Pneumatics Instructions Class Kit Page 1 of 15

Instructions

© David Eckold 2011

Class KitPneumatics

Page 1 of 15

Introduction

TechCard has been specially developed for use in schools to teach Design & Technology and Science. The newly designed kits are curriculum focused and allow pupils to gain a hands-on understanding of how important simple mechanisms and structures work. These simple mechanisms and structural forms are the basis of our built environment and the mechanical world around us.

The TechCard elements are made from sturdy high quality card and are pre-punch and scored for fast accurate model building. The card elements are easily modified to create endless construction possibilities. Building with TechCard allows pupils to gain an understanding of how real structures work as the performance of the material mirrors the real world much more accurately. Plastic and metal construction systems are disproportionately strong and pupils do not experience how strong structures are made. As a simple example, take a TechCard girder and test it’s strength before folding it to shape. Then fold it to shape and you will immediately experience how rigid and useful it has become. This is exact how the steel girders that form our tall building, bridges and cranes work! TechCard allows pupils to experience these principles in their own hands.

The TechCard elements are fixed together with unique reusable plastic rivets which make assembly quick, easy and mess-free and a wide range of specifically selected and manufactured mechanical components are supplied with the kits.

The new TechCard range of kits consists of five Starter Kits and five Class kits. Each Starter Kit builds three models and can be used to introduce and explore specific curriculum topics. The large Class kits each build twenty models - two each of ten different designs. TechCard kits are uniquely flexible. For example, pupils can follow the instructions to assemble the pre designed models as a ‘focused practical task’ and following this the models can be dismantled and the components used for pupils to ‘design and make’ their own designs.

Please check www.techcard.co.uk for more regularly updated information and to forward your questions and suggestions.

The new TechCard range include: Starter Kits: Simple Mechanisms, Simple Circuits, Pneumatics, Power Cars and Power Robots. Class Kits: Links & Levers, Build-It, Power-It, Pneumatics and Vehicles.

Teachers Notes

The Pneumatics Class Kit enables pupils to develop two each of ten different controllable models using simple pneumatic systems. The models include realistic working machines like a lifting bridge, hoist and clamp as well as a tipper truck, earth mover and robot arm. The last two models use a twin pneumatic system for particularly realistic operation. In addition to these models there is a snapping alligator, rower, flapping wings and a crawling monster!

Using a large piston (syringe) to power the mechanism with a smaller piston inside the mode allows for stretch in the tubing and the fact that air ‘squashes’ a little when compressed. Before assembling the pneumatic system, extend one piston and close the other. In many applications the nozzle of the piston can simply be passed through a hole in a TechCard component and secured in place by fixing the tubing to the end. As with all types of mechanism, friction can cause problems. Pupils need to keep friction to a minimum by making sure mechanisms move freely and are properly aligned.

The simple pneumatic system demonstrates that air has substance and that it takes up space. When one piston is closed the air is forced along the tubing where it pushes the other piston ‘open’. Similarly when an closed piston is pulled air is drawn along the tube pulling

The ‘control’ piston is larger

Where heavy work is to be done, pneumatic systems are replaced by hydraulic systems in the real world. Hydraulic systems are filled with liquid (usually a special kind of oil) rather than air. This hydraulic fluid does not compress (get squashed) as easily as air so the hydraulic system can do heavier work. Pupils can use water instead of air in their systems but leaking water is likely to damage models (and the pistons make very good water pistols!)

An advantage with pneumatic systems over other types of mechanism, such as gears and axles for example, is that they are flexible and can literally be used around corners.

Stock Code For building tips, photos & downloads visit: techcardkits.com

Instructions


Class KitPneumatics

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TechCard

There are six basic TechCard parts that are easy to fold to shape along the scored lines.

Strip Girder Beam

Base Project Base Chassis

Forming TechCardFold the TechCard parts and fix together with the plastic rivets and collars or use glue. (PVA glue is the best)

The Project Base has a useful bracket that can be fixed to the base in lots of places.

The rivets and collars can come apart and are reusable.

Modifying TechCardTechCard is easy to cut with scissors or a craft knife. You can measure between the holes as a guide.

Measure between the holes

Mechanical and Electrical Parts

There is a wide range of components that work with TechCard for building exciting working mechanical models.

