Name Standard or Description QTY.

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1 Part List Part Number Name Standard or Description QTY. 1 Base Nut Hexagon Nut ISO M Motor/Encoder Assembly Mabuchi RS-645VA and Encoder M3x10 Screw ISO M3 x Steel Flat Washer ISO 7092 M6 2 6 Motor Pulley T2.5 14T, 1/8 bore 1 7 Set Screws ISO 4026 M3 2 8 Motor Cover Cooling Fan 50x50x25mm 1 10 Fan Guard M3x25 Screw ISO M3 x Printed Circuit Board M3x20 Screw ISO M3 x Plastic Washer M3x6x Handle Base Carriage (top) Handle Base Shaft Ø2x22mm 1 18 Carriage (bottom) Linear Bearing 5x10x15mm 4 20 Timing Belt T mm 1 21 M3x16 Screw ISO M3 x Tensioner M3x30 Screw ISO M3 x Idler Shaft Ø5x Idler bearing Flanged 5x11x5mm ball bearings 2 26 Guidance Shaft Ø5x Cover Power Switch Handle Ball Bearing (lower) 10x19x5mm 1 30 Handle Handle Ball Bearing (upper) 3x10x4mm 1 32 M3x16 Screw ISO M3 x The encoder is a quadrature encoder with 448 lines, taken from a motor that can be purchased online. If necessary, we can provide the full assembly Faculty of Engineering, University of Porto 1

2 Assembly Instructions Before beginning the assembly, it should be made sure that all the holes on the printed parts are open and that all the parts fit each other where expected. If any of the parts does not fit, the overlapping surfaces should be filed until there is enough clearance. 1. Start by inserting two nuts (2) in their respective slots on the base part (1), as shown. These will be used to secure the fan assembly on a later step. Once the nuts will be inaccessible on this stage, glue may be applied to ensure they remain in place throughout the assembly process and when fastening the screws Faculty of Engineering, University of Porto 2

3 2. Insert two screws (4) in the holes located on the motor holding tab at the base part. Slide the two steel washers (5) over the screws, so that they are opposite to the screws heads. Place the motor (3) on the base part, sliding the shaft through the tab s middle opening, and fasten the screws. Make sure the protrusion on the base of shaft goes completely through the matching orifice and that the motor is flush with the washers. The back of the motor should sit on the back support, as shown in the figure. Slide the pulley (6) over the motor s shaft. It should be placed as close to the motor body as possible, but far enough to assure there isn t contact during the typical operation of the device. Secure the pulley to the shaft by fastening the set screws (7) Faculty of Engineering, University of Porto 3

4 3. To assemble the cooling system, begin by placing one nut (2) in the proper cavity on the top of the motor cover (8) and assembling the fan (9) and its guard (10) on this same part. To do so, place the fan and the fan guard in the appropriate position within the motor cover, hold the two topmost nuts in place, and fasten the two topmost screws (11). Afterwards, set this assembly in its correct location over the motor and base parts and fix it by tightening the two lowermost fan screws (11) and the screw (11) under the base part, as shown Faculty of Engineering, University of Porto 4

5 4. To mount the printed circuit board (PCB, 12) place it on the base part, making sure the holes are aligned, set the plastic washers (14) and nuts (2) in place and fasten the screws (13). Connect the motor/encoder and fan cables to the proper connectors on the PCB Faculty of Engineering, University of Porto 5

6 5. In order to begin mounting the carriage assembly, set a nut (2) in one of the halves of the handle base (15). Spread glue over the flat surface of any of these parts, being careful not to let any reach the screw and nut compartments, and join them together. Take care to ensure proper alignment of the parts during the gluing process Faculty of Engineering, University of Porto 6

7 1. Mount the handle base assembly on the top half of the carriage (16), so that its holes align themselves with the semi-cylinder along its lowest face. Slide the Ø2mm shaft (17) through the hole, in order to secure the assembly Faculty of Engineering, University of Porto 7

8 6. Place the linear bearings (19) on the bottom half of the carriage (18), along the side channels, and one edge of the timing belt (20) on its toothed surface. Bring both halves together. Insert four nuts (2) on the bottom face and slide 4 screws (21) along the corresponding holes. Fasten the screws just enough so that the assembly holds together, while making sure the timing belt is secure Faculty of Engineering, University of Porto 8

9 2. Insert a nut (2) in the tensioner (22) and place the free edge of the timing belt on its toothed surface. Insert this set into the trapezoidal hole on the carriage assembly. While doing so, make sure that the belt is properly seated on the tensioner and does not slide back. Insert the tensioning screw (23) in the opposing hole. Push the tensioner so that the screw can reach the nut. Fasten the screw just enough so that the whole assembly is kept together. Make sure that the timing belt can withstand force by pulling it from both ends. If slippage occurs, loosen the screws holding the two halves of the carriage together and reinsert the belt Faculty of Engineering, University of Porto 9

10 7. Slide one end of the timing belt loop over the pulley, so that the tensioner faces the opposite direction Faculty of Engineering, University of Porto 10

11 8. Insert the idler shaft (24) through the hole on the end of the base part so that it can hold exactly one flanged bearing. Mount one flanged bearing (25) on the shaft. Slide the free timing belt loop over the bearing. Set the second bearing (25) in place and slide the shaft through the full length of its opening. The flanges of each bearing should be facing outwards, close to each of the supports Faculty of Engineering, University of Porto 11

12 9. Insert the guidance shafts (26) through the linear bearings on either side of the carriage and place their ends in the supports on the base part. Make sure they are properly seated on each of the four support points. Fasten tensioning screw to apply tension to the belt. If necessary, some applications may be tested at this point to ensure ideal belt tension. However, precautions should be taken to avoid injury due to the moveable shafts Faculty of Engineering, University of Porto 12

13 10. Insert the power switch (28) in through the back of the cover part (27) and place the five nuts in the orifices at the top. Connect the power button cable to the PCB and place the cover part over the rest of the assembly. Insert the 5 M3 screws in the remaining holes on the base part and fasten them to secure the assembly Faculty of Engineering, University of Porto 13

14 1. Assemble the remaining ball bearing on either side of the handle and mount this assembly on the handle base. Secure it using a screw (M3x16). The 1 DOF Haptic Device should now be fully assembled and functional. To use it connect it to a 15VDC, 2.4A power supply and to a computer s USB port (using a mini- USB to USB cable), and load one of the applications available at Faculty of Engineering, University of Porto 14