v3 FINAL FINAL PDF SOLAR PANEL PROJECT BY MYLES MARCUS

EML 2023 Design Project 2016Solar Panel

By: Myles Marcus

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A. Introduction

Within the past few years, there has been an increased interest in “green” energy to power our every day lives. Through this “green” energy, people will be able to perform every day functions without the feeling that they are significantly harming the environment. In order to meet this need for “green energy”, we are going to devise a platform to hold and rotate a 15 watt solar panel along an axis parallel to its long horizontal axis in order to track the sun and obtain the maximum amount of solar energy possible. The platform will include a denso motor to control the speed of rotations of the solar panel, an optical encoder to measure the number of rotations, as well as homing and limit switches to detect where the solar panel is and to limit its position. Through our NI USB 6009 DAQ, we will be able to computer program our platform to move the solar panel to its respective locations aligned with the sun throughout the day.

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A. Introduction

•Solar Panel

Figure 1 Watt Solar Panel

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B. Design Specifications • any actuators must be either the 135 RPM 12 VDC Buehler Gearmotor or the Denso DC Motor,

• every actuator will have a Honeywell / Clarostat 600128CBL Optical Encoder so that closed loop feedback control can be used

• every actuator must have a homing switch

• every actuator must have motion limit switches if there are limits to the actuator's rotation

• if a solenoid is needed, use the 12 V DC solenoid available from McMaster Carr (part number 70155K49),

• the design must include one Device Craft Motor Driver for each motor

• the design must include one National Instruments (NI) 6009 DAQ for each motor

• the device must fit within a 40"x40"x40" volume,

• the cost of building one prototype device must be identified (not including the NI DAQ)

• the weight of the device, must not exceed 100 lbs.

• The solar panel must rotate about an axis parallel to the longer side of the panel

• Requires minimal maintenance: 2x a year (in order to check on its function)

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• Must rotate at speed of at least .20 rev/s (in order to make sure the solar panel will be able to keep up with the sun’s course)

• Generates minimal noise, less than 30 decibels (so that the solar panel design does not bother people nearby)

• Structure must be built to last at least 5 years

• Must withstand temperatures between 35 and 110 degrees Fahrenheit (in order to verify that it will not shut down in a particular environment)

• The solar panel must be able to be set up in less than an hour using power drills with Philips head, flat head, and hex shaped screw inserts (in order for it to be appealable to the public market)

• The total cost of the solar panel assembly should not exceed $2000 (for any exceeding cost would make the solar panel seem overpriced)

• The solar panel must be able to withstand rain with winds up to 35 mph, and not carry more than 20 volts to electrocute someone (so that the solar panel does not have the potential to fall over, nor cause harm to others)

• The solar panel must be able to rotate both counter-clockwise and clock-wise (to allow its motion to change when transitioning to the next day)

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C. Background

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Works Cited

1. http://www.sunsaluter.com/

2. https://www.google.ch/patents/US20120227788

3. http://sunenergyworld.blogspot.com/

4. http://www.solarnavigator.net/sun_tracker_wings.htm

5. https://www.pc-control.co.uk/howto_tracksun.htm

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http://www.sunsaluter.com/

https://www.google.ch/patents/US20120227788

http://sunenergyworld.blogspot.com/

http://www.solarnavigator.net/sun_tracker_wings.htm

https://www.pc-control.co.uk/howto_tracksun.htm

D. Design Concept 1- Conveyor Belt

Figure 10

In the Conveyor Belt Design concept (as shown in figure 10), the premise is that the solar panel would be attached to part of the conveyor belt. The conveyor belt will be driven by the motor, and the motion of the conveyor belt will be controlled using an optical encoder (not shown). The encoder will be able to determine the solar panel’s location through a homing switch (not shown). Although not shown in figure 10, the actual design will incorporate a Device Craft Motor Driver and a National Instruments (NI) 6009 DAQ. The whole conveyor belt will be attached to the base. The Conveyor Belt Design works by having the solar panel start out on the end of the belt where it is slanted. As the sun comes up throughout the day, the conveyor belt will slowly move to allow the solar panel to flatten out. As the sun starts to set, the solar panel will be moved by the motor to the other side of the conveyor belt and will be rotated at an angle at the other side of the conveyor belt. After the sun sets, the conveyor belt will reset so the solar panel starts out at its original position.

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D. Design Concepts 2- Ball and Socket

Figure 11

In the Ball and Socket Design concept (as shown in figure 11), the solar panel is attached to Arms CD and AB with ball and socket joints. The Ball and Socket Design works by having Arms AB and CD move up and down at different times using the motor to drive the conveyor belt to allow the lifter (which is attached to the conveyor belt) to lift Arms AB and CD. The motion of the conveyor belt will be controlled using an optical encoder (not shown). The encoder will be able to determine the solar panel’s location through a homing switch (not shown). Although not shown in figure 11, the actual design will incorporate a Device Craft Motor Driver and a National Instruments (NI) 6009 DAQ. The base is there to give support to Arms AB and CD through bearings (not shown) that will be placed at the holes that Arms AB and CD go through in the base.

