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Merge pull request #292 from dcschooley/pvc_hub
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3D Printed PVC hubs
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dcschooley authored Jul 2, 2021
2 parents b6380e7 + 9f79eca commit 1681caf
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61 changes: 36 additions & 25 deletions mechanical/body_assembly/README.md
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Expand Up @@ -14,7 +14,7 @@ The body is the housing of all the electronics for the rover. It is the attachme

| Author/Creator | JPL |
| -------------- | ------- |
| Cost without 3D printer | 240.38 |
| Cost without 3D printer | 253.28 |
| Cost with 3D printer | 240.38 |
| Date Added | 4/11 |
| Group/Organization/School | JPL |
Expand Down Expand Up @@ -73,12 +73,14 @@ To get the above parts from Sculpteo, go to Laser cutting and then upload these

### 4.1 Chassis

| Item | Ref | Qty | Image | Item | Ref | Qty | Image |
| Item | Ref | Qty | Image | Item | Ref | Qty | Image |
| :--- | :-- | :-- | :---: | :--- | :-- | :-- | :---: |
| Dual Side mount A | S17 | 4 | <img src="../../images/components/structural/S17.png" width="200"> | #6-32x1/4" Button Head Screw | B1 | 16 | <img src="../../images/components/screws/B1.png" width="70"> |
| 4.5"x12" Aluminum Plate | S37 | 2 | <img src="../../images/components/structural/S37.png" width="200"> | #6-32x3/8" Button Head Screw | B2 | 4 | <img src="../../images/components/screws/B2.png" width="70"> |
| 1" PVC Clamp | S24 | 1 | <img src="../../images/components/structural/S24.png" width="200"> | Allen Key Set | | | <img src="../../images/components/tools/D2.png" width="200"> |
| 3D-printed PVC Clamp | S50 | 1 | <img src="../../images/components/structural/S24.png" width="200"> | Allen Key Set | | | <img src="../../images/components/tools/D2.png" width="200"> |
| 9"x12" Aluminum Plate | S35A | 1 | <img src="../../images/components/structural/S35.png" width="200"> | 5/16" Wrench | | | <img src="../../images/components/tools/D1.png" width="200"> |
| #6-32x5/8" Button Head Screw | B4 | 6 | <img src="../../images/components/screws/B4.png" width="70"> |#6 Washer| W1| 2| <img src="/images/components/washers/W1.png" width="70">|
| #6-32 Heat set insert | I2 | 6 | <img src="/images/components/inserts/I2.png" width="70">|

#### 4.1.1 Top panel

Expand All @@ -97,20 +99,29 @@ Attach the 4.5x12 plates **S37** to the dual side mounts using screws **B1**
|:-:|
| Figure 3: Attach the side panels |

#### 4.1.3 Assmble the PVC clamping hub

#### 4.1.3 Attach the PVC clamping hub
* Insert the #6-32 Heat Set Inserts **I2** into the 3D-printed clamping hub **S50** in the locations shown in Figure 6. The inserts on the side of the clamp should go in from the left side as shown in Figure 4.
* Using washers W1, insert screws **B4** into clamp part of the clamping hub and screw part of the way into the brass inserts. Inserting these screws now simplifies inserting the PVC pipe later.

Attach the 1-inch PVC bore clamping hub **S24** to the top plate of the body using screws **B1** Use the location shown in Figure 4.

| <img src="../../images/body/hub_lower.png" height="300"> <img src="../../images/body/hub_lower_screws.png" height="300">|
|:-:|
| Figure 4: Assemble PVC Clamping Hub |

#### 4.1.4 Attach the PVC clamping hub

Attach clamping hub **S50** to the top plate of the body using screws **B1** Use the location shown in Figure 5.

| <img src="../../images/body/body_pvc_1.png" height="300"> <img src="../../images/body/body_pvc_2.png" height="300">|
|:-:|
| Figure 4: Attach the PVC clamp to top plate |
| Figure 5: Attach the PVC clamp to top plate |

### 4.2 Differential Pivot Block

The differential pivot is used to transfer weight off of the wheel that is currently climbing to the other front wheel, allowing the rover to climb more easily. Additionally, it serves as a second contact point for the rover’s body such that it does not rotate freely about the cross rod.

| Item | Ref | Qty | Image | Item | Ref | Qty | Image |
| Item | Ref | Qty | Image | Item | Ref | Qty | Image |
| :--- | :-- | :-- | :---: | :--- | :-- | :-- | :---: |
| 0.5" Pillow Bearing Block | S11 | 2 | <img src="../../images/components/structural/S11.png" width="200"> | #6-32x1" Button Head Screw | B6 | 4 | <img src="../../images/components/screws/B6.png" width="200"> |
| #6-32x1/4" Spacer | T1 | 8 | <img src="../../images/components/standoffs/T1.png" width="70"> | Allen Key Set | D2 | | <img src="../../images/components/tools/D2.png" width="200"> |
Expand All @@ -119,11 +130,11 @@ The differential pivot is used to transfer weight off of the wheel that is curre

#### 4.2.1 Mount the pillow bearing blocks

Using spacers **T1**, screws **B6**, and hex nut **B11**, mount the pillow blocks **S11** to the top of the body over the hole in the aluminum plate that you drilled earlier as shown in Figure 5.
Using spacers **T1**, screws **B6**, and hex nut **B11**, mount the pillow blocks **S11** to the top of the body over the hole in the aluminum plate that you drilled earlier as shown in Figure 6.

| <img src="../../images/body/Step_5_a.png" height="250"> <img src="../../images/body/Step_5_b.png" height="250">|
|:-:|
| Figure 5: Mounting the pillow bloc |
| Figure 6: Mounting the pillow bloc |

### 4.3 Control Board PCB

Expand All @@ -132,28 +143,28 @@ Using spacers **T1**, screws **B6**, and hex nut **B11**, mount the pillow block
| Assembled Control Board PCB | E1 | 1 | <img src="../../images/components/electronics/E1.png" width="250"> |
| #6-32x3/8" Button Head Screw | B2 | 4 | <img src="../../images/components/screws/B1.png" width="70"> |

You may want to skip this step until the PCB is completed and tested and insert the PCB late
You may want to skip this step until the PCB is completed and tested and insert the PCB later.

