Basic Assembly Eng

Micom Car Rally Kit

Main Unit Assembly Manufacturing Manual Version3

1.00E Edition 19/06/2006 Japan Micom Car Rally Executive Committee

Main unit assembly manufacturing manual

Important Notice Copyright *Copyright concerning this manual belongs to the Japan Micom Car Rally Executive Committee. *This manual is protected by the copyright law and the international copyright agreement.

Prohibited Use User must not do the following things. *Selling, advertisement to sell, use, trading, reproduction of this manual for the third party *Assigning the usage right or approval of this manual to the third party *Change or remove part or whole of this manual *Translate this manual without authorization *Use wherein harm might be caused to life and human body by using the content of this manual

Reprinting, reproduction Prior approval of Japan Micom Car Rally Executive Committee is necessary for reprinting and reproduction of this manual.

Liability Restrictions The information described in this manual is carefully prepared to ensure accuracy. However, Japan Micom Car Rally Executive Committee does not assume any responsibility, if any damage occurs due to the description error of this manual.

Other In this manual the model car controlled by microcomputer is defined as the micom car. The information contained in this manual represents information at the time of publication of the manual, and Japan Micom Car Rally Executive Committee is liable to occasionally change this information or specification described in this manual without prior notice. Refer to the information published on the official homepage (http://www.mcr.gr.jp/) of Micom Car Rally when manufacturing micon car.

Contact Address Head Office, Renesas Technology Micom Car Rally Executive Committee 162-0824 Tokyo Shinjukuku, Ageba cho,2-1 Karuko saka, MN Building TEL (03)-3266-8510 E-mail : [email protected]

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Main unit assembly manufacturing manual

Index (Table of contents) 1. Outline ..........................................................................................................................3 2. Photograph on Completion ..............................................................................................3 3. Components list..............................................................................................................4 4. Essential Tools ...............................................................................................................5 5. Assembly.......................................................................................................................6 5.1. Gear Box Assembly ....................................................................................................................... 6 5.2. Manufacturing Connector for Motor ........................................................................................... 9 5.3. Tire Assembly.............................................................................................................................. 13 5.4. Battery box Assembly ................................................................................................................. 15 5.6. Manufacturing of front parts ..................................................................................................... 27 5.7. Installation of Stud ..................................................................................................................... 32 5.8. Assembly of chassis parts........................................................................................................... 34 5.9. GearBox Installation .................................................................................................................. 38 5.10. Servo Assembly/installation..................................................................................................... 40 5.11. Tire Assembly/installation........................................................................................................ 42 5.12.Circuit Board Assembly............................................................................................................. 46 5.13. Manufacturing and installation of cable ........................................................................................... 52 5.14. Installation of Kagu-Suberu (skidding material) ............................................................................... 58 5.15. Manufacturing of CPU board communication cable .......................................................................... 60

6. Conclusion...................................................................................................................65

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Main unit assembly manufacturing manual

1. Outline This manual is meant for manufactures of micom car. • Main unit of micom car (Ver.2) newly designed in 2002 • Sensor board (Ver.2) newly designed in 2002 • Motor drive board (Ver.3) newly designed in 2005 Though only the motor drive board (Ver.3) of the current micom car kit (Ver.2) was changed, since the detailed version might cause confusion, it was made as [Micom car kit Ver. 3] Though in this manual [motor drive board (Ver.3)] is explained with photographs, when using [motor drive board (Ver.2)] + [motor drive extension board (Ver.2)], assembly should be done by replacing the board. The mounting location of the board is mounted is unchanged. While making kit main unit, it is assumed that the motor drive board and sensor board have already been manufactured. Therefore, if they are not manufactured before, then assemble each board by referring to the motor drive board manufacturing manual and sensor board manufacturing manual.

2. Photograph on Completion After completion, the kit looks as shown in the photograph below. It has become more practical compared to the previous kit.

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Main unit assembly manufacturing manual

3. Components list Name Tire set Gear Box Motor Plate set Servo

Screw Screw Screw Screw Plate screw Delrin collar

Model Maker Sports tire set (2 pieces) (Comfort Industry series Tamiya Company No.111) High-speed gear box HE Tamiya Company RC-260RA18130 6V Carbon brush Universal plate set (Comfort Industry series No.98) HS-425BB 0.20second/60 degrees by 4.8V and 3.3kg/cm Pan head machine screw (diameter 3mm×length 60mm) 31mm of front end of twisted part Pan head machine screw (diameter 3mm×length 20mm Pan head machine screw (diameter 3×length 15mm) Pan head machine screw (diameter 3mm×length10mm) Plate screw (diameter 3mm ×length 15mm) SJE-303 white, internal diameter 3.2mm, external diameter 6mm, height 3mm

Quantity 2 2

Mabuchi Motor Co., Ltd.