Motors Buzzers Bulbs Battery Holders

Axles Axle Plugs Wheels Tyres Steering Links Cranks Foam Washers

Worm Gears Spur Gears Cams Pulleys Propellers Pistons

Score TechCard with a craft knife so you can form new fold lines.

=

When folding TechCard, fold each panel right over and then return it to the final position. This will give a neat 90 degree fold.

Tip:


Cut three TechCard Beams to shape. Use the holes as a guide.

1

4

Fold the beam as shown.2

3 Use two rivets and collars to fix the short beam into a long beam where shown.

Attach a second long beam with two rivets and collars. Do not press the rivets and collars together tightly. Keep them loose to the beam moves easily.

6

Fold the two jaws to shape and fit to the beams with rivets. Keep the rivets loose so the jaws can move.

8

Closing the large piston will force air down the tube and push the small piston open. As the small piston opens the jaws will close. Opening the large piston will suck air down the tube forcing the small piston to close and open the jaws.

Pneumatic Clamp

Fit a length of tube to the end of the small piston. Fit the of the end of the tube onto a large piston.

7

5

Trim a sticky foam pad and use it to stick a small piston in place as shown.

loose rivets

Fit the end of the piston through this hole.

fit the tube with the small piston ‘closed’ and the large piston ‘open’

Instructions


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x 2

punch holes


Fix the beam to the base with two rivets and collars.

4

Fold the beam up and down along the score line to form a hinge.

2

3 Assemble a TechCard Project Base with four rivets and collars.

Trim a sticky foam pad and fix a small piston to the girder as shown.

6

8

Fold the two guard rails along the dotted lines and stick in place.

9

Pneumatic Bridge

5 Trim and fold a piece of girder and rivet it to the beam as shown.

Pass the end of the piston through the base where shown.

7

Score a TechCard Beam as shown.1

score on the underside

trim

Fit a length of tube to the end of the small piston. Fit the other end of the tube onto a large piston.

Fit the tube with the small piston ‘open and the large piston ‘closed’.

Closing the large position will force air down the tube and push the small piston open. As the small piston opens the bridge will rise. Opening the large piston will suck air down the tube forcing the small piston to close lowering the bridge.

Instructions


Class KitPneumatics

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axle x 1

Pneumatic Hoist


4


Score a cut a TechCard Beam as shown.1

trim

Fold the beam to shape as shown.2

cut

score



6

Fold the strip to shape and cut an axle to the length shown.9

8 Fit a length of tube to the end of the small piston. Fit the other end of the tube onto a large piston.

Fit the tube with the large piston ‘closed’ and the small piston ‘open’.

10 Fit the strip and axle with four foam washers as shown. Make sure the strip can swivel.

11 Fold the platform and stick it into the strip as shown.

Closing the large position will force air down the tube and push the small piston open. As the small piston opens the hoist will rise. Opening the large piston will suck air down the tube forcing the small piston to close lowering the hoist.

Instructions


Class KitPneumatics

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Stock Code


7

For building tips, photos & downloads visit: techcardkits.com

axle x 2

Row Boat

Cut a TechCard Beam to size as shown.

43 Cut two axles to the size shown.

Assemble a TechCard Project Base with four rivets and collars.

1

Enlarge hole where shown so plastic tube fits through easily.

2

axle plugs

5 Fold the beam to shape.

Pass the axles through the base and fix to the beam with two axle plugs as shown.

6

Fit two foam washers onto the axle as shown leaving a gap.

7

Trim a sticky foam pad and fix to the end of the small piston.

8

9 Fit the nozzle of the small piston through the beam and stick the plunger of the piston to the back of the base as shown.

Fit the tube with the large piston ‘open’ and the small piston ‘closed’.

Fit a piece of tubing on to the nozzle of the small piston. Fit the other end to a large piston.

10

Fold the oars and figure to shape as shown.11

Closing the large position will force air down the tube and push the small piston open. As the small piston opens the oars will move forward. Opening the large piston will suck air down the tube forcing the small piston to close moving the oars back.

enlarge hole

gap

sticky foam pad

Fit the oars and stick the figure in place.12

Instructions


Class KitPneumatics

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punch


Flapping Wings

Cut a TechCard Beam to size as shown.4

3 Cut two axles to the size shown.

Assemble a TechCard Project Base with four rivets and collars.

1

Enlarge hole where shown so plastic tube fits through easily.

