[R]ed[U]x Lab: TMU Department of Architectural Science Design Lab

Sunday, September 16, 2012

Detail Development and Construction Sequencing

So as promised, today we constructed a single 8' unit of our box frame and proceeded to develop 1:1 details for both our vertical (wall mounted) and horizontal (ceiling suspended) panels. This mock-up also allowed for us to test the structural capabilities of our cable, bolts and framing in a controlled environment. We were able to make significant decisions regarding the on-site sequence of construction and how to make details more efficient and practical. Here's some shots of our exploration:

The team assembling our framing unit from two 10' wall panels and an 8' ceiling panel

Testing bolt strength while hoisting the vertical panels to height with a temporary rope and James' boy scout knots

We decided that for added safety, we would suspend the wall panels with a single length of braided cable - providing easier maneuverability and a fail-safe panel mounting

We first mounted steel conduit from the framing to the panel's MDF skirts. The conduit is cut to length then flattened at each end to provide a mounting flange. These flanges are easily bent and rotated allowing us to efficiently negotiate the panels' irregular curvature. We quickly found that the skirts were difficult to screw into and were also too thin to handle this kind of structural stress.

We then decided to mount the conduit to the rear eye bolts (as seen in our last post) with large washers and a 1/4" nut/bolt. We also added another screw to the opposite end of conduit to prevent rotation/pivoting. This ended up being extremely rigid as the bolt extends through all layers of the panel.

Vertical (wall mounted) panels rigidly fastened and illuminated

The guys mounting our suspended panels with 4 lengths of braided steel cable each fastened to one eye bolt at the panels rear. The crimped cables allow us to easily adjust the placement and angle of each panel.

A shot of a single horizontal panel from below

A second panel is lifted into place to test angling conditions and seam connections

The wall panels and suspended panels lay completed

The team and some DAS visitors admiring the completed mock-up

So what's next for the Aura team? This week we will be adding corner braces to our triangular panels and fabricating our sheet steel gusset plates for the panel seam connections. We will also be doing a mock-up of the final panel configuration in 16' sections. We will then mark all the cable lengths, conduit members and panel placements using an alpha-numeric system to ensure a speedy on site assembly.

Let There Be Light!

So the Aura team has been working feverishly over the last week to get things in order well ahead of our September 29th deadline. We have been fortunate enough to experience a huge outpouring of volunteers interested in helping out with our Nuit Blanche 2012 submission from all facets of the Department of Architectural Science. This has really helped to accelerate our fabrication process over the last seven critical days.

This week we managed to complete all of our CNC milling, laser cutting and manual cutting. With the help of our volunteers, we also managed to complete all of our nearly 1700 plunger assemblies to be inserted in our triangular panels. Most recently, under the supervision of our team electrician, Andrew Santaguida, we wired and installed our lighting components - allowing us to then complete the final assembly of all 30 panels. Here are some shots of the exciting progress:

Aura headquarters on a typical weekday evening

Volunteers painting the back panels white to ensure optimal illumination

A hand full of our 1700 plunger assemblies

Our professor and project supervisor Vincent Hui checking up on our progress

Volunteers from the Dept. of Architectural Science hard at work

It actually works!

Exploring hot and cold spots of light within the panel

Light diffusing through the syringe barrels at the back panel

Syringe barrels inserted into CNC milled recessed slots at our back sandwich panel

A peak at our wiring assembly: A single ballast hardwired to two 24" 20 Watt Fluorescent luminaries

Wired back panels on deck to be inserted into the panel boxes

And finally, a sneak peak at our panel assembly process:

1. Connect face bolt and coupling through pre-assembled panel box

2. Insert plastic conduit spacers around each bolt and coupling assembly

3. Ensure all wires, marettes and ballasts avoid obstruction of bolts, spacers and plungers

4. Insert back panel assembly into panel box

5. Insert eye bolts through back panel assembly to connect with hex couplings within conduit spacers

6. Tighten eye bolts through panel creating a rigid connection for suspension

7. Secondary test of lighting and wiring to ensure no connections were affected during assembly

8. Reunite the panel with its 29 companions

In the coming days, the team plans on mocking up some panels to our structural framing to test and further develop connection details for both the vertical and horizontally suspended conditions. We have a ton of work still to do, but we are all excited to finally see this thing materialize. Stay tuned for more exciting content!

Monday, September 10, 2012

The Beginnings of Panel Assembly

A lot of the day was spent getting the 30 panels started. Each panel is constructed of a series of MDF, acrylic and plywood planes held together through the use of perimeter skirts and spacers for support. Syringes are mounted in a backer panel comprised of a plywood sheet routed to accommodate the syringes which are held in place by an MDF plane allowing plungers to move in and out of the barrels. The plungers are attached to a dowel which is in turn fastened to a circular MDF cap which acts as a pushing surface. The frontal plane of the panel is comprised of an acrylic sheet fastened to the back of a final MDF plane which lies behind the outer membrane. So far the Aura team built and assembled the perimeter skirt for each panel, as well as attached the spacers and the frontal plane of the panel.

Gluing the Perimeter Skirts Together.

Frontal Plane of Panel

16 More to Go!

Key to Efficient Production - The Assembly Line

Acrylic Layer of Frontal Plane

Adding the spacers

Horizontal Frames of Structure

Attaching Spacers to Vertical Frames

Horizontal and Vertical Frames For the Supporting Structure

Always Clean Up!

Coming Soon!

Sunday, September 9, 2012

Aura Installation Coming Together

It's nice to see everything coming together after cutting so many individual pieces. The structure is being framed and now that the individual components are finished, the panels are ready to be assembled. The Aura team has been working hard over the past week to ensure that everything is ready and continually progressing. A big thank you to all the volunteers that continue to help us in their spare time!