Gear Clock Assembly Instructions and User Guide

Rev 1.0 February 2010 www.alan-parekh.com Copyright 2010 Alans Electronic Projects Inc.

Gear Clock Assembly Instructions and User Guide

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Gear Clock Assembly Instructions and User Guide

1. Introduction ................................................................................... 5
1.1 Concept of Operation................................................................................................ 5 1.2 Device Features......................................................................................................... 5

2. Kit Assembly Electronic Control Board ....................................... 6

2.1 Unpack the Control Board Parts ............................................................................... 6 2.2 Control Board Assembly........................................................................................... 9 1. Install the resistors. ............................................................................................. 9 2. Install the diodes ............................................................................................... 11 3. Install the transistors ......................................................................................... 12 4. Install the 22pF capacitors ................................................................................ 13 5. Install the crystal oscillator ............................................................................... 14 6. Install the 0.1uF capacitor................................................................................. 15 7. Install the buttons.............................................................................................. 16 8. Install the 47uF capacitor.................................................................................. 17 9. Install the chip socket........................................................................................ 18 10. Install the 100uF capacitor............................................................................ 20 11. Install the terminal blocks............................................................................. 21 12. Install the voltage regulator .......................................................................... 22 13. Install the microcontroller chip..................................................................... 23

3. Kit Assembly Clock Gears ........................................................ 24

3.1 Unpack the Gears and Hardware ............................................................................ 24 3.2 Mechanical Clock Construction.............................................................................. 28 1. Install the power cable ...................................................................................... 28 2. Install the clock control board and connect power ........................................... 30 3. Install the stepper motor.................................................................................... 31 4. Hour gear assembly........................................................................................... 35 5. Minute gear assembly ....................................................................................... 37 6. Lower 72 tooth gear assembly .......................................................................... 39 7. Mount gear assemblies to backplane ................................................................ 41

4. Clock Operation .......................................................................... 45

4.1 How to read the time............................................................................................... 45 4.2 How to Adjust the Time.......................................................................................... 46

5. MDF Clock Gear Finishing .......................................................... 47

5.1 Tab removal ............................................................................................................ 47 5.2 MDF cleaning ......................................................................................................... 48 5.3 MDF painting.......................................................................................................... 48

6. Clock Hanging............................................................................. 49 7. Maintenance................................................................................ 49 8. Appendix ..................................................................................... 50

8.1 Gear Clock Control Board Schematic..................................................................... 50 8.2 Circuit Board Diagram All Layers....................................................................... 51 8.3 Circuit Board Layout Diagram ............................................................................... 52 8.4 Circuit Board Top Copper Layer ............................................................................ 53 8.5 Circuit Board Bottom Copper Layer....................................................................... 54 8.6 Circuit Board Assembled Photo.............................................................................. 55

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Gear Clock Assembly Instructions and User Guide

Revision History
Date Feb 2, 2010 Revision 1.0 Author(s) Alan Parekh Description Document creation.

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Gear Clock Assembly Instructions and User Guide

1. Introduction
Thank you for purchasing the Gear Clock kit. This document will walk you through the assembly and usage of the kit. If you have any questions please dont hesitate to send us an email at support@alan-parekh.com. Additional information can be found at http://alan-parekh.com/kits/gear-clock-kit.

1.1 Concept of Operation

The Gear Clock project is microcontroller based, what this means is there is a small self contained computer that controls the clock. This microcontroller uses an external 20MHz crystal oscillator to accurately keep track of time. The microcontroller is interfaced to two buttons and a motor. The buttons are used to set the clock and the motor is used to precisely control the gear rotation. The six clock gears are arranged in such a way that the two large upper gears can be used to read time directly from them. The gear arrangement is as follows: 9 tooth motor gear 72 tooth minute gear with a 24 tooth secondary 72 tooth intermediate gear with a 18 tooth secondary 72 tooth hour gear

1.2 Device Features

Unique clock design. Simple to read. Accurate time keeping since a crystal oscillator is used.

