HowTo: Nerdiskerator - Assembling the brake actuator

For the assembly of the brake actuator you need the parts shown.

For the following assembly of only one actuator you will need only the half of the parts shown.

In this step, the punch is assembled. This also includes the force sensor for measuring the contact pressure.

Screw the brake block as shown with the inserted M6 nut.

Other view.

And put together the prepared component as shown.

The force sensor is then inserted into the slot between the 3D printed components.

To build the first gear, you will need the parts shown.

Now set the first ball bearing as shown....

...into the top of the gear.

Then turn the gear over and insert the spacer sleeve....

...into the axle guide.

Now you can insert the second ball bearing into the recess on the other side.

View of the inserted ball bearing.

In this step, the slide resistor is installed in the holder of the position sensor.

To do this, insert the slide resistor into the holder as shown....

...and screws it into it.

Other view.

Other view.

View of the finished screwed sliding resistor in the holder.

View of the finished screwed sliding resistor in the holder.

You will now need the components shown for further assembly.

First place the ball bearing in the recess as shown.

After that you can mount the brake actuator sensor bracket with the M3 nuts.

View of the inserted M3 nuts.

This allows the sliding resistor holder to be mounted on the brake actuator cover as shown.

This is done with the help of the previously inserted M3 nuts....

...and the M3 countersunk screws screwed.

To prepare the gear motor, you will now need the parts shown.

Place the gear wheel on the axis of the gearmotor.

Make sure this is seated almost all the way on the axle....

...and then fasten it with the screw shown.

View of the finished prepared gearmotor.

Now it is time to install the gearmotor in the brake actuator bracket.

To do this, place the prepared gearmotor in the recess in the base of the brake actuator as shown.

Now you can insert the M3 countersunk screws through the housing of the...

...into the base of the brake actuator.

Other view.

The screws are screwed with M3 nuts that you have to insert on the back.

Once you have screwed the gearmotor in place, the first gear can now be fitted.

For this you need the individual parts shown.

Now first place the ball bearing back into the recess shown in the base of the brake actuator.

Then insert the M3 countersunk screw through the base of the brake actuator so that it protrudes as shown.

The previously prepared gear can now be placed on top of this.

To be able to integrate the next gear into the gearbox, you now need the components shown.

Insert the M3 countersunk screws as shown....

...in the screw holes provided for this purpose here...

...and here.

So that the gear can be placed immediately on the axis of the brake actuator, you should now insert the M6 nut into the gear as shown.

You can then position the gear wheel on the base of the brake actuator.

Other view.

Now you can mount the prepared cover on the prepared holder of the brake actuator.

Other view.

Sets these for this purpose as shown on...

...and screws them to the base

To do this, place an M3 nut in each of the recesses provided.

Another view of one of the inserted M3 nuts.

Another view of one of the inserted M3 nuts.

Another view of one of the inserted M3 nuts.

Your brake actuator should now look like this when screwed together.

The parts shown are now required to install the brake cylinder.

Mounts the M6x100 screw to it ...

...as shown in this picture.

Then insert the remaining M6 nut into the recess provided in the brake socket.

Further view of the inserted M6 nut.

Now you can insert the brake block from below into the recess provided in the brake socket.

The connection lug of the force sensor should protrude from the base as shown.

Another view of the inserted brake cylinder.

Another view of the inserted brake cylinder.

Now you can screw the prepared M6 screw from above into the brake cylinder.

The M6 nut should ultimately be locked non-rotatably tight in the brake cylinder.

Once you have completed this step, you can build the mechanics for the brake position sensor.

Another view of the parts needed.

To do this, first build the driver for the sliding resistor of the sensor...

...together...

...and plugs it onto the sliding contact of the slide resistor.

Another view of the prepared slider of the slide resistor.

Now you can attach the lever of the mechanism and bring it into position as shown.

Then screw the lever point with one of the M3 countersunk screws and M3 nut.

Another view of the partially installed sensor lever.

In the last step you need to fix the anchor point of the lever.

. For this purpose, sets a M3 countersunk screw incl. M3 nut into the...

...screw hole shown here.

The M3 bolt is screwed on the other side with an M3 nut.

When finished, this should look like this.

Other view.

That was it with the construction of the first brake actuator. Now you only have to repeat these steps for the other half.

Another view of the partially assembled brake actuator.

The finished brake actuator could then look like this.

Other view.