Projector design primer ?
To: Builders of RGB projectors
From: CDBEAM
Re: Thoughts on projector design, ONE way to do it !
In that my RGB Projector#1 is nearing completion… I would like to offer some thoughts I have on projector design. Let’s first state that any of us….which would undertake such a project, are truly designing and building as we go. For most, this will be the first projector…and maybe the last !!! For some….there will be future iterations !!! For others…..”NEVER AGAIN” may be the order of the day !!
It begs the question….Why would you build another ??? More Power ? Converting to DI Blue or 635 Red ? Better optics ? Better optic layout ? Additional colors ? More compact design ? Adding safety features ? Improved Beam Table rigidity ? Additional Fans or fan monitoring ? New scanners ? New software ? …..and a dozen other things I have failed to mention !! So there then….many, many reasons why the current projector might need to be replaced by the next generation.
But, is it efficient to start ALL over ???? If the design of the first unit could be such that….Modifications / additions are considered IMPORTANT…right from the start and are assumed as issues that WILL happen…..then design / build with this in mind !!! Have maximum flexibility as a core value …not an after thought.
Starting with the above philosophy…ONE way to arrive at maximum flexibility is a multi-level adjustable stacked design. By this I mean a series of levels or plates, at least (2) two, with the levels being connected by (4) four SS 3/8” (10mm) allthread rods. The levels could be 3/8” (10mm) plain Aluminum plate. OR…the levels could be ¼’ (6mm) plain Aluminum plate with square aluminum bar stock secured to the perimeter to achieve acceptable rigidity. The levels are secured with SS nuts, one atop the each level and one below each level…going up/down on the allthread rods, at the (4) corners of the layout. I do not think pre-drilled / pre-tapped holes are at all useful ! Drill and tap as needed !
This approach achieves several goals ; Keeps the Optics isolated from all other components, Keeps the Optics on top where adjustments and cleaning can be done, Minimizes the projector footprint, and lastly, Provides complete flexibility in selecting level-to-level dimension. I look at it like a “ Post and Beam” style construct….Frame + cover. The advantage of adjustable levels comes into play in (2) two ways… as you build…the distance between levels can be driven by the various components and you can adjust as required, and…if (read when ) later modification is desirable…..you can adjust the level-to-level distance to suit… whatever your new additions need !
During the construction…..as the various components arrive, I started laying them out….and moving things around. Yes….I know….rather basic…no Cad/Cam, no 3D renderings….just “ movin the furniture around” fun !!! For me….this was the best way…..to “ fit“ the various components together. I do CAD….but the time you need to do a good job….covering ALL the details…Forgetaboutit !! My Projector#1 uses a 12 ½” ( 317.5mm ) deep by 14 ½” (368.3mm) per level dimension. There are (3) three, ¼”levels, with the upper and lower level having ½” (12.7mm) Aluminum bar stock bolted to the perimeter.
Lower level has Laser PS’s(3), Scanner PS, (2) fans, Fan monitor, PLC thermal controllers and power control sub-assembly…. And many, many terminal strips. The middle level has the 12vdc PS, ILDA input sub-assembly, (2) two SSR, (2) fans and Scanner amps. The upper level has RGB lasers, Dichros. Bounce mirror,and Scanner atop…and bolted to the underside TE/fan units and Laser drivers (2).
As of this time, I have yet to cover/skin Projector#1. The (4) four allthread rods will then provide the top cover support and secure points. I have no shutter, but have room for one.. The (1) one downside I see to this construct is the need to connect the various levels with power/control wires. ALL terminal strip connections should be kept at the perimeter….so the unit can be takes apart, level by level…in an orderly fashion and you have easy access to break/make the connections. I suppose…the other downside is the need to replace cover plates….should your projector grow in vertical dimension !!!!
I have given projector layout / design a fair amount of thought !!! Perhaps I am bias because THAT is the way my build is…mmmmm???? Maybe ?? but the above argument seems to be grounded in flexible engineering concepts !!! You may have noticed that….I have and do identify my projector as “ Projector#1”….this would imply the likelihood of a sequel….viz…” Projector#2”….You damm betcha !!! Building the first one was very rewarding….it is likely, that someday…I will do another !!! or...if maybe, modify Projector#1...with a flexible design, this is not as big a deal !!
Have fun !!! Enjoy your build !!! Be careful !!! Watch your eyes !! …+/- does NOT =….-/+ !!!
Note: I will put more pics in my gallery within the next several days !
CDBEAM
Ventre a` Terre
Beam Axiom #1 ~The Quantum well is DEEP ! Photons for ALL !!
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Beam Axiom #2 ~Yes...As a matter of fact...I DO wear tinfoil on my head !!
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Beam Axiom #3 ~Whe'n dout...Po ah Donk awn et !!
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Beam Axiom #4 ~A Chicken in every Pot, and a Laser Lumia in every Livingroom !!
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Beam Axiom #5 ~"Abstract Photonic Expressionism"....is "Abstractonimical" !!
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Beam Axiom #6 ~ "A Posse ad Essea" ~ From being possible to being actual ...is the beam target !