Opitec 107.388 User manual

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Premium-Line
Electro motor
107.388
Warning!
This product contains small parts that can be swallowed.
There is a danger of choking!
This product contains a magnet.
Swallowed magnets can block the intestines and cause
severe internal injury.
If a magnet is swallowed by accident contact a doctor as
soon as possible.
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
Technolo- gy.These projects should only be undertak-
en and tested with the guidance of a fully qualified
adult. The finished projects are not suitable to give to
children under 3 years old. Some parts can be swal-
lowed. Dan- ger of suffocation!

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1. Product information:
Art: Functioning model using metal & plastic
Use: In Design Technology , Key stage 4
2. Materials:
2.1 Material: Aluminium ( Light, non ferrous metal )
Working: cutting ,filing, drilling
Joining: machine screws.
Finish: polish ,varnish.
2.2 Material: Acrylic plastic
PMMA ( Polymethylmethacrylate ) transparent
Working: drilling , threading , cutting;
Joining: machine screws.
Finish: no special finish needed.
3. Tools:
Cutting: Use metal shears or side cutters for the holed metal, spring and copper wire
Note ! cut metal edges can be sharp!
Remove any burr with a file
Filing: choose the correct grade of file for the work
Use needle files for small notches.
Note! Files only cut on the forward stroke.
Sawing : Use a hacksaw for cutting metal parts
Note ! hold the work in a vice.
Drilling: Use a pillar drill;
Note! Adhere to the safety rules when drilling. Wear safety
glasses and an apron. Tie long hair back , remove rings
and jewellery! Hold the work to be drilled in a machine vice.
Ensure the drill is set at the correct speed
Gluing: We recommend using a quick setting glue.
Do not apply the glue too thickly
Read the instructions before use !!

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4. Parts list :
No. Quantity Description Material Size (in mm)
1 1 Base Acrylic 8 x 70 x 70
2 1 Holder Aluminium strip 2 x 10 x 250
2 Holed strip metal 0,5 or 0,8 x 10 x 150
3 1 Shaft Metal axle Ø 3 x 95
4 1 Iron core Machine screw &nut M6 x 25
5 1 Winding Varnished copper wire Ø 0,6 x 2400
6 2 Commutator Double gears 30/10 Zähne
7 1 Contacts Spring steel Ø 0,5 x 500
8 2 Permanent Magnets Ring Ø 18/5 x 5
9 2 Sundries Machine screws M3 x 16
10 2 Sundries Nuts M3
11 6 Sundries Machine screws M3 x 6
12 2 Sundries Washers M4
13 1 Jig Beech wheel Ø 40 x 10
Also needed :
A few drops of a turbo glue ( not included in the pack )
311.619 4g-tube
311.620 10g bottle

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6. Making the base
6.1 Making the holder and bearings
6.2 Making the core and commutator
6.3 Final assembly and testing
6.4 Principles of the electric motor
General:
In the pack are different materials for making the holder and bearings
This choice depends on the difficulty of which level of model you make.
6.1 Making the base
6.1.1 Cut or mark out the pattern ( see page 9) and selloptape it to the acrylic base. Mark the middle of each hole that is to
drilled with a pointed hole maker or similar
Note! Do not remove the protective foil from the acrylic !
6.1.2 Drill the 2.5 diameter holes ( Use a drill for plastic or metal )
6.1.3 Tap the M3 threads ( Use a 3 part drill and a tap wrench or a single cut tap )
Note! Ensure that the tap is at right angles to the base.

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6.2 Making the holder and bearings
At this stage you can chose your material
Version 1
Using the holed metal strip, this is easy to bend into the U shaped holder. No need to drill holes..
Version 2
A more testing way is to make the U shaped holder from the aluminium strip
This version has more stages of construction which must be accurately carried out.
The holes must be marked out and drilled.
The instruction show you how to make the aluminium strip version.
6.2.1 Mark or cut out the plan for the holes on the aluminium strip ( See page 9). If you cut out the plan pattern fix it with
sellotape. Mark out and centre punch the holes for drilling. Mark out with a pencil the bending point ( broken line )
in the middle of the strip.
Note! Only use a pencil to mark out where to bend
so that no weakness occurs in the metal that can lead to it snapping !
6.2.2 Cut the bearings and U shape holder to size with a junior hacksaw
File the ends and round off
Note! Use vice soft jaws
6.2.3 Drill the 3mm dia holes in the holder and bearings. To make it easier you do not need to drill the holes for fixing the
magnets as these can be glued in position
6.2.4 Bend the ends of the U shaped holder at 90 degrees
Note ! use a vice with soft jaws-ensure that the bends are accurate
6.2.5 Use wooden wheel (13) to bend the holder around. Just fasten the wheel to a piece of wood ( not in pack) and use
the wheel as a former, hold the strip in the middle of the wheel and bend it left and right .
Note ! Ensure that the shape is accurate !
70,0
35,0
5,0
15,0
10,0
20,0
50,0
60,0
70,0
5,0
10,0
28,0
145,0
10,0
147,0
5,0
10,0
28,0
35,0
R 5,0
10,0
37,0
Ø 3,0
Ø 3,0
2x
U shaped
holder
Bearings

