wictronic rev.: mp-0003-00 25-may-05€¦ · the whole production of the levitron 50 power board is...
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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.
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Doc. No.: MP-0003-00 Rev.: 00 Tronicwic
www.wictronic.ch Production and Assembly of Levitron 50
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
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Doc. No.: MP-0003-00 Rev.: 00 Tronicwic
www.wictronic.ch Production and Assembly of Levitron 50
Eff. Date: 25-May-05
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
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Doc. No.: MP-0003-00 Rev.: 00 Tronicwic
www.wictronic.ch Production and Assembly of Levitron 50
Eff. Date: 25-May-05
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
Aluminium anodized - -
RM1: half Aluminium Housing
9.20
3*1 1 Upper Half Housing Bottom
RM-0001-02:
100mm x 60mm x 17mm
Aluminium anodized - -
RM1: half Aluminium Housing
9.20
4*1 1 Upper Half Housing Top
RM-0001-03:
100mm x 60mm x 17mm
Aluminium anodized - -
RM1: half Aluminium Housing
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
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Doc. No.: MP-0003-00 Rev.: 00 Tronicwic
www.wictronic.ch Production and Assembly of Levitron 50
Eff. Date: 25-May-05 Pos QTY Descrip-
tion Drawing / Picture Dimension [mm] Material Standard Distributor Art.- Nr. Price / Pc.
@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
Aluminium anodized - -
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
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Doc. No.: MP-0003-00 Rev.: 00 Tronicwic
www.wictronic.ch Production and Assembly of Levitron 50
Eff. Date: 25-May-05 Pos QTY Descrip-
tion Drawing / Picture Dimension [mm] Material Standard Distributor Art.- Nr. Price / Pc.
@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
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Doc. No.: MP-0003-00 Rev.: 00 Tronicwic
www.wictronic.ch Production and Assembly of Levitron 50
Eff. Date: 25-May-05
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
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Doc. No.: MP-0003-00 Rev.: 00 Tronicwic
www.wictronic.ch Production and Assembly of Levitron 50
Eff. Date: 25-May-05
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:
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Doc. No.: MP-0003-00 Rev.: 00 Tronicwic
www.wictronic.ch Production and Assembly of Levitron 50
Eff. Date: 25-May-05
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:
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Doc. No.: MP-0003-00 Rev.: 00 Tronicwic
www.wictronic.ch Production and Assembly of Levitron 50
Eff. Date: 25-May-05
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'
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Doc. No.: MP-0003-00 Rev.: 00 Tronicwic
www.wictronic.ch Production and Assembly of Levitron 50
Eff. Date: 25-May-05
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:
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Doc. No.: MP-0003-00 Rev.: 00 Tronicwic
www.wictronic.ch Production and Assembly of Levitron 50
Eff. Date: 25-May-05
6.2.2 Insertion of Isolation Sockets
Parts affected: QTY Pos Description Doc. Nr.:
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
Parts affected: QTY Pos Description Doc. Nr.:
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:
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Doc. No.: MP-0003-00 Rev.: 00 Tronicwic
www.wictronic.ch Production and Assembly of Levitron 50
Eff. Date: 25-May-05
6.2.4 Insertion of Power Board
Parts affected: QTY Pos Description Doc. Nr.:
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
Parts affected: QTY Pos Description Doc. Nr.:
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:
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Doc. No.: MP-0003-00 Rev.: 00 Tronicwic
www.wictronic.ch Production and Assembly of Levitron 50
Eff. Date: 25-May-05
6.2.6 Assembly of Distance Column
Parts affected: QTY Pos Description Doc. Nr.:
2 - Assembled Distance Column AS-0001-03 Insert the assembled distance column:
6.2.7 Assembly of Upper Half Housing Bottom
Parts affected: QTY Pos Description Doc. Nr.:
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:
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Doc. No.: MP-0003-00 Rev.: 00 Tronicwic
www.wictronic.ch Production and Assembly of Levitron 50
Eff. Date: 25-May-05
6.2.8 Assembly of Coil
Parts affected: QTY Pos Description Doc. Nr.:
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
Parts affected: QTY Pos Description Doc. Nr.:
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:
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Doc. No.: MP-0003-00 Rev.: 00 Tronicwic
www.wictronic.ch Production and Assembly of Levitron 50
Eff. Date: 25-May-05
6.3 Explosion view Levitron 50
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