edge.rit.eduedge.rit.edu/edge/P09011/public/week/Supp/Repair Gui… · Web viewObserve the location where the hole is drilled in the pulley and drill a ¼” hole in the same location

Beluga Object Recognition Research StudyRepair Guide

Table of Contents

How to replace a thumbscrew 3

How to restring a cable for objects or object shields 8

How to replace a spring clip11

How to replace a leveling foot 15

How to replace a gas spring 16

How to replace a thumbscrew nut 18

How to replace a broken latch 20

How to replace an object cable pulley 21

How to replace an object shield grommet 22

How to remove sharp edges or rust from an object or apparatus component 24

How to restring a cable on an object 25

2

How to Replace a Thumbscrew

If a thumbscrew is lost or damaged, it will need to be replaced. This procedure outlines the process of reattaching a thumbscrew to the apparatus.

Materials Needed: 120lb nylon coated steel wire Size 5 Metal Cable Sleeves Thumbscrew with 1/8” hole drilled near edge of

top (size 1-1/4” for object frame thumbscrew, size 1-1/2” for drive frame thumbscrew)

Cable cutter/crimper

Procedure:1. Using the blade section of the cable

cutter/crimper, cut a 10” piece of stainless steel wire.

2. Using the blade section of the cable cutter/crimper, cut two metal cable sleeves into equal sized pieces.

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3. Using the flat edge of the cable cutter/crimper, compress the flattened ends of the cable sleeves to return the sleeves to a round tube shape.

4. Using the crimping section of the cable cutter/crimper, crimp one of the half-sized cable sleeves at one end of the 10” piece of stainless steel wire. Ensure that the steel wire is inserted completely into the cable sleeve with nothing protruding out the other end.

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5. As a secondary measure to ensure adequate crimp strength, flatten the crimp a second time using the flat section of the cable cutter/crimper. The crimp should be completely deformed to a flat shape.

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6. Slide the free end of the stainless steel wire through the hole in the thumbscrew from the bottom (threads) side to the top.

7. Slide on a half-sized cable sleeve from the free end of the stainless steel cable.

8. Crimp the sleeve next to the top of the thumbscrew, leaving a small 1/8” space to allow movement of the stainless steel wire. Use the two-step crimp process mentioned previously to ensure adequate crimp strength.

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9. Matching the other thumbscrews still attached, slide the free end of the stainless steel wire through the small hole in the apparatus drilled below the location where the thumbscrew mounts to the frame.

10. Crimp a half-sized cable sleeve at the free end of the stainless steel wire, as in step 4-5.

11. Give the thumbscrew a gentle tug to ensure it is securely attached.

12. Test the thumbscrew to check that there is adequate reach in the cable and that the screw turns smoothly.

8

How to Restring a Cable for Objects or Object Shields

If an object or object shield cable is frayed, permanently bent, spiraled, or otherwise damaged to the point where it can no longer be used, that cable must be replaced. This procedure outlines the process of restringing an object or object shield cable. For the process of replacing a cable on an object, see “How to restring a cable on an object” in the table of contents.

Materials Needed: Object cable Size 4 Metal Cable Sleeves Spring clip and black 8oz weight for object

cable Cable cutter/crimper Liquid electrical tape

Procedure:1. Using the cable cutter/crimper, remove old

cable from all spring clips, grommets, and weights that old cable was attached to.

2. With the apparatus fully assembled and in the lower position with shields raised, measure out the length of cable needed to run from the central spring clip to the object location of object shield. Take care to run the cable through all the correct eyebolts in the correct direction. (Follow similar cables already attached to the apparatus as an example)

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3. Loop one free end of the cable around the central spring clip and fasten using a cable sleeve. The loop formed by the cable should be similar in size to the other adjacent loops, and the free end of the cable should be fed entirely through the cable sleeve, with no cable protruding out.

Wrong cable position in sleeve. Do not allow extra cable to protrude out of cable sleeve.

Correct cable position in sleeve. Cable is fully inserted into sleeve but no extra cable protrudes from the other side.

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4. Using the crimper section of the cable cutter/crimper, crimp the cable sleeve.

5. Use the flat section of the cable cutter/crimper to crimp the cable sleeve a second time.

Correctly crimped cable sleeve.

