The project began at the 7th of August 2010, and finished at the 30th of November the same year. I ran many experiments and discovered different ways to dissipate heat from water. I tried with copper tubes, with falls, with peltiers and other methods, but i finally came to the conclusion that the best way to keep the water cold is... not to warm it. Then i began making different designs for the base of the lamp, i added a reflector made of empty soda cans etc etc etc. You can read all the process in the worklog.
Here is the heater finished (as always, click on an image to see it in bigger size):
The control panel (white box) carries a fuse (for security reasons) and an on-off switch on the side, that turns on the heater, powers the dimmer, powers the fan and also provides power to the water pump simultaneously. On top, there is a potentiometer that controls the power of the lamp. The lamp itself is 35cm long (this is the maximum piece length that can be heated), and is about 850 watts. But i never provide all that power, because the plastic will burn within a few seconds. Usually i have the potentiometer at one fourth of the full brightness. At that power, a 6mm Plexiglas bends within 3 minutes.
Here is an example of my first sculpture that i made with this tool (the piece bellow is 6mm thick):
I managed to make extreme bending angles in very small distances, due to the fact that only a narrow area on the material is heated. The aluminum profiles left and right of the lamp are kept cold with water that circulates non-stop.
@Emmanuel the schematic is similar to the circuit that i link to. Very small changes (such as some zerner diodes and staff) are all marked on the new schematic. The parts are labeled on the schematic. Which of the parts are you having problem to clarify?
hallo again sir, i'd like to clarify the bills of requirement. im having troubles about it since you've change the circuitry of the PCB. i was wondering if you could post it as well so i can figure out where and what requirements to use.. im abit confuse on that part... TIA..
@Emmanuel Ah i see what you mean, you want the PCB and the parts layout. Ok, i uploaded them in the 3rd page (http://pcbheaven.com/projectpages/Acrylic_Glass_Folding_Heater/?p=2&topic=worklog)
Keep in mind that:
1. You need to CONFIRM twice that the TRIAC is correctly connected. Check the datasheet of the triac. If it is not correctly placed, then the optocoupler may be damaged.
2. There is LIVE HIGH VOLTAGE on the board. Take super extra precautions, and make sure you've read and understand this first:
@kammenos Bro im abit confuse on how to translate the diagram, i don't know much about electrical diagrams or how translate it, i just wanted to see/ask the full drawing which i can read, like where these 1 ohm resistor goes to etc. basically a drawing type with labels on it so i can understand which and where to put those capacitors, resistors, diodes etc on full PCB look. like on your worklog page 3 on "electronic staff" you labeled a pic there named "the artwork" for your final PCB design. if i could just have that drawing with labels on it so it would be easy for me to follow through..
@kammenos yeah sure im trying to find out where are the details and the design of your circuit board so that i can create it. i really do need some helping doing this project of mine. so i can use it for my other project.. please do reply.
i've been searching for this kind of bending Machine, and i found it.. i build the same thingy but mine has no cooling type and i can control the heat it produces. i tried looking something to control the amount it gave out, i use a wire from a microwave oven "microme wire" (thats what it is called here in my place). it gives out up to 1500 degrees of heat. i don't know much about circuitry. can you dimmer which can control the amount of heat of the rod will do the same for my "microme wire"? thanks and im looking forward for your reply.
@Miodrag the special glue is a kind of glue that is completely transparent and looks very much alike water. When the glue is poured onto plexiglass, the plastic melts temporary. So, when two plastics are put together under pressure and there is this glue between them, they melt and they join together. When the glue evaporates, they become solids again. The bond is very strong. I do not have the glue bottle, as i was given a small quantity into a glass bottle. But if i find more info i will post it.
Hi SoftEe. All materials are listed within the worklog pages. i am not sure about the type of the lamp. actually , it is not lamp, i think it is something like this:
The one i have i measured it at 800 Watts, which is super high. If you get yours, get at least half smaller. The dimmer materials are listed on the schematic (click to enlarge). When you finish it, send me images of your design and i will post it in my blog.
Impressive! This reminds me when I was in junior high. Pretty much everything electrical I owned I took apart to see if I could improve it or make something different. Do you have a full materials list available? I would love to build one of these for projects around my house. One main project to hide electrical components behind my flat screen TV like this company without having to pay their outrageous prices. HIDEitmounts.com. Following my completion I will post a picture if that's ok. I live a block from a Radio Shack and 1/8 of a mile from a hardware store. I'm thinking this should be pretty straight forward. I'm excited to try it!
My grandfather had already made something similar (but simpler) in the 50-s/60-s when plexiglass was still pioneer stuff. Instead of aluminium/water, he used two sheets of asbestos. Instead of a lamp he used 4 resistor wires (3 on bottom, 1 on top) in between the asbestos sheets, where he put the plexi. Operated on 50 volts.
I like your work and way of thinking I though you might have used marble insted of aluminume I think I saw someone do that using thick marble I have no idea what type is that marble but it was thick one anyway keep the good work you did realy great job, I just love it and your site is full of matirials I would come back and sure got it in my feeder.