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Gear Clock Assembly Instructions and User Guide

2. Kit Assembly Electronic Control Board

Many of the components in this kit are sensitive to static discharge. Before you begin it is important that you remove any static electricity from your body by grounding yourself. This is simply done by touching any grounded metal that is by the area you are going to be assembling the board in. A bare metal computer power supply is an example of something that might be close at hand and provides a good ground point. You must ground yourself again if you walk away and return to the location where you are assembling your control board. An antistatic wrist strap is a good investment if building many kits such as this one is in your future.

2.1 Unpack the Control Board Parts

Before we begin assembling the clock control board, make sure that your kit came with everything needed. Below are some pictures of the items that should be in the kit. Please note that some items might be in antistatic or crush protective casings.

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Gear Clock Assembly Instructions and User Guide

Mounting Hardware

Terminal Blocks

20 MHz Crystal Oscillator

22pF Capacitors

LM7805 5 Volt Regulator

18 pin Socket and Microcontroller

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Gear Clock Assembly Instructions and User Guide Capacitors (left to right) 35V 100uF, 10V 47uF, 50V 0.1uF

Tactile Buttons

2N4401 Transistors (or compatible)

1N4001 Diodes (or compatible)

330 Ohm Resistors

Custom Printed Circuit Board

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Gear Clock Assembly Instructions and User Guide

2.2 Control Board Assembly

To assemble the Gear Clock control board you will need a soldering iron, solder and wire cutters. Some masking tape would be helpful but is optional. Many of the components look similar but if installed in an incorrect location can cause damage to the control board. It is very important to ensure that components are installed in the correct positions. We are going to start by installing the shortest components and progress to the larger ones. When the instructions say to install this means to place the leads through the required holes allowing the component to sit close to the board, soldering the component in place and trimming the leads. If you have never soldered before it is recommended that some online tutorials are reviewed prior to put this kit together. 1. Install the resistors. Resistors positions are marked with an R followed by a number. Resistors are non-polarized, this means that they can be install in either direction. There is only one value of resistor used in this kit to keep things simple. Please note that R4 selects the type of stepper motor that is being used, see the chart below to determine if you need to install it or leave it out. R3 is for future use, this resistor location should be left empty. The value of the resistor is represented by colored bands on the resistor. 330 ohms is ORANGE, ORANGE, BROWN, GOLD. R1: 330 ohms R2: 330 ohms R5: 330 ohms R6: 330 ohms R7: 330 ohms R8: 330 ohms Motor Type 48 Steps per rotation 200 Steps per rotation R4 R4 Should be left empty R4 should have a 330 ohm resistor installed

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Gear Clock Assembly Instructions and User Guide Resistors ready to install 330 ohms resistors

Insert resistors into PCB

Flare leads to hold them in place

Solder all leads to PCB

Trim leads

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Gear Clock Assembly Instructions and User Guide

2. Install the diodes. There are five diodes to install and they are polarity sensitive. These components are listed as D1, D2, D3, D4 and D5 on the board. The white bar on one end of the diode represents negative, this marking is also on the board for easy reference.

Diodes ready to install

Note the white band on the top

Note the white band on the PCB

Insert diodes into PCB

Flare the leads to hold them in place

Solder all leads to PCB

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Gear Clock Assembly Instructions and User Guide Trim leads Diode installation complete

3. Install the transistors. There are four transistors to install and they are polarity sensitive. These components are listed as Q1, Q2, Q3 and Q4 on the board. The image on the board has a curved section which represents the correct part orientation.

Transistors ready to install

Insert transistors into PCB

Masking tape is helpful to hold the transistors in place

Flip the board and ensure good alignment of the parts

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Gear Clock Assembly Instructions and User Guide Solder all leads to PCB Trim leads

Transistor installation complete

4. Install the 22pF capacitors. There are two 22pF capacitors to install, they are non-polarized, this means that they can be installed in either direction. These components are listed as C1 and C2 on the board.

Capacitors ready to install

Insert capacitors into PCB

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Gear Clock Assembly Instructions and User Guide Flare the leads to hold them in place Solder all leads to PCB

Trim leads

Capacitor installation complete

5. Install the crystal oscillator. The 20 MHz crystal oscillator gets installed in the position marked as OSC1 on the board. The oscillator is non-polarized, this means that it can be installed in either direction.

