Manufacturing Process: This document is an operations manual describing the steps taken in order to build the 12442 Haitian stove. Included is a list of materials and tools needed to complete the construction of the stove and ducting for the complete assembly. The following instructions are modeled after the methodology taken in order to create the stove and ducting in a third world country setting. Additional help and tooling may come from the Rochester Institute of Technology Machine Shop and staff as needed for prototype production. Material: Stove: Component Material Quantity 1 Combustion Chamber 50 Gallon Drum Material 1 2 Radiative Barrier 50 Gallon Drum Material 3 Outer Barrier 50 Gallon Drum Material 4 Flange 1 and 2 50 Gallon Drum Material 5 Stand Off 1 inch Angle Iron 4 6 (T) Window 50 Gallon Drum Material Ducting: Component Material Quantity 7 T-Beam 1016 Cold Drawn Steel (or equivalent) 1 8 Plate 1016 Cold Drawn Steel (or equivalent) 1 9 Heat Sink Aluminum 1 10 Ducting Housing 1016 (0.06 inch gage) Steel Sheet Metal 1 Tooling: A B C D E F G H I J K Cutting wheel Sanding disk Hammer Chisel Punch at 0.75 diameter File Steel bar (or equivalent weight) Flat surface for hammering Welding equipment Roller or equivalent machine Drill
Operations guide for Stove: **Take care to remove any coating or paint from the barrel material, as it is toxic to weld this coating.** 1. Obtain a 50 gallon drum. 2. Cut the top and bottom so that the barrel now has two open ends with (A) or (C) and (D) 3. Cut the barrel from end to end and flatten the remaining material by using the steel bar ( F) and flat surface (G).
4. Take care that the ribs shown in the above picture are also flattened out, as the drum cannot be rolled if the ribs are present. 5. Cut the material to size as specified in the engineering drawings provided. Make sure to cut the metal at the 2-D, sheet metal dimensions from the steel drum material. Cut a little extra metal than the dimension calls for, you ll need it for the weldment overlap. Material for Stove 6. Take the combustion chamber and cut holes into the bottom of the metal. This can be done using a punch made of steel (I) and a hammer (H) or a drill of the appropriate diameter.
7. Mark out where the T-slot will be removed from the material in one section (Combustion Chamber, Radiative Barrier, or Outer Chamber), measuring from the designated top of the stove. Cut out the T-slot and use this as a template for the remaining two pieces of metal. 8. Using a roller or the equivalent machine/method (J), roll the cut outs so that the edges slightly overlap. 9. Weld the overlapped section together (I). Use the finished welding assembly to measure and cut the base enclosure for the combustion chamber and the outer barrier. Cut these circles out and weld the bases for the combustion chamber and outer chamber respectively. Do the same for flange 1 and flange 2. The inner diameter for these flanges coincides with the inner diameter of the combustion chamber and outer chamber respectively. 10. Weld the flanges to the combustion chamber and the outer chamber and use 1 L-bracket cut-offs as standoffs for the pot. These are welded to the combustion chamber flange.
11. Cut the steel beam to the appropriate size and bevel the length of the thicker section to aid in the process of welding. 12. Weld these pieces together and use them to fit the T-slots in the stove body for proper alignment. 13. Weld the flanges to the combustion chamber and the outer chamber, making sure that the T-beam fits easily into the slots cut into the material. 14. Remove the T-beam and the combustion chamber after cooling. Cut corresponding tabs out of the barrel material to seal the outer chamber and the radiative barrier together. Weld these pieces, creating the T-shaped window for the T-beam to fit through. There should be an approximate 0.5 spacing between these two shells. 15. Take the 0.25 steel plate and drill clearance holes for the bolts to pass through according to the provided drawings. Once this is done, you may fit it to the T-beam and weld it into place. You will use the positions of the holes as the template to drill the holes in the ducting and heat sink later.
Ducting: 1. Take the 0.06 sheet metal and trace out the template for the ducting according to the provided drawing. A B D C 2. Cut the ventilation hole in part (B) and the TEG clearance hole in part (D) according to the provided drawings.
3. Weld the pieces for the ducting together, taking care that the ventilation slot on part (A) is as flat as possible. The sliding door tabs will be welded onto the sides of the ducting, adjacent to the ventilation slot on part (A) to create the damper system. Tabs A 4. Use the holes drilled in the 0.25 plate welded onto the T- beam to locate the clearance holes for part (D). Take a punch and locate the center of the holes, using the T-beam as a template, and drill so that the holes mate correctly. D 5. Mill the heat sink, according to the provided drawing, so that there is a properly spaced step for the TEG unit to sit on. 6. Fit the heat sink to the ducting, mating the surfaces so that the step for the TEG is properly placed through the TEG hole cut into part (D). Using the holes drilled in the ducting, use a punch to locate the holes for the heat sink and carefully drill and tap these holes according to the provided drawings.
7. Cut the damper slot (E) and bend it to the appropriate size, as per the engineering drawing, as well as the (2) Fan-L (F) used to hold the fan to the bottom of the ducting from the steel sheet metal. E(x2) F Conclusion: By now, all manufactured piece parts for the stove and ducting should be done. Additional fitting may be done for closer fits. Please refer to engineering drawings for additional information and dimensional tolerancing.