6. Ensure that the other free end of the cable is still run properly through all the necessary eyebolts.

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7. Perform steps 3-5 again, this time looping the cable around the outermost grommet on the object shield, or around the spring clip and black 8oz weight for an object cable, depending on which is being replaced. The cables should be cut as follows: For an object shield, the cable should be cut so that the grommet is 20” below the PVC frame above, so that the shield hangs level. For an object cable, the cable should be cut so that the base of the cable loop is 3.5” below the PVC frame. (Use similar cables already attached to the apparatus as an example)

8. Ensure that the cable has been securely attached.

9. Apply a layer of liquid electrical tape to the crimped metal cable sleeve to cover any sharp edges.

10. Let the liquid electrical tape dry for 30 minutes and apply a second coat if needed, to cover up sharp edges.

12

How to Replace a Spring Clip

If a spring clip wears out and no longer operates correctly, it will need to be replaced. This procedure outlines the steps to replace the spring clips used on the object and object shield cables, safety latch cable, and rope handle cables. For replacing spring clips on object cables, also refer to “How to Restring a Cable for Objects or Object Shields” in the Table of Contents for additional assistance.

Materials Needed: Correct length of same type of cable being

replaced Correct size cable sleeves (1/16” aluminum

cable sleeves for thick steel cable, size 4 metal cable sleeves for narrow diameter object/object shield cable)

Spring clip Cable cutter/crimper Red-handle cable cutter (for thicker cable) Liquid electrical tape (for object/object shield

cable)

Procedure:

1. To replace a spring clip, it is likely that the entire length of cable will need to be replaced. Begin by measuring the cable section to be replaced. Make sure to account for the cable loops.

2. Using the red handle cable cutter for cutting the thicker cable and the cable cutter/crimper for the

thinner cable, cut the required length of cable.

3. Remove the old cable, cutting it off with the correct cable cutter as necessary.

4. Run the new cable and, using the correct cable sleeve as identified in the materials list, loop the free ends of the cable around the necessary eyebolts, spring clips, etc. in the same manner as the cable was previously routed. (Use similar cables already mounted to the apparatus as an example)

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5. The cable loops should be small and the cable should be fed completely into the cable sleeve with nothing protruding out the other side.

Incorrect Loop: Loop is too large and too much cable is protruding out of the cable sleeve.

Correct Loop: Loop is small and there is no cable protruding out of the cable sleeve.

6. Using the crimping section of the cable cutter/crimper, crimp the cable sleeves into place using sufficient force to deform the cable sleeve fully. (Use similar cable sleeves already mounted to the apparatus as an example)

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7.

Correctly crimped cable sleeve.

8. Check to make sure there is smooth, adequate travel for newly mounted cable.

9. If necessary, use liquid electrical tape to coat the cable sleeve to cover any sharp edges. Wait 30 minutes and apply an additional coat as needed.

15

How to Replace a Leveling Foot

Materials Needed: Replacement 316 Stainless Steel Swivel

Leveling Mount (5/16”-18 x 2”, 316 Stainless Steel, minimum 250lb load rating)McMaster-Carr Part #6111K117

Procedure:1. Unscrew the leveling foot to be replaced,

completely out of the base frame. If the foot is stuck, use the correct size crescent wrench to assist in removing it.

2. Ensure that the threads inside the base frame are clean and free of debris and salt residue.

3. Carefully thread the new leveling foot into the base frame completely

16

How to Replace a Gas Spring

If a gas spring is damaged or no longer operates with sufficient force, it will need to be replaced.

Materials Needed: Replacement gas spring (Type 316 Stainless

Steel with M6 threaded ends, 18.62” extended length, 8.27” stroke, 130lb force) McMaster-Carr Part # 4175T914

Flathead screwdriver 10mm crescent wrench

Procedure:1. With the drive frame detached, rotate the

drive frame upside down so that it is resting on the upper parallel arms.

2. Press down on the drive frame to engage the black latch.

3. Detach the safety latches.

4. Carefully release the black latch. The drive frame will suddenly open up completely.

5. Using the wrench and screwdriver, loosen the screw which retains the gas spring onto its mounts on one end of the gas spring only. Hold the nut in place with the wrench while simultaneously turning the flathead screw counterclockwise to remove it.

6. Once the screw is loose, you should be able to remove it by sliding it out of the mounting hole. There will be a sleeve around the screw, which should also be removed. If this is difficult, use the soft-headed mallet and a pointed object to tap the sleeve out. The gas spring should now be able to swing freely of its mounting bracket at one end.

7. Observe that at both ends of the gas spring, a removable end mount is attached. This is easy to spot by its slightly different metallic color.

8. Remove this end mount by unscrewing it from the free end of the gas spring.

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Mounting Bracket

End Mount

Gas Spring

Mounting Screw

End Mount

Mounting Bracket

Mounting Screw

How to Replace a Gas Spring

9. By turning the gas spring, remove the spring from the other end mount which is still attached to the apparatus.

10. Replacement of the damaged spring is simply the reverse of the removal process described above.

11. With the skinner portion of the gas spring pointing toward the base of the drive frame (match to the other gas spring), screw the spring into the end mount that is still attached to the drive frame.

12. Attach the loose end mount which was removed in step 8 to the free end of the gas spring.

13. Align the mounting hole on the free end of the gas spring with the hole on its mounting bracket. It is important that the end mounts both be screwed on completely, but they may be unscrewed slightly to allow for alignment of the end mounts with the mounting brackets.

14. Replace the screw, screw sleeve, and nut, using the wrench and screwdriver to tighten. Compare with the other spring to ensure correct mounting.

15. Compress the drive frame and engage the black latch. This will require one person to assist in holding the drive frame in place, while another person folds the drive frame and engages the black latch.

16. While maintaining pressure on the drive frame, engage the safety latch spring clips.

17. Pull on the drive frame to disengage the black latch. The drive frame will open slightly and the safety latch cables will tighten, preventing further opening of the drive frame.

18

How to Replace a Thumbscrew Nut

The thumbscrew nuts are small nuts mounted in the slots of the base and drive frame that enable the thumbscrews to mount to the apparatus. Over time, they could fall off or wear out. If a thumbscrew nut appears to be missing or is very difficult to properly thread even when correctly aligned, the nut is in need of replacement.

Materials Needed: Replacement drop-in nut with set screw from

toolbox (10S smaller size for drive frame to object frame nut, 15S large size for base frame to drive frame)

Correct size allen wrench to fit set screw in replacement nut

Procedure:1. Make a note of the exact location of the

mounting nut.

2. If the old nut needs removal, unscrew its set screw and make sure the nut slides loosely.

3. Remove the nut from the slot by rotating it onto its side and pulling it out.

4. Place the new nut into the slot by dropping it in on its side and rotating it.

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How to Replace a Thumbscrew Nut

5. Slide the nut to its correct location, making sure that the threaded hole is in the middle of the t-slot.

6. Tighten the set screw using the allen wrench.

7. Attempt to mount the mating apparatus module. Make a note if the new nut is incorrectly aligned, and change the location as necessary by unscrewing the set screw in the nut and sliding the nut to its proper position.

8. Once the nut is in the correct location, use the allen wrench to securely tighten the set screw on the mounting nut to prevent movement.

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How to Replace a Broken Latch

Because the black grab latch is plastic and receives a reasonable shock when it is engaged, one or both of the pieces could eventually break and need replacement.

Materials Needed: Replacement grab latch

McMaster-Carr Part #1739A22 Correct size allen wrench to remove #10 size

mounting screws

Procedure:1. Using the allen wrench, loosen the mounting

screws for the part of the latch which is damaged.

2. Remove the damaged part and replace it with a new latch part.

3. Line up the mounting nuts in the slot in which the latch mounts with the mounting holes on the latch.

4. Use the previously removed mounting screws with the mounting nuts in the t-slot to firmly affix the latch to the drive frame.

5. Tighten the mounting screws sufficiently to avoid loosening.

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How to Replace an Object Cable Pulley

If an object cable pulley wears sufficiently that it requires replacement, follow this procedure..

Materials Needed: Replacement Pulley with hole drilled

McMaster-Carr Part #9466T61 Pliers

Procedure:1. Using the pliers, flatten the protruding end

of the retaining pin on the pulley mount and pull the pin out. This should allow the removal of the small rod which holds the pulley in place, and the pulley wheel as well.

2. Observe the location where the hole is drilled in the pulley and drill a ¼” hole in the same location on the new pulley.

3. Making sure to lay the metal cable across the new pulley as shown in the above graphic, align the drilled hole with the center hole on the pulley mount.

4. Insert the small rod completely through the pulley.

5. Insert the retaining pin and bend the protruding end as shown in the graphic.

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Pulley Mount

Retaining Pin

Pulley

How to Replace an Object Shield Grommet

Object shield grommets, while securely attached, could be accidentally ripped out and require replacement.

Materials Needed: Mallet White plastic disc Grommet mounting hole cutter Grommet mounting die Grommet mounting punch Grommet(s) Grommet washer(s)

Procedure:1. Locate the desired location on the object

shield where the new grommet will go, or skip to step 3 if using a previously punched hole (provided it is in good condition).

2. Place the white plastic disc beneath the hole being cut to protect the work surface below.

3. Using the yellow side of the mallet, pound a hole into the object shield with the grommet mounting hole cutter. Note that one side of the hole cutter is sharp and should be facing the material to be cut. Do not hammer the

sharp end. About 10 strong hammer blows are required per layer of fabric to completely punch the hole.

4. Stack the following components in order: White plastic disc, grommet mounting die, grommet, object shield, grommet washer, and grommet mounting punch.

5. Ensure that the grommet mounting die is face up as shown in the above graphic. Ensure that the grommet is face up, with the metal projection pointing up through the hole in the fabric. Ensure that the grommet

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How to Replace an Object Shield Grommet

washer is mounted with the rounded (convex) side facing up.

Plastic disc, grommet mounting die, grommet, and shield fabric.

Same as previous image, but with grommet washer in place.

Grommet mounting punch is set in place and grommet is ready to be installed.

6. Pound the top of the grommet mounting punch with the hammer powerfully about 10 times.

7. Check to see that the grommet projection has been deformed sufficiently to bind the grommet together.

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How to Remove a Sharp Edge or Rust from an Object or Apparatus Component

Sharp or rusty objects are prohibited near the whales at Mystic Aquarium, so it is imperative that any rust or sharp edges be found and removed, coated, or covered. It is also important that these locations be monitored periodically to ensure that the rust does not return or edges do not become sharp again.

Materials Needed: Round File Flat File Black rubber coating Brush Liquid electrical tape Standard electrical tape

Procedure:1. To remove sharpness from an object, use the

round and flat files to shave the edge until it is no longer sharp. If the sharp location requires coating, use the liquid electrical tape for small jobs or black rubber coating with the brush for large jobs.

2. Apparatus components such as the cable sleeves used to crimp wires on the object frame and objects are inherently sharp and must be coated with liquid electrical tape to be safe for the whales.

3. Objects that are prone to rusting must be coated with black rubber coating.

4. All coatings may be used in multiple coats until the desired effect is achieved. Wait at least 30 minutes between coats.

5. As an alternate means of coating, standard electrical tape may be used to cover up sharp edges. Because of its poor water resistance, standard electrical tape must be maintained frequently.

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Cable sleeve coated in liquid electrical tape

Cable sleeve coated in liquid electrical tape

How to Restring a Cable on an Object

If the cable attached to an object wears out, falls off, or otherwise becomes unusable, it is necessary that it be replaced.

Materials Needed: 120lb Nylon Coated Object cable Size 5 Metal Cable Sleeves Cable cutter/crimper Liquid electrical tape

Procedure:1. Make a note of the size, position, and

orientation of the old cable before you remove it. It is important that you duplicate the cable exactly.

2. Using the cable cutter/crimper, cut off the old cable.

3. Cut a new piece of cable and, using metal cable sleeves, orient the cable as it was before.

4. To make a single loop, run the cable through a cable sleeve, out the other side, and back through.

5. To complete that loop, ensure that the cable is run entirely into the cable sleeve and that no cable is protruding beyond the cable sleeve.

6. To make a double loop, run the cable back into the cable sleeve until it reaches the other side.

7. Using the crimp section of the cable cutter/crimper, crimp the cable sleeve.

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How to Restring a Cable on an Object

8. As a secondary means of crimping the cable sleeve, crimp the sleeve using the flat section of the cable cutter/crimper.

9. Coat the entire cable sleeve with liquid electrical tape to cover any sharp edges.

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Documents

edge.rit.eduedge.rit.edu/edge/P09011/public/week/Supp/Repair Gui… · Web viewObserve the location where the hole is drilled in the pulley and drill a ¼” hole in the same location