Lightning Ball Tools Required: ø 2 ø 3,5 ø 4 Pencil. Drill. Ruler. Fretsaw. Handsaw with Metal Saw Blade. Hot Glue Gun.

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Tobias Ferguson
5 years ago
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113.185 Tools Required: ø 2 ø 3,5 ø 4 Pencil Ruler Drill Fretsaw Handsaw with Metal Saw Blade Sandpaper Hot Glue Gun Soldering Iron

Not suitable for children under 36 months. Choking hazard!

Plywood 1 5x200x200 Base Plate 1 PVC Roll, oval 1 ø 10 Propulsion 2 Motor R20 1 ø 21 Propulsion 3 Battery Holder 1 2x Mignon 4

1 Tools Required: ø 2 ø 3,5 ø 4 Pencil Ruler Drill Fretsaw Handsaw with Metal Saw Blade Sandpaper Hot Glue Gun Soldering Iron Please note: The OPITEC handicraft packs are not toys in a typical off-the-shelf sense, but rather additional teaching and learning material for educational purposes. This craft pack may only be constructed by children and adolescents under the guidance and supervision of experienced adults. Not suitable for children under 36 months. Choking hazard! Choking hazard! Side Cutter File Tape/ Insulating Tape Phillips Screwdriver Stocklist Quantity Size (mm): Description Part-No. Plywood 1 5x200x200 Base Plate 1 PVC Roll, oval 1 ø 10 Propulsion 2 Motor R20 1 ø 21 Propulsion 3 Battery Holder 1 2x Mignon 4 Connecting Wire Circuit 5 Push Button 1 12x29 Circuit 6 Plastic Pipe 1 ø 25x340 Cover Shaft 7 Metal Shaft 1 ø3x70 Bearing 8 Silicone Tube 1 ø2/4x20 Bearing 9 Aluminium Roll, oval 1 ø 10 Propulsion 10 Washer 2 ø7 Bearing 11 Bolt 2 2,9x9,5 Circuit 12 Elastic Band 1 approx Stainless Steel Ball with Hole 1 ø

1 2 3 1 2 Copy the drawing (page 11) onto the

Saw out the base plate and smooth the sawn edges.

5 6 4 3 6 Clip off 3 cm of the red wire of the

Strip the insulation from the red wire ends at a

Solder the black wire end of the battery holder

2 Copy the drawing (page 11) onto the plywood (1). Saw out the base plate and smooth the sawn edges. Press the PVC-roll (2) onto the motor shaft (3) with approx. 1 mm clearance Use hot glue to fix the motor centered onto the centere of the base plate.. Support the motor with hot glue on both sides Clip off 3 cm of the red wire of the battery holder (4). Strip the insulation from the red wire ends at a length of approx. 3mm. Solder the black wire end of the battery holder and the short red wire to the motor - polarity is unimportant! 2 Connect the short red wire of the motor to one button (6) pole. Then solder the red wire of the battery holder to the other pole.

7 8 4 6 Fix the battery holder with hot glue (position as per

!!) of hot glue (position as per drawing on page 11).

Cut the plastic pipe (7) to a length of 7a = 160mm + 7b = 80

3 Fix the battery holder with hot glue (position as per drawing on page 11). Fix the button with just a little bit (!!!) of hot glue (position as per drawing on page 11) Insert battery and give the motor a test run. Cut the plastic pipe (7) to a length of 7a = 160mm + 7b = 80 mm as per cutting template (see pg. 9). Smooth the cuts with a file Mark the motor opening and the slits for the shaft as per template on page 9. Saw the motor openings - smooth the cutting edges properly. 3

13 14 ø4 ø2 Pre-drill the ø 4mm slits for the shaft before sawing the out thoroughly. Mark and drill the two ø 2mm holes as per template (see pg 9). 15 16 9 Saw the metal shaft (8) in half.

4 13 14 ø4 ø2 Pre-drill the ø 4mm slits for the shaft before sawing the out thoroughly. Mark and drill the two ø 2mm holes as per template (see pg 9) Saw the metal shaft (8) in half. Deburr the cutting edges. Cut off 2 x 6mm pieces from the tube (9) using scissors. 17 ø3, Drill the aluminium rolls (10) ø 3,5mm and place the shaft (8) centered. Put the washers (11) + both tube pieces (9) on the shaft as illustrated. 4

Pull the rubber band out of the pipe from below and put it over the PVC roll. Please note: the rubber band must not be twisted inside the pipe.