#### 4.3.1 Mount the PCB

Mount the PCB **E1** to the top of the chassis using screws **B2**. Note the position of the PCB below.

| <img src="../../images/body/body_5.png" height="300"> <img src="../../images/body/body_6.png" height="300">|
|:-:|
| Figure 6: Mounting the PCB |
| Figure 7: Mounting the PCB |

| <img src="../../images/body/body_7A.png" height="300"> |
|:-:|
| Figure 7: Mounting the PCB |
| Figure 8: Mounting the PCB |

Note the screw positions in Figure 7. You might not be able to get the screw circled in light blue in
Note the screw positions in Figure 8. You might not be able to get the screw circled in light blue in
because of the PVC clamping hub. This is okay, install the other 3 circled in yellow.

### 4.4 Closing the body



| Item | Ref | Qty | Image | Item | Ref | Qty | Image |
| Item | Ref | Qty | Image | Item | Ref | Qty | Image |
| :--- | :-- | :-- | :---: | :--- | :-- | :-- | :---: |
| Dual Side Mount A | S17 | 12 | <img src="../../images/components/structural/S17.png" width="200"> | Laser Cut Back Panel | S40 | 1 | <img src="../../images/components/structural/S40.png" width="200"> |
| #6-32x1/4" Button Head Screw | B1 | 28 | <img src="../../images/components/screws/B1.png" width="70"> | Switch | E39 | 1 | <img src="../../images/components/electronics/E39.png" width="200"> |
Expand All @@ -167,66 +178,66 @@ Mount Dual Side Mounts A **S17** using screws **B1** on the side plates in both

| <img src="../../images/body/body_8a.png" height="300"> <img src="../../images/body/body_8.png" height="300">|
|:-:|
| Figure 8: Dual Side Mount A locations |
| Figure 9: Dual Side Mount A locations |

#### 4.4.2 Attach dual side mounts (2)

Also attach Dual Side Mounts A **S17** using **B1** screws on the top plate, in the front and back

| <img src="../../images/body/body_9.png" height="300"> <img src="../../images/body/body_10.png" height="300">|
|:-:|
| Figure 9: Dual Side Mount A (cont) |
| Figure 10: Dual Side Mount A (cont) |

#### 4.4.3 Front and back panels

Using screws **B1** attach the front and back laser cut panels to the chassis.

| <img src="../../images/body/body_12.png" height="300"> <img src="../../images/body/body_13.png" height="300">|
|:-:|
| Figure 10: Front and Back Panels attached |
| Figure 11: Front and Back Panels attached |

#### 4.4.4 Attach the switch and volt meter

Take the Volt Meter **E38** and the Switch **E39** and attach them to the back panel. Note that the switch goes in from the inside of the body, and the volt meter should snap press fit in from the outside.

| <img src="../../images/body/voltmeter_switch.png" height="300"> <img src="../../images/body/voltmeter_switch_b.png" height="300">|
|:-:|
| Figure 11: Volt Meter/Switch Installation |
| Figure 12: Volt Meter/Switch Installation |

#### 4.4.5 Attach the Battery Holder

Take the 3D printed Battery holder **S41** and using a solder Iron at 460 degrees F, push the #6-32 heat-set insert **I2** into the battery holder as shown below.

| <img src="../../images/body/battery_holder_a.png" height="300"> <img src="../../images/body/battery_holder_b.png" height="300">|
|:-:|
| Figure 12: Installing heat set inserts|
| Figure 13: Installing heat set inserts|

#### 4.4.6 Install the battery holders

Mount the Battery holders onto the body assembly using screws **B1** as shown in Figure 13.
Mount the Battery holders onto the body assembly using screws **B1** as shown in Figure 14.

| <img src="../../images/body/battery_install_a.png" height="300"> <img src="../../images/body/battery_install_b.png" height="300">|
|:-:|
| Figure 13: Battery holder installation |
| Figure 14: Battery holder installation |

#### 4.4.7 Build bottom plate assembly

Take the 9x12 Aluminum Plate **S35** and attach 6 dual side mount A **S17** along the edges as shown in Figure 14. Be sure to verify that the orientation of the dual side mounts **S17** matches the pictures.
Take the 9x12 Aluminum Plate **S35** and attach 6 dual side mount A **S17** along the edges as shown in Figure 15. Be sure to verify that the orientation of the dual side mounts **S17** matches the pictures.

| <img src="../../images/body/body_bottom_1.png" width="50%"> |
|:-:|
| Figure 14: Building the Bottom Panel |
| Figure 15: Building the Bottom Panel |

#### 4.4.8 Attach the bottom plate

Take the bottom plate assembly you constructed in the previous step and attach it to the chassis.

| <img src="../../images/body/body_bottom.png" width="50%"> |
|:-:|
| Figure 15: Attaching the Bottom Panel |
| Figure 16: Attaching the Bottom Panel |

The Body Assembly is now Complete!

| <img src="../../images/body/finished_body_a.png" height="300"> <img src="../../images/body/finished_body_b.png" height="300">|
|:-:|
| Figure 16: Completed Body Assembly |
| Figure 17: Completed Body Assembly |
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