Pneumo Kit Manufacturing
Instructions for assembling the pneumatics workshop kits
Questions? Contact Will Durfee, wkdurfee@umn.edu, 612-625-0099
Version: April 13, 2015
Tools and Supplies
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#9 drill
Unibit step drill, 3/16 to ½ by 16ths
De-burring tool
Socket wrench
Sockets (deep): 5/16” 3/8”, 7/16”, 9/16”, 5/8”
Open-end wrenches: 3/8”, 7/16”, 9/16”, 5/8”, 11/16”
Adjustable wrench
Pliers
Measuring tape or yard stick
Scissors
Teflon thread seal tape, ¼”
Kit components
5-Kit Bill of Materials
Patience and good humor
Note: If no socket wrenches, can make do with set of open-end wrenches
2
Cap and Cup Machining
1”
Cap: hole with #9 drill
in exact center, de-burr
until finger smooth
Plastic cup: hole with #9 drill in side
wall, 1” down from lip, de-burr until
finger smooth
Tools: #9 drill, drill press, de-burring tool
3
Paint Can Machining
Drill both holes using
step bit (regular bits tear
thin sheet metal). Deburr holes until feels
smooth under finger
Drill first hole in side, 1”
down from top lip
Drill second 3/8” hole in exact center of bottom
Tools: step drill, drill press, de-burring tool
4
Fill Valve
Fill valve
Tape
1/8” F NPT to QC
Tools: 9/16”, 7/16” wrenches, tape
5
Pressure Gauge
Pressure gauge
Tape
1/8” F NPT to QC
Tools: 9/16” wrenches (two, or one and an adjustable wrench), tape
6
Pneumatic Switch
Tape
Tape
1/8 NPT to QC
1/8 NPT to QC
Switch
Tools: 7/16” wrench, adjustable wrench, tape
7
Power Supply
11/16
wrench
5/8 wrench
Tape
Pressure relief valve
1/8 NPT to 1/4 NPT
Tape
Tape
1/8 NPT nipple
1/8 NPT to QC
1/8 NPT Tee
Tape
1/8 NPT to QC
Tank
7/16 wrench
7/16 wrench
7/16 wrench
Tools: 7/16”, 5/8” and 11/16” wrenches, adjustable wrench, tape
8
Lab Stand
Rod
Tighten hard with pliers,
gripping knurled section of rod
Base
Tools: Pliers
9
Cylinders
10-32 to QC
Cylinder
Ball-launcher cylinder. See
Ball Launcher page for final
assembly.
Gentle,
hand
tight
Tools: 5/16” wrench
10-32 wing nut
Ball-catcher cylinder. No
further assembly needed.
#10 fender washer
Cylinder
#10 fender washer
10-32 to QC
10-32 wing nut
5/16” wrench, no tape, be gentle
10
Tube Cutting
Using scissors to cut, each kit gets this set of tubing pieces:
Quant
Length (in.)
1
48
2
24
2
12
2
6
4
3
In addition, the instructors spares bag (one for every five kits)
gets one 10 ft. length
Tools: scissors, measuring tape or yardstick
11
Ball
Launcher
10-32 lock nut
3/8” wrench
#10 fender washer
cap
3/8” wrench
#10 fender washer
10-32 nut
9/16” wrench
3/8” cylinder nut
3/8” washers
paint can
After mounting cylinder, run 24” tubing
through hole in side of can and attach to
quick connect fitting on the cylinder.
Ball-launch cylinder
assembly
(see earlier page)
Tools: 3/8” wrench (2), 9/16” wrench
12
Final Kit-of-5
Assembly
Using the BOM at right:
1. Fill five kit bags, mark
2. Fill spare parts bag,
mark
3. Fill hockey bag
4. Stuff tag holder with
insert, attach to bag
handle with zip-tie
(loose), trim zip-tie
flush
Inspect at all stages!
For 5-kit traveling set
Ref Quant Description
In the large hockey bag
K001
5
bicycle pump
K002
5
cylinder (mounted to paint can, with cap)
K003
7
plastic catching cup (2 spares)
K004
5
support stand with post
K005
5
yardstick
K006
1
Discovering Fluid Power DVD
K007
1
Instructors spare parts bag (see below)
5
Kit bags (see below)
In each of the five 2.6-gal zip lock kit bags
K008
1
fill valve
K009
1
power supply (tank, relief, fittings)
K010
1
pressure gauge
K011
2
pneumatic switch
K012
1
cylinder (with wing nut and washers)
K013
2
fitting, tee
K014
2
fitting, plug
K015
1
air tubing, 5/32", 12 ft, cut into pieces
K016
1
right angle clamp
K017
1
tennis ball
K007
5
5
5
5
2
1
10 ft
2
2
3
1
1
1
n
INSTRUCTOR SPARE PARTS BAG, in 1 g zip
10-32 fender washer
10-32 lock nut
10-32 nut
10-32 wing nut
3/8 washer
tennis ball
tubing, one piece
tee fitting
plug fitting
cap
pressure gauge
Other (from CCEFP web site)
Instructor's Guide
presentation slides
student handout
13