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D. Design Concepts 3- Two Gears

Figure 12

In the Two Gears Design concept (as shown in figure 12), the premise is that the solar panel will be attached to Rod 3. The motor will rotate Rod 4 which is attached to Gear 2. The speed and direction of the motor will be controlled using an optical encoder (not shown). The encoder will be able to determine the solar panel’s location through a homing switch (not shown). Although not shown in figure 12, the actual design will incorporate a Device Craft Motor Driver and a National Instruments (NI) 6009 DAQ. As Gear 2 rotates, Gear 1 will rotate. As Gear 1 rotates, Rod 3 will rotate as well since Rod 3 and Gear 1 are attached to each other. Rod 1 and Rod 2 are used to support Rod 3. The End Cap is used to ensure that Gears 1 and 2 will have more surface contact and will therefore have better rotation. The Supporting Rod is an extension of Rod 2 and is used to support Rod 4. The Base is used to hold everything together. Lastly, bearings will be inserted into the holes located in Rods 1, 2, and the Supporting Rod to allow Rods 3 and 4 to rotate freely. 14

E. Selection of Design Approach

Figure 13

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E. Selection of Design Approach

Figure 13

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F. Design Description The Solar Panel Project is mostly made from aluminum and steel, with the majority of the parts being order from McMaster-Carr. The whole entire design is made from 6 subassemblies, and one main assembly which implements the 6 subassemblies as well as other components. Throughout the course of this section, the design of each of the subassemblies will be explained, as well as how the subassemblies are implemented into the main assembly.

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SUBASSEMBLY 1

The components of SUBASSEMBLY 1 are shown in the bill of materials in Figure 14. SUBASSEMBLY 1 is made by performing the following steps. First, the SOLAR PANEL BEARING should be press fit into BLOCK 1. Then, BLOCK 1 SUPPORT is to be orientated in the way Figure 15 depicts. BLOCK 1 SUPPORT should be oriented so that the 2 threaded holes nearest to the edge are on the top face of BLOCK 1 SUPPORT. Once oriented properly, BLOCK 1 SUPPORT should be placed against BLOCK 1. Then, the 4 BLOCK CORNER BRACKETS should be placed on the top and bottom face of BLOCK 1 SUPPORT and mated to the top and bottom face so that the holes on the 4 BLOCK CORNER BRACKETS are concentric with the threaded holes on the top and bottom face of BLOCK 1 SUPPORT. After this, the 4 BLOCK CORNER BRACKETS should then be mated to BLOCK 1 so that the holes in the 4 BLOCK CORNER BRACKETS are concentric with the threaded holes on the right face of BLOCK 1. After everything is aligned, the 8 BLOCK CORNER BRACKET SCREWS should be screwed through the 8 BLOCK CORNER BRACKETS and into BLOCK 1 SUPPORT and BLOCK 1. The 8 BLOCK CORNER BRACKET SCREWS are used to secure the corner brackets to BLOCK 1 and BLOCK 1 SUPPORT. After everything is screwed in properly, the finished SUBASSEMBLY 1 should look like it appears in Figure 16 and Figure 17.

Figure 14

Figure 15

Figure 16 Figure 17

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SUBASSEMBLY 2

Figure 18

Figure 19

The components of SUBASSEMBLY 2 are shown in the bill of materials in Figure 18. SUBASSEMBLY 2 is made by performing the following steps. First, the SOLAR PANEL BEARING should be press fit into BLOCK 1. Next, the MOTOR BEARING should be press fit into MOTOR SHAFT SUPPORT. Then, the MOTOR SHAFT SUPPORT is to be orientated in the way Figure 15 depicts. The MOTOR SHAFT SUPPORT should be oriented so that the 2 threaded holes nearest to the edge are on the top face of the MOTOR SHAFT SUPPORT. Once oriented properly, the MOTOR SHAFT SUPPORT should be placed against BLOCK 2. Then, the 4 BLOCK CORNER BRACKETS should be placed on the top and bottom face of the MOTOR SHAFT SUPPORT and mated to the top and bottom face so that the holes on the 4 BLOCK CORNER BRACKETS are concentric with the threaded holes on the top and bottom face of the MOTOR SHAFT SUPPORT. After this, the 4 BLOCK CORNER BRACKETS should then be mated to BLOCK 2 so that the holes in the 4 BLOCK CORNER BRACKETS are concentric with the threaded holes on the right face of BLOCK 2. After everything is aligned, the 8 BLOCK CORNER BRACKET SCREWS should be screwed through the 8 BLOCK CORNER BRACKETS and into the MOTOR SHAFT SUPPORT and BLOCK 2. The 8 BLOCK CORNER BRACKET SCREWS are used to secure the corner brackets to BLOCK 2 and the MOTOR SHAFT SUPPORT. After everything is screwed in properly, the finished SUBASSEMBLY 2 should look like it appears in Figure 20 and Figure 21.

Figure 20 Figure 21

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SUBASSEMBLY 3

Figure 22

Figure 23

The components of SUBASSEMBLY 3 are shown in the bill of materials in Figure 22. SUBASSEMBLY 3 is made by performing the following steps. First, the rotating part of the ENCODER should be put through the center hole in the ENCODER BLOCK. The small semicircle of the ENCODER should be placed within its respective hole in the ENCODER BLOCK as well. After, the ENCODER NUT should be screwed onto the ENCODER after the ENCODER has been placed into the ENCODER BLOCK. After the ENCODER is firmly secured into the ENCODER BLOCK, the ENCODER GEAR should be placed on the rotating part of the ENCODER and then secured using the set screw provided on the ENCODER GEAR. The set screw should be screwed tightly to prevent the gear from rotating separately from the rotating part of the ENCODER. After everything is properly secured, the finished SUBASSEMBLY 3 should look like it appears in Figure 24 and Figure 25.