Oscillator ready to install

Insert oscillator into PCB

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Gear Clock Assembly Instructions and User Guide Flare the leads to hold them in place Solder all leads to PCB

Trim leads

Oscillator installation complete

6. Install the 0.1uF capacitor. The 0.1uF capacitor gets installed in the position marked as C5 on the board. This capacitor is non-polarized, this means that it can be installed in either direction.

Capacitor ready to install

Insert capacitor into PCB

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Gear Clock Assembly Instructions and User Guide Flare the leads to hold them in place Solder all leads to PCB and trim

Capacitor installation complete

7. Install the buttons. The two buttons get installed in the positions marked as S1 and S2 on the board.

Buttons ready to install

Insert buttons into PCB

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Gear Clock Assembly Instructions and User Guide The leads will snap into position Solder all leads to PCB

Button installation complete

8. Install the 47uF capacitor. There is one 47uF capacitor that needs to be installed in location C4 on the board. This component is polarity sensitive, the positive lead is marked on the board and the negative lead is represented by a black stripe on the capacitor.

Capacitor ready to install

Insert capacitor into PCB

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Gear Clock Assembly Instructions and User Guide Flare the leads to hold them in place Solder all leads to PCB and trim

Capacitor installation complete

9. Install the chip socket. The chip socket gets installed in the location marked as U1. U1 is actually the listing for the microcontroller however since the microcontroller gets plugged into the socket the location is the same. This part is polarity sensitive, there is a notch on the socket and a notch shown on the board. Align these notches when installing.

Capacitor ready to install

Note the notch on the left side of the socket

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Gear Clock Assembly Instructions and User Guide Note the notch on the board Insert socket into PCB

Bend two opposing pins to hold it in

Solder all pins

Socket installation complete

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Gear Clock Assembly Instructions and User Guide 10. Install the 100uF capacitor. There is one 100uF capacitor that needs to be installed in location C3 on the board. This component is polarity sensitive, the positive lead is marked on the board and the negative lead is represented by a black stripe on the capacitor.

Capacitor ready to install

Insert capacitor into PCB

Flare the leads to hold them in place

Solder all leads to PCB

Trim leads

Capacitor installation complete

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Gear Clock Assembly Instructions and User Guide 11. Install the terminal blocks. There are two terminal blocks that need to be installed. They are listed as TB1 and TB2 on the board. The terminal blocks need to be installed so that the wire openings are facing outward.

Terminal blocks ready to install

Insert terminal blocks into PCB

Ensure correct orientation of TB2

Ensure correct orientation of TB1

Solder pins

Terminal Block installation complete

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Gear Clock Assembly Instructions and User Guide 12. Install the voltage regulator. The voltage regulator needs to be installed in position U2 and is polarity sensitive. The heat sink side is indicated on the board with a white bar. The regulator lettering should be facing out when installed correctly.

Regulator ready to install

Insert regulator into PCB

Solder pins

Trim leads

Regulator installation complete

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Gear Clock Assembly Instructions and User Guide 13. Install the microcontroller chip. The microcontroller chip gets installed in the location marked as U1. There should be a socket soldered into this location already. The pins may need to be bent inward slightly to allow it to plug into the socket easily. If this is the case gently press all of the pins on one side against a table to slightly tweak the pins, perform this action equally on the opposite side pins. This part is polarity sensitive, there is a notch on the microcontroller that needs to be aligned with the notch shown on the board and socket. Align these notches when installing. Microcontroller ready to install Note the notch on the left side of the chip

Gently bend pins inward if needed

Align notches on board, socket and chip

Press chip in place

Microcontroller installation complete

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Gear Clock Assembly Instructions and User Guide

3. Kit Assembly Clock Gears

The clock gears are made from MDF (medium density fiberboard) wood. If you ordered them painted you are ready to start the gear assembly, if not you will need to paint the MDF gears prior to assembly. See the gear finishing section for some tips on painting them. Assembly of the clock gears is quite simple, screws hold the gear sections together and the completed gears turn on large bolts. Everything is pre-drilled so there should be no alignment issues.