2

Tamiya Company

2

Hitec

1

2 2 4 2 4 Teishin Company

Electric

2

Nut

Nylon nut 3mm

5

Stud

For 3mm screw, height 8mm metallic, female-male

8

Stud Washer Washer Washer ”Kagu-Suberu” Battery box

For 3mm screw, height 15mm metallic, female-male Flat washer Outside diameter φ8mm Inside diameter φ3.2mm Flat washer External diameterφ6mm Internal diameter φ3.2mm Spring washer Internal diameter φ3.2mm

2 30 2 34

“Kagu-Suberu” round shape Nichias Corporation diameter 37mm MD-4B for 4 pieces of size AA Takachi Electric Industry battery W35×H19×D72.5mm

Toggle Switch

MS240

Mamiya Company

Flat Cable

10 color flat cable 1.27mm pitch

Cable

Twisted wire Red 0.3KV 12 core

Cable

Twisted wire black 0.3KV 12 core -4-

1 2 2 Approx. 50cm Approx. 1m Approx. 1m

Main unit assembly manufacturing manual Japan Aviation Electronics Industry, Ltd.

10 pin female connector

PS10SEND4P1-1C

RS-232C connector RS-232C connector Rubber Bush

9 pin female Connector cover for 9 pins BU-687 Special small

2 pin female connector

IL-2S-S3L

Contact pin

IL-C2-10000

Solder

Diameter 0.6mm

Heat shrinkable tube

Transparencyφ1.5mm

6 1 1 1

Sato parts Company Japan Aviation Electronics Industry, Ltd. Japan Aviation Electronics Industry, Ltd.

Fujikura Ltd.

3 10 Proper quantity 10cm

4. Essential Tools Manufacturing is possible with the help of following tools.

Tool Name

Explanation

Driver

Minus and plus drivers are used. It is better to keep large and small size of each type prepared

Pliers (large, small) Lead nipper

Used for various operations. Used to cut the wire and components of Industrial series of Tamiya.

Crimping tool/Pressure pliers

Used to pare off the wire cover. Though it can be pared off by nipper, it is comparatively difficult. Better to use P-906. of Hozan Tool Industrial Co., Ltd. Used to fix the contact pin in the connector and wire. Better to use P-706 etc. of Hozan Tool Industrial Co., Ltd.

Saw for plastic cutting

Used to cut universal plate set

Wire stripper

Drill

Used to drill a hole. Though hand drill is OK, electric drill is convenient. Drill bit is, Diameter 3.5mm, 5mm, and 6mm.

Jack/Vice

Used to fix flat cable and connector. Moreover, depending on the usage, can be used for fixing of components.

The following are also necessary. CPU board RY3048F-ONE Rechargeable size AA batteries 1.2V Nickel metal-hydride battery Or, Ni-Cd battery

It is a board of the microcomputer, main part, which operates the kit.

Power supply to operate the micom car. 8 batteries can be operated. Moreover, the battery charger is also necessary.

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Main unit assembly manufacturing manual

5. Assembly 5.1. Gear Box Assembly

“MCR" stamp

1.

This is [High-speed gear box HE] manufactured by Tamiya. The photograph shows only one side set, however there are 2 sets since right and left motors are used in kit.

2.

This is [RC-260RA18130] manufactured by Mabuchi Motor Co., Ltd. Size is interchangeable to RE-260 which is readily available in the market. The operating voltage range is 4.5-6.0V. The carbon brush has a longer durability than metal brush of RE series. If higher voltage is applied, the speed increases but the motor durability span shortens.

3.

At first the pinion gear should be inserted in the motor.

4.

The motor is installed in the gear box as shown in the photograph. The motor has a cut as shown in the encircled [c] part, should face upwards.

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Main unit assembly manufacturing manual

5.

A plastic case is attached to the rear side of the motor.

6.

Screws are fixed in 3 locations.

1mm

7.

A mark is put at the location in the photograph after removing the perforated shafts from their respective boxes. Note: There is 1 perforated shaft in 1 box. 2 are taken out from 2 boxes.

8.

9.

The part where the mark was put is cut with iron saw. The cut edge is filed and made smooth.

10.

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It is an enlarged photograph. A mark is put at about 1mm below the hole and is only one side.

Enlarged photograph.

Main unit assembly manufacturing manual

Joint

Joint

21mm

3mm

11. Right side gearbox. Fixed at joint. The distance between the gear box and the edge of the shaft is adjusted to about 21mm.

12.

Left side gearbox. Fixed at joint. The distance between the gear box and the edge of the shaft is adjusted to about 3mm.

13. Hereafter follow the handling manual which is in the paper box of the gear box set. The gear can be selected from 2 types [A] 18:1 and [B] 11.6:1 but, currently [B] 11.6:1 has been selected. Yellow and orange colored gear is used. This is the photograph after completion. The right gearbox is for right side and the left side gear box is for left side.

14. Finally, the ceramic condenser attached to motor drive board (V0l.3) set is installed between the terminals of the motor. Please refer to the motor drive board-manufacturing manual for details. Note: In case of motor drive extension board Ver.2), though there is no ceramic condenser installed between the motors, obtain the component separately and install it. Reset of problem CPU by electrostatic defect and etc. can be eased.

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Main unit assembly manufacturing manual

5.2. Manufacturing Connector for Motor

×2 20cm

1.

Make provision for two of 2 pin connectors, 10 contact pins (4 will be used), red and black twisted wire (0.3KV, 12 center core).

2.

Connector x 1 piece, contact pin x 2 pieces, red and a black wire are coupled. 2 cords of 20cm are made. Keep the remaining wire for later use.

Coating

Copper wire

2mm

3.

