STEP  4 : Mount it in the board/base-plate
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Four nut-bolts mounts the fan rotor washers can be used optionally
 
STEP  5 : Examine the Stator Coil / Primary coil bobbin
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Used to hold primary coil Mounts on fan motor holding "ribs"
 
STEP  6 : Wind the secondary coil 120+120 turns winding.
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The primary or stator winding Insulated Copper wire of φ=0.33mm or xx-gauge
NOTE: This is a "center tap" winding. It will have 3 terminals. (φ means diameter)
STEP  7 : Mount the stator bobbin on the fan "motor holding ribs"
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STEP  8 : Examine the "Rotor Bobbin"
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STEP  9 : Wind the secondary coil on the rotor
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Insulated copper wire of approx Φ=0.33mm or xx-gauge  
Note: There are two terminals of this (secondary) coil. The winding has 240 turns.
STEP  10 : Insert the "Fan rotor" into the "rotor bobbin"
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STEP  11 : Unpack the Arduino board
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STEP  12 : Persistence of Vision Propeller Display-PCB (POVPD-PCB)
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Examine Solder the RGB LED's Solder all components Perform simple testing
 
STEP  13 : Connect the POVPD with Arduino
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Test it Run test programs Test Remote Control code Test Index sensor code
 
STEP  14 : Mount Arduino to "Rotor Bobbin" with two bolts
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NOTE: The 2-wires of the secondary coil are connected to the 2-bolts. Polarity dosen't matters here. Why?
STEP  15 : Align and properly mount the "index sensing" mechanism
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The sensor must be aligned with the source The mounting must be firm    
It may be IR-LED and Photo-diode combination OR a Hall Effect sensor and magnet combination. Using IR-LED and Photo-diode may be more economical.
STEP  16 : Mount the "Base PCB" with the system
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NOTE: The Base PCB has two main purpose:
a) To provide Pulsating DC to the primary coil so that e.m.f can be induced in the secondary coil
b) To control the Rotation Per Minute (RPM) of the propellor using Pulse Width Modulation (PWM)
STEP  17 : Run test programs
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Use remote to increase & decrease number of glowing LEDs & change colours  
 
STEP  18 : Use Graphical User Interface (or develop your own tool) to make display patterns
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Simple Flower Pattern SUCCESS
 The GUI returns a numerical representation of the "desired-pattern"
STEP  19 : Mixing C-with Assembly code OPTIONAL (Advanced Users only)
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STEP  20 : Generating dynamic visual patterns: Like the Propeller Clock
Static Background Dynamic Foreground Dynamic Foreground Dynamic Foreground
Static Background  and  Dynamic Foreground  
The dial of the Clock is made using the GUI and the clock-hands are positioned dynamically. Real taste of real time programming !



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