Figure 25 Figure 24

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SUBASSEMBLY 4 Figure 29

Figure 28

Figure 26

Figure 27

The components of SUBASSEMBLY 4 are shown in the bill of materials in Figure 26. SUBASSEMBLY 4 is made by performing the following steps. First, the 4 THREADED INSERTS should be placed under the overhanging part of the SOLAR PANEL under the holes that are already made in the SOLAR PANEL. For proper positioning, refer to the detailed view in Figure 28. After placing the 4 THREADED INSERTS in their proper positions, the TOP SOLAR PANEL SUPPORT BEAM and the BOTTOM SOLAR PANEL SUPPORT BEAM can be placed onto the top of the overhang. Care must be taken to insure that the correct support beam is placed on the correct side of the SOLAR PANEL. For proper placement, refer to Figure 27 and Figure 28 being sure that the extra threaded hole on the side of the TOP SOLAR PANEL SUPPORT BEAM is in the correct orientation. After placing the TOP SOLAR PANEL SUPPORT BEAM and the BOTTOM SOLAR PANEL SUPPORT BEAM over their respective holes, the 4 SOLAR PANEL SUPPORT BEAM SCREWS should be screwed into the holes in the two support beams, through the holes in the overhang, and finally into the thread holes in the THREADED INSERTS. After everything is properly secured, the finished SUBASSEMBLY 4 should look like it appears in Figure 29.

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SUBASSEMBLY 5

Figure 30

Figure 31

Figure 32 Figure 33

The components of SUBASSEMBLY 5 are shown in the bill of materials in Figure 30. SUBASSEMBLY 5 is made by performing the following steps. First, the MOTOR SHAFT GEAR KEY should be placed into its respective slot on the side of the MOTOR SHAFT. The SOLAR PANEL/MOTOR GEAR should then be placed concentrically onto the side of the MOTOR SHAFT with the key inserted into the slot. Care must be taken to insure that the slot in the SOLAR PANEL/MOTOR GEAR lines up with the MOTOR SHAFT GEAR KEY. After the MOTOR SHAFT is firmly inserted into the SOLAR PANEL/MOTOR GEAR, the set screw provided on the SOLAR PANEL/MOTOR GEAR should be screwed down tightly down onto the MOTOR SHAFT GEAR KEY connecting the two parts. After everything is properly secured, the finished SUBASSEMBLY 5 should look like it appears in Figure 32 and Figure 33.

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SUBASSEMBLY 6

The components of SUBASSEMBLY 6 are shown in the bill of materials in Figure 34. SUBASSEMBLY 6 is made by performing the following steps. First, the MOTOR SHAFT GEAR KEY should be placed into its respective slot on the side of the SOLAR PANEL SHAFT. Make sure that the MOTOR SHAFT GEAR KEY is being placed into the correct side of the SOLAR PANEL SHAFT by referring to Figure 35 and Figure 36. The SOLAR PANEL/MOTOR GEAR should then be placed concentrically onto the side of the SOLAR PANEL SHAFT with the key inserted into the slot. Care must be taken to insure that the slot in the SOLAR PANEL/MOTOR GEAR lines up with the MOTOR SHAFT GEAR KEY. After the SOLAR PANEL SHAFT is firmly inserted into the SOLAR PANEL/MOTOR GEAR, the set screw provided on the SOLAR PANEL/MOTOR GEAR should be screwed down tightly down onto the MOTOR SHAFT GEAR KEY connecting the two parts. After everything is properly secured, the finished SUBASSEMBLY 6 should look like it appears in Figure 37.

Figure 34

Figure 35

Figure 36 Figure 37

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MAIN ASSEMBLY

Figure 38 Figure 39

The components of the MAIN ASSEMBLY are shown in the bill of materials in Figure 39. As can be seen from Figure 38, the MAIN ASSEMBLY contains many extra components not including the subassemblies. Therefore, the next few pages will be used to give an in depth understanding of the individual steps involved in creating the MAIN ASSEMBLY. The complete MAIN ASSEMBLY is shown in Figure 40.

Figure 40

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STEP 1

Figure 43

For STEP 1, the NI-USB-6009 (DAQ) is secured to the BASE by inserting the DAQ SCREW through the DAQ WASHER, through the hole on the side of the NI-USB-6009 (DAQ), and screwing it into the corresponding threaded hole in the BASE. Next, the DIN RAIL is secured to the BASE by inserting 2 DIN RAIL SCREWS through the holes in the DIN RAIL and screwing them into their corresponding threaded holes in the BASE. Afterwards, the DEVICE CRAFT MOTOR DRIVER is slid onto the DIN RAIL. Lastly, the DENSO 12V DC MOTOR is secured to the base by inserting 3 MULTIPURPOSE SCREWS into the threaded holes on the side of the DENSO 12V DC MOTOR, through the 3 MOTOR SPACERS, and screwing them into their corresponding threaded holes in the BASE (see Figure 42). Refer to Figure 41 and Figure 44 for all components involved in STEP 1 as well as proper orientation of all parts involved. After everything is properly secured, the finished STEP 1 should look like it appears in Figure 44.

