This document provides details on the design, fabrication, and testing of a solar-powered forge cart. Key points include: - The cart is designed for strength, ease of movement/storage, and to provide a convenient work space for fabrication. - Fabrication involves welding, riveting, bolting, and using steel and aluminum construction. - The forge uses roller bearings, ball transfers, a serpentine belt, and motor to provide azimuth rotation. Light sensors control the pitch. - Testing showed the forge could burn wood in seconds and boil water in under a minute, reaching over 500 degrees Fahrenheit. Problems encountered included ensuring components were concentric,

1. PLANETARY GREEN FORGE
Alvin Yen CMfgT
Jason DiPietro CMfgT
Graham Cochrane CMfgT
Justin Estano CMfgT
Group 6
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2. CART DESIGN
- Strength
- Ease of movement/storage
- Convenient work space for
fabrication purposes
- Relatively cheap to build
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3. CART FABRICATION
- Welding
- Riveting
- Tapping and Bolting
- Steel and Aluminum Construction
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4. AZIMUTH BASE ACTUATION
• Roller Bearings provide concentric rotation
• Ball Transfers maintain concentricity of rings
• Serpentine belt and azimuth control DC motor
• Light dependent resistors placed sides of lens frame
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5. PITCH CONTROL
• Max 120 degrees (exposure)
• Light resistors placed on top and
bottom of lens frame
• Maintains perpendicular angle to
sun’s rays
• Emergency beam break
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6. AUTONOMOUS
SOLAR TRACKING
Solar Tracking
Concept Diagram
Wiring Schematic
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7. PYLON ACTUATION
• Allows control of temperature of
focal beam
• 6rpm motor – Traverses at
.0175552608 ft./s
• Upper and Lower limit switches
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8. GC

9. PID/DPDT WIRING SCHEMATIC
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10. X – Y TABLE
• Precision axial motion
• Table interface incorporates On-
Off-On rocker switched that
allow for precise axial motions
• JOG Control
• Small to Medium sized work
pieces
• High temperature platform
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11. AY

12. PROGRAMMING
• Assigning Values
• Setting input pins
• Assigning Logic
• Potentiometer RPM
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13. Focal length 1 = .9144m
Focal Length 2 = .3048m
Optical Power of Lens 1 = 1.09m-1
Optical Power of Lens 2 = 3.28m-1
• Energy loss through
- Reflection
- Environmental factors (wind)
LENSES AND
LIGHT FOCUSING
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14. Combined Lens Power = 1.0708m-1
BFL= -.1524m (about 6”)
1
𝑓
=
1
𝑓1
+
1
𝑓2
−
𝑑
𝑓1 ∗ 𝑓2
𝐵𝐹𝐿 =
𝑓2 𝑑 − 𝑓1
𝑑 − (𝑓1 + 𝑓2)
COMBINED LENS
SPECIFICATIONS
JD
Back Focal
Length

15. TEST RESULTS
Test 1
• Burned a piece of 2x4 pine in seconds*
• Boiled water on an aluminum plate in under 1 min*
• Melted aluminum chips in under 3 min*
Test 2
• 586F in 15 Seconds (maxed out range of thermometer) *
• 415F in 1 Minute (Focusing Lens)
• Burned/melted aluminum chips with compound lens design
Note: Results marked with an asterisk (*) denote that only the primary lens was used
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16. TEST RESULTS CONTINUED
Test 3
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17. ELECTRICAL COMPONENT POWER LAYOUT
• Removed one solar panel
(unnecessary)
• Added second terminal block (24v)
• Added fuses (safety and equipment
protection)
• DC and Stepper motors used
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18. ENCOUNTERED PROBLEMS
- Rings were not perfectly concentric - diameters varied
- Program debugging- inputs/outputs were inconsistent
- Compatibility issues with stepper motors - motor drivers were not
rated correctly
- Keeping table frame perpendicular
- Gear sizing issues
- Lens complications - purchasing a lens with proper diameter and
focal length
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19. COST ANALYSIS
Materials Cost Total
Stepper Motors $65
$1800
Motor Driver $85
Ball Bearings/Transfers $74
Aluminum Rings $675
Solar Panels $113
Misc. Electrical Components $340
Gears $110
Aluminum Stock $140
Concentrating Lens $30
Donations Cost Total
Table Stock $180
$540
Cart Stock $200
Battery $100
Belts $60 AY

20. ACKNOWLEDGMENTS
We would like to personally thank the following parties, who contributed to the successful outcome our project.
Lawrence Metal Forming (Peabody) - for manufacturing our ring combination at a reduced cost. Their generous
contribution helped make our project possible.
Andrew Sharaffa – for aiding us in determining the necessary electrical components needed to safely meet our power
requirements, which helped us in turning our project completely “green”.
Professor Bo Tao – for assisting us in various aspects of our design, offering helpful feedback, and keeping our group on
track.
Mr. Joe Estano – for supplying us with various materials that aided in the construction of our project.
Tramlaw LLC – for supplying us with various equipment and transporting our larger parts to the lab.
Jim Hersh – for generously donating gear racks, linear slides, and other components which assisted in the linear control of
our systems.
THANK YOU!

21. Questions?
Comments/Discussion