Steam Engines and Stephenson Linkage Team

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About The Project

The Lombard Log Hauler is powered by a two-cylinder horizontal engine and uses a gear and sprocket chain for transmission of power to the driving members. These two cylinders can propel the 19-ton hauler at speeds up to 5mph when fully loaded (300tons). See specifications below, as called out in the Lombard Operating Manual and Parts Diagrams.

Engine:

  • Two-Cylinder, double acting.
  • Horizontal, reversible type, 9-in bore and 10-in stroke.
  • 90-horsepower @ 175lbs steam pressure.
  • 250 RPM equals 4 and 7/10 mph.
  • Crank pins are set at 90 degrees to one another.
  • Valve, Balance D type, eccentric driven, link motion.
  • Cylinders equipped with automatic relief valves.

Engine Control:

  • Throttle lever in cab.
  • Hand reverse lever in cab.

The Lombard Log Hauler has been an on-going project at the Maine Forest and Logging Museum in Bradley Maine for over 20 years, but the UMaine MET Senior Capstone Teams have resolved to complete the restoration by spring of 2014!

 

Project Objectives:

The objective of our project is to fully restore a 1910 Lombard Log Hauler to its original capacities, while maintaining a reasonable likeness to the original design.  Specifically, our team is concerned with the two steam engines and the Stephenson linkage. These are key components involved in running the Lombard, as well as successfully moving it. We will to work together, as a coordinated team, to restore both the engines and the linkage system to full working order. We are working under under the oversight of Prof. Herbert Crosby and Prof. Joel Anderson, as well as the staff of the Maine Forest and Logging Museum at Leonard’s Mills Historic Settlement. The long-term objective of our team coincides with the objective of the entire project; to offer any assistance possible to other teams in order to achieve full restoration, in the event that we complete our restorations before this coming May.

Follow our team as well as our fellow capstone teams as we aim to restore history this year!

 

Updates

April 25, 2014:

Initial Steam Test! On April 22, 2014 the teams assembled for the first initial steam test. The day was long as the boiler had to be brought up to temperature and pressure very slowly since this is the first time it has seen any heat. Building steam took from about 9:30am until working pressure was achieved at about 2:30pm. The Lombard ran about 100ft total on steam before there were a few problems realized that could not be fixed while under pressure. The problems found could really only be uncovered by getting to working steam pressure so the day was far from a loss. The next steam run, currently planned for next week, is expected to be more extensive and have a longer run. Below is some footage and photos our team gathered during the steam test as well as some footage from Professor Crosby’s collection.

Initial Steam Test Photos

Professor Crosby’s Footage:

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April 20, 2014:

Air Test Success! Below are a few videos from the air testing that took place this weekend. Happy Easter!

 

April 11, 2014:

The boiler passed certification since the last update here and now its just a matter of paperwork before we can run air tests, using the boiler as a storage tank, and shortly after we will run steam tests. A member of the team spent a day with Peter Grant of the Odd Duck Foundry learning the process and techniques needed to make some quality castings, highlights of this can be seen below and in the Photos & Videos section of this page. All of our custom grease fitting parts have been finished, many of the linkages and levers are all falling into place, and all of the modifications we needed to make from last time are also done. There are a few parts that need tweaking such as the actual forward/reverse lever in the cab needs to be bent to accommodate some newly added plumbing work. Aside from these tweaks the team is also looking to put together some posters covering both our progress on this project and some historical points of the Lombard. More photos were added to the March & April Uploads album.

Links: video clips and photos from the Odd Duck Foundry.

Peter Grant pouring cast iron parts
Separated cope and draft
Original eccentrics with a new grease fitting
Poppet actuation lever CNC’ed

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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April 4, 2014:

The recent ‘Hydro test’ went off without a hitch but a few things were brought to our attention while everything was being inspected over the last week or two. Overall we needed to adjust things so that they have a little more play, IE the eccentrics and the connecting rods. With the connecting rods we over looked leaving a ‘wear gap’ for the bearings (pictures below). These bearings on the Crooker family Lombard still have a decent amount of ‘wear gap’ before they’d need re-machining where as ours were not machined with a gap in mind. This is a simple fix though, merely knocking back each side by about a 16th of an inch will do. Along with making adjustments, replacements that have been requested, and re-timing the engines with a new method; the team has been moving along with manufacturing. A few progress photos have been highlighted below but also check out our updated photo album of March & April.