Figure 41

Figure 44

Figure 42

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STEP 2 Figure 46

For STEP 2, SUBASSEMBLY 1 and SUBASSEMBLY 2 are secured to the base. First, both subassemblies should be oriented as seen in Figure 48. Afterwards, 8 BASE CORNER BRACKETS are to be placed on the threaded holes on the top face of the BASE and on the sides of the subassemblies so that the holes in the 8 BASE CORNER BRACKETS are concentric with the threaded holes in the BASE and on the sides of the subassemblies. Make sure that the 8 BASE CORNER BRACKETS are oriented so that the longer side rests on the sides of the subassemblies. Next, place 8 BASE CORNER BRACKET WASHERS on top of each hole of the 8 BASE CORNER BRACKETS horizontal to the BASE (not the holes on the side of the subassemblies) so that they are concentric with the threaded holes in the BASE. Afterwards, screw the 8 BASE CORNER BRACKET SCREWS through the washers, through the 8 BASE CORNER BRACKETS, and into the threaded holes of the BASE. Lastly, screw the 8 SIDE BLOCK CORNER BRACKET SCREWS through the 8 BASE CORNER BRACKETS and into their corresponding threaded holes in the sides of the subassemblies. Refer to Figure 45, Figure 46, and Figure 48 for all components involved in STEP 2 as well as proper orientation of all parts involved. After everything is properly secured, the finished STEP 2 should look like it appears in Figure 48.

Figure 48

Figure 45

Figure 47

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STEP 3

Figure 51

For STEP 3, SUBASSEMBLY 3 and the HOMING SWITCH will be screwed in. First, the threaded holes on the bottom of SUBASSEMBLY 3 will be lined up with the holes on the top face of BLOCK 1 SUPPORT in SUBASSEMBLY 1 so that they are coincident with each other. Afterwards, 2 MULTIPURPOSE SCREWS will be put through the holes in BLOCK 1 SUPPORT of SUBASSEMBLY 1 and then screwed into the threaded holes on the bottom of SUBASSEMBLY 3. Refer to Figure 49 and Figure 50 for all components involved as well as proper orientation of all parts involved. Next, the HOMING SWITCH will be aligned with the threaded holes on the side of SUBASSEMBLY 2 so that they are concentric with each other. The roller button of the HOMING SWITCH should be oriented on the top of the HOMING SWITCH (see Figure 53) as this will allow the HOMING SWITCH to be activated when the MULTIPURPOSE SCREW attached to the SOLAR PANEL in SUBASSEMBLY 4 hits it. The HOMING SWITCH will be secured by putting 2 HOMING SWITCH SCREWS through the HOMING SWITCH and into the threaded holes on the side of SUBASSEMBLY 2. Refer to Figure 52 and Figure 53 for all components involved as well as proper orientation of all parts involved.

Figure 50

Figure 49

Figure 53

Figure 52

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STEP 4

Figure 56

For STEP 4, SUBASSEMBLY 5 will be placed into its proper position. First, align the MOTOR SHAFT COLLAR WASHER, the MOTOR SHAFT COLLAR, and SUBASSEMBLY 5 above the center of the MOTOR BEARING in SUBASSEMBLY 2 as seen in Figure 54. After, put the bottom of SUBASSEMBLY 7 through the MOTOR SHAFT COLLAR, the MOTOR SHAFT COLLAR WASHER, and finally through the MOTOR BEARING in SUBASSEMBLY 2 until it looks like Figure 55. Afterwards, place the MOTOR SHAFT ADAPTER into the shaft of the DENSO 12V DC MOTOR (see Figure 57). Next, connect the MOTOR SHAFT ADAPTER and SUBASSEMBLY 5 by placing the MOTOR ADAPTER KEY against the flat side of the MOTOR SHAFT ADAPTER and bring down the bottom of SUBASSEMBLY 5 until both the MOTOR ADAPTER KEY and the MOTOR SHAFT ADAPTER lie inside the keyed hole in the bottom of SUBASSEMBLY 5 (see Figure 58). Lastly, tighten the screw on the MOTOR SHAFT COLLAR around SUBASSEMBLY 5 in a position that allows the MOTOR ADAPTER KEY and the MOTOR SHAFT ADAPTER to lie inside the keyed hole in the bottom of SUBASSEMBLY 5, but to not have any of the weight of SUBASSEMBLY 5 rest on the DENSO 12V DC MOTOR. After screwing the MOTOR SHAFT COLLAR, the MOTOR SHAFT COLLAR should lie on top of the MOTOR SHAFT COLLAR WASHER which should in turn lie against the MOTOR BEARING in SUBASSEMBLY 2. The placement of these parts will allow the DENSO 12V DC MOTOR to rotate SUBASSEMBLY 5 with a considerable amount of torque.

Figure 58

Figure 57

Figure 54 Figure 55

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STEP 5

Figure 61

For STEP 5, SUBASSEMBLY 6 will be placed into its proper position in SUBASSEMBLY 1 and SUBASSEMBLY 2. First, align the SOLAR PANEL COLLAR WASHER and the SOLAR PANEL COLLAR with the center of the SOLAR PANEL BEARING in SUBASSEMBLY 2 so that all of these parts are coincident (see Figure 59). Afterwards, put SUBASSEMBLY 6 through the SOLAR PANEL BEARING, the SOLAR PANEL COLLAR WASHER, and then the SOLAR PANEL COLLAR (see Figure 60 for completed step). Next, align the SOLAR PANEL COLLAR WASHER and the SOLAR PANEL COLLAR with the center of the SOLAR PANEL BEARING in SUBASSEMBLY 1 so that all of these parts are coincident (see Figure 62). Afterwards, put the other end of SUBASSEMBLY 6 with no gear through the SOLAR PANEL COLLAR, the SOLAR PANEL COLLAR WASHER, and then the SOLAR PANEL BEARING (see Figure 63 for completed step). Lastly, place the ENCODER GEAR on the side of SUBASSEMBLY 6 with no gear and then secure it using the set screw provided on the ENCODER GEAR. The set screw should be screwed tightly into the small slot provided on the end of SUBASSEMBLY 6. Lastly, the 2 SOLAR PANEL COLLARS should be pressed against the 2 SOLAR PANEL COLLAR WASHERS which should in turn be pressed against the SOLAR PANEL BEARINGS in a way that would allow both the ENCODER GEAR and the SOLAR PANEL/MOTOR GEAR to mate with their respective gears. After everything is properly placed, the finished STEP 5 should look like it appears in Figure 63.