3.1 Unpack the Gears and Hardware

Before we begin assembling the clock hardware make sure that your kit came with everything needed. Below are some pictures of all the items that should be in the kit. Please note that some items such as the power supply and stepper motor might look slightly different than shown below. The clock control board needs to be assembled prior to this step, the assembled board is shown below.

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Gear Clock Assembly Instructions and User Guide 72 tooth hour gear 72 tooth minute gear

72 tooth lower gear

Spacers and small gears, more details below

5 hole spacers, Qty 4

3 hole spacers, Qty 3

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Gear Clock Assembly Instructions and User Guide 9 tooth motor gear 24 tooth gear

18 tooth gear

Motor spacer

Wire clamps and screws (8 X 3/8), Qty 2

Motor screws (8 X 1 3/4), Qty 2

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Gear Clock Assembly Instructions and User Guide Washers, Qty 3 Gear screws (8 X 3/4), Qty 18

Bolts (1/4 X 2 1/2), Qty 3

Control Board and mounting hardware

Stepper motor

Clock backplane

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Gear Clock Assembly Instructions and User Guide

3.2 Mechanical Clock Construction

To assemble the Gear Clock mechanical portion you will need a Robertson #2 screw driver, terminal driver (small flat blade screw driver), 11mm wrench, wire cutters, wire strippers, painters tape. Some electrical tape may be also needed. MDF wood is a strong material but use caution when tightening screws. It is possible to strip the material if a screw is over-tightened. You want the screw connections to be snug only. 1. Install the power cable. The power cable enters the bottom center of the clock backplane. There is a wire path routed in the rear of the backplane to allow the wire to be concealed. Two nylon wire clamps are used to secure the wire in place and a hole behind the control board location allows the wire to pass to the front. Depending on the diameter of the wire being used, it may be necessary to increase the diameter of the wire using a few wraps of electrical tape to allow the wire clamps to hold it securely. If the length of the wire is not long enough the power supply wires can be extended using some similar wire, the joints should be soldered and protected using some heat shrink.

Power supply ready to install

Nylon clamps and 3/8 inch screws

Check to see how the clamp fits the wire, in this case it is too loose

Electrical tape is needed if the diameter of the wire is too small

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Gear Clock Assembly Instructions and User Guide Run the power wire in the channel Leave about 4 inches past the second clamp

Pass the wire to the front through the provided hole

Adjust wire thickness with tape if needed

Secure the clamp

Keep the wire taught and connect the lower clamp the same way as the first

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Gear Clock Assembly Instructions and User Guide Wire routing completed Front view of wire exit location

Front view of backplane

Strip the power wires

2. Install the clock control board and connect power. The clock control board needs to be installed onto the backplane. There are 4 pre-drilled holes surrounding the power cable. The control board gets mounted on top of 4 standoffs. The power wires also need to be connected to the control board. The control board is expecting a 12 volt DC supply to be connected to the first 2 locations of TB1. If you are unsure of the power supply polarity use a meter to determine which lead is positive and which lead is negative. Control board ready to install Place the 4 standoffs over the holes

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Gear Clock Assembly Instructions and User Guide Place the control board and screws over the standoffs and adjust wire as shown

Gently screw in all 4 screws

Connect the power leads as shown positive on the left and negative on the right Tuck any remaining wire under the board

3. Install the stepper motor. The stepper motor needs to be mounted to the backplane and wired to the control board. There is a gear that needs to first be press fit onto the stepper motor shaft. Then the motor is attached to the backplane using 2 screws, a motor spacer is used to achieve the correct final height.