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6.3Making the core, coil and commutato
6.3.1 Drill two holes in one of the double gears (6) these holes should be between two teeth on the small gear and 1mm
in diameter. Drill one side first and then the other on the opposite side.
6.3.2 Use the drawing ( page 11) to mark out and drill the bolt (4) and then insert the shaft 3dia x 95mm to 40mm.Use a
drop of glue to hold it in place. Screw on the nut so that it is level with the end of the bolt and glue it in place.
6.3.3 Glue the drilled double gear on the shaft 40mm in. Slide and glue on the second gear
With the small gear first 20mm in
Arrange the holes in the gear so that they are 90 degrees to the bolt ( iron core )
( see page 11)
6.3.4 Cover the thread of the bolt with sellotape or insulating tape.
Wind the varnished copper wire around the bolt , winding it doubled, making sure there
are no kinks. Wind it around one half of the bolt until there is about 40mm over .
Now wind the second half of the wire in the”same direction “ until there is also about
40mm left over.
Remove the varnish with from both ends of the coil with emery cloth then threasd the ends through the small holes
in the gears so that they lay cleanly (use pliers if necessary) the wire should lay parallel to the shaft ( With a version
with one gear the ends should protrude 5-10mm and not touch the shaft )
Note! Keep to the winding direction ! check the gears with the coil
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40,0 40,0
20,0
95,0
Ø 1,0
90,00°
5,0
30,0
30,0
15,0
5,0

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6.3.5 Bend the two spring (7) contacts as shown.
6.4 Final assembly and testing:
6.4.1 Machine screw (9) and bolt ( nuts 10) the magnets to the U shaped holder or glue them in place.
Note ! Check the polarity of the magnets !!
Fix the magnets to the holder type as shown
6.4.2 Screw the bearing strips to the base as shown using two machine screws (11)
Ensure that the hold the shaft and that it can turn easily.
Now screw (11) on the U shaped holder checking that the rotor can turn easily
Now mount the two contact springs using the screws (11) and washers and check that the have a light contact with
the copper wire
6.4.3 Connect to a 4.5 volt battery and give the rotor a light twist and
the motor should run !
Note : apply a few drops of oil the bearings and the
contacts!
40,0 40,0
20,0
95,0
Ø 1,0
90,00°
5,0
30,0
30,0
15,0
5,0
SN
2x

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Principles of the electric motor
How does an electric motor function
Look at the diagram below
Note:
The same magnetic poles push against each other. Unlike attract each other.
As the two permanent magnets here are always attracting each other –they can be switched on & off with an electro
magnet. The plus pole and the minus pole are then changed over. The North becomes a South pole and the South
pole a North pole and so on
The iron core increases the magnetic power of the coil.
When a current flows through the coil the core becomes magnetic. Its pole is pulled by the permanent magnet . As
the collector turns each end of the coil touches a different contact. Because the coil receives current in different di-
rections so the poles of the coil change. The iron core is pushed and pulled by the permanent magnets causing it to
turn
Schematic diagram of the collector
A schematic diagram of how the motor coil turns and the wire ends in the 1mm holes
wire ends
Brushes Brushes

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70,0
35,0
5,0
15,0
10,0
20,0
50,0
60,0
70,0
5,0
10,0
28,0
145,0
10,0
147,0
5,0
10,0
28,0
35,0
R 5,0
10,0
37,0
Ø 3,0
Ø 3,0
Patterns
Scale 1:1
Base
Looped
holder
No need to drill if the magnets are
glued in position !
Bearings
2x 2x
Looped
holder
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Patterns
40,0 40,0
20,0
95,0
Ø 1,0
90,00°
5,0
30,0
30,0
15,0
5,0
gear
commutator
Drilled gear