wictronic rev.: mp-0003-00 25-may-05€¦ · the whole production of the levitron 50 power board is...

Doc. No.: MP-0003-00 Rev.: 00 Tronicwic

www.wictronic.ch Production and Assembly of Levitron 50

Eff. Date: 25-May-05

PRODUCTION AND ASSEMBLY OF LEVITRON 50

Author: S. Wicki

Filename: MP-0003-00 Rev00 Production and Assembly of Levitron 50 en.doc

Project: Levitron 50 Document: This Document describes the production and assembling procedure of Levitron

50.

All Rights reserved. Copyright reserved. 1 / 16



Eff. Date: 25-May-05 Contents: 1. Partlist for a complete Levitron 50 .........................................................................................3

1.1 Parts to work over again (Raw Material: RM) ...................................................................................3 1.2 Complete Partlist for one Levitron 50................................................................................................4 1.3 Internet-Links to the distributors........................................................................................................6

2. Manufacturing of mechanical components ...........................................................................7 2.1 Documents ........................................................................................................................................7

3. Assembly of Distance Column ...............................................................................................8 3.1 Documents ........................................................................................................................................8 3.2 Pictures of Distance Column.............................................................................................................8

4. Assembly and manufacturing of coil .....................................................................................9 4.1 Documents ........................................................................................................................................9 4.2 Manufacturing of Coil ........................................................................................................................9 4.3 Pictures of Coil ..................................................................................................................................9

5. Assembly and Production of the Power Board...................................................................10 5.1 Documents ......................................................................................................................................10 5.2 Manufacturing of PCB .....................................................................................................................10 5.3 Gerber Data Power Board...............................................................................................................10

6. Assembly of the Levitron 50 .................................................................................................11 6.1 Documents ......................................................................................................................................11 6.2 Steps of assembly ...........................................................................................................................11

6.2.1 Glueing of Lens...........................................................................................................................11 6.2.2 Insertion of Isolation Sockets ......................................................................................................12 6.2.3 Assembly of Housing Feet ..........................................................................................................12 6.2.4 Insertion of Power Board ............................................................................................................13 6.2.5 Insertion of Threaded Rod ..........................................................................................................13 6.2.6 Assembly of Distance Column....................................................................................................14 6.2.7 Assembly of Upper Half Housing Bottom ...................................................................................14 6.2.8 Assembly of Coil .........................................................................................................................15 6.2.9 Assembly the rest of the Housing ...............................................................................................15

6.3 Explosion view Levitron 50..............................................................................................................16





1. PARTLIST FOR A COMPLETE LEVITRON 50

1.1 Parts to work over again (Raw Material: RM)

Pos QTY Descrip-

tion Drawing / Picture Dimension [mm] Material Standard Distributor Art.- Nr. Price / Pc.

@50Pc. 2 x

105mm x 60mm x 17mm

Aluminium anodized -

2 x

105mm x 1.9mm x 34mm

Aluminium anodized -

RM1 2

complete aluminium housing with two cover plates and eight screws

8 x

M3x10 Steel galvanized

DIN966A ISO7047-H 4.8

Fischer Elektronik (Astrel AG)

KOH1 + KOH1-60 ME 18.40

RM2 1 disks without hole

60x3mm Steel galvanized - Kuewi 0512Z06030 1.00

RM3 1 disks without hole

60x2mm Inox A2 - Kuewi 11512B06020 3.00

RM4 ∼0.25 Distance Column

a=10mm, b=10mm, c=1mm, L=1000mm

Aluminium anodized - alfer 40011160108

04 5.90

RM5 ∼0.33 threaded rod M4x1000 Inox A2 DIN975 Kuewi 0219B00040 1.50





1.2 Complete Partlist for one Levitron 50

Pos QTY Descrip-tion Drawing / Picture Dimension

[mm] Material Standard Distributor Art.- Nr. Price / Pc. @50Pc.

1*1 1 Lower Half Housing Bottom

RM-0001-00:

100mm x 60mm x 17mm

Aluminium anodized - -

RM1: half Aluminium Housing

9.20

2*1 1 Lower Half Housing Top

RM-0001-01:

100mm x 60mm x 17mm



9.20

3*1 1 Upper Half Housing Bottom

RM-0001-02:

100mm x 60mm x 17mm



9.20

4*1 1 Upper Half Housing Top

RM-0001-03:

100mm x 60mm x 17mm



9.20

5*1 4 cover plate

105mm x 1.9mm x 34mm

Aluminium anodized - - RM1: Cover

Plate -

6 16 screws for housing M3x10 Steel

galvanized

DIN966A ISO7047-H 4.8

- RM1: Housing Screws -

7 1 Lens for LEDs

RM-0001-04:

∅35x1.5 Plexiglass sand-radiated

- - - 3.00

8 1 Magnet

RM-0001-05:

∅19x20 BN45 - - - 2.00




Eff. Date: 25-May-05 Pos QTY Descrip-


@50Pc.