Figure 63

Figure 62

Figure 60

Figure 59

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STEP 6

Figure 66

For STEP 6, SUBASSEMBLY 4 will be placed into its proper position onto SUBASSEMBLY 6. First, align the threaded holes on the 2 support beams of SUBASSEMBLY 4 with the holes on SUBASSEMBLY 6 so that these holes are concentric with each other (see Figure 64). Next, place the 2 SOLAR PANEL SUPPORT BEAM SCREWS through the holes of SUBASSEMBLY 6 and into the threaded holes in the support beams of SUBASSEMBLY 4. Finally, screw in the MULTIPURPOSE SCREW into the extra threaded hole on the side of the TOP SOLAR PANEL SUPPORT BEAM. Make sure that the MULTIPURPOSE SCREW is screwed in far enough so that the head of the MULTIPURPOSE SCREW will hit the roller button of the HOMING SWITCH (see Figure 65). After everything is properly placed, the finished STEP 6 should look like it appears in Figure 67 and Figure 68. SUBASSEMBLY 4 is attached onto SUBASSEMBLY 6 with the 2 SOLAR PANEL SUPPORT BEAM SCREWS which allows SUBASSEMBLY 4 to rotate with SUBASSEMBLY 6. Additionally, the 2 SOLAR PANEL/MOTOR GEARS will turn each other, which will turn SUBASSEMBLY 6 and SUBASSEMBLY 4 as a result. As SUBASSEMBLY 6 rotates, the 2 ENCODER GEARS will rotate which will allow the ENCODER to track the rotation of SUBASSEMBLY 4. After STEP 6 is completed, the MAIN ASSEMBLY is complete.

Figure 64

Figure 67

Figure 65

Figure 68

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Figure 69 shows a rendering of how the SOLAR PANEL PROJECT would look in the real world on top of grass with the sun reflecting off of the SOLAR PANEL.

Figure 69

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Mass Properties

Mass is 70.35 pounds. So, it meets the design specification of being less than 100 lbs.

Figure 70

Figure 12 32

G. Cost Analysis

• Overall, the sum total of all the parts purchased was $1631.97, which was less than the $2000 established in the design specifications.

• The Cost Analysis sheet follows:

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Appendix Subassembly Drawings............................................................................................................................... 36

SUBASSEMBLY 1 ...................................................................................................................................... 36

SUBASSEMBLY 2 ...................................................................................................................................... 38

SUBSSEMBLY 3 ........................................................................................................................................ 40

SUBASSEMBLY 4 ...................................................................................................................................... 42

SUBASSEMBLY 5 ...................................................................................................................................... 44

SUBASSEMBLY 6 ...................................................................................................................................... 46

MAIN ASSEMBLY ..................................................................................................................................... 48

Part Drawings ............................................................................................................................................. 51

MOTOR SHAFT ........................................................................................................................................ 51

SOLAR PANEL SHAFT ............................................................................................................................... 52

BLOCK 1 ................................................................................................................................................... 54

BLOCK 2 ................................................................................................................................................... 56

MOTOR SHAFT SUPPORT ........................................................................................................................ 58

ENOCODER BLOCK .................................................................................................................................. 59

BLOCK 1 SUPPORT ................................................................................................................................... 60

MOTOR SPACERS ..................................................................................................................................... 62

BASE ........................................................................................................................................................ 63

BOTTOM SOLAR PANEL SUPPORT BEAM ................................................................................................ 66

MOTOR SHAFT GEAR KEY ........................................................................................................................ 67

MOTOR ADAPTER KEY ............................................................................................................................. 68

THREADED INSERTS SOLAR PANEL SUPPORT BEAM ............................................................................... 69

TOP SOLAR PANEL SUPPORT BEAM ........................................................................................................ 70

SOLAR PANEL COLLAR WASHER .............................................................................................................. 71

MOTOR SHAFT COLLAR WASHER ............................................................................................................ 71

DAQ WASHER .......................................................................................................................................... 73

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ITEM NO. QTY. PART/ASSEMBLY NUMBER PART/ASSEMBLY NAME

1 1 8975K226 BLOCK 12 1 60355K607 SOLAR PANEL BEARING3 1 8975K226 BLOCK 1 SUPPORT4 4 15705A450 BLOCK CORNER BRACKET5 8 91735A242 BLOCK CORNER BRACKET SCREW

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COMPUTER AIDED GRAPHICS AND DESIGNPROJECT: SOLAR PANEL

ENGINEER:APPROVED BY:

PART/ASSEMBLY NUMBER:

NEXT ASSEMBLY NUMBER:

MATERIAL:

FINISH:

DATE CREATED:DATE APPROVED:

SHEET SCALE: SHEET NUMBER:

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C. CRANEMYLES MARCUS

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SPECIFICATIONS AND TOLERANCESUNLESS OTHERWISE NOTED

DRAWINGS ARE CREATED ACCORDING TO ASME Y14.5-2009

DEFAULT DIMENSIONAL TOLERANCES:LINEAR DIMENSIONS [inches]: X .5, X.X .1, X.XX .03, X.XXX .005

ANGULAR DIMENSIONS [degrees]: X 3, X.X .5, X.XX .1MINIMUM SURFACE FINISH: 1000 microinches

THIRD ANGLE PROJECTION

PART/ASSEMBLY NAME: SUBASSEMBLY 1

SUBASSEMBLY 1

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SOLIDWORKS Student Edition. For Academic Use Only.