Motor gear ready to install

There is a small shaft hole in the gear

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Gear Clock Assembly Instructions and User Guide Position motor shaft into the hole Gently press the gear straight onto the shaft

Completed gear attachment

Motor assembly ready to install

Position the motor spacer over the Pre-drilled holes as shown

Place the motor onto the motor spacer ensure the wires are exiting to the rear

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Gear Clock Assembly Instructions and User Guide Position mounting screws as shown Screw them in place till snug

Loop the motor wire under the control board as shown

Tighten the wires against the standoff as shown

Loop a cable tie around the wires and around the standoff

Tighten the cable tie and clip off excess

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Gear Clock Assembly Instructions and User Guide Cut off excess motor wire Make sure you leave enough to work with

Strip off the ends of all motor wires

Attach the motor wires to the controller Stepper + = both red wires Coil 1 = brown wire Coil 2 = yellow wire Coil 3 = black wire Coil 4 = orange wire

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Gear Clock Assembly Instructions and User Guide 4. Hour gear assembly. The hour gear consists of one 3 hole spacer, 2 five hole spacers, the large hour gear and 6 mounting screws. All of the pieces are attached together using screws starting with the 3 hole spacer which will eventually rest against a washer on the backplane. It is important to use the 2 1/2 inch bolt during this assembly process to ensure that the assembly remains properly centered.

Hour gear assembly ready to assemble

Set a 5 hole spacer above a 3 hole spacer

Insert the bolt in the center hole

Tighten the screws until snug

Set a 5 hole spacer above the assembly

Insert the bolt in the center hole

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Gear Clock Assembly Instructions and User Guide Tighten the screws until snug Set the hour gear above the assembly

Insert the bolt in the center hole

Tighten the screws until snug

Assembly complete, side view

Assembly complete, top view

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Gear Clock Assembly Instructions and User Guide 5. Minute gear assembly. The minute gear consists of one 3 hole spacer, a 24 tooth gear, 1 five hole spacers, the large minute gear and 6 mounting screws. All of the pieces are attached together using screws starting with the 3 hole spacer which will eventually rest against a washer on the backplane. It is important to use the 2 1/2 inch bolt during this assembly process to ensure that the assembly remains properly centered. Minute gear assembly ready to assemble Set the 24 tooth gear above a 3 hole spacer

Insert the bolt in the center hole

Tighten the screws until snug

Side view of assembly so far

Set a 5 hole spacer above the assembly

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Gear Clock Assembly Instructions and User Guide Insert the bolt in the center hole Tighten the screws until snug

Side view of assembly so far

Set the minute gear above the assembly

Insert the bolt in the center hole

Tighten the screws until snug

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Gear Clock Assembly Instructions and User Guide Side view of completed assembly

6. Lower 72 tooth gear assembly. The lower 72 tooth gear assembly consists of one 3 hole spacer, the large 72 tooth gear, 1 five hole spacers, an 18 tooth gear and 6 mounting screws. All of the pieces are attached together using screws starting with the 3 hole spacer which will eventually rest against a washer on the backplane. It is important to use the 2 1/2 inch bolt during this assembly process to ensure that the assembly remains properly centered. 72 tooth gear assembly ready to assemble Set the 72 tooth gear above a 3 hole spacer

Insert the bolt in the center hole

Tighten the screws until snug

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Gear Clock Assembly Instructions and User Guide Set a 5 hole spacer above the assembly Insert the bolt in the center hole

Tighten the screws until snug

Set the 18 tooth gear above the assembly

Insert the bolt in the center hole

Tighten the screws until snug

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Gear Clock Assembly Instructions and User Guide Side view of completed assembly Side view of completed assembly

7. Mount gear assemblies to backplane. All three large gear assemblies need to be bolted to the clock backplane. A washer will be inserted between the gear assembly and backplane to reduce friction. The center bolts are used as rotating shafts and should not be tightened all the way down. There should be about 1/16 of an inch play in the gear when properly mounted to allow it to rotate with little friction. The bolts will self tap threads into the MDF when they are inserted, it is important that they are inserted very straight so that the gears run true. Gear assemblies ready to install Place a washer over center gear location

Place lower 72 tooth gear on washer

Gear in place, ready to secure

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Gear Clock Assembly Instructions and User Guide Place the tape where the wrench will contact the gear

Painters tape can be used to protect paint

Gently tighten till there is about 1/16 inch of play

Bolt head will be partially countersunk when complete

Lower 72 tooth gear install complete Ensure the screw pattern remains vertical

Place a washer over left gear location

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Gear Clock Assembly Instructions and User Guide Gear in place, ready to secure Ensure the screw pattern remains vertical

Place hour gear on washer

Place tape where the wrench will contact the gear

Insert this bolt the same as the last one

Hour gear install complete

Place a washer over right gear location

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Gear Clock Assembly Instructions and User Guide Gear in place, ready to secure Ensure the screw pattern remains vertical

Place minute gear on washer

Place tape where the wrench will contact the gear

Insert this bolt the same as the last one

Clock assembly complete

Side view of completed clock

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Gear Clock Assembly Instructions and User Guide

4. Clock Operation
The clock was designed to be simple to read and operate. There are only two buttons used to set the clock and the clock numbers are large enough to easily be seen from across the room.

