Assembly of the Pump

A key component of this system is a specially designed rotary pump. Though the pump is designed with the concept of easy fabrication, sometimes you have to pay attention to the assembly of some parts. Be careful, for accuracy of this assembly may affect the performance of the pump.

Step1: Prepare a Motor

The team used a Maxon 273752 DC motor (15V 90W). You can make smaller pumps using small motors if you find a good way to seal a small diameter shaft.

	You need to file a flat surface on the tip of the shaft.
	If you need a rotary encoder, attach the other side of the main output shaft. We installed a CUI AMT103.

Step2: Assemble the Motor Mount and Shaft Sealing

Parts List and Assembly

	Oil seal mounting O-ring NOK 1A S-20 Oil seal NOK SC6167 Low profile cap screw (M2.5x6mm) x6 Motor mounting Silicone oil
	Motor mounting with insert screws
	Attach the mounting on the motor.
	You need a wrench to fit the cap screws.
	Use a wrench, tighten cap screws.
	Use an oil seal (Outer:16mm Inner:7mm).
	Oil seal mounting
	Push the oil seal into the hole of the mounting.
	Oil seal should be inserted all the way down into the hole.
	Install an O-ring.
	Spread silicone oil on the shaft.
	Spread silicone oil also on the lip of the oil seal.
	Insert the oil seal mounting into the hole of  the motor mounting.
	The seal mounting would be tightly fitted to the hole.

Step3: Assemble a pump box

Parts List and Assembly

	Cover side plate Rotor casing O-ring NOK 1A S29 Shim ring Bottom slide plate Thin bearing x2 NMB DDA-2520 Outer rotor and inner rotor
	Outer rotor and inner rotor were machined by a wire EDM.
	Using a jeweler's file, smooth down the burrs on the side.
	Using sandpaper (#400), sand the surface until smooth.
	Using the jeweler's file, smooth down the burrs on the side.
	Using the jeweler's file, smooth down the burrs on the side as well.
	Using sandpaper (#180 and #400), sand the surface until smooth.
	Using sandpaper (#180 and #400), sand the surface until smooth.
	Using a router bit, remove any burrs from the center hole.
	Using sandpaper (#180 and #400), sand the surface of the inside until smooth.
	Place the slide plate into the pump casing.
	Place the first bearing into the pump casing.
	Push the bearing down carefully all the way making sure it is straight.
	Place the second bearing into the pump casing.
	Push the bearing down until it touches the first bearing.
	Place the outer rotor into the bearings.
	Make sure that the outer rotor touches the surface of the bottom slide plate.
	Place a shim ring.
	Place an O-ring.
	Push the casing into the motor mounting until it touches the surface of the mounting.
	Insert the inner rotor into the outer rotor and D shaped shaft.

Step4: Assemble the outlet casing

Parts list and Assembly

	Use three stainless steel spacers (Hirosugi CU-2616PH Outer:3.8mm Inner:2.8mm).
	Install spacers.
	Put the cover slide plate on the casing.
	Tighten stainless steel cap screws (M2.5x20mm).
	3D printed outlet casing
	To make a flat on the mounting surface, sand the surface until smooth.
	Remove dust.
	You need two kinds of taps, M5 and Rc 1/8 (short type).
	Tap the two small holes with a M5 tap making sure it is straight.
	Tap the two big holes with a Rc1/8 tap making sure it is straight.
	Tube fitting (inner hex, straight type) x2 PISCO POC8-01 Outlet casing Fitting (plug type) PISCO SLP-M5  Fitting (barb straight type) PISCO SLC-0640-M5 O-ring x2 NOK 1A SS-145
	Install the straight type fitting.
	Install the plug on the other one.
	Using a large wrench, tighten the fittings.
	Place o-rings.
	Put the outlet casing onto the rotor casing. Tighten with three screws (M2.5x25mm).