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1 1 8975K226 BLOCK 22 1 60355K607 SOLAR PANEL BEARING3 1 8975K226 MOTOR SHAFT SUPPORT4 4 15705A450 BLOCK CORNER BRACKET5 8 91735A242 BLOCK CORNER BRACKET SCREW6 1 60355K506 MOTOR BEARING

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1 1 8975K226 ENCODER BLOCK 2 1 600128CN1 ENCODER3 1 600128CN1 ENCODER NUT4 1 6867K557 ENCODER GEAR

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1 1 SOK-030WP-12 SOLAR PANEL2 1 8975K14 TOP SOLAR PANEL SUPPORT BEAM3 1 8975K14 BOTTOM SOLAR PANEL SUPPORT BEAM

4 4 8975K14 THREADED INSERTS SOLAR PANEL SUPPORT BEAM

5 4 91772A548 SOLAR PANEL SUPPORT BEAM SCREW

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1 1 1346K240 MOTOR SHAFT

2 1 6843K140 SOLAR PANEL/MOTOR GEAR

3 1 8975K14 MOTOR SHAFT GEAR KEY

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DETAIL ASCALE 2 : 3

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1 1 5947K560 SOLAR PANEL SHAFT

2 1 6843K140 SOLAR PANEL/MOTOR GEAR

3 1 8975K14 MOTOR SHAFT GEAR KEY

D

C

B

AA

B

C

D

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8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0006

N/A

NONE


4/4/20164/19/2016







SUBASSEMBLY 6

1:3 1 of 2


46

D

C

B

AA

B

C

D

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8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0006

N/A

NONE


4/4/20164/19/2016







SUBASSEMBLY 6

1:3 2 of 2


47

17

13

11

Note: The following items (5,7,11,12,13, and 17) are the subassemblies. The main assembly (shown above) is made from the subassemblies. Items 19,20,22,23, and 24 are not labeled in this picture. These items will be shown in later figures.

3

4

86

21

1012

9

7

15

164

18

1

1615

145

4

29

3028

27

2

25

26


1 1 88685K984 BASE2 1 DCGM1501 DENSO 12V DC MOTOR3 3 9056K62 MOTOR SPACERS4 6 90272A155 MULTIPURPOSE SCREW5 1 SUBASSEMBLY 1 SUBASSEMBLY 16 1 N/A MOTOR SHAFT ADAPTER7 1 SUBASSEMBLY 5 SUBASSEMBLY 58 1 8975K14 MOTOR ADAPTER KEY9 1 6435K150 MOTOR SHAFT COLLAR10 1 8975K14 MOTOR SHAFT COLLAR WASHER11 1 SUBASSEMBLY 6 SUBASSEMBLY 612 1 SUBASSEMBLY 2 SUBASSEMBLY 213 1 SUBASSEMBLY 3 SUBASSEMBLY 314 1 6867K557 ENCODER GEAR15 2 8975K14 SOLAR PANEL COLLAR WASHER16 2 6435K230 SOLAR PANEL COLLAR17 1 SUBASSEMBLY 4 SUBASSEMBLY 418 2 91772A548 SOLAR PANEL SUPPORT BEAM

SCREW19 2 91735A146 DIN RAIL SCREW20 1 N/A DIN RAIL21 1 N/A DEVICE CRAFT MOTOR DRIVER22 1 779026-01 NI-USB-6009 (DAQ)23 1 8975K14 DAQ WASHER24 1 91735A151 DAQ SCREW25 1 7779K140 HOMING SWITCH26 2 91772A099 HOMING SWITCH SCREW27 8 1556A650 BASE CORNER BRACKET28 8 90107A010 BASE CORNER BRACKET WASHER29 8 97124A339 SIDE BLOCK CORNER BRACKET

SCREW30 8 91735A194 BASE CORNER BRACKET SCREW

D

C

B

AA

B

C

D

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MATERIAL:

FINISH:



CAD-MA-0007

N/A

NONE


4/4/20164/19/2016






PART/ASSEMBLY NAME: MAIN ASSEMBLY

MAIN ASSEMBLY

1:6 1 of 3


48

D

C

B

AA

B

C

D

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8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0007

N/A

NONE


4/4/20164/19/2016







MAIN ASSEMBLY

1:5 2 of 3


49

24

23

22 1920


1 1 88685K984 BASE2 1 DCGM1501 DENSO 12V DC MOTOR3 3 9056K62 MOTOR SPACERS4 6 90272A155 MULTIPURPOSE SCREW5 1 SUBASSEMBLY 1 SUBASSEMBLY 16 1 N/A MOTOR SHAFT ADAPTER7 1 SUBASSEMBLY 5 SUBASSEMBLY 58 1 8975K14 MOTOR ADAPTER KEY9 1 6435K150 MOTOR SHAFT COLLAR10 1 8975K14 MOTOR SHAFT COLLAR WASHER11 1 SUBASSEMBLY 6 SUBASSEMBLY 612 1 SUBASSEMBLY 2 SUBASSEMBLY 213 1 SUBASSEMBLY 3 SUBASSEMBLY 314 1 6867K557 ENCODER GEAR15 2 8975K14 SOLAR PANEL COLLAR WASHER16 2 6435K230 SOLAR PANEL COLLAR17 1 SUBASSEMBLY 4 SUBASSEMBLY 418 2 91772A548 SOLAR PANEL SUPPORT BEAM