Crooker LLH, Connecting Rod Adj. Gap
Our LLH Connecting Rod, before machining gap.
New Gibbs & Keys
Half welded grease fitting before cleaning.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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March 18, 2014:

Student’s are back from spring break and the Steam Engines and Stephenson Linkage Team certainly doesn’t have a shortage of work. Team members have been nearly living in the machine shop over the last few weeks to get our current manufacturing list finished. From fixing up the connecting rods and reworking the eccentrics to manufacturing brand new grease fittings, gibb keys, and dripcock linkages; there is a lot of excitement and buzz with the whole project really coming together. The next log book is due on March 19, 2014 and shortly after we will be finalizing most of manufacturing and installing it for the next test run.

Machining new gibbs.
Machining new gibbs.
Machining new gibbs.
Machining new gibbs.

 

 

 

 

 

 

 

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February 21, 2014:

Our nearest deadline is shortly after spring break, where Professor Crosby would like every team ready to go for a new test run. This test run will is essentially a step up from the ‘air test’ we ran in spring; including much more of the LLH’s working systems that have had some well needed fine tuning. Much of our team’s work since the Feb. 7th update has been around plans and drawings for what we need to manufacture and also starting the work on those parts. Below is our current list of working drawings of parts that have either already been manufactured or currently being worked on:

Additionally, our working Gantt chart and Bill of Materials have been updated since they were last posted and can be viewed here:

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February 7, 2014:

There has been a lot of progress and good news in the last few weeks. So far the project is full steam ahead as we’ve been receiving a lot of “insider advice” from key people within Maine’s Steam Community. Some great news for our team is that we’ve been advised that the pressure relief valves are not needed, so we won’t have to go through with that and we’re glad because it was going to be a big hassle. Since the last update the team has been finalizing our drawings of the Lombard based on the requests and suggestions of both Prof. Anderson and Prof. Crosby. Below is our current list of working drawings for the LLH:

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January 24, 2014:

We’re back from break and all teams have hit the ground running! These first two weeks have been pretty hectic as we’re all trying to make sure we’ve got our ducks in a row. Our biggest problems that have come up are primarily in regards to the entire steam system getting certified. Between potential cost of repairs, time line and available personnel, Professor Crosby has informed us that there is the unfortunate possibility of the project not being completed within the original scope. If we find that we are not able to get the money and steam certification, all teams will shift gears a bit toward completing everything possible. We will focus more on developing ways to show the public how the whole thing would work if it were a completed restoration by providing presentation material to the museum. This doesn’t mean that the LLH couldn’t be finished in the future, but the class of 2014 is nearing graduation.

In the meantime, the teams are not holding back and moving forward with everything that can be completed while we get a final word and projection. Our team has focused on the following during the last week or so:

  • Updated and revised the Bill of Materials (BoM).
  • Updated our team Gantt Chart with more specific details to follow through the semester.
  • Looked into potential requirements for Lombard historic documentation and presentations.prv
  • Started developing prints to manufacture parts as we look into automating the dripcock actuation system.
  • Looked into improving the fits of the brass connecting rod bushings.
  • Bench-marked pressure pressure relief valve holes on the Crooker Lombard for when we start drilling our cylinders.
  • Started conceptualization plan for dismantling the engine assembly to be worked on at the UMaine machine shop.
  • Tested fits and took measurements on the eccentric straps to prepare for making improvements.
  • Looked into options for lube fittings in collaboration with the drive team for standardization and creating an authentic look.
  • Updated our previous working drawings based on recommendations and preferences of our professors.
  • Ordered stock materials for manufacturing the new cross head pins as well as the dripcock actuation system.
  • Discussed options for final cleaning and painting of LLH.

New photo album has been added as well, hop down to the photos & videos section.

