It’s Hard Work Being Lazy or Chicken Coop Automation Part 1: Door Hardware

That title might be a little deceptive. Let me elaborate. I will work hard on something now anticipating it will allow for laziness in the future. “Laziness in the future” allows time to work hard on something else in the future, so I can be lazy about that in the more distant future… which allows me to be even more lazy about even more things in the even more distant future. I guess I am just doing my best to maximize my laziness.

All of that leads into an update on my first post. It was about a chicken coop and my reluctance to got out and open it every morning and close it every night. It has been in operation for years now, I’ve automated another, and I want to provide an update. Maybe it will help someone else to maximize their laziness.

 

BACKGROUND

My original coop is a semi-portable “chicken tractor” designed to be moved about the yard on wheels. In theory, I could periodically move the tractor and fertilize different sections of the yard. In practice, it obliterated all plant life anywhere near its presence. While it failed as a fertilizer, it succeeded that much more in my maximization of laziness! I no longer need to move it about the yard.

I bought the chicken tractor on Craigslist, so the coop door (visible here and here) was a 12″ X 12″ piece of plastic that slides horizontally to open and close.

My second coop was built around laziness with a door that opens and closes by sliding vertically. It also has features allowing it to be cleaned in a few minutes, supplying weeks of food and water, and can be shut in if it is cold. However, my FAVORITE feature is the slick ramp out of the door. If I “accidentally” increase the slope by removing the bricks at the bottom, the chickens can’t get enough traction and fall right down it.

Door Automation Hardware:

I am not going to provide details on the watering and feeding system in this post. I decided not to actively control those because mechanical systems were too simple and reliable. I am also not going to go into details due to space, boredom of the reader, and my laziness. Feel free to comment with questions and I will elaborate.

The chicken tractor door was not designed with electric controls in mind, so it required some jackassery. Its motive force is supplied by an electric screwdriver. I removed the guts and wired it directly to a relay that is controlled via an Arduino microcontroller. It has an angle attachment from a drill that rotates the drive axis by 90 degrees. It also has micro switches to detect when the movement of the door has reached its limits.

The chicken coop door uses a universal power antenna mechanism for the automotive industry but controlled by an Arduino microcontroller. Using an antenna was not my idea, there are multiple examples on the internet so I don’t know who to give credit.

The power antenna took some adaptation due to the door’s weight. When winter brought colder temperatures, an internal clutch mechanism would slip rather than lifting the door. I disassembled the antenna and found I could modify the clutch mechanism to increase its torque output. Things were great until summer brought warmth and the modified clutch transferred too much torque, stripping the internal gears.

Rather than continually adjusting the clutch mechanism based on the weather forecast (minimizing laziness), I opted to make a counterweight (maximizing laziness). It consisted of a couple clothesline pulleys, an Oxford comma, some string, and couple pieces of 2×4. Notice their odd shape. I cut off pieces off to balance their weight with the door (with the drive mechanism unattached).

After putting all of the work into these coops, I began to wonder if it was worth it. Do the chickens even need a door that closes at night? If they’ve been around for thousand and thousands of years, shouldn’t they be able to fend for themselves? The answer is no, they are unable to fend for themselves. One night there was a glitch and the door didn’t close. When I went out to check on them, I found a headless chicken laying on the floor. I have since remedied the glitch, and the offender has been dispatched to a better (maybe worse) place.

This has gotten longer than intended, so I have provided some information on the control algorithm in this link.

Overall, both of the coop’s door mechanisms have afforded me the opportunity to be quite lazy indeed! So lazy that I can’t even bring myself to finish this senten

How I Found Myself with a Foundry

Ever wanted to know the steps to building and using your own foundry? It has been quite a few years and involved some jackassery, but as I recall it went something like this:

 

  1. Start working on a Lotus Esprit and realize you need a unique washer that is hard to come by (about $5 if available).
  2. Buy a metalworking lathe to make said spacer.
  3. Discover that the lathe is missing a part.
  4. Get frustrated that the part is just an aluminum block but costs $100 with shipping.
  5. Realize that the part wouldn’t be too hard to cast.
  6. Source aluminum flashing, ceramic wool, ceramic paper, sodium silicate, nichrome wire, a temperature controller, a crucible, and castable refractory mortar (totaling well over $100).
  7. Assemble sourced items to resemble a foundry.
  8. Obtain approximately 100 cans of Miller Lite.
  9. Drink approximately 100 cans of Miller Lite.
  10. Melt approximately 100 cans of Miller Lite.
  11. Sand cast the part for the lathe.
  12. Use the lathe to make the $5 washer for the Esprit.

Seems legit, right? I have a kiln now and will probably never use the foundry again, but I am glad I built it for two main reasons: it was a lot of fun and it was really dangerous!

I am including some pictures, but I am not going to include detailed instructions on actually making it. It is unsafe, and doing anything like this is a very bad idea. However, I will include some generalities and observations in case anyone wants to use any of this for a more rational project.