SCREW19 2 91735A146 DIN RAIL SCREW20 1 N/A DIN RAIL21 1 N/A DEVICE CRAFT MOTOR DRIVER22 1 779026-01 NI-USB-6009 (DAQ)23 1 8975K14 DAQ WASHER24 1 91735A151 DAQ SCREW25 1 7779K140 HOMING SWITCH26 2 91772A099 HOMING SWITCH SCREW27 8 1556A650 BASE CORNER BRACKET28 8 90107A010 BASE CORNER BRACKET WASHER29 8 97124A339 SIDE BLOCK CORNER BRACKET

SCREW30 8 91735A194 BASE CORNER BRACKET SCREW

D

C

B

AA

B

C

D

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8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0007

N/A

NONE


4/4/20164/19/2016







MAIN ASSEMBLY

1:8 3 of 3


50

.6250

R.1275

.1480+-.0010.0000

.1027

6.3300

6.2675

5.2525

.2720.2555

.227545.0000°

.1885

units are in inches

D

C

B

AA

B

C

D

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MATERIAL:

FINISH:



CAD-MA-0005

will edit manually

NONE


8/13/20124/19/2016






PART/ASSEMBLY NAME: MOTOR SHAFT

1346K240

1:1 1 of 1


51

33.000032.4360

29.63553.13551.0200 .8750

.6250

29.0288

3.7417

2X .2660 THRU ALL

.1750

1.1500+-.0000.0010

1.5000

A

R.1250

.0630+-.0010.0000

.0950

DETAIL ASCALE 2 : 1

For Left View, see sheet 2

units are in inches

D

C

B

AA

B

C

D

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8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0006

will edit manually

NONE


8/13/20124/19/2016






PART/ASSEMBLY NAME: SOLAR PANEL SHAFT

5947K560

1:7 1 of 2


52

1.5000

R.3125

.1953

.0943

Left View

D

C

B

AA

B

C

D

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MATERIAL:

FINISH:



CAD-MA-0006

will edit manually

NONE


8/13/20124/19/2016






PART/ASSEMBLY NAME: SOLAR PANEL SHAFT

5947K560

2:1 2 of 2


53

12.0000+-.0000.0100

B

C

.6250

A

4.0000

2.6230

2.0000

.4375

3.5625

.9375

3.0625

3.7500.2500

.6500

9.2600

6.2350

4X .1495 .510010-24 UNC .3800

2X .1360 .55008-32 UNC .4000

.001 M A B C

.001 M A B C

units are in inches

For left view, see sheet 2

D

C

B

AA

B

C

D

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MATERIAL:

FINISH:



CAD-MA-0001

6061-O (SS)

NONE


4/3/20164/19/2016






PART/ASSEMBLY NAME: BLOCK 1

8975K226

1:3 1 of 2


54

3.2500.7500.6500

2X .1360 .55008-32 UNC .4000

.001 M A B C

Left View

For datums A,B,and C, see sheet 1

D

C

B

AA

B

C

D

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MATERIAL:

FINISH:



CAD-MA-0001

6061-O (SS)

NONE


4/3/20164/19/2016







8975K226

1:3 2 of 2


55

12.0000+-.0000.0100

B

C

.6250

A

4.0000

3.56253.7500

3.0625

.9375.4375

.2500

2.0000

2.6230

6.7000

3.6750

.6500

4X .1495 .510010-24 UNC .3800

2X .1360 .55008-32 UNC .4000

9.5000

.001 M A B C

.001 M A B C

.001 M A B C

For the left view, see sheet 2

units are in inches

D

C

B

AA

B

C

D

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MATERIAL:

FINISH:



CAD-MA-0002

6061-O (SS)

NONE


4/3/20164/19/2016







8975K226

1:3 1 of 2


56

3.2500

2.7913

1.9173.7500

5.9150

5.5088

.6500

2X .0785 .46003-48 UNC .4000

2X .1360 .55008-32 UNC .4000

.001 M A B C

.001 M A B C

Left View

For datums A,B, and C, see sheet 1

D

C

B

AA

B

C

D

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8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0002

6061-O (SS)

NONE


4/3/20164/19/2016







8975K226

1:3 2 of 2


57

6.0000+-.0000.5000

B

4.0000

3.5625

2.0000

.4375

2.2500

1.2000

2X .1495 .510010-24 UNC .3800

1.3730

.001 M A B C

.001 M A B CA

.6250C

units are in inches

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0002

6061-O (SS)

NONE


4/3/20164/19/2016






PART/ASSEMBLY NAME: MOTOR SHAFT SUPPORT

8975K226

3:4 1 of 1


58

.1750+-.0050.0000

B

C

1.7500+-.0050.0000

.8750.1875

.2510

.3750.8125

.001 M A B C

.001 M A B C

A

1.3125

.4375

.0875

2X .1065 .77006-32 UNC .5800

.001 M A B C

Bottom View

units are in inches

D

C

B

AA

B

C

D

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8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0003

6061-O (SS)

NONE


4/3/20164/19/2016






PART/ASSEMBLY NAME: ENCODER BLOCK

8975K226

2:1 1 of 1


59

4.0000B

4.0000

3.5625

2.4375

1.5625

.4375

2.8000

1.3505

2X .1495 .510010-24 UNC .3800

2X .1495 THRU ALL

.001 M A B C

.001 M A B C

A C

.6250 units are in inches

For Bottom View, refer to sheet 2

D

C

B

AA

B

C

D

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8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0001

