GSC 1858 User manual
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GSC International Inc.
Phone: 417.374.7431
Fax: 417.374.7442
Toll Free: 888.756.4592
service@gosciencecrazy.com
2076 James River Court
Nixa, Missouri 65714
Introduction
Almost every electrical device that has
something moving, uses a type of motor
and a switch. Understanding how a motor
works will give you a good foundation for
understanding many other electrical
devices as well as generators. Motors and
generators are just the inverse of each
other. A motor is a device that converts
electrical energy into mechanical energy,
and a generator is a device that converts
mechanical energy into electrical energy. If
a permanent magnet is used for a magnetic
energy supply, then a motor can become a
generator or a generator can become a
motor.
Since a generator coverts mechanical
energy into electrical energy, and a motor
converts electrical energy into mechanical
energy, is it possible that motor could be
mechanically connected to the generator
and the generator electrically connected to
the motor in such a manner that once you
started the system it could run continually
with no outside infuence? Hint: Think
FRICTION!
DC Motor Kit
#1858
Warning:
• California Proposition
65 Warning: This product
can expose you to
chemicals including
Lead, which are known
to the State of California to cause cancer, birth
defects, or other reproductive harm. For more
information go to www.P65Warnings.ca.gov.
• Choking hazard – small parts
The DC Motor Kit has been designed to give a student hands on
experience with the basic construction and operation of a simple
DC electric motor. Although simple in operation, the motor
requires a basic understanding of how it works in order to make it
work. A tiny misplacement of a brush or a bad connection in many
areas of the motor will cause it to fail.
Take each step slowly and make sure that the student understands
why each step is needed before they begin.
Assembly Instructions
1. Insert brass plates (#6) into base slots marked number 1
and number 2 (as shown in Fig. 1). These will be the
connection plates for your battery. The hole in the brass
plates should be on the top and extending above the slots.
These holes are for the connection of wire.
2. Insert the two posts (#5) in the holes of the base marked number 3 and number 4 (see Fig. 1) as
shown in Figures 2 and 3. These posts will hold the armature shaft.
3. Attach the "U" shaped bracket (#3) to the metal bracket
(#2) by first wrapping the smaller piece of insulation paper
(#4) around both brackets with the glossy side down. If the
paper is too wide, trim to fit the "U" shaped bracket. Wrap the
paper all the way around both brackets so as to bind them
together (see Fig. 4). Leaving about 4cm of wire, start
wrapping one of the coils of magnet wire around both
brackets. When you get close to the end of the roll, stop when
you have about 8cm left. Place the bracket on the base, lining
up the holes marked number 5 and number 6 (see Fig. 1) on
the base and as in the illustration. Place screws into the holes
and thread on the hex nuts from the underside of the base.
4.You will now construct the armature and the commutator.
Refer to the Part List (Fig. 1). You will need both armature
plates (#11), motor shaft (#10), bigger piece of insulating paper
(4), one coil of copper wire (#7), both commutators
(#12), and a plastic sleeve for insulation of motor shaft (#14).
Take the two armature plates (#11) and place them together in
such a way that the protrusions (bumps in the center) are facing
outward, which causes a hole to be formed for the motor shaft.
(See Fig. 5). Wrap the big piece of insulation paper with the
glossy side down around the armature. Pu8sh the armature shaft
through the hole created by the two halves of the armature
plates by piercing through the insulated paper. Push the motor
shaft through until it is approximately 1.5cm from the front
edge of the armature plates.
Take a second coil of wire and leaving
approximately 4cm of wire, begin
wrapping the wire around the armature.
Try to keep the number of wraps even
on both sides of the shaft. as you get
close to the end of the coil, leave
approximately 4cm of wire to make
connections later (see Fig. 5)
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Next take the plastic tube and cut four pieces from it: one 1cm, one 8mm, and two 6mm pieces. Slide the
6mm piece first onto the shorter end of the shaft so that it touches the armature assembly. Then on the
longer end, slide in the following sequence: 6mm sleeve, commutator, 1cm sleeve, commutator, 8mm sleeve
(see Fig. 5). After this, the loose ends of the wire that you wound on the armature need to be sanded and put
through the holes of the commutator (see Fig. 5). The wire at one end can go through the holes on one side
of the commutators and the wire at the other end can go through the other side. After the wires are in the
commutator, clip and bend back the wires to secure them in place so the whole motor can spin. Your
armature and commutator assembly is now ready. This should be placed on the grooves of the plastic pillars.
The armature should now rest in between the arms of the "U" shaped pole. Ensure that the armature does
not touch the pole. If it does, just push the arms of the pole away from the armature with your hands. Trim
the rubber tubing if the motor shaft is tight against the support pillars and commutator to allow for easy
rotation.
5. You will now set up the wire brushes (#9) and clips (#13). Using the sandpaper, sand the ends of the
brushes (both sides). Place a T-Clip through the hole of one of the wire burshes and then place the end of the
clip down through hole number 7 (labeled in Fig. 1). On the bottom side of the base, spread the clip apart and
then flatten so that it holds the wire brush in place. After securing T-Clip through the hole of the brush, the
wire is threaded through the second T-Clip and now the T-Clip is secured in hold 9. The wire brush is bent
slightly so it contacts the wires in the commutator. Repeat for the other side of the armature by using holes
number 8 and 10 (labeled in Fig. 1). The wire brushes should rest on the copper wire between the two
commutators. If they don't, adjust them.
6. Finally, you are now going to
make the connections. Use sand
paper to sand the coating from
the wire coming from the free
ends of the "U" shaped bracket.
Connect one of these ends to the
base of one of the wire brushes.
The other wire end is to be
connected to one of the battery
plates by threading it through the
hole on top and wrapping it
together.
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