9 1

Copper Coil with a wire diameter of 0.63mm

RM-0001-06:

60x25 Copper - - - 13.50

10 1 Coilbody Top

RM-0001-07:

60x3 Steel galvanized - - RM2: Disks

without hole 1.00

11*1 1 Coilbody Bottom

RM-0001-08:

60x2 Inox A2 - - RM3: Disks without hole 2.00

12 1 threaded sleeves M6x20 Steel

galvanized - Kuewi 0140Z06020 0.18

13 1

fillister-head screws with female hexagon

M6x25 stole galvanized

ISO7380 10.9 Kuewi 0127Z06025 0.22

14*1 2 Distance Column

RM-0001-09:

a=10mm, b=10mm, c=1mm, L=100mm


RM4: Distance Column

1.50

15* 2 threaded rod M4x140 Inox A2 DIN975 - RM5:

threaded rod 1.50

16 6 teethed lock washer

M4 Inox A2 DIN6798A Kuewi 0550B00040A 0.10

17 6 hexagon nuts M4, 0,8d Inox A2 DIN934

ISO4032 Kuewi 0155B00040 0.10




Eff. Date: 25-May-05 Pos QTY Descrip-


@50Pc.

18*2 4 isolation socket M4x5

L=3,2, ∅A=8,7, B=1,6, ∅C=5,2, ∅D=4,4

Nylon 6/6 Rms-48 transparency

- Richco Distrelec

MINI 8-8 650751 0.25

19*2 6

round spacers plastic M4x5

L=5, ∅l=4.2, ∅A=8

PP glass-fiber reinforced

- Distrelec 341048 0.06

20 4 rubber feet, self adhesive

∅l=7,9, h=2.2,

PU, transparency

3M Distrelec

SJ-5302 340467 0.12

21 2

lugs, isolates M4, for wire diameter of 0.5...1mm2

∅D1=4,3, ∅D2=8

Copper tins, with PVC isolation

DIN 46237 Vogt Distrelec

3609A 504345 0.11

22 1 Levitron 50 Power Board

60x100mm FR4 - PCB Pool 13.50

23 1 power supply 12V / 0.5A

96 x 63 x 48 mm - - Friwo

Distrelec EP2 920267 12.00

1.3 Internet-Links to the distributors

Fischer Elektronik: www.fischerelektronik.de Kuewi: www.kuewi.ch alfer: www.alfer.com Distrelec: www.distrelec.com Farnell: www.farnell.com PCB Pool: www.pcb-pool.com

*1: Material can be exchanged by any non-magnetic material *2: Material can be exchanged by any non-magnetic and non-conductive material


http://www.fischerelektronik.de/

http://www.kuewi.ch/

http://www.alfer.com/

http://www.distrelec.com/

http://www.farnell.com/

http://www.pcb-pool.com/




2. MANUFACTURING OF MECHANICAL COMPONENTS

2.1 Documents

The manufacturing of the mechanical components is described in following documents: Doc. Nr.: Rev.: Name: Remarks: RM-0001-00 00 Levitron 50 Lower Half Housing

Bottom Pos 1

RM-0001-01 00 Levitron 50 Lower Half Housing Top Pos 2 RM-0001-02 00 Levitron 50 Upper Half Housing

Bottom Pos 3

RM-0001-03 00 Levitron 50 Upper Half Housing Top Pos 4 RM-0001-04 00 Levitron 50 Lens for LEDs Pos 7 RM-0001-05 00 Levitron 50 Magnet Pos 8 RM-0001-09 00 Levitron 50 Distance Column Pos 14

Table 1: Documents for manufacturing of mechanical components





3. ASSEMBLY OF DISTANCE COLUMN

3.1 Documents

The assembly of the distance column is described in following documents: Doc. Nr.: Rev.: Name: Remarks: AS-0001-03 00 Levitron 50 assembled Distance

Column whole distance column, explosion view

Table 2: Documents for the assembly of the distance column

3.2 Pictures of Distance Column

Distance Column explosion view:

Distance Column:





4. ASSEMBLY AND MANUFACTURING OF COIL

4.1 Documents

The whole production of the Levitron 50 coil is described in following documents: Doc. Nr.: Rev.: Name: Remarks: AS-0001-01 00 Levitron 50 assembled Coil Body whole coil body, explosion view RM-0001-06 00 Levitron 50 Coil Pos 9, winding RM-0001-07 00 Levitron 50 Coilbody Top Pos 10 RM-0001-08 00 Levitron 50 Coilbody Bottom Pos 11

Table 3: Documents for the production of the Levitron 50 coil

4.2 Manufacturing of Coil

Isolate the coil body with 0.10mm of Capton tape before manufacturing the coil.