  • A good source of nichrome wire is from the heater elements of an electric dryer, and it seems to be good to about 2000 F. It is important to do your homework on the length. It must have enough resistance to limit the current or it will be annihilated as soon as it is powered up.
  • Sodium Silicate (or water glass) is really neat stuff. I used it as a stiffener and makeshift adhesive for the ceramic paper, but it can also be used for making things fire resistant.
  • Ceramic wool seems to be good to at least a couple thousand degrees Fahrenheit. It is also a good thermal insulator. I had no problem touching the outside when it was 1700 F inside. You can also see that the electrical tape around the flashing didn’t melt or deform after operation.
  • I heard that ceramic wool became readily available due to technology development for the space industry. That might be a rumor, but I would rather perpetuate it than research it. Feel free to let me know if I am wrong, and you will be eligible for today’s Pettiness Award.
  • The crucible is not shown, but I initially used a cast iron pot to hold molten aluminum. I do not know if anything leached from the cast iron into the aluminum, but it hasn’t effected the functionality of the part.
  • the whole thing ended up fairly light weight. I remember it being about 20 lbs.
  • If you are thinking about making something like this to avoid buying a part, don’t. Just buy the part.

Feel free to comment if there are any questions. I don’t think I will ever use this again, but I might use some of things I learned for another project. Anyone interested in a portable electric “wood fired” 1000 Fahrenheit pizza oven?

Let’s Mix Things Up

KIMG0063For some reason, I have been fascinated with KitchenAid mixers since I was a little kid. I think it is because my parents had a large Hobart mixer at their restaurant, and I thought the smaller home edition was novel. Or more likely, they have gears, mechanical attachments, and a motor… three of the things that are dearest to my heart.

I bought one a while ago from Craigslist, and it leaked oil the first time we tried to use it. After getting over the initial horror of oil dripping into the dip we were concocting, I read up and found out this problem is fairly common. KIMG0064The grease they used breaks down over time and becomes a combination of a cakey substance and a fairly thin oil which drips from the case. I disassembled it, replaced the grease with Food Grade Machinery Grease, and all was good. This was about a year ago, and there has not been another drop of oil.

Tonight I was at a good friend’s house, and she mentioned she was having the same problem. She was even thinking about getting a new KitchenAid. I brought it home, did the same procedure, and it is now as good as new. I am posting this as a public service announcement. Don’t throw out your KitchenAid mixer if it drips oil! It is a fairly simple fix.KIMG0065

I included some pictures of the inside in case you’re curious. I know that I was. I didn’t include a picture, but it also has an interesting electromechanical governor system that adjusts the power delivered to the motor to maintain the selected speed under varying load conditions.

A couple more things:

  • Yes, the pictured mixer is purple.
  • No, it is not mine. Mine is much more masculine.

Next Boost Test

KIMG0048For those of you on the edges of your seats about the functionality of the cheap ebay boost controller, you can relax. It didn’t work. It would initially over boost before settling back down.  I took apart the tee, and found this (photo on left). I thought the tee contained just a check valve, but the spring was strong enough that it acts as a relief valve. It would boost up to about 18 psi, crack open the ball, and then settle back down. I dropped the spring seconds after taking this picture, and it bounced off the shop floor and into oblivion. I don’t think that is necessarily a bad thing. I will explain.

 

The following three sketches show:

  • The stock configuration
  • What I thought I was buying
  • What I actually bought

The first uses an electric solenoid to control boost (which the Grand National tries to do blindly). The second uses a “Grainger Type” boost valve that is so named because one can modify parts from Grainger to make it.  I didn’t initially go this route because adjustment results in burned knuckles.  It consists of a simple adjustable home made relief valve. The third sketch shows the Cheap Ebay Manual Boost Controller (CEMBC) that I purchased. As shown in my last post, the CEMBC came with a tee and a variable orifice. Internal to the tee is a fixed orifice and relief valve. The problem was that the boost required to overcome the relief valve was greater than the boost I want to dial in. It was overboosting before the relief valve even opened.KIMG0049

Now for the next test. I’ve completely removed the ball and spring in what I call the Modified Cheap Ebay Manual Boost Controller (MCEMBC). I think that this will provide more accurate feedback to the waste gate actuator, and I do not think they are necessary if no vacuum actuated circuits are connected to that loop. I initially thought that this would cause inconsistencies between immediate Wide Open Throttle and rolling into the throttle more slowly. I’ve thought about it more, and now I think that its operation will be similar to a pneumatic version of a voltage divider. The signal to the waste gate actuator should be a nice, smooth percentage of the boost pressure.KIMG0050The only disadvantage I see to this setup is increased spool up time because it won’t lock the waste gate closed until it reaches the desired boost. Instead, it will open gradually. I think my final solution will be a combination of a “Grainger Type” controller and the MCEMBC. It will really depend on the adjust-ability of the fuel map when I get a chip I can tune.

This post really isn’t for the general populace. I just want to log what I am doing so that I can bounce it off of other car guys to see if they agree. I promise to make the next post about cats, chickens, interior decorating, or something along those lines.

Getting Closer

My KIMG0044Grand National is getting closer to running correctly in its almost stock form. I put a manual boost controller on today. Before you start complaining about everything being zip tied together, I need to point out a couple of things. First of all, I find the term “zip tie” rather offensive. They are called racing ties. Secondly, this isn’t permanent. Even though they seem to have decent reviews, I don’t trust the boost controller I bought.  I will re plumb it in a semi professional manner if it works as advertised.

The biggest reason that I don’t trust the boost controller is that it cost only $11.99 on ebay (with free shipping). The second biggest reason is its theory of operation. It simply has a variable KIMG0043orifice that releases boost feedback on the waste gate side of a combination orifice/check valve. It seems to me that it will change the ultimate boost if I am at Wide Open Throttle vs accelerating at a moderate pace. I pondered tossing this out when I figured out how it works. Then I noticed the smaller printing. It states “HIGH PERFORMANCE” right on the label, so I decided to give it a try. I hope to report back with good news.