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December 13, 2013:

We are winding down for the semester as it is getting too cold to work on the LLH on site. Many of us are preparing for final exams and looking ahead for what we will accomplish next semester on this project.

CAD - Lombard Engines

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November 26, 2013: MILESTONE – COMPRESSED AIR RUN!

It’s getting cold out there but we got it done!

The video is a quick glimpse from Tuesday! Skip to ~3:20 to see things run after some tweaking.

  • Generated more CAD parts and assemblies from hand drawings on site.
  • Wrote a piston positioning procedure; including installation and adjustment.
  • Installed poppet valves.
  • Created remaining hand sketches needed for finishing CAD models.
  • Torqued down many fasteners for air run.
  • Ground a stud for mounting the gland for the piston rod.
  • Installed connecting rods.
  • Centered Pistons.
  • Cleaned and tightened connections on the rod connecting the Stephenson Linkage to the lever in the cab.
  • Trimmed extra gasket material off of cylinder head ends.
  • Shimmed and attached linkage straps to eccentrics.
  • Adjusted the valve rod position for proper timing.
  • Installed proper pipe plugs.
  • Torqued for valve rocker cover.
  • Bored out central hole in gland for the piston rod.
  • Performed final checks and tightened remaining fasteners for the air test.
  • Coordinated with the Steam Team for running the air test.
  • Generated the remaining CAD parts and started on assemblies.
  • Logbook due date #3!

Don’t forget to check out our November Uploads!

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November 22, 2013:

Busy days are upon us as we approach our milestone of running the LLH on compressed air by November 26th, 2013!

CAD assembly animation:

  • Took measurements needed for CAD drawings and assemblies.
  • Located both original and non-original pressure relief valves for the LLH.
    • Noted that the Crooker Lombard doesn’t have pressure relief valves installed at the cylinder.
  • Machined counter bore in jam nuts for piston rods.
  • Machined a punch for enlarging holes in gaskets.
  • Started actual CAD assembly and created a short animation.
  • Started organizing bill of materials (BOM).
  • Reamed out a few bolt holes on the cylinder heads to fix stud alignment issues.
  • Measured and calculated for TDC.
  • Installed valves on both engines.
  • Test fit right side connecting rod.
  • Remachined gibbs to size.
  • Updated torque calculations with a K factor for NEVER-SEEZ.
  • Researched torque patterns.
  • Ran spring calculations.
  • Packed both the pistons and valve rods.
  • Continued with hand sketching parts needed for the remainder of CAD parts and assemblies.
  • Re-cut threads on crosshead pins
  • Punched connecting rod bushings with letters to track matching pairs.
  • Cut aluminum shims for undersized connecting rod bushing A (temporary solution for air test).
  • Milled new connecting rod keys.
  • Bored out the jam nut to clear piston rod.
  • Machined 4 new gibb keys.

Installing valve packing:

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November 15, 2013:

  • Revised plans to help us get the engines running on compressed air before Thanksgiving break.
  • Wrote a procedure for centering the pistons.
    • TDC from front of cylinder to the piston face =0.986″
  • Made bigger holes in some of the gaskets that needed adjustment.
  • Made more shims for eccentric shafts.
  • Mounted cylinder covers and gaskets.
  • Bored out holes in cylinder covers to better fit the studs on the cylinder.
  • Installed both left and right pistons in cylinders.springs
  • Installed both rear cylinder heads.
  • Attached Left piston to cross head.
  • Installed new springs for valves.
  • Discussed valve connection with Frank Greenleaf.
    • Recommended tight interface between washer and valve.
    • Adjustment is achieved  by pulling PN32 (Valve Stem Stud) and rotating PN29 (Valve Stem Connection) in 180° increments.
  • Wrapped the dripcock threads in Teflon tape to prepare for installation.
  • Collaborated on BOM as requested by Prof. Crosby.
  • Engraved more gaskets on the Epilog Laser Printer at the AMC.
    • Discovered a way to tweak settings and improved engraving rates; These new gaskets finished almost 60 times faster than previous versions.
  • Collected Motor oil to donate back to the Odd Duck Foundry.