4.3 Pictures of Coil

Explosion view of Coilbody:

Coilbody:

Manufactured Coil:





5. ASSEMBLY AND PRODUCTION OF THE POWER BOARD

5.1 Documents

The whole production of the Levitron 50 power board is described in following documents: Doc. Nr.: Rev.: Name: Remarks: MP-0002-00 00 Power Board Schematic not needed for production MP-0002-01 00 Levitron 50 Power Board Protel File not needed for production MP-0002-02 00 Levitron 50 Position of Components component placement

MP-0002-03 00 Levitron 50 Power Board Position of Testpoints not needed for production

MP-0002-04 01 Levitron 50 Power Board Partlist partlist MP-0002-05 00 Levitron 50 Power Board Gerber Data manufacturing of PCB MP-0002-06 00 Levitron 50 Power Board Top Paste tin mask for SMD components

MP-0002-07 00 Levitron 50 Power Board Values of Components not needed for production

Table 4: Documents for the production of the Levitron 50 Power Board

5.2 Manufacturing of PCB

• Geometry: 100 x 60 mm • Copper: 2 x 35µm final copper • Solder: reciprocally differently • Surface: partially tinned • Top Overlay: white • Check: no electrical test

5.3 Gerber Data Power Board

File extension: Description: • GTL: Gerber Top Layer • GBL: Gerber Bottom Layer • GTS: Gerber Top Solder (soldering stop above) • GBS: Gerber Bottom Solder (soldering stop down) • GT0: Gerber Top Overlay • GTP: Gerber Top Paste (tin solder above) • GD1: Gerber Drill File (to visual control) • GG1: Gerber Guide (also to visual control, Drill Guide) • REP: Report-File • APR: Aparture File for Gerber Data • TXT: Drill-Data as ASCII-File • DRL: Drill-Data as Machine-Code • DRR: Report file for the drillings

NC Drill Data, all in the format: 'Keep leading and trailing zeros'





6. ASSEMBLY OF THE LEVITRON 50

6.1 Documents

The assembly of the Levitron 50 is described in following documents: Doc. Nr.: Rev.: Name: Remarks: AS-0001-00 00 Levitron 50 assembled whole Levitron 50, explosion view

Table 5: Documents for the assembly of the Levitron 50

6.2 Steps of assembly

6.2.1 Glueing of Lens

Parts affected: QTY Pos Description Doc. Nr.:

1 2 Levitron 50 Lower Half Housing Top RM-0001-01 1 7 Levitron 50 Lens for LEDs RM-0001-04

Glue the lens in the lower half housing top:





6.2.2 Insertion of Isolation Sockets


1 2 Levitron 50 Lower Half Housing Top RM-0001-01 1 3 Levitron 50 Upper Half Housing Bottom RM-0001-02 4 18 isolation sockets M4x5 -

Insert the isolation sockets in the in the lower half housing top and the upper half housing bottom:

6.2.3 Assembly of Housing Feet


1 1 Levitron 50 Lower Half Housing Bottom RM-0001-00 4 20 rubber feet, self adhesive -

Mount the housing feet on the lower half housing bottom:





6.2.4 Insertion of Power Board


1 2 Levitron 50 Lower Half Housing Top RM-0001-01 1 22 Assembled Power Board AS-0001-02 2 19 round spacers plastic M4x5 -

Insert the power board and the round spacers:

6.2.5 Insertion of Threaded Rod


2 15 threaded rod M4x140 - 2 16 teethed lock washer M4 - 2 17 hexagon nuts M4 -

Insert the threaded rod and mount it with washer and nut:





6.2.6 Assembly of Distance Column


2 - Assembled Distance Column AS-0001-03 Insert the assembled distance column:

6.2.7 Assembly of Upper Half Housing Bottom


2 - Assembled Distance column AS-0001-03 1 3 Levitron 50 Upper Half Housing Bottom RM-0001-02 2 16 teethed lock washer M4 - 2 17 hexagon nuts M4 -

Insert the upper half housing bottom and mount it with washer and nut:





6.2.8 Assembly of Coil


2 - Assembled Coil AS-0001-01 2 21 lugs isolated M4 - 2 16 teethed lock washer M4 - 2 17 hexagon nuts M4 -

Insert the coil and mount it with washer and nut:

6.2.9 Assembly the rest of the Housing


1 1 Levitron 50 Lower Half Housing Bottom RM-0001-00 1 4 Levitron 50 Upper Half Housing Top RM-0001-03 4 5 cover plate aluminium -

16 6 screws for the housing - Assemble the rest of the housing:





6.3 Explosion view Levitron 50
