Introduction: Reverse Engineering- Vacuum Cleaner - 1B Grp 4

By www.kea.dk
About: KEA is located in the Danish capital of Copenhagen where we teach more than 9000 students in the disciplines within design and technology. These instructables are created by students as documentation of their …

This is a Vacuum Cleaner from Nilfisk - Model Action Plus Special

Step 1: Open Lid

Open the lid of the front and remove the extra pieces

Step 2: Open the Whole Front

You open the front and take out the bag, remove the rubber band, and screw out the bag holder

Step 3: Open the Rear

Open the rear, take out the filters and unscrew the holders

Step 4: Remove the Rubber

Remove the rubber band at the hose connection point and pull out the opener in the front

Step 5: Pull Out the Wheels

Take out the screw inside the wheels, and pull the wheels off. Use force if necessary

Step 6: Take Off the Top Shelter

Take off the top shelter. Push the hinges to the side, to be able to get it out

Step 7: Take Out the Screws

There's one at the top, two at the bottom and two inside of it

Step 8: Take Out the Cable Holder

Open the top and take out the two screws. Pull the screw out, to be able to seperate it from the cable. (There is a hole you can pull it out of)

Step 9: Remove the Suction Power Controler

Screw out the technology, then the controller part itself. Pull it out

Step 10: Remove Cables From Power Switch

Remove the cables from the power switch, to be able to get the motor out

Step 11: Remove the Upper Rear

Remove the upper rear. Then pull off the buttons for power and cable pull. Then you screw out the screws that hold the plastic case. Pull it off. Lastly you remove the power connector, it may require some force

Step 12: Remove the Power Cable

Remove the cable, by removing the power connection first. You do that just by pressing the cable holder aside, and pulling cables out. It is not screwed into anything

Step 13: Disassemble the Cable Pull

Take off the pull button first. You do that by screwing it off. Screw out the screw that holds the steel band and it's cover together. Then pull both apart.
Remove the wire from the cable, then remove the cable. Remove the cable holder last

Step 14: Pull Out the Motor

The motor is not connected to anything, so you can freely pull it out

Step 15: Take Out the Last Screws

Screw out the last screws and remove the rubber pieces

Step 16: Disassembling the Motor - Step 1

Take away the plastic by taking out the screws, then pull it apart, and pull the rubber off at the front afterwards. You can now freely extract the motor.

Step 17: Disassembling the Motor - Step 2

Remove the cables from the motor. Screw out the technology, and pull it out of the plastic. Remove the foam from the plastic. Then screw the cables off the motor directly.

Step 18: Disassembling the Motor - Step 3

Hold the motor core with a pair of pliers, to be able to remove the nut at the top. Carefully open the motor case with a chisel and hammer. Remove the front housing, turbine blade and plastic air conduction piece. Then pull out the motor core and hammer the turbine piece out. Then remove the steel wire and metal.

Step 19: Remove the Steel Wire

Remove the steel wire by pulling it off, either with force or by slowly following the pattern the opposite way. When done so, you can take off the plastic and metal, by carefully moving the plastic grips on the sides.

Step 20: Count All the Pieces

Put all the pieces in order, and count them all

Step 21: Weigh It

Weigh all the pieces

Step 22: Cut Pieces in Half

Cut the top and bottom shelter in half, to get a full view of both sides. They both matter

Step 23: Design

Set up the concluded the design of the group and measure the necessary size needed

Step 24: Cut the Boards

Make two different boards. One for the motor, and one for the shell (Use the table saw)

Step 25: Line It Up

Line everything up, to get an overview of the product.

Step 26: Put Wires Into Tubes

Put wires into tubes to show the path of electronics

Step 27: Glue

Glue all parts onto the board following the concluded design and hammer in seams to make things become more visible

Step 28: Make a Headline of Screws

To be creative and give the board a name: S.M.D. ( Suck My Dust)

Step 29: Wood Holders

First measure the parts you want to place on wooden holders, then sketch some sturdy holders. Cut the holders with a band-saw.

Step 30: Chisel

Use a chisel to cut out space for the wood holders

Step 31: Glue and Set

Glue the motor parts onto the wood and glue the wood onto the board into their specific space

Step 32: Create a Wooden "box" - Step 1

First use the website: http://www.makercase.com/ and use the settings described in picture one. Then press the "Generate Laser Cutter Case Plans" button. Then use the settings described in picture two.

Step 33: Create a Wooden "box" - Step 2

Use Adobe Illustrator (or equivalent program) to draw rounded rectangles inside the pieces of the box you need, remove one of the sides of the box so you have 5 parts; 3 long pieces and 2 square ones. the distance from the rectangle to the outer edge is 10mm on the top and sides, but 20mm in the bottom.

Step 34: Create a Wooden "box" - Step 3

Choose the cut through feature on your laser printer, and send the file to print. Use the 3mm wooden plate preset for the printer and click start. Then wait for the machine to cut out the pieces. Finally identify the pieces and assemble the "box".