Crimp the contact pin to the wire. First, about 2mm of coating/cover from the wire tip is peeled off with wire stripper.

4.

Set the copper wire in the center of the contact pin so that the cover comes in the protruded triangular part.

6.

It is ok if it is same as shown in the photograph.

1.7L

5.

The center of contact pin is crimped. The installation of copper wire uses the [1.7L] of crimping tool. The crimping tool is pressed to the maximum.

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Main unit assembly manufacturing manual

2.0L

7.

Next is the crimping of the coating part. [2.0L] of crimping tool is used. Since the coating part is crushed when pressed to the maximum, stop the crimping tool to about 2/3 of the maximum open state and maximum pressed state.

8.

It is ok if the metal is inserted into the insulation cable, same as shown in the photograph.

Black line

CoatingCopper

1 | JAE

line

1

Red line

9.

If it crimped properly, it becomes as shown in the photograph. There is probability of failure, because crimping is a comparatively difficult work. However since there are 4 spare contact pins, in case of failure these can be used. 2 pairs of pins for each right and left side of motors are used.

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10.

2

Contact pins are inserted in the connector. The connector photograph is seen from top. 1|JAE is written which can be seen if looked carefully. [ 1] side is 1 pin.

Main unit assembly manufacturing manual

Black

Red

Projection 1

1

2

2

Hole 11. The contact pin is inserted in the connector. The marked 1 pin side of the connector is inserted with black wire, and the marked 2-pin side is inserted with red wire. As shown in the photograph, the hole of the connector and the direction of the projection of the contact pin are matched and inserted. When inserted till the end, a [click] sound is heard and the contact pins get locked. Confirm that the pins do not come out with a slight tug.

12.

Red wire is put in 2 pin side after that.

13. Next the wires are twisted. Red and black wires are twisted and bundled together.

14.

It becomes as shown in the photograph.

15. Since the length of the red and black wires goes on changing as the wires are twisted, the leftover part is cut in order to match them. The twisting should be balanced well so that the difference in the lengths is least.

16.

Cut and arrange them as shown in the photograph.

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Main unit assembly manufacturing manual

Incision

Red Black

17. The 3mm coating of the wire is pared off, and soldered.

18.

After soldering, the upper side facing in the photograph is red and also the side where motor has incision is red. A black wire is soldered to the motor terminal on the opposite side.

Right gear box

Left gear box

19. The processing of the gear box is complete. The upper side becomes the right gear box and the lower side becomes the left gear box.

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Main unit assembly manufacturing manual

20. The connector for the battery box is also made here. Connector, contact pin, and remaining wire are used.

21.

Connector is installed in the same way by, paring the coating of the wire and crimping the contact pin. 1 pin is black wire, and 2nd pin is red wire. (Refer to "12." on page 11.)

22. It is complete now. This wire is used in assembling the battery box.

5.3. Tire Assembly

Front side

1.

The contents are of the sports tire set. This is used for making two sets.

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2.

Rear side

One with more depth becomes rear side. The wheel hub (triangular components) is installed from the rear side.

Main unit assembly manufacturing manual

1

2

1

2

3.

Two wheels fit the wheel hub (1 part of photograph) for the hexagonal shaft fitting and the other two wheels fit the wheel hub (2 part of photograph) for a round shaft.

4.

Screws are fixed from front side.

5.

Rear side is fixed with nut. Nut wrench is inserted in sports tire. Wrench may break if it is tightened with too much power, because it is made of plastic.

6.

4 pieces are ready now. Upper side is fitted with wheel hub for round shaft and lower side is fitted with wheel hub for hexagonal shaft.

7.

It is completed by fitting tires.

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Main unit assembly manufacturing manual

5.4. Battery box Assembly

Front side

1.

Rear side

This is the battery box. Two styles of box are processed. One is for Motor and the other is for CPU.

For Motor

The lid has been taken off.

17

8 7

8

2.

5.0 -2

15

30

3 .5 -2

17

For CPU

8 7

8

15

30

3 .5 -2 5.0 -2

3.

This is perforation process diagram of the battery box. There are two types. Though hole of φ5mm is in the same position on both boxes; hole of φ3.5mm are symmetrical on left-right, therefore utmost care should be taken while drilling the holes as their positions are different.

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Main unit assembly manufacturing manual

4.

Measurements are marked with pencil. Using a magic marker is also OK. Plus marks shown by arrow indicate the place where holes are to be drilled. The hole is drilled using a drill but should be carried out with utmost caution so as to prevent any accidental error.

5.

Holes are drilled as shown by arrows in the photograph. ド drill リル 6.0mm 2.

1.

Battery 電 池ボッbox クス 断面 Section 3.5mm

3. 皿ネジがぴった The plate screw is り 、 収まり ます installed accurately

6.

This part is fitted with the plate screw. Therefore it is processed in such a way that the plate screw can be fitted with diameter 6mm drill.

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7.

It becomes like this. While handling the plate screw, it is difficult to stop the drill during the drilling, thus it is recommended that it should be done by hand

Main unit assembly manufacturing manual

8.

The side surface is drilled with diameter 5.0mm. Rear side is also drilled. With this the drilling of the holes is completed.

25cm 10. Connector already manufactured at the time of assembling gearbox is twisted in same way as before. It is twisted approximately at 25cm and it is not yet cut.

9.

Next, soldering is carried out. Gearbox, cable with connector, two-pin connector attached to CPU board, 2 switches, which are made at the time of assembling 2 battery boxes are used.

11.

This is the switch. There are two of them, for CPU power supply and for motor power supply.

Cable is Hole on the right side.

12. If all the screws that are attached to the switch are taken off, it becomes as shown in the photograph. Among these, components enclosed with… (black frame) are used. Switch is soldered in advance.

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13.

inserted

Battery box that has the hole drilled on right side is used. The cable is inserted from the outside in the hole on a right side in the battery box.

Main unit assembly manufacturing manual

14. As shown by arrow mark in the photograph stopper knot is tied at approximately 25cm. This part becomes more than 5 mm in diameter and therefore it cannot come off through the hole, through which it has been passed.

15.

This is an enlarged photograph.

5mm 16. The wire is pulled out from outside and it stops here, the soldered part does not have to bear more load.

17.

Black wire is cut at the point shown in the photograph. The distance is approximately 5 mm from left edge.

18. It becomes like this.

19.

Red wire is also cut at the same length, and the coating is pared off by approx. 2mm and presoldered. Moreover, the terminal of the battery box shown by the arrow is also presoldered.

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Main unit assembly manufacturing manual

-

+

20. Black wire is soldered to the terminal on a minus side of the battery box.

21.

Red wire is connected to the terminal with a short side of switch.

+

22. The Surplus red wire left after cutting, is soldered to the long terminal of switch center.

23.

Cut the wire at approximately 5cm. This wire is soldered on the side with + on the battery box.

25.

It becomes like this.

+

24. Approx. 2mm of terminal coating is pared off and then soldered.

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Main unit assembly manufacturing manual

Front Outer terminal

Back

26. Switch is inserted from inside.

27.

The switch is made in such a way that outer terminal of the switch faces front side of the battery box as shown in the photograph.

28. Fit the tooth lock washer and nut.

29.

Switch is fixed in straight position by the pliers and it can be stopped by turning the nut for 4mm.

30. After it is fitted.

31.

The inside wire is pressed below. The purpose is to prevent the stopper from colliding, when the lid of the battery box is closed.

Tooth lock washer

Nut

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Main unit assembly manufacturing manual

Lid

32. It is a photograph where the lid was capped. If the wire is not pushed down, it gets stuck and the lid cannot be closed till the end. 33.

The battery box and the connector for the motor power supply are complete and ready.

7～8cm

Hole in the left side.

34. Battery box for the CPU board is ready. First of all the red wire and black wire of 2-pin connector attached to the CPU board are twisted and bundled together. Note: CPU board is not attached in kit.

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35. 7-8cm of the wire at the end is left without twisting. Further, terminals of battery box and switch are presoldered in advance. The battery box with a hole drilled on left side is used.

Main unit assembly manufacturing manual

6～7cm

1. After the line is passed

2. Stopped knot

36. After the wire is passed from outside, stopped knot is tied at about 6-7 cm from the edge of wire.

37.

The black wire is turned back.

38. The Black wire is turned and cut as shown in the photograph. Approximately 2 mm of the coating from the edge of the wire is pared off and presoldered. It is soldered to the part of the battery box marked [-] sign as shown in the photograph.

39.

It becomes like this.

40. Pare off the red wire coating of the point for approx. 2mm and presolder it.

41.

Solder it to the short terminal of switch end side.

－

＋

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Main unit assembly manufacturing manual

3cm

42. Cut the remaining red wire for approx. 3cm and pare off 2mm coating from both edges and presolder it.

43.

Solder the wire to long terminal of switch center.

44. Solder the reverse side of wire attached to switch center to the + side of battery box.

45.

Switch is inserted in the hole from inside. Switch is fixed by nut and tooth lock washer from outside by screwing in.

47.

Inside wire is pushed out.

Front External

Rear 46. As shown in photograph, the switch is put in such a way that the external terminal of the switch faces the front side of the battery box.

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Main unit assembly manufacturing manual

Lid

48. If the wire is not pushed up and the lid of the battery box is closed, stopper collides with the wire and the lid does not close properly.

49.

After it is completed.

50. 2 battery boxes are arranged in the way shown in the photograph. If a white connector attached to the left side battery box, then it is a battery box on CPU side and if a brown connector attached to the left side battery box; then it is for the motor drive board side.

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Main unit assembly manufacturing manual 5.5. Processing of plate

1.

The universal plate set is processed. The photograph shows 1 set of the universal plate set. In the kit, 2 such sets are used. Part encircled with c is cut beforehand. Cut-off piece is not used.

1 2.

10

The line is drawn lengthwise at the 6th and 10th hole from the left and is cut on 2 lines using a plastic cutting saw.

1 3.

5 6 7

5

6 7

9 10 11

Cutting is complete. After cutting, filing is done and burr is collected. All 4 corners are rounded off

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Main unit assembly manufacturing manual

1

1

4

3

3 1

4.

1

4

1

Another plate is also processed. The lines are drawn as shown in the photograph. A vertical line is drawn at the 4th hole from the right and as shown in the photograph, 2 diagonal lines are drawn on the left. Since screws will be fixed later to the hole enclosed in circle, the 5th hole from the left side should be left. Note: If you need the frame to protect servo, the vertical line must be changed 4th hole to 8th hole from the right.

1 5.

4

5

4

4 3

1

After cutting it becomes like this. The 2 diagonally cut ends are not used.

3

2

1

6.

Processing of the angle material attached in the universal plate set. As shown in the photograph, it is cut in the middle of 2nd and 3rd hole.

7.

It becomes like this. The marked part is cut and filed.

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Main unit assembly manufacturing manual 5.6. Manufacturing of front parts

1.

These are contents of servo box. The servo 2. main unit contains the bag of joints. Contents of bag are not used.

Screws of the fixed servo horn are removed and the servo horn is taken out and kept.

3.

This is aerial view of servo horn.

4.

Holes of 3.5mm are drilled at 2 places of ○ mark shown in the photograph.

5.

Servo horn is drilled after the holes. It is fitted 6. in the plate having 3-drilled holes that are cut before.

At the reverse side of servo horn, there is projection in the center part. This part is made smooth with the file or cutter etc.

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Main unit assembly manufacturing manual

7.

This is after filing is done.

8.

It becomes flat/smooth.

5 4

1 9.

Next, the servo horn and plates is screwed 10. together. 2 screws and 2 nuts are used from the universal plate set.

11.

The part of servo horn where hole is drilled is 12. passed through the part where screw is inserted and both are screwed together. If the filing of the protruding part is not done in the process7, screw can not be fitted properly.

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3

2 1

2 3 4 5 The screws are inserted in the fifth position of the upper row from the right side and the fifth position of the lower row from the left side.

The plates fitted in the servo horn and angle materials, which are not cut, are prepared.

Main unit assembly manufacturing manual

13.

The screws are fitted after matching c with 14. c and … with ….

15.

16.

It becomes like this.

Next is shaft installation for the front tire. Here, 2 screws of 60mm, 2 Delrin collars of 3mm height, 4 flat washers, 2 nuts are used. The nuts used are from the sports tire set.

First, the angle material of the smaller size that is cut previously is prepared.

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Main unit assembly manufacturing manual

17.

A flat washer and the angle material are passed through the screw.

18.

Next, the screw is passed through the angle material of the plate side.

19.

After the screw is passed through the angle, the short angle is screwed to the plate. 2 nuts and 2 screws from universal plate set are used.

20.

Flat washers, Delrin collars, and nuts are 21. passed through the screw in the order given.

It becomes like the photograph. As the groove is only on half of the screw length, turning of the screw is continued till the nut stops.

22.

The opposite-side is also similarly fitted.

The shaft for the front tire is completed. Confirm whether or not it is smoothly rotating by turning the screw. When it is not rotating smoothly, the positions of long angle and short angle are adjusted in such a way that it rotates smoothly.

23.

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Main unit assembly manufacturing manual

24.

Next, the servo is installed.

25.

The servo is inserted in the servo horn, as shown in picture.

100～ 110 degree 100～ 110 degree

26. Turn to full right. Turn up to approximately 27. 100-110 degrees. When it does not turn up to these degrees or when it turns more than these degrees it means that left-right balance is not proper. Therefore after turning to full right remove the servo horn once and reinsert it so that it can be turned in 100-110 degrees.

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If turned to full left, even left side becomes approximately 100-110 degrees. If the degree of angle of the left and right side differs then keep adjusting the insertion of servo horn till they become same.

Main unit assembly manufacturing manual

28.

Finally connecting parts of the servo and 29. plates are screwed and the assembly is complete. The screws, while removing the servo horn in the beginning are used as it is.

In the end the projected/protruding part shown by c mark is cut by nippers etc. and then the process is complete.

5.7. Installation of Stud

1.

It is manufacturing of the fuselage part of the micom car. 2 big plates and 8 stud of 8mm height, 8 flat washers, 8 spring washers and 8 nuts are kept ready. The nuts used are from the sports tire set.

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Main unit assembly manufacturing manual

1

5

10

15

17

2.

First, Stud is installed in the plate that is chamfered. The position is topmost and bottommost hole in 5th, 17th line from left side. The flat washer and the spring washer are inserted from reverse side and it is tightened by fitting the nuts.

3.

It is tightened from the top and bottom by using 2 wrenches from sports tire set. It is fastened tightly so that it doesn’t become lose.

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Main unit assembly manufacturing manual

11

7

1 1 4.

4

4

1

Studs are fixed in 1 more plate. 4 places where studs is fixed are 4th position from left and right side of the bottom most line (line 1) and 4th position from left and right side of the 7th line from below as shown in photograph. The flat washer and the spring washer are inserted and it is fitted with the nut.

5.8. Assembly of chassis parts.

3

1

1.

2

(1) ~ (3) plates, 2 battery boxes, 4 plate screws of 15mm, 4 flat washers, 4 spring washers and 4 nuts are used. The nuts used are from the sports tire set.

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Main unit assembly manufacturing manual

1

2 Battery box for motor power supply

3 1

2.

1 6 6 1 Plate 1 is kept on top of plate 2. The position is adjusted in such a way that, bottom left hole of plate 1 is aligned with the hole of plate 2 in 6th position from left and 3rd position from bottom. Battery box is kept ready as power source for motor.

9

1

3.

1 2

Plate screw is passed through in the sequence of “ battery box → plate 2 → plate 1“ in the position 2nd from left and 9th from bottom of plate 1 that is encircled with c mark. Flat washer and spring washer are passed from the topside of this screw end and fixed with a nut in position.

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Main unit assembly manufacturing manual

1

3

4.

Plate 3 is passed through the space between battery box and plate 1.

5 4

1

Plate 3

1 2

1 2 5.

Plate screw is passed through from the lower side in the sequence of “ battery box→ Plate 3→Plate 1” at the position indicated by c that is 2nd right and 5th in upward direction from the stud position shown in the photograph. Then flat washer and spring washer are put and fixed by nut. Mount the plate 3 as shown in the photograph by ….

6.

It looks like this from side view.

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Main unit assembly manufacturing manual

Battery Box for motor

Battery Box for CPU

7.

Battery box for CPU board is also screwed by plate screws in 2 places having symmetrical positions in similar method used for fitting battery box for motor.

8.

The assembly of chassis part is completed.

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Main unit assembly manufacturing manual 5.9. GearBox Installation

1.

Mount the gearbox on the chassis. 2 gearboxes, 4 screws, 4 flat washers, 4 spring washers and 4 nuts are used. Screws used are from universal plate set and nuts used are from the sports tire set.

Left Gear 2.

Right Gear

Put and Mount in the directions shown in the photograph. Mounting/installation position for left gearbox is shown by cand for right gearbox by….

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Main unit assembly manufacturing manual

Collide

Left Gear

Right Gear

3.

The position of the gearbox is reversed in the photograph as it is seen from the opposite side. (Refer to “2.” on page 39. ) Gearbox must be partly chipped off because left gearbox collides at the part marked with c.

4.

Cut the part of left gearbox shown as cin the photograph into V shape using either a file or large nipper. Keep approx. 2mm depth. Now it will not collide even though mounted in the position mentioned before. Cut/chip off the colliding part again if it still collides with the nut.

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Main unit assembly manufacturing manual

5.

Pass the screw from the lower side. “Screw → gear box → plate” is the sequence. Flat washer and the spring washer and nut are inserted from upper side of the screw and fixed. It becomes as shown with symbol c.Gear box assembly is completed.

5.10. Servo Assembly/installation

1.

Install the servo on the chassis. Align and fix the servo mounting holes with part of chassis marked as c. - 40 -

Main unit assembly manufacturing manual

2.

Use 2 screws of 15mm length, 2 spring washers and 2 nuts and bearings material of universal plate set for assembly. Nuts used are from the sports tire set.

3.

Pass the 15mm screw through plate, servo, bearing material, spring washer from the lower side and fit it with the nut at the end. Use bearing material for strengthening servo assembly.

4.

It is a top view. Here the Servo assembly is completed. - 41 -

Main unit assembly manufacturing manual

5.11. Tire Assembly/installation

1

2

1.

Mount the tires. c is a component called as split pin. 2 split pins of c and 2 nuts of d are used. It is a component of high-speed gear box set HE (High Efficiency).

2.

Insert the split pin. Insert it in such a way that it is in the center as shown in the photograph. Push it with pliers, as it is very hard. If the split pin is crushed and inserted, it can fall off/come off easily so do not crush it.

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Main unit assembly manufacturing manual

Gap

3.

Mount the tire that is made and kept ready. The tire that is fitted with the wheel hub for round shaft is used as rear tire. Assemble in such way that the split pin and wheel hub groove match together.

Tighten the nut

4.

Mounted. Inserted till inner side.

5.

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Fit the tire from side with the nut. Mount the tire on a reverse-side similarly.

Main unit assembly manufacturing manual

6.

Next, mount the front wheel. The tire, which is attached with a wheel hub for hexagonal shaft is used for front wheel.

7.

The front wheel shaft is fixed by pliers and tires are screwed in. It is similar to inserting nut in the screw. Here, there is a tire in place of nut. Keep turning until it penetrates.

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Main unit assembly manufacturing manual

8.

Come close to be penetrated.

9.

Penetrated.

5mm

5mm

10.

Screw till the gap becomes 5 mm. Mount the opposite side tire similarly.

11.

Assembly is completed.

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Main unit assembly manufacturing manual 5.12.Circuit Board Assembly

1.

Install the motor drive circuit board, sensor circuit board, (Main , Sub) and RY3048F-ONE (CPU) board on the main body. In case RY3048 or MS304CP01 boards are used for CPU board , refer to the "Remodeling for using the RY3048F and MS304CP01 board” described later. Use 8 screws of 10mm length,2 screws of 15mm, 2 screws of 20mm ,10 flat washers,2 small flat washers, 12 spring washers, 2 studs 15mm high, 2 nylon nuts, 2 angles that are already cut and 2 "I" shape horns. 6 screws of 10 mm are from universal plate set and remaining 2 are components from kit. Other nuts and screws are also components of kit. The nylon nut (right side photograph) is difficult to fall off even in case of vibrations as the ring shape nylon is built in the nut that causes friction with the screw. This time the sensor circuit board, is used in the movable part to maintain the constant distance with the course for Micom car. They are frequently used in the radio control model car etc.

2.

Mount the motor drive circuit board first. Match 4 holes of the circuit board with the 4 studs.

