Tie rack assembly

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1.Place Bottom cover (023) wood finished side up.

2.Place Belt gear (008) in hole on Bottom cover (023). The Belt Gear (008) fits into only one of the two holes, whereas the Belt rotator (009) fits into both. Since the Belt gear (008) is assembled first, it is not possible to misassemble the Belt rotator (009).

3.Attach Rotating belt (007) to Belt gear (008) with hook side downward.

4.Place Belt rotator (009) in other hole on Bottom cover (023), such that it engages with the Rotating belt (007).

5.Attach Belt cover (006) to the assembly, so that the two projections engage with both the Belt gear (008) and the Belt rotator (009). The holder is symmetric and its function does not vary with direction of assembly.

6.Screw the Belt cover (006) into place. There are 6 Screws (005). This step was most likely completed by using an automated magnetic screwdriver with a maximum torque reading. The torque reading tells the operator when screw is completely assembled, and slips after maximum torque is reached so that the Screws (005) are not stripped and the plastic is not stressed. We concluded this because the screws show no evidence of stripping and the plastic is not damaged in any way.

7.Flip the Bottom cover (023) over.

8.Place the Switch (022) so that the hole in the Switch (002) is aligned with the projection in the Bottom cover (023).

9.Place the electrical subassembly consisting of the Circuit board (020), Light bulb (021), both Battery end plates (025), Springs (019) and Motor (018) into Bottom cover (023). a.Put flat Battery end plate (025) into grooves on side closer to the Switch (022). The tab side should face upward. It does not fit into the groove when placed the other way, because there is an indentation that fits over the divider in the battery holder on the Bottom cover (023). b.Place Circuit board (020) into grooves with the lever side downward. Ensure that the lever engages with the switch (022) arms c.Put Battery end plate (025) with attached Springs (019) into grooves on opposite side of battery holder. d.Place the Light bulb (021) into the hole on the Bottom cover (023). It snaps into place so that the Light bulb (021) is on the finished side of the Bottom cover (023).

10.Place plastic Motor cover (017) over Magnetic motor (018).

11.Insert into the Bottom cover (023) so that the arms on the side of the plastic Motor cover (017) are aligned with the two projections (the holes should match up). Make sure that connecting tabs for the circuitry wires on the Magnetic motor (018) are located at the cutouts on the plastic Motor cover (017). The clearances on the Motor cover (017) are aligned to ensure that the wires do not interfere with projections on the Bottom cover (023).

12.Screw the Magnetic motor (018) into place using two Screws (005).

13.Attach the Gear, yellow (016) to the Bottom cover (023), ensuring that it engages with the. The hexagonal shape of the inner diameter of the Gear, yellow (016) eliminates an additional manufacturing step. The hexagonal shape allows the Gear, yellow (016) to drive the Belt gear (008). If it were circular, the two would need to be mated by an additional manufacturing process.

14.Place one Gear, clear (015) onto the Pin (025) at the lowest level (near the Gear, yellow (016)). The Gear, clear (015) should be placed projection side downward.

15.Place the second Gear, clear (015) onto the higher Pin (025).

16.Attach the Gear driver (014) onto the post nearest to the Magnetic motor (018).

17.Attach the Gear belt (012) to the Magnetic motor (018) and then stretch it so that it also attaches to the Gear driver (014).

18.Place 4 Gear caps (013) over the Pins (025).

19.Lubricate the drive train with Lubricant (026).

20.Place Top cover (011) over Bottom cover (023). The Top cover (011) has a rectangle cut out of it that goes over the battery holder, and is designed in such a way that if you try and place it the other way around (thus, covering the battery holder) it does not mate. This is done by making the projections on either side of the cover different lengths.

21.Screw the Top cover (011) in place using seven Screws (005). The Rotating belt (007) is made of a flexible material that avoids interference with a screwdriver.

22.Snap the Light cover (010) into place. First, mate the curved sides to the Top cover (011) and then snap into place by pressing down from the top.

23.Flip the entire assembly over and fit Battery cover (004) into the Top cover (011).

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