Hardware Assembly

Introduction:

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This part of the guide describes how the Parker01 is put together. It focuses on the hardware assembly where as the electronic assembly can be obtained from information from
their individual sections.

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Parts List:

Each wheel of the 4 wheeled Parker 01 robot requires the following:

One version of the Parker01 robot requires:
1) 1 Electric DC motor
2) Aluminum Drive Shaft
3) 2 Aluminum Separators
4) Encoder (with encoder assembly if needed)
5) Connector plate
6) Screws to attach motor to connector plate
7) 8 hexagonal nuts
8) 4 pressure washers
9) 8 washers
10) 4 plastic/rubber spