Step 37: Place Rotor in Stator

Gently insert upside down rotor into upside down stator. The reason for having the stator up on blocks is to allow space for the rotor shaft to go through the bracket tube.
Very interesting project that I just happened to come across in the search for DIY lightweight concrete. Anyway, have you considered making the molds from vacuum formed styrene? You can make the positive from ren wood, which would allow for a few hundred molds. Styrene properties may just fit your requirements as it is fairly inexpensive, lightweight, smooth surface texture, and water proof.
Can you provide a link to somewhere to get styrene? and some more information about its composition
<p>Here's what it says about styrene on Wikipedia. https://en.wikipedia.org/wiki/Styrene</p>
Hi Roey This is from Peshawar Pakistan, do you intend to test your product in Pakistan?
Here is a sample site. I have never used them before but just to give you an example. I do suggest getting the 0.06&quot; or even the 0.08&quot; thick sheets as they can be reused several times over and easily repaired. As you can see the prices are fairly inexpensive. You may even get a discount if you order in bulk and mention what you will be using it for as large companies can use this as tax deduction. <br/><a rel="nofollow" href="http://www.usplastic.com/catalog/variant.asp?catalog%5Fname=usplastic&amp;category%5Fname=76&amp;product%5Fid=3008&amp;variant%5Fid=43334">http://www.usplastic.com/catalog/variant.asp?catalog%5Fname=usplastic&amp;category%5Fname=76&amp;product%5Fid=3008&amp;variant%5Fid=43334</a><br/><br/>Also call around. Here is a link to the Thomas Registry, which has the contact information for many companies. <br/><a rel="nofollow" href="http://www.thomasnet.com/">http://www.thomasnet.com/</a><br/><br/>here is some info on styrene<br/><a rel="nofollow" href="http://www.camd.lsu.edu/msds/s/styrene_polymer.htm">http://www.camd.lsu.edu/msds/s/styrene_polymer.htm</a><br/><a rel="nofollow" href="http://members.shaw.ca/sask.rail/construction/lsbuild/workstyr.html">http://members.shaw.ca/sask.rail/construction/lsbuild/workstyr.html</a><br/><br/>If you need help, look for industrial designers who are familiar with styrene&#8217;s properties as many are idealist (mostly students) and would love to help for a good cause. As for me, I haven't worked with styrene for quite sometime, nor do I have the facilities to work with it. But I have seen very simple vacuum form setups that use halogen lights, peg board, and a shop vacuum.<br/>
<p>I like this product a lot and would like to own one. But I cannot find any contact address on the website. Could you please let me know how to get in touch with someone. Thanks </p>
<p>Really-really-really great idea and realization, IMO. Two questions: </p><p>1) Some nuts have really hard shells, like for example hazelnuts. I imagine the harder the shells, the heavier the toll on the concrete walls. How durable is such a mill?</p><p>2) Did you reach to the specific angles and dimensions via lots of experiments, or did it work right off the bat? I mean, are angles and dimensions very important, or could someone just build something similar with slightly off angles and still have a usable machine?</p>
<p>If this could be adapted to processing coffee (shelling the ripe bean), the poor coffee farmers could hold their product and sell at the higher prices as dried beans... now they sell the raw coffee at 12 cents a pound (about 30 cents dried) and the large processing companies export it at $3.00 a pound or more.... the dried beans could be sold to tourist at $4 or more per pound as it is the best of the local coffee since it is picked at the best moments.... any ideas?????? </p>
Trying to get the nuts out of certain shells can be really annoying. So hearing about something like this that can crack any shell makes me really curious. Why are these not commercialized yet? I mean in a compact home-friendly sense. If they had them like that I would buy one today. <a href="http://www.electronicdiecorp.com">.</a>
The Full Belly Project looks like a really great idea. I heard about the LDS (Mormon) church creating some sort of highly nutricious grain based substance that they are shipping over there to feed people who have literally nothing to eat. http://www.aviorframes.com
it's morphing to an open source like project being worked on 24 seven so cool see what allowing your design out does all sortsw of help abouve and beyond they will go to feed the people of the world whats next affordable housing cast an idea that fixes that they need houses in hati
stay with what works and get it into the field. then prototyp other designs. i suspect different designs may be required for different nuts. Also the idea of mass produced styrofoam forms to construct the concrete casting in the field or once in country great idea to uses cad cam to design after the prototype is tested molds could be made cheaply.
Love it.
Is incredible, <br /> with a few simple things, how much good can be done.<br /> <br /> Wonderful Work<br />
Wonderful Work! Congratulations!
I have a request from "Ashanincas" amazon jungle tribes to provide them with some way of shelling their peanut crops, these people were a common target of the Shinning Path terrorist group in the 90's and still are being hit by narcoterrorist bands that use them a forced labor for their "work", some tribes are reinstalling thmselves at their traditional fields and they have the usual hard work of shelling their local grown peanut crop (peanuts are original from here, Peru). I have seen your sheller design and it seems perfect for their needs, I have already downloaded the metal parts drawings and need a simple cross section of the sheller with basic starting dimensions in order to avoid the redesign of the machine. I am going to build the molds from steel plate and make a about 20 or 30 shellers to send them as donations from my company (we deal in heavy minning equipment) and afterwards try to reach most tribal settlements through some aid organization and furnish them with several molds. I wonder if installing a reinforcing wire wound inside the outside shell will not give the equipment a higher shock and effort resistance with very little added cost. Thanks for your feedback Marcelo Cabello SACEM
I've started looking into harvesting local acorns here in Southern California as an alternative food source. This would make the shelling process worlds easier, if they're amenable. I'll be looking into finding plastic children's buckets or flower pots for stator/rotor mold forms (to be modified as needed, of course). The CAD diagram above is IMMENSELY helpful for those of us trying to come up with ways to make a form for less than $500. Now I only wish I had a better idea of the hardware. I was disappointed the CAD drawings weren't available at the Full Belly website as indicated by the clip on CNN.com. But thanks so much for the idea - it's a fabulous design!
Hi stacy, Im looking to use this for acorns here in southern oregon, im just about to start building a makeshift model. Let me know how your machine works with acorn! Good luck!
Hello everyone, thanks for your comments. Actually we already are working with the D-Lab folks. They helped us distribute some of these machines in Zambia, Ghana and the Philippines (http://illacdiaz.multiply.com/photos/album/31). We also just one 2nd place at the MIT IDEAS for a pedal powered version <a rel="nofollow" href="http://illacdiaz.multiply.com/photos/photo/57/17">http://illacdiaz.multiply.com/photos/photo/57/17</a> (we would have taken first but a pedal broke in shipment) Jock is going to be teaching a class at MIT in October with D-Lab. Right now what we're looking for is folks that would be interested in collaborting on designing and/or distributing some OSAT technology. Or working with us to improve this design. For instance the fibreglass molds cost $200 to make. But its the only material we can think of that will work with concrete, won't break easily, and is light to ship. If anyone has any ideas for a better material for the molds let us know. <br/>
I saw the nut sheller a year+ ago at the Olin Expo. My comment then, which I still think is valid, is that you can dispense with the fibreglass molds. Use a hole in the ground as your mold. The outer shape doesn't matter much--what matters is the inner shape. Dig a hole in the ground the approximate shape of the sheller housing. Line with plastic if soil conditions require. Fill hole with cement. Press the "innards", wrapped in plastic if necessary, into the wet cement. Remove innards while cement is soft. Dig cement housing out of the ground when cement is fully hard.
I have been reading about your project and decided to give this a try as my family has several pecan trees. After looking at your fiberglass forms I took a trip to the local Walmart and picked up a couple of recycled plastic flower pots. I don't recall the exact size, big. Both the same shape but one smaller allowing for a 1" to 1 1/2" of concrete. I poured it last night and all worked well. I am looking for the perfect size for the rotor now. These are very light but only available where you can find them. Also they released from the concrete very easily. If possible please post a link to allow for donations. I did use your idea as an example. Awesome project by the way. Jural
Hey Jural consider this - since the rotor and stator are tapered, you need only get close with the rotor size, and slide it up and down to get the perfect gap dimensions... Make sure the rotor is quite a bit shorter, and put shims (washers) under the bottom until it's at the perfect height.