4.1 How to read the time

Time is read by seeing what number is on the top of each number wheel. The left number is the hour indication and the right number is the minute indication. Below are some examples. Time shown is 12:00 Time shown is 7:25

Time shown is 9:52

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Gear Clock Assembly Instructions and User Guide

4.2 How to Adjust the Time

There are two buttons on the control board which are used to adjust the time displayed. To increment time press the Increment button which is the lower button when the control board is mounted on the backplane. To decrement time press the Decrement button which is the upper button when the control board is mounted on the backplane. To release the stepper motor allowing the minute gear to be turned by hand press both buttons at the same time.

Increment is on the left, decrement is on the right

When mounted the lower button is increment

When mounted the upper button is decrement

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Gear Clock Assembly Instructions and User Guide

5. MDF Clock Gear Finishing

If you ordered your clock un-painted you will need to follow some simple steps to achieve a nice looking finish.

5.1 Tab removal

Some of the MDF parts will have small tabs left over from the milling process. Since they are so small they will often break apart by themselves. If the tabs still connect two pieces together simply twist the part to remove it. Once the parts have all been separated there will be some small bumps on some of the surfaces. Three or four light sweeps of 120 grit sand paper will remove the bumps completely. Example of a part that has small tabs Three inner tabs can been seen here

120 grit sand paper can be used to remove the remaining bumps

3 or 4 light rubs is all it take to remove them

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Gear Clock Assembly Instructions and User Guide

5.2 MDF cleaning

All of the parts are thoroughly vacuumed after they are cut out however there may still be some dust deposits in tight spots such as in the wire channels and in the gear teeth. It is recommended that a small stiff brush be used to remove any remaining light dust, then vacuum all the wood pieces a final time. A few blasts of compressed air is also effective at cleaning out the brush loosened dust.

5.3 MDF painting

It is a good idea to prime the MDF parts prior to painting them. Pay special attention to the center gear holes since if you build up too many layers in there the gears may not spin freely on the bolt shaft. You can stuff the center holes with cotton balls if you want to prevent this from happening. One tip for painting the recessed numbers of the two time gears is to paint the number color first then when that is dry use a foam roller with just a bit of paint to lightly roll paint on the surface. This has to be done in a number of very light coats to prevent any paint from getting into the recessed number area. The edges of the gears will be rubbing against each other for a long time. To ensure the paint in this area lasts a long time it is important that the gears spin freely and are not being pinched anywhere. A tough clear coat can be painted onto the edges of the gears to enhance the wear protection if desired.

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6. Clock Hanging
The final weight of the clock will be around 3KG (6.6 LBS). Because of this weight a standard picture hanger will not be strong enough. To support the weight it is recommended that a screw with a length of around 2 inches is used. It is preferable for this screw to be driven into a wall stud however a drywall anchor can also be used as shown below.

Drywall anchor and screw mount

Leave out a little more than 1/2 inch

Due to the weight imbalance caused by the heavy stepper motor the notch right of center should be ideal

A few felt pads could be installed on the rear of the clock to prevent direct wall contact

7. Maintenance
Any dust accumulation on the Gear Clock Control circuit board should be blown off. Canned compressed air works well for this purpose and is available at any computer store. We recommend powering down the controller during cleaning.

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8. Appendix
8.1 Gear Clock Control Board Schematic

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8.2 Circuit Board Diagram All Layers

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8.3 Circuit Board Layout Diagram

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8.4 Circuit Board Top Copper Layer

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8.5 Circuit Board Bottom Copper Layer

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8.6 Circuit Board Assembled Photo

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