 

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November 8, 2013:

Testing Stephenson Linkage Movement:

  • Referenced the Machinery’s Handbook for stress area and amount of thread engagement for threads.
  • Research into safety considerations.
  • Gantt Updates to reflect 11/4/13 and moving forward.
  • Received a response from Paul Francis from Thermoseal with insight on gasket installation.
  • Determined torque required for steam chest gaskets.
  • Cut and punched out circular gaskets.
  • Punched holes into shim stock for eccentric straps.
  • Attached both cross-head guides.
  • Machined Gibbs and keys to fit.
  • Fabricated springs for steam chest.
  • Installed valve stem stud on RH side of Lombard.
  • Test and fit steam chest gaskets.
  • Built a spreadsheet for calculating length of engagement and factor of safety.
  • Tapped holes in ‘Crank End Cylinder Head’ for mounting the gland for the piston rod.
  • Compiled a new ‘hit list’ for getting the engines running.
  • Completed our second Log Book submission due 11/6/13.

 

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November 1, 2013:

Laser Engraving at the AMC time-lapse:

  • Created Part files for all gaskets to be laser engraved at the AMC.
    • Additional file formats; .dwg, .pdf and .dxf for various applications in the process.
  • Industrial Packing in Bucksport, ME donated some larger sheets of gasket material needed for the steam chest!
  • Gasket test fits on paper and revisions.shims
  • Cut and deburred brass shim stock for eccentric strapping.
  • Started machining of new valve stem stud.
  • Machined brass cross head gibbs running surface flat.
  • Machined a bore gauge for test fitting.
  • Machining on eccentric straps for final fit.
  • Test fit newly machined eccentric strap – no shims required!
  • Joel found the valve stem stud – slight machine work done to make it work.
  • Cut packing for piston and valve stem.
  • Final gasket revisions made, laser engraved at the AMC, cut and ready to go.
  • Measurements taken to figure out piston centering and engine timing.
  • Gantt Updated to reflect these next few weeks. (Note: PDF file for all to view, but cannot be kept in a standard Gantt format).
  • Contacted Thermoseal about gasket stress and torquing the bolts on the steam chest and cylinder.
  • More web-format updates; Created inter-page links for easier navigation.
  • Human factors research.
  • More benchmarking from the Crooker’s Lombard.
  • Emailed Anette Rodrigues with questions regarding intended users.

 

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pn106-1

October 25, 2013:

  • Researched and made adjustments for the sliding fit needed by the crosshead gibbs.
  • Made prints for brass gibbs.
  • Finished CNC-ing PN106 at the Advanced Manufacturing Center and deburred.
  • Fasteners donated by Fastenal!
  • Measured hole patterns for steam chest and cylinder.
  • Found valve stem pivot on-site, missing the valve stem stud – measurements taken to machine a new stud.
  • Collaborated with another team on fittings for piping air directly to engines through steam chest – Tested.
  • Measurements for centering piston.pn106-2
  • Valve rod comparisons and measurements.
  • Adjustments to the brass gibb that was test fit.
  • Research into making a new webpage format.
  • Everyone had a great time working the Engineering Job Fair on 10/23/13.

 

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October 18, 2013:

  • Machined gibb keys.
  • Received six sheets of gasket material and three feet of packing from Industrial Packing in Bucksport, ME as a donation!
  • Ran FeatureCam for PN106 and started CNC machining in the Fryer at the Advanced Manufacturing Center.

featurecam - engine team

 

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October 11, 2013:

  • Measurements taken for eccentric straps and rods.
  • Ran calculations and then torqued piston rod castle nuts.
  • Started cutting out steam chest gaskets.
  • Made opening in cab for Stephenson Linkage.
  • Took measurements for cross head opening and guide for gibb adjustments.
  • Found out the left engine needs a pipe plug.
  • The Crooker’s Lombard arrived on Oct 7!
  • Bench marked off of the Crooker’s Lombard.
  • Cleaned up and oiled cylinders.
  • Made rigid holder for drilling cotter pin holes and drilled the holes.
  • Coated studs and bolts with never-seez.
  • Started fitting and measuring for Stephenson Linkage.
  • Setup Team Gmail for photos and videos.
  • Published first draft of team website.
  • Team presentation to class and first logbook due on 10/9/13.