Umm okay I do have an idea for very cheap molds that you could ship to anywhere - Nursery plant pots. <br/><br/>They come in a range of sizes in similar sizes and tapers, you can nail one down inside another larger one to form the stator, and use the next size down as the rotor form, the existing drainage holes can serve as guides for placing the bolts and centreing the axle, and you don't care afterwards if you cut the forms and throw them away as they are only a few cents apiece. And if you coat them with an oil or release agent first then you can even re-use them. <br/><br/>(A roll of plastic tape covers the drainage holes so you don't lose cement or get odd protuberances.) <br/><br/>Want more ideas? Please check <a rel="nofollow" href="http://zencookbook.blogspot.com/">http://zencookbook.blogspot.com/</a> and contact me there am happy to discuss. <br/>
hmmm, I'm sure you could make an inflatable rubber mold. That fibreglass wont last long after a couple of whacks from a hammer the first time it sticks to the concrete. Interesting, I'll have a think about this...
or plastic if you were to secure funding for a larger production run. I'm sure there will be times when people forget, or dont have to hand, any grease. Once fibreglass cracks its done, very hard to fix. Concrete will have a much harder time sticking to plastic... I would imagine?? This is an awesome project and I'd like to help out in any way I can.
seems like the molds are simple enough to with minor modifications be built using a vacuum forming process if so hobbyists could put the molds together on a distributed small scale basis out of thermal plastic.
Anothe reason that we have for using fiberglass is that is can be manufactured locally in Wilmington NC by a boat builder who makes the molds for us at cost. This can be replicated easily wherever people work with fiberglass, which is usually every port city in the world. If we had a factory that could pump out plastic molds that would be great but we don't. An inflatable mold....I would think that the weight of the concrete would be such that you would need a lot of air pressure to keep the mold in the shape that you wanted it. Also you are left with the problem of making plastic molds...unless you have a factory it would be difficult.
very true, I assumed you might have trouble finding fibreglass in some places away from the coast. Not sure where peanuts like to grow. I do a little work with fibreglass and its not a simple tech. I mentioned the inflatable mold in passing, I know they can be pumped hard, they can make surfboards out of it. And most averyone has a bicycle pump. But again, these are mass production molds, fibreglass is your best bang for buck as they say.
see my shapelock post below. It's a hard, very easy to mold plastic, can mold it by hand after putting in 160 degree Farenheit water, solidifies at room temperature.
Wow...this stuff is neat. I wonder how much you would need to make our molds. Got any rough estimates?
it's hard for me to estimate cause I don't know how thick the mold would have to be to hold cement. As far as I remember, the 500g containers of shapelock come in cylindrical cases of ~4" diameter and ~4" tall (filled with plastic pellets). You might be able to get a big discount for large quantity purchases (cause they mostly sell small quantities to hobbiests). If you could get away with making scaled down versions of the grinder that might be more cost effective if using this product. The nice thing is if the mold breaks or is cut away to free the cement, you can just melt it and remake or patch it very easily. If you ship the molds back from countries after their used, you could melt it down into an easy to ship brick too.
just measured a 250 gram shapelock container I have (turns out I didn't have a 500g container). The 250g container is: <br/><br/>radius = 4.25 cm<br/>height = 8 cm<br/>volume = h*pi*r<sup>2 = 453.7 cm</sup>3<br/>
I think that's a great suggestion, provided that we could set up a plastic mold factory, for the meantime our fiberglass is made at cost by a Wilmington boat builder.
You may want to consider injection molding the molds from polypropylene. Based on what I have seen of the project, you could probably make the molds for $10 per set or less. For comparison, think of plastic 5 gallon buckets. If you would like some help, please feel free to contact me. Regards, Dwayne Esterline www.giengineeringco.com desterline@giengineeringco.com
out of curiosity, would two flat pieces of concrete (two slabs) slanted at an angle and moving back and forth, work?
Hi, do you have plans available for this machine yet? I'd like to build some for here in the Negev and to pay to have some built for friends in Uganda. Great idea! Thanks for doing the work! Have Fun, dschutt
I wrote the above on pic #48 page. What I'm asking for is: how do I buy a set of molds and pedal powered sheller/seperater plans? Thanks! dschutt
How about using cardboard forms? Many concrete posts are poured into cardboard tubes. After the concrete hardens, the cardboard is cut away. I can imagine a flat sheet of appropriately thick cardboard with cutting lines (or already laser scribed cutting lines) that field workers could assembly into molds. Once assembled, the molds could be strengthened by wrapping them in rope or evening putting them in a hole in the ground and filling the space around them with dirt.<br/><br/><a rel="nofollow" href="http://www.langorigami.com/">Robert Lang</a> has been using the Squid Labs laser cutter to score paper, which he folds into some pretty amazing shapes. The laser cutter allows him to do beautiful curved folds that are nearly impossible by hand. The newer stuff isn't on his website yet, but he can fold a <a rel="nofollow" href="http://www.langorigami.com/art/gallery/gallery.php4?section=objects">Klein bottle</a>, so I'm sure he could fold your molds!<br/> <br/>
Check out the <a rel="nofollow" href="http://www.newyorker.com/printables/fact/070219fa_fact_orlean">New Yorker article</a> on <a rel="nofollow" href="http://www.langorigami.com">Lang</a>! <br/><br/>They talk about using the laser cutter scoring technique; Forum post <a rel="nofollow" href="https://www.instructables.com/forum/EARX4KX4ZKEXCFNTGQ/">here</a>.<br/>
excellent idea, and would make it easy to flatpack and mail to anywhere in the world. Here's a cross section of my suggestion
peanut fed in through the top, right hand piece move from side to side
This entire project could be financed if the sheller will really work on pecans, everyone in texas would buy one,a small non commercial sheller for pecans does not exist, a commercial version costs $5,000 so.... feed back please...I could sell 50 in one day I am sure ....
Hi Belize Boy, We have considered selling the shellers on eBay for this exact purpose in the past.Are you located in Texas? Do you think you could create a market for us? Roey
Spray diesel fuel on the molds before you put concrete in them,cement will not stick to a surface that has been coated in this manner.
What happens when the market collapses because peanuts are suddenly a tenth of the price?
Then at least those people who grow peanuts to eat will still be fed, as will all the people who couldn't afford peanuts at the original price.
In Uganda, peanuts despite being a good source of protein, oils and essential vitamins and minerals, especially for people with HIV/AIDs where it is food that is recommended to prevent wasting, are very expensive about $0.60 a kg. The average Ugandan makes $280 a year or about $0.70 cents a day. If the price of peanuts went down it would only mean more affordable food.
Well in the Phillippines there is a peanut trade deficit, they import 90% of them from China, even though they could easily be grown in the Philippines because of the shelling issue they are cheaper to ship. In most countries peanuts are used in subsistence agriculture or intercropped with a cash crop like cotton, that would otherwise destroy the soil. The problem has been that people don't want to grow peanuts because it requires too much labor to shell them by hand. This solves this problem.
Hello Roey, Can you point me to the contact person if any in the Philippines. I would like to get the mold for this peanut sheller. I am now working with the Cebu City school board and I think this would be an excellent idea to promote more peanut farming to help our malnourished students in thier diet. I am sure I can get our mayor to support this project. Thanks.
Mr. Joy I believe you have already had the oppurtunity to communicate with my collegue Jock Brandis who will be leaving for Manila on Saturday and arriving by next monday I believe. What level of malnourishment are we talking about? Are any of them suffering from protein defficiences like Kishworkian? Simple hunger is of course also a problem. Jock appears fairly dedicated at getting you a set of molds, I have no doubt that he will. A fellow named Allen Armstrong has also just completed some CAD drawings and we can forward those to you. I just need to get some free time...however I'll let Jock know that you requested them. Roey

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