6061-O (SS)

NONE


4/3/20164/19/2016






PART/ASSEMBLY NAME: BLOCK 1 SUPPORT

8975K226

1:1 1 of 2


60

3.0625

.9375

2.8000

2X .1495 .510010-24 UNC .3800

.001 M A B C

Bottom View

For datums A,B, and C, refer to sheet 1

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0001

6061-O (SS)

NONE


4/3/20164/19/2016






PART/ASSEMBLY NAME: BLOCK 1 SUPPORT

8975K226

1:1 2 of 2


61

.5550+-.0010.0000

.2500

.1520

units are in inches

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0007

6061-T6 (SS)

NONE


4/3/20164/19/2016






PART/ASSEMBLY NAME: MOTOR SPACERS

9056K62

4:1 1 of 1


62

36.0000

B

C

24.0000

.6500

.7500

1.7500+-.0050.0000

9.6800+-.0050.0000

For locations of holes in Top View, refer to sheet 2 A

.3750 units are in inches

D

C

B

AA

B

C

D

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8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0007

1100-O Rod (SS)

NONE


4/3/20164/19/2016






PART/ASSEMBLY NAME: BASE

88685K984

1:6 1 of 3


63

24.0000

19.6004

19.1400

13.5845

13.7500

13.250011.4773

10.750010.4612

10.2500

13.7500

13.2500

10.7500

10.2500

13.40006.7165

5.1417

5.9149

4.5399

4.1613

2.70632.2849

2.83511.4601

For hole depth and size, see sheet 3All dimesnions in this sheet have a tolerance of

+.0010-.0000

D

C

B

AA

B

C

D

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MATERIAL:

FINISH:



CAD-MA-0007

1100-O Rod (SS)

NONE


4/3/20164/19/2016







88685K984

1:4 2 of 3


64

2X .1065 .34006-32 UNC .2800

.1065 .34006-32 UNC .2800

AB

.0010 M A B C

.0010 M A B C

8X .1360 .35508-32 UNC .3000

DETAIL ASCALE 2 : 5

.0010 M A B C 8X .1360 .35508-32 UNC .3000

3X .1065 .33006-32 UNC .2800

3X .1065 .33006-32 UNC .2800

3X .1065 .33006-32 UNC .2800

DETAIL BSCALE 2 : 5

.0010 M A B C

.0010 M A B C

.0010 M A B C.0010 M A B C

For datums A,B,and C, refer to sheet 1

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0007

1100-O Rod (SS)

NONE


4/3/20164/19/2016







88685K984

1:5 3 of 3


65

1.0000

.01 A B C

A

16.1250

12.0025

8.0625

4.1225

2X .2660 THRU ALL

.2010 .65001/4-20 UNC .5000

.001 M A B C

B

.7500

C

units are in inches

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0004

6061-O (SS)

NONE


4/3/20164/19/2016






PART/ASSEMBLY NAME: BOTTOM SOLAR PANEL SUPPORT BEAM

8975K14

1:3 1 of 1


66

.2060+-.0050.0000

.002 A B C

B

.1885+-.0050.0000

1.0150

A

C

units are in inches

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0005

6061-O (SS)

NONE


4/4/20164/19/2016






PART/ASSEMBLY NAME: MOTOR SHAFT GEAR KEY

8975K14

4:1 1 of 1


67

.1480.001 A B C

B

.2720+-.0060.0000

.0260

A C

units are in inches

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0007

6061-O (SS)

NONE


4/4/20164/19/2016






PART/ASSEMBLY NAME: MOTOR ADAPTER KEY

8975K14

16:1 1 of 1


68

.5000

B

.5000

.2570 THRU ALL5/16-18 UNC THRU ALL

.001 M A B C

1.0000

A

C

units are in inches

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0004

6061-O (SS)

NONE


4/3/20164/19/2016






PART/ASSEMBLY NAME: THREADED INSERTS SOLAR PANEL SUPPORT BEAM

8975K14

3:1 1 of 1


69

1.0000+-.0040.0000

B5.0078

.1065 THRU ALL6-32 UNC THRU ALL .5170

C

16.1250+-.0040.0000

11.9600

8.0625

3.0400

.5000

2X .2660 THRU ALL

.2010 .65001/4-20 UNC .5000

.001 M A B C

.001 M A B C

A

units are in inches

.001 M A B C

D

C

B

AA

B

C

D

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8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0004

6061-O (SS)

NONE


4/3/20164/19/2016






PART/ASSEMBLY NAME: TOP SOLAR PANEL SUPPORT BEAM

8975K14

1:3 1 of 1


70

1.8000

1.5100

.1250+-.0100.0000

units in inches

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0007

6061 Alloy

NONE


4/3/20164/19/2016






PART/ASSEMBLY NAME: SOLAR PANEL COLLAR WASHER

8975K14

2:1 1 of 1


71

.8500

.6260

.1250+-.0100.0000

units are in inches

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0007

6061 Alloy

NONE


4/3/20164/19/2016






PART/ASSEMBLY NAME: MOTOR SHAFT COLLAR WASHER

8975K14

4:1 1 of 1


72

.1000+-.0100.0000

.3000

.1600

units are in inches

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1





MATERIAL:

FINISH:



CAD-MA-0007

6061-O (SS)

NONE


4/3/20164/19/2016






PART/ASSEMBLY NAME: DAQ WASHER

8975K14

12:1 1 of 1


73

Documents

v3 FINAL FINAL PDF SOLAR PANEL PROJECT BY MYLES MARCUS