2

axle plugs

5 Fold the beam to shape.

Pass the axles through the base and fix to the beam with two axle plugs.

6

Fit two foam washers onto the axle as shown leaving a gap.

7Trim a sticky foam pad and fix to the end of the small piston.

8

9 Fit the nozzle of the small piston through the beam and stick the plunger of the piston to the bottom of the base as shown.


Fit a piece of tubing onto the nozzle of the small piston. Fit the other end to a large piston.

10Fold the wings to shape and fit onto the axles as shown.

11

Closing the large position will force air down the tube and push the small piston open. As the small piston opens the wings will move down. Opening the large piston will suck air down the tube forcing the small piston to close moving the wings up.

enlarge hole

gap

sticky foam pad

axle x 2

Instructions


Class KitPneumatics

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punch


Instructions


Class KitPneumatics

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Tipper Truck

Use four rivets to fix the chassis together.

fold

score score

score

score

Fold the chassis to shape.1

Carefully follow the steps to fold the girder to shape.7

Cut this shape from a TechCard Girder and score where shown.6

Use two rivets to fix the girder to the top of the rear body.

5Cut this shape from a TechCard Girder and score where shown.

4

Cut and fold the rear body panel to shape as shown.

3

2


Instructions


Class KitPneumatics

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Set the pistons so that when the small piston is all the way closed the large piston is nearly all the way open. You may have to disconnect the large piston to do this.

As the large piston is closed, the air is forced along the tube and into the small piston which is pushed open. Closing the large piston creates a vacuum which pulls the air back into the large piston closing the small piston.

Pass the end of a length of tube through the chassis where shown. Push the end of the tube onto the piston.11

Fix the body panel to the chassis with two extra rivets.

13

Follow the instructions and fit four 50mm wheels to the ends of the axles.15

Fit the tube onto the end of a large piston.16

Position a small piston as shown. Use a piece of sticky foam pad to fix the top of the piston to the girder as shown.

10

Cut and fold the front body panel to shape.

12

Cut two axles to the lengths shown.14

Use two rivets to fix the girder assembly to the back of the chassis.

9Use two rivets to fix the rear body panels into the folded girder.

8

Piston

Tipper truck Continued

Front Axle

Rear Axle

Fitting Axle PlugsSlide wheel onto axle as shown.

Push Axle Plug into end of axle.

Pull wheel towards end of axle.


Instructions


Class KitPneumatics

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Pneumatic Robot Arm

Fixed Jaw Moving Jaw

Cut and score these shapes from a girder and beam.

10

Fold the project base to shape.

1

Pass the axle through the beam and the tower as shown. Fit a washer onto the ends of the axle to hold everything in place.

9

Cut two axles to the length shown.8

Fold a TechCard beam to shape and rivet the girder inside where shown.

The girder acts like a hinge.

7

Cut, trim and fold a TechCard girder as shown.

6

Use three rivets to fix the beam to the base where shown.

5Carefully fold the tower to shape.

4Cut and score a TechCard beam to the shape shown.

3

tower

axle 2

trim

Rivet the base together with four rivets and collars.

2

score

cut

trim


Instructions


Class KitPneumatics

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Set the pistons so that when the small pistons are all the way closed the large pistons are nearly all the way open. You may have to disconnect the large pistons to do this.

As a large piston is closed, the air is forced along the tube and into the small piston which is pushed open. Closing the large piston creates a vacuum which pulls the air back into the large piston closing the small piston.

Fold the moving jaw to shape. Fold the trimmed girder and rivet it inside the jaw.

11

Fix the first small piston between the top of the beam and the moving jaw as shown. Use a piece of sticky foam pad to fix the end of the piston to the girder inside the jaw.

17

Use the second axle to fix the moving jaw into the beam.

12

Use two rivets to fix the fixed jaw into the end of the beam.

15

Cut and fold the body into shape.

16

Pass a length of tube through the back of the beam and push it onto the piston.

18

Fold the fixed jaw to shape.

14

Secure the axle with two washers.

13

Fix a second small piston between the beam and tower as shown. Use a piece of sticky foam pad to fix the end of the piston to the girder inside the beam.

19

Pass a length of tube through the front of the tower and push it onto the piston.

20

Fit large pistons onto the ends of the tubes.