 

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October 7, 2013: Crooker Family Lombard Arrives!

Crooker's Lombard Arrives 10/7/13

The Crooker’s Lombard Log Hauler arrived at Leonard’s Mills on October 7, 2013!

Having this beautiful machine as a working reference will be a great help to all of the MET Teams during the restoration process and we can’t thank them enough!

Crooker's Lombard Backing up - 10/7/13

 

Watch a short video of the Crooker’s Lombard backing into Machinery Hall:

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October 4, 2013:

  • Our Lombard was moved into Machinery Hall.
  • Ramsay Machining donated the Piston Rods and labor.
  • Research into gasket materials, steam packing and Stephenson linkages.
  • Measurements were taken for  Jam Nuts, team decision to machine our own.
  • Machining work on the gibbs.
  • Lombard historical research.
  • Assembled a missing parts list.
  • Formed Team Contract.

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Team Bios

Justin Arseneau – Justin Arseneau is a 24 year old transfer student from Maine Maritime Academy. He currently lives in Bucksport ME, and enjoys the outdoors, travel, and working with youth.

Michael Brown – Energetic self-starter with a passion for innovation and continual improvement. Natural and cultivated leader who utilizes excellent interpersonal, verbal and written communication skills to lead teams to success while fostering a collegial environment. One who sees failure as a chance to learn and “status quo” as unacceptable.
I am pursuing employment where I can use innovation in leading culture change, product development and process improvement among a diverse group of individuals. Cross training opportunities and integrity are two characteristics I look for in future employment.

Patrick Dean – I am a senior in the Mechanical Engineering Technology program, with an Engineering Entrepreneurial minor. I have a previously earned an A.A.S in Business Management from EMCC. For the past year and a half I have worked at the Advanced Manufacturing Center on the Umaine campus, where I have been able to hone my skills in CAD/CAM. I also have worked at the Alfond Arena on the Umaine campus for the past year. I come from a family that spends as much time as possible working with their hands and this motivated me to pursue a career in engineering technology. I look forward to building a career around CAM and NC programming. During my free time, I’m learning to play the bass guitar and am putting the finishing touches on one I have made myself.

Emmett Hodder – Emmett is a senior at the University of Maine pursuing a B.S. in Mechanical Engineering Technology. He is pursuing a career in energy efficiency with a particular focus on alternative energy systems and residential design. Emmett is from North Haven Island in Penobscot Bay and races sailboats in the summer. He is also preparing a 1970 Honda motorcycle for competition in the US Classic Racing Association.

William R. Long II – I’m currently pursuing a Double Degree in Mechanical and Electrical Engineering Technologies while having previously earned an A.A.S. in Advanced Welding and Pipe Fitting from EMCC. I have worked for companies such as IBM [Systems and Technology Group] in Burlington, VT as well as the Advanced Manufacturing Center in Orono, ME. In my free time you may find me involved with one of my interests including; tinkering with electronics, computer hardware, pyrotechnics (especially rocketry), robotics/automation or learning to play the piano.

Thomas Mckay – After graduating high school I spent a few years exploring the labor force in the greater Bangor area, and decided that I wanted something more.  I decided to pursue a degree at the University of Maine at Orono.  I attended for a few years then took a couple years off.  I’m back in school now and graduating in May of 2014.

 

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Photos & Videos

FOLLOW THE PHOTOS:

April 22nd – Initial Steam Test Photos.

April 5th – Odd Duck Foundry PICTURES.

April 5th – Odd Duck Foundry Video Clips.

March & April Uploads.

January Uploads.

December Uploads.

November Uploads.

October Uploads.

A collection of photos from Justin up through 10/8/13.

Torquing at Leonard’s Mills on 10/6/13.

Drilling the first piston rod for a cotter pin on 10/7/13.

 

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