3.

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The screw is fitted in the sequence of “ Stud → circuit board →Flat washer →Spring washer ”. It is fitted in 4 places.

Main unit assembly manufacturing manual

4.

Same as shown in the photograph.

5.

Next, mount the CPU board. It is screwed and fixed using flat washer and spring washer in the 2 places near the motor drive circuit board.

6.

Mount 15 mm high studs in the 2 holes to the left of the CPU board.

7.

Mount in the sequence of “ Flat washer → Spring Washer → Stud ”. Tighten the studs using plastic wrench from the sports tire set.

8.

2 screws and 2 studs are mounted.

9.

Connect the connector from the battery box to the CPU board.

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Main unit assembly manufacturing manual

out put side Input Side

The side with the resistor network is input side. 10. Connector is attached.

Input Side

12.

11.

Mount the sensor sub circuit board on the studs of the CPU board. Mount in 2 places in the sequence of “ Flat washer → Spring washer → 10mm screw ”. The input connector side is the servo side (left in the photograph).

13.

Next, mount the sensor circuit board with the movable part which is used to maintain the constant distance with the course for Micom car. Use angle material, 15mm screws and nylon nuts.

15.

It is an enlarged photograph. It is difficult to move when tightened too much and rattles when too loose. Adjust the firmness so that angle material moves perfectly.

Output Side

Side view.

14. Fit the screw from inside and stops with the nylon nut. Should be able to move up and down as shown by arrows.

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Main unit assembly manufacturing manual

16.

Complete the other side assembly in the same way.

17. Next, mount the sensor circuit board. Take 2 each of “I” horn, 20mm screws, small flat washers, spring washers and nuts.

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Main unit assembly manufacturing manual

18. Cut the “I” horn at the base. It is easily cut using nipper, as it is a plastic component.

19.

Magnified photograph after cutting. Do not use the right side part.

20.

Cut the projected/protruded part diagonally, as shown in the photograph, as it may hit against this part while fitting the screw.

21.

It becomes like this after cutting.

22.

Pass the screw from lower side through the position of the sensor circuit board as shown in the photograph.

23. Place the “I” horn that is cut before in the screw. - 50 -

Main unit assembly manufacturing manual

24. Insert the screw from lower side of the head of the angle material then passing flat washer and spring washer and fit it using the nut.

25.

Use pliers etc. as wrench cannot be used for fixing the nut. When it is fitted it looks as shown in the photograph.

26. With this, the sensor circuit board assembly is completed.

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Main unit assembly manufacturing manual

5.13. Manufacturing and installation of cable 1.

Connect ten-pin connector with flat cable. 6 pieces of 10 pins female connectors and flat cable of 51cm length are kept ready. The 51 cm concerns with a multiple of 3. The minimum length of the flat cable that we can cut is just 3cm.

C B A

2.

Connection diagram for flat cable installation. Cable A is connected to sensor circuit board ~ sensor sub circuit board, cable B is connected to sensor sub circuit board ~ CPU board (port 7) and cable C is connected to CPU board (port B) ~ motor drive circuit board. 27cm of cable A and 12cm of cable B, C each are made. A little shorter length is also permissible but there may be cases where distance is increased after reconstruction.

Cutting part

3cm 3.

Cutting part

3cm

3cm

Since the flat cable of the kit is 51cm, cut it in 3 pieces, each of 27cm, 12cm, 12cm. As shown in the photograph, the flat cable is repetition of 3cm of connected 10 wires part and 3 cm of separated 10 wires part. Position to be cut is central of the connected 10 wires part.

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Main unit assembly manufacturing manual

4.

Cutting can be done by ordinary/usual standard 5. scissors also. The cutting direction has to be at right angles.

If it is right-angled like this, it is OK.

A B C 6.

After it is cut.

Stopper

7.

The flat cable is inserted from the place where the T sign on the 10-pin connector is printed. The stopper is made on the reverse-side such that the inserted cable stops there. Each pin in the 10-pin connector has V-cut tooth.

Brown

8.

Black

Pin #1 of the connector is shown by T sign. 9. A brown colored wire of the flat cable is fitted Pin #1 together and inserted in crevice of connector. - 53 -

Inserted till the flat cable reaches the stopper on reverse-side.

Main unit assembly manufacturing manual

10. In the case of applying pressure to the flat cable, special pressure application device is used. However, ordinary/usual vise is also acceptable.

11.

Hold while pressing the connector edge from both sides. While doing this, precaution is taken so that the flat cable is not inclined and shifted.

12. Half of the connector is placed between the vise. Precaution is taken so that the flat cable does not shift.

13.

Tightening is done by turning the handle of the vise. The force of tightening is such that it cuts a little bit into the flat cable.

14. Insert the10-pin connector into the vise with your thumb so that the whole of connector is pinched between the vise

15.

The connector was pinched completely between the vise.

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Main unit assembly manufacturing manual

16. The vise is tightened. Ten all wires of the flat cable are wedged into the V-cut pins of the connector at once.

17.

If it is tightened little by little, "snap" sound is heard and if tightened still further, the sound "snap" is heard again. It means you hear the sound “snap” twice. You can understand right and left stoppers of the connector and entered completely with the sounds. Tightening is now complete.