5 19 20 Clean the rubber band (13) properly with spiritus, alcohol or soapy water. After drying, put the rubber band around the alu-rolls, insert them into the standpipe and press the shaft into the slits. Pull the rubber band out of the pipe from below and put it over the PVC roll. Please note: the rubber band must not be twisted inside the pipe Put the pipe centered over the roll. Start the motor and give it a test run. Adjust the height of the pulley until the band runs smoothly around its centre Fix the shaft successively on both ends with cellotape. Centre the pipe one more time and start the motor. If everything functions properly, fix the position of the pipe with sufficient hot glue. 5

25 26 7b 7a Screw the two bolts (12) in the 2mm holes with just 2-3 turns.

Then undo screw until band runs properly again. Adjust 2.

Fix the spacer tube (7b = 80mm) centred on top of the standpipe (7a)

27 5 28 Cut off a 160 mm piece from the wire and strip its insulation

Wind the end of one wire aound the bolt without changing its position.

6 b 7a Screw the two bolts (12) in the 2mm holes with just 2-3 turns. Screw one bolt in until the rubber band runs slower. Then undo screw until band runs properly again. Adjust 2. bolt the same way. Fix the spacer tube (7b = 80mm) centred on top of the standpipe (7a) using cellotape Cut off a 160 mm piece from the wire and strip its insulation completely. Wind the end of one wire aound the bolt without changing its position. Use adhesive tape to attach the loose end of the wire on both sides above the spacer tube so that the wire loop protrudes approx. 3-5mm at the top Put the metal ball onto the spacer pipe. Saw the two pipe pieces 7c = 35mm (motor cover) and 7d = 70mm (battery cover) legthwise in half. 6

31 Bend up the motor cover (7c) as illustrated and place it on top of the motor.

32 33 Function Test: One finger has to be in contact with the lower bolt!

When starting the lightning ball for the first it might take a couple of minutes until high voltage is reached!

On days with a higher level of humidity, the function may be restricted partially or even completely.

7 31 Bend up the motor cover (7c) as illustrated and place it on top of the motor. Then bend up the battery holder and put it on the battery holder as illustrated. Done! Function Test: One finger has to be in contact with the lower bolt! Approach the ball with the back of the other hand until a spark is generated. This experiment only works with dry skin. Clammy hands will discharge voltage. Important notes and tips: The high-voltage generator only works if the lower bolt is touched (current supply). When starting the lightning ball for the first it might take a couple of minutes until high voltage is reached! Humidity + Grease are the enemies of high-voltage! On days with a higher level of humidity, the function may be restricted partially or even completely. Only use high power batteries (replace in time)! 34 Improving the high-voltage generator: [[softreturn /]] To prevent unwanted spraying of high voltage, insulate the ball opening with adhesive tape. [[SoftReturn /]] Cover the hole with adhesive tape. Afterwards, cut the adhesive tape 6-8 times from the center to the edge of the hole and stick it to the inside. Eventually, the ball is put back on again. 7

8 Experiments: Loosen some cotton wool and place it on the ball. Then turn on the generator and touch the lower screw with one hand. Hold the other hand over the cotton wool. The cotton starts to jump between the steel ball and the hand. You can also let the cotton fly if no hand is held above the ball. Loosen some cotton wool and place it on the ball. Then turn on the generator and touch the lower screw with one hand. Hold the other hand over the cotton wool. The cotton starts to jump between the steel ball and the hand. You can also let the cotton fly if no hand is held above the ball. Suggestions for additional experiments: Hold a wiggy tester to the ball. The bulb lights up. - hold a rainbow LED (202871) close to the ball. If polarity is correct, the diode suddenly shines. For that to happen, bend up the connecting wires and hold one connector of the LED between your fingers and the other connector towards the ball. - polystrene shreds stick to the ball. A second ball creates beautiful lightnings in between the two balls. With this high-voltage generator various interesting experiments can be conducted. Examples can be found on the internet. Safety instructions: High-voltage generator must not be operated close to electrical devices such as cellphones, computers, etc.! High-voltage might damage these devices. The power of this high-voltage generator is so low that people are not at risk. 8

9 Cutting Template Plastic Pipe (7) M 1:2 Standpipe (7a) M 1:1 Frontal View Side View Covers (7c + 7b) M 1:1 Side View 9

10 10

11 Base Plate M 1:1 11

Solar Trike w i t h A C C U b a t t e r y d r i v e a n d LED lighting

1.693 Solar Trike w i t h A C C U b a t t e r y d r i v e a n d LED lighting Necessary materials Fretsaw with metalworking blade drills. dia. 3,, 6, 7, Machine vice with soft jaws Soldering iron, solder