Assembly Procedure:

  1. Electronics Box
  2. Box Assembly
  3. Mark the holes from the bracket on the plastic box with permanent marker.
  4. Flip the bracket over and spot the holes on the bottom of the bracket then transfer the marks from the plastic box to the bracket so the holes are mirrored on either side of the bracket.
  5. Use a vice to hold the bracket steady so the holes can be easily drilled using a drill press and #3 drill bit.
  6. Drill the holes in both the plastic box and the alternate side of the bracket.
  7. Drill a small hole in the lid of the box to attach the chain to the lid.
  8. Cut a piece of clear plastic so it will fit in the plastic box fitting snugly against the walls. Approximately 4”x 6”. Be sure to measure your exact box to allow for differences in the size of the box.
  9. Drill four holes with the #36 drill bit in the pattern of the circuit board. PLEASE measure each circuit board as they are known to be various sizes. Drill two more holes for standoffs 4” away from the furthest circuit board holes and 1.25” away from center.
  10. Using a 3/16” or ¼” end mill machine out the slot for the USB port. Oversize the slot just slightly to allow the USB port to pass though easily.
  11. In the acrylic drill two additional holes with a #3 drill to match the hole pattern in the bottom of the bracket.
  12. Using a #3 drill bit drill one hole in the plastic box directly under the circuit board to allow access to the wires. Be sure to put the wires through the box before the quick connects are attached
  13. Use two ¼-20 x ½” bolts and nuts to attach the bracket to the plastic box utilizing 2 large washers on the inside of the box. Start by putting the washers on the bolts and then inserting them into inside of the plastic container wall. Starting in the left hand side of the side of the wall of the box. Then attach the rubber connector over the bolt before putting the bracket on. Insert the right wall bolt connecting the box and the bracket.
  14. Attach the nuts using an adjustable wrench and a Phillips head screwdriver.
  15. Attach the chain to the lid and clip through one of the holes on the edges of the bracket.
  1. Circuit Board Assembly

Parts:

Motor

Wire (6 inches)

Quick Connector

Circuit Board

Voltage Regulator

Capacitors- 3

USB Female Connector

Assembly Plan:

1.  First solder the end of the 6 foot section of wire on motor. Red wire to “+” and black wire to “-”.

2.  Pull wire through hole on the motor container gently. Let motor sit in middle of the container.

3.  Measure length of the wire, and cut for exactly 6 inches in length.

4.  Solder wire to male pins (Black and red separately) of the quick connector.

5.  Push connector pins into male connector. Red to round hole and black to square hole.

6.  Solder 5V voltage regulator, two 10 uF Capacitors, one 0.1 uF Capacitor, and USB Female connector on circuit board following the circuit schematic below.

The pins on USB female connector are as shown below:

Data pins will be grounded.

7.  Solder female connector pins creating inputs for the circuit board (Black-B and red-A separately).

8.  Insert connector pins into female connector housing. Red to round hole and black to square hole.

  1. Electronics Box
  2. Lid Assembly
  3. Cut aluminum extrusion to size
  4. Face aluminum block in lathe and drill the specified center hole.
  5. Secure block in mill, center drill using the previous center hole and zero the mill.
  6. Proceed to cut the three specified holes in aluminum block.
  7. Re-orient aluminum block on its side and mill specified cut.
  8. Proceed to drill specified centered hole on previously milled face.
  9. Add specified tap to the three outer holes on the top face and the hole on the previously milled surface.
  10. Rough up bottom portion of the drive shaft tubing and center hole in the aluminum block. Clean with acetyl.
  11. Add epoxy to previously roughed outer face of drive shaft tubing and the center hole of the aluminum block. Insert shaft and align bottom faces. Allow to set.
  12. Screw lid onto motor housing and secure in lathe. Drill specified center hole.
  13. Remove assembly from the lathe and secure in the mill. Center drill using previously cut center hole. Drill specified outer holes.
  14. Unscrew lid from motor housing. Use specified bolts to assembly lid to the aluminum block.
  15. Cut roller material to specified length. Secure in lathe and drill specified center hole.
  16. Cut drive shaft and attach crimp to one end of the shaft.
  17. Press fit roller over crimped end. Insert shaft into drive shaft tubing.
  18. Attach crimp, close to the lid, to the remaining protruded end of the roller shaft.
  19. Secure spring grip in mill. Mill specified holes.
  20. Thread lid onto motor housing. Drill specified holes in the side of the motor housing.
  21. Remove motor housing from lid. Run wire through upper hole on motor housing.
  22. Solder wire to motor. Proceed to wrap motor using insulation. Wrap 360 degrees twice.
  23. Insert bolt into bottom hole of motor housing from the inside. Place motor assembly into motor housing and pull on wire to remove slack. Make sure assembly is centered.
  24. Cut shaft adapter to length and drill center hole.
  25. Press fit the adapter onto the drive shaft on opposite end from the roller.
  26. Thread lid onto motor housing, carefully pressing the adapter onto the shaft of the motor simultaneously.
  27. Thread nut onto specified bolt, insert bolt through slotted end of spring grip, thread on remaining nut.
  28. Insert bolt into hole on the milled side of the aluminum block. Tighten two turns.
  29. Slide remaining hole of the spring grip over the bolt protruding from the motor housing. Thread on specified nit and tighten.
  30. Tighten previous bolt snuggly.
  31. Apply sealant to holes in motor housing.

Manufacturing of components

Lid holes: To put the correct holes in the lid of the round container utilize a dial gauge in the Bridgeport to center the lid attached to an extra container in the vice.

Drill a small hole (2mm) in the center of the lid. Place the other three holes drilled with size #3 drill bit at the proper locations according to the print.

Holes in round container: Put one hole into the side of the container for the wire.

Solder the wires for the motor to motor module.

  1. Bottom Assembly

1.  Take motor with attached wire and run the wire through the correct hole in the housing from the inside of the container to the outside.

2.  Place screw into correct hole with the head of the screw on the inside of the container to hold the bracket and glue to wall of housing.

3.  Wrap motor twice around with insulation and place into housing.

  1. Top Assembly

1.  Take drive shaft and insert into roller

2.  Screw aluminum housing to the motor housing top with 3 screws

3.  Apply super glue to the center hole of the aluminum housing and insert aluminum tube.

4.  Take drive shaft and roller assembly into aluminum tube and apply crimp.

  1. Full Assembly

1.  Place rubber adapter onto crimped end of drive shaft.

2.  Connect other end of adapter to the motor.

3.  Screw cap onto housing bottom

4.  Take screw and thread one nut to the top of the screw.

5.  Place screw though slider portion of bracket and thread on final.

6.  Thread screw into aluminum housing.

7.  Slide remaining end of bracket over the remaining screw protruding from housing and thread on nut until tight.