18. Is, as shown.

19. The opposite connector is installed. When a brown colored wire of the flat cable is fitted Pin #1 (T) of connector together and the final shape of the cable will be the crank like the above.

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Main unit assembly manufacturing manual

A B C 20. Three are made. The pressure application of flat cable is completed.

C B A

21. Three cables are fixed to 10-pin connector.

Right motor Left motor

Motor power supply

Servo

22. The connectors of servo, motor power supply, right motor and left motor are also wired together.

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Main unit assembly manufacturing manual

Flat cable

Motor supply

Black Yellow Servo Left motor

Right motor

23. Enlarged photograph of motor drive circuit board (Vol.3) part.

Flat cable （From below plate）

Motor power

Left motor Right motor Servo Black

Yellow

24. Incidentally if motor drive extension circuit board (Vol.2) is installed it becomes like shown here.

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Main unit assembly manufacturing manual

5.14. Installation of Kagu-Suberu (skidding material) 12～13mm 37mm

12～13mm 1.

The skidding material called Kagu-Suberu is 2. pasted to the reverse side of the sensor circuit board. Round in shape with a diameter of 37mm approx.

3.

It is installed at the location shown by mark O.

Cut at approximately 12~13mm distance as shown in photograph. The lower side is also the same. It can be cut by scissors.

Adhesive face 4.

The white surface of the Kagu-Suberu is a seal and when it is taken off, it can be pasted. This is then pasted on the part marked by ○. The edge of Kagu-Suberu at ● part and the edge of circuit board should be matched together.

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Main unit assembly manufacturing manual

5.

Is, as shown here. Precaution should be exercised so that it does not cover/touch the Modulation-type Photo sensor.

8mm

6.

The side view looks like this photograph. Since the course and sensor always at constant intervals, the sensitivity of sensor is not changed even before or after the downward and upward slope.

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Main unit assembly manufacturing manual

5.15. Manufacturing of CPU board communication cable

1.

RS-232C of DOS/V personal computer is equipped with 9 pin male connector. Therefore, connector to be created uses the RS-232C 9 pin female. Here, RS-232C 9-pin female, cover component, thermal contraction tube and 3-pin connector cable enclosed in CPU board are used. Note: 3-pin connector cable is not enclosed in the micom car kit. 1

2

3

2mm

2.

A 3-pin connector used for communication. There is a projection between Pin #1 and Pin #2 as shown by the arrow mark. The side that has 1 pin is Pin #1.

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3.

It is a cable on a 9-P connector's reverse-side. Insulation of the cable is pared off by approx. 2mm and it is presoldered.

Main unit assembly manufacturing manual 1

5 2

6 4.

3

5

9

The reverse side of 9 pin male connector is the surface to be wired. Blue part of the connector holds the pin number and is seen, if looked carefully.

8

5.

Hereafter the location where the pin is to be wired is presoldered and kept ready. Pin #2, #3, #5, #7 and #8 are presoldered. In the photograph, Pin #2, #3 and #5 have already been presoldered.

7 3mm

6.

In the photograph Pin #7 and #8 have been 7. presoldered.

8

Jumper of 3mm width is made by the remaining lead wire for jumping the Pin #7 and #8. And both side of the jumper is presoldered.

7

10mm 8.

Jumper wire is soldered to Pin #7 and #8.

9.

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Next, thermal contraction tube is put in the wire before soldering the wire. Approximately 10mm of tube is cut and inserted in 3 wires.

Main unit assembly manufacturing manual

2

3

5 2

1

2

1

3

3

5

3

2

10. Next, 3 wires are wired to the connector. Wire connection is as follows, Connector → RS-232C 1 2 2 5 3 3

11.

After wires are connected, it becomes like this.

12. Thermal contraction tube is pushed towards the connector side. And, tube is contracted by heating the tube with a drier or a soldering iron, etc. At this time, precaution must be taken while heating the tube because, if the connector or the wire is heated too much, it may melt.

13.

It becomes like this.

14. Next, installation arrangements in connector case is done. Components shown in the photograph are prepared.

15.

Wire is inserted in the 2 clasps/clamps and clamps are screwed together.

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Main unit assembly manufacturing manual

Little long

40mm 16. Clamp is positioned at a short distance from the connector cover. Standard position of the clamp is approximately 40mm from the connector.

17.

Wire is tied making a stopper knot with clamps at the position of the clamp adjusted.

18. Wire is set in the connector case. First of all, clamps are put in ○ part.

19.

Next, the connector is set in the case like the part highlighted with ○frame. At this time, the cable is made in the shape of S and play is brought about.

20. Screw and clamp as shown in the photograph are prepared.

21.

Screw passes through the clamp and screw is inserted in the connector in the direction of the arrow.

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Main unit assembly manufacturing manual

22. Covered. Screw and nut are kept ready as shown in the photograph.

23.

Connector is screwed in, at the 2 places indicated by the arrow.

24. It is completed.

25. Incidentally, 3-pin connector is used by connecting it to the part indicated by c mark on CPU board.

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Main unit assembly manufacturing manual

6. Conclusion With this, the manufacturing of main body of micom car is complete. Next, development environment is installed in the personal computer by referring to "Development environment installation manual". Additionally, operation test of the micom car being currently manufactured is done by referring to "Operation confirmation manual".

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