11.727 PremiumLine SolarMotor Necessary tools: Please Note The OPITEC range of projects is not intended as play toys for young children. They are teaching aids for young people learning the skills of Craft, Design and Technology. These projects should only be undertaken and operated with the guidance of a fully qualified adult. The finished projects are not suitable to give to children under years old. Some parts can be swallowed. Danger of suffocation! Fretsaw or hacksaw Drills ø2, ø, ø,, ø8 Forstner bit ø15 Thread tap Side cutters, Crimp pliers Hacksaw Soldering iron,solder Workshop file Wire strippers All purpose glue Machine vicel Try square Centre punch Countersink Oil Wood strip Brass nails(40 x 2) Content Solar cell 2 Solar cell 0,5V 150mA 1 Acrylic 1 xx12 Stand, Magnet 2 Ready made spool carrier 2 Coil carrier and axle Brass tube 1 x0,5x Motor axle 4 Distance discs 2 ø2,9 Fixing rotor to axle 5 Nails 2 40x2 Axle points/ weights 6 Metal axle 2 1x Connection for stand 7 Machine screws 2 16x4 Bearing 8 Magnet 1 15x6 Magnet 9 Copper wire 1 000x0, Spool 10 Cable 1 500 Wiring 11 D11727#2 1
Instructions General: The instructions describe 2 variations one of which the rotor is lying and the second varaition ( see diagram 1)where the rotor is vertical.the construction of the rotor is the identical. The different patterns for the stands are on page 5. Step 1: Trace the pattern (Page 5) on to the acrylic sheet. Use a forstner drill ø 15mm x mm deep to make the housing( Part c) for the magnetsl Saw out all the parts with a hacksaw, use salad oil as a lubricant a Lay the parts a and b on top of each other and fix with sellotape Drill all the ø/ø, mm holes.all theway through : ensure that the drill bit runs vertically! Mark and drill the ø mm dia holes in part (c) on the edges Make sure that the holes are vertical! Use a thread tap in the holes in the.mm holes in the sides of parts ( ab) Finally counter drill a blind hole in the two threaded holes in part ( ab) ø 8mm x mm deep ( See diagram ). ab 2 12, Ø,, b 62 10 40 50 12 c Step 2: Use an all purpose glue to fix the magnets (9) in the 15mm blind holes Step : Insert the two metal axles (7) in the holes of the acrylic block as shown The block and magnet (9) should be exactly in the middle ( part 2) Step 4: Assemble parts a and b on the two metal axles (7) The blind holes on both parts (ab) should show to the outside b a Step 5: Drill a ø. mm hole into a wooden strip or the rest of the acrylic sheet. Use the thread tap to cut a suitable thread into the drill hole. Insert the screw (4) and fit the wooden strip with the screw into the machine vice. Use a centre punch to mark the centre and use the ø2 mm drill to drill a 12 mm hole. 2 D11727#1
Step 6: Screw both screws into the two feet a b. Countersink the screw head into the predrilled blind hole.. Step 7: Glue the two spool carriers (2) to a solar cell (1) as shown. Let the glue dry well! Step 8: Sharpen the tip of both nails (6) cleanly with a workshop file. Shorten both nails(6) with side cutters to mm as shown. Deburr the cutoff ends thorougly. Step 9: Shorten the brass tube (4) with a fretsaw or hacksaw to 80mm. Deburr the ends of the tube thoroughly. Deburr the tube openings from both sides with the countersink. Insert both nail tips (see Step 8) as shown into the brass tube, so that they stick out on both sides by approx. 5mm. Step 10: Clamp the nail to the end of the brass tube by pressing down hard with the pliers. Repeat at the other end. Step 11: Stick the metal motor axle from one side through the central drill hole in the spool carrier as shown. Stick the tow distancer disks (5) on to the motor axle as shown and feed the other end of the axle through the middle drill hole in the second spool carrier (2). Centre the axle and fix the two distancer disks (5) by pressing them to the spool carrier. Step 12: Cut off four lengths of approx. 40mm wire (11), strip both ends and tin. Solder one cable each to the connectors of the solar cells. Step 1: Glue the second solar cell (1) with glue to the spool carriers (2) as shown. Let the glue dry thoroughly! D11727#2
Step 14: Now wind the coil with copper wire (10) onto the spool carrier according to the calculator to the right. Leave approx. 80 mm overhanging at both ends. Once the coil is wound, strip the ends of the coil carefully with sandpaper. Make sure, that whilst winding the coil no windings get stuck at the corners of the spool carrier. Winding calculator (Wind exactly according to the number of wraps) Left 10 0 40 50 60 70 80 Right 90 105 110 Step 15: Feed the cable that is connected to the negative pole of the left solar cell through under the windings to the positive pole of the right solar cell. Solder to the cable that is already soldered on to it, and the piece of the winding (coil) that ends on this side. (see circuit diagram) Strip the ends of the copper wire carefully with sandpaper! Circuit diagram Feed the cable that is connected to the negative pole of the right solar cell through under the windings to the positive pole of the left solar cell. Solder to the cable that is already soldered on to it, and the piece of the coil that ends on this side. coil solar cell Step 16: Cut off an approx. 0mm piece of copper wire and tie the coil together on both sides as shown. Twist the wire ends together and shorten with a side cutter. Step 17: General: To ensure smooth running align the rotor. To balance the rotor insert it in the frame. If the rotor turns away to one side, a balancing weight has to be added to the opposite side. For this insert the brass nails into the spool carrier drill holes. Depending on weight it might be necessary to add weights to both spool carriers. Shorten nails accordingly. 4 D11727#1
Step 18: Place the finished morot between the twoscrews (8), so that it can turn freely and easily! Place the motor in sunlight and Den Motor ins Sonnenlicht stellen und turn it on. Done! Template Acrylic glass Base/sides M 1:1 Variation 1, Variation 2, D11727#2 5