Wednesday 26th February 2020

Worklist:
Review latest pallet 3D prints.
Tidy up top shelf of storage rack.
Discuss wiring scheme.

Stephen had produced two variations of the pallet design with wider spaced top planks and Geoff was running one off as S & L arrived. Another, with slightly different print parameters was started before going down to the workshop.

We'd had a lot of trouble recently finding 'things' due to the build-up of bits and pieces dumped on the shelving at the end of a session. Geoff suggested a good sort-out, which we all agreed was over due. John's stock and 'vericles' (sic), not already in the exhibition boxes was examined and sorted for overhauling, re-purposing or loft storage. Redundant spare parts and materials were thrown away and we even found the new point motor units that Geoff started three weeks previously! The morning had gone, but instead of starting the low level shelving, Stephen insisted that after lunch, we do some modelling and 'saved' the sorting out for next week. However, lunch took longer that usual as the pallets were reviewed and reprinted a couple of times. There are many parameters that affect the quality of the prints including nozzle and platten temperatures, nozzle speed etc. These aren't perfect quality, but once cleaned up and painted, they will certainly enhance the clutter in the masons yard.

We also discussed packing cases for the more delicate stone products. Yes, you can get quite carried away with a 3D printer.

What was left of the afternoon was spent going over Stephen's wiring proposals. The new control panel proposal met with approval. Instead of treating each of the 11 sections individually, which required 11 three-way rotary switches, the panel would be divided into Quarry line and 'Front-of-house. Just these two overall sections would select the controller to be used, which meant all sections could have our standard illuminated push-buttons.

Stephen reported that since successfully ordering some knobs and switches on eBay after the last meeting, the Chinese suppliers were now reporting that deliver times could not be given, due to the health problems. We'll have to see how that develops. We then reviewed the plugs and sockets for the new boards and while most were straight forward, Geoff's experience came through on one connection. The existing fiddleyard 8-way plug connects into an on-board socket,  Geoff decided that, to minimise connections and soldered joints, rather than replicate this on the new arrangements, it made more sense to create a fly lead with an 8-way socket from the Engine Shed board rather than run all wires through the baseboard. This also reduced the number of connector pins required.

Wednesday 19th February 2020

Worklist:
Review 3D printed plug shells.
Test wiring on Adaptor board #1.
Continue wiring new boards.
Review the new two-way switching unit.
Discuss installation and cabling.
Source components.
Discuss Local control panel.
Review 3D printed pallets.

Yes, it was a busy day, but it progressed at a comfortable and very satisfying pace.

The 3D printer had just started to produce a shell for the 12-way plug shells as Stephen & Laurence arrived and immediately viewed a couple of 8-way shells. These were required for the new Cinch plugs as no shells were available. Although the surface was coarse, the units were very solid and should work very well.

In the workshop, the layout and the newly wired Adaptor board #1 were set up. While Stephen and Geoff made a final modification to its wiring, Laurence tested the board using John's Planet diesel. Everything worked well.

Stephen had produced a mock-up of the two-way selector switches he favoured for the change-over areas (boards #2 & #3). As agreed the previous week, the arrangement, without a centre-off facility, was only acceptable if separate section switches were added to the Local panel. The switches used were actually 220vac SPDT push-button versions similar to the main panel section switches, but with the LED and resistors replaced with standard 5v units. Two more will be required for the two boxes.

The switching unit uses DPDT relays to switch the power source and LED indicators with the main relay circuit mimicking domestic staircase two-way switching.

Stephen talked through a wiring sketch of the new main selector switch box. He then presented two multi-cable options. Originally, a 10-way cable was anticipated and so VGA monitor leads (15-way) were an option. Then, the wiring sketch exercise showed that only 8-way cables were required for the two remote switches and so standard 8-way Cat5e network cables were tested for flexibility and were provisionally accepted. For the adaptor board DIN connections, Geoff proposed single strand wire exactly like the main loom rather than buying new wire. Most are 3-core with one 5-core and the option was agreed. While reviewing the switch wiring sketch a suitable box was discussed. Geoff retrieved the basic wooden box the main Worton Court power supplies had been housed in before the first exhibition required a non-flammable enclosure. As the new box was the right size and would never attend an exhibition, it was approved for use.

Rather than a loom, the cables will all radiate from the main box. The box brass nails down the centre will be the internal soldering posts, with terminal blocks around the perimeter for the outgoing lead connections. The board with the two relays will be located in the centre. The power supply may or may not be housed inside as well.

Geoff and Laurence moved on to wire-up board #2, whilst Stephen started making up the DIN cables.

Stephen later displayed a preliminary control panel design, for comments, and to allow the overall box size to be assessed. The two extra isolation switches were confirmed and subsequently added. Geoff was able to supply the three point switches and the 11 three-way (centre off) rotary section switches required, from his 'left-overs' box. Due to its location inside the layout, the box needs to be as narrow as possible. Designs to be investigated.

Stephen displayed the 3D printed pallets that he had painted and weathered with powders. After being challenged by Laurence to see if they fitted on the forklift truck, Stephen was able to confirm that they did.

The shelf units made 'last minute' for the Burton show (but never glued down) had worked their way out of the store room and were finally snapped for the blog.

Wednesday 12th February 2020

Worklist:
Discuss wiring!
Wire-up a new baseboard.

Laurence was a bit under-the-weather again so just Geoff and Stephen this week. Geoff reported that most of the connectors he'd ordered had arrived, although the Cinch connector shells were now unavailable, leading Geoff to surmise that they were not being manufactured anew, but simply selling old stock. Geoff was expanding his 3D drawing skills with a view to 3D printing the shells himself. Watch this space!