21

Pneumatic Robot Arm continued

second piston

fixed with a sticky foam pad

first piston


Instructions


Class KitPneumatics

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Pneumatic Earth Mover

score

trim

Rivet the two beam sections together. Rivet the bucket hinge into the end of the boom assembly.

12

Pass the axle through the tower and boom and secure with two washers.

14

Fold the bucket hinge to shape.

11

Cut an axle to the length shown.13

Fold the chassis to shape.1

Fold one of the beam sections to shape and rivet the bracket inside as shown.

9

Cut this shape from a TechCard Beam for the bucket hinge.

8Cut two of these shapes from a TechCard Beam for the boom.

7Cut and trim this shape from a TechCard Girder to form a bracket.

6Use three rivets to fix the tower to the chassis where shown.

5

Carefully fold the tower to the shape shown.

4

Cut and score the tower from a TechCard Beam.

3

Use four rivets to fix the chassis together.

2A

xle

15 Fix the tower to the side of the chassis with a rivet and collar.

x 2

Rivet the two beam sections together.

10


Instructions


Class KitPneumatics

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Closing a large piston forces air along the tube and pushes the small piston open. Opening the large piston will suck air back along the tube forcing the small piston to close. One large piston controls the up and down movement of the boom. The other controls the tipping of the bucket.

Pass the nozzle of the piston through the boom and push a second tube onto it.

Pass a tube through the back of the chassis and push it onto the end of the piston underneath the chassis as shown.

1618 Position a small piston between the boom and the

bucket hinge as shown. Cut a sticky foam pad and use it to fix the end of the piston to the bucket hinge.

17

Pass the tube through the gap in the back of the boom and through the chassis as shown. Pass the tube out through the chassis next to the first tube.

19

Fit a small piston between the chassis and boom as shown. Cut a sticky foam pad and use it to fix the end of the piston to the bracket inside the boom.

20

21 Fold the body to shape and fix to the chassis with two rivets.

Fold the bucket to shape and rivet to the hinge as shown below.

22

Cut two axles to the length shown and follow the instructions to fit four 50mm wheels to the axles. with axle plugs.

23axle x 2

fix with sticky pad

Pneumatic Earth Mover Continued

Fitting wheels with axle plugs

Slide the wheel on the axle as far as it will go.

Push the plug into the end of the axle.

Pull the wheel back to the end of the axle so it is gripped tightly.

Make sure both small pistons are ‘closed’. Open two large pistons and fit onto the ends of the tube.

24

bucket

body

hinge


1

2

3

Trim the small TechCard Girder to shape and fix into the beam shown.

5

Rivet the two beams together but make sure the rivets are loose.

Use a piece of sticky pad to fix the syringe to the small girder inside the beam. Pass the nozzle of the syringe out through the rear beam.

Connect a length of tubing to the end of the small syringe. Fit the other end of the tube to the large syringe.

6

Moving Monster

Cut two TechCard Beams and a TechCard Girder as shown.

Instructions


Class KitPneumatics

Page 14 of 15

trim

4 Rivet the girder to the bottom of the beam as shown.


Closing the large position will force air down the tube and push the small piston open. As the small piston opens the beams will spread and the beams will crawl forwards.

Cut out and fit the head and fix to the girder.

7


Instructions


Class KitPneumatics

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4

Fold the beam up and down along the score line to form a hinge.

2



6

8

Fold the head to shape and stick in place.

9

Pneumatic Alligator



7

Score a TechCard Beam as shown.1

score on the underside

trim

Fit a length of tube to the end of the small piston. Fit the other end of the tube onto a large piston.

Fit the tube with the small piston ‘open and the large piston ‘closed’.

Closing the large position will force air down the tube and push the small piston open. As the small piston opens the jaw will open. Opening the large piston will suck air down the tube forcing the small piston to close lowering the jaw.


Body Panels


Class KitPneumatics

Page 1 of 4

Carefully cut out the shapes. Cut along the solid lines. Crease and fold along the dotted lines.

tipper truck

pneumatic clamp


Body Panels


Class KitPneumatics

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pneumatic clamp

Alligator

pneumatic earth mover


Body Panels


Class KitPneumatics

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row boat

row boat

pneumatic hoist

robot arms


Body Panels


Class KitPneumatics

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pneumatic bridge

monster

wings


Documents

Pneumatics Instructions Class Kit Page 1 of 15