Stephen had updated the wiring schedules and layout sketches for the existing boards and also proposed wiring references for the two new exhibition boards.

Whilst doing so, he'd come across a possible problem with the number of pins required for some boards, specifically relating to the no-mans-land switching. Geoff and Stephen went through the sketches and proposals, and although the issues were more complex than first thought, Geoff was able to bring some rationality to the problem. There were a couple of areas of excessive wiring running through the boards, but these were reduced using simplified wiring and expanding the loom for the Adaptor boards. Geoff created an alternative wiring diagram to check the connections and record the new arrangement.

As lunchtime approached, both were pleased to have resolved all bar one issue - the physical nature of the 'change-over' area (boards #2 and #3), and over lunch the matter was discussed again. Geoff had proposed a mechanical solution mounted on the storage rack, with DPDT switches and push rods operated from each end. Stephen thought that operation of the layout would be better served with an electrical/electronic solution with detachable button boxes adjacent the control panels. Stephens previous solution (push buttons, staircase lighting and relays) was then reassessed to include the 'sections off requirement'. When no immediate solution was found, the question of whether the sections needed to be switched off was considered. After assessing working train operations in conjunction with the proposed wiring, it was decided it was not essential as there were sections on the adjacent boards that would provide the isolation. After deciding these switches ought not be built-in to the control panels, the bones of a solution were discussed that comprised project boxes Velcroed to the two control panels, with switches and 'live track' indicators and long wander leads. All would have to be developed in detail, in due course.

After a late lunch they finally made it to the workshop and decided to wire-up the first new board - Adaptor #1. This involved fitting a new 8-way socket, the feeds to each section and the stock-rail/frog wiring using the DPDT slide switch that also acted as point operator. Note the four brass nails in the baseboard that act as soldering posts - something Geoff developed on a school layout project.

Wednesday 5th February 2020

Worklist:
3D printing update.
Wiring survey.
'No-mans-land' switching investigation.
Plug and socket order.

Stephen had been disappointed with the balusters and had suggested that larger versions might be more successful, so Geoff had scaled them up and run off another set. The size looked much better, but the surface finish was still poor, so a 'thinner slice factor' was applied and a new print run started. We all adjourned to the workshop.

The End board was set up with the control panel and loom, and continuity testing carried out to establish all required information. We found a pin was missing, reducing it to an 11 pin plug, a spare wire in the loom that was unattached at both ends and there was an unused pin. Finally, the siding had two feeds looped-together, but the rail break had also been soldered together. None of us could remember why, but there you are - it's called getting old. The survey was well worth doing.

We then looked at creating a shopping list for the plugs and sockets we would need. After reviewing the track diagrams, a list was prepared and we went indoors for lunch. The new baluster print had finished, but the support structure would have to be removed before viewing the items. However, we weren't very hopeful. Geoff suggested that making up a tool and turning-up such items was probably a better option. Stephen could also split the unit, making the overhanging cap a separate piece, saving the upper support.

We then went online to assemble our shopping basket of Cinch plugs and sockets. Even with free postage, it came to £60. We then reasoned that the Adaptor boards didn't need 8-way connectors, and cheaper 4/5-way phono plugs would be perfectly suitable. However, as these would come from another supplier, it invoked P&P for the cinch units. We left it to Geoff to sort it out.

Back in the workshop, Stephen's fixation on how to allow operators on the Main and Local panels to share control of the inner and outer tracks on boards #2 and #3 was finally understood. However, Stephen's previous electrical solution using relays and wiring based on staircase light switching was dismissed as it didn't have an off position. Instead, Geoff's idea of using two rotary DPDT switches operated by rods extending to both operating areas was voted in despite it needing the operators to go to the shelving unit to make the switch-overs. We'll have to see how the arrangement works in due course.



The first run on the left had very obvious layer lines, but the second batch on the right will need to be removed from their support casing to see the final result. The top half of the support can be obviated by having the overhanging top pad printed separately, which Stephen will investigate.

Wednesday 29th January 2020

Worklist:
Review 3D print output.
Print latest items.
Wiring survey.

Laurence was busy in the morning, but arrived at lunchtime.

As an initial test, Stephen had produced a set of 3D drawings of stone items taken from a reconstituted stone manufacturers online catalogue (with dims). This included basic flat and angled ashlar blocks, a lintol with keystone, a cill, two corbels and from general photos, 5 gravestones. Geoff had run-off a set in orange and grey PLA material. To keep the items flat on the print bed, a base mesh had been used. The items are cleverly laid down onto the mesh that enables them to be reasonably easily popped off. Geoff has ordered a metal print base sheet to, hopefully, obviate the mesh layer that wastes material and extends the print time.

Stephen's second batch of items, which comprised an urn with separate plinth and a baluster, was now loaded and set to print, then Stephen and Geoff adjourned to the workshop to start the wiring survey. The trestles were set out and the control panel and loom laid out across them. Slowly, each control panel connection 'nail' was traced through to the plug pins and all references recorded. There were a few surprises such as spare wires and plug pins with double wires (loops onto adjoining boards), but all went well.

Back indoors for lunch, the print had finished and the second batch had been started as Laurence arrived. After lunch, the wiring survey was continued and the two main boards and fiddleyard completed. Back indoors again, the print run had finished. All three items had required additional support material to be built up around them due to overhanging elements, that might otherwise deform or collapse. This would have to be removed before the final effect could be seen, so they were divided between Stephen and Geoff to complete.

Some items will need more work to prepare them and others might be easier to laser cut from card. Painting them will bring its own problems, but on the whole, it beats making them from scratch and with a large yard to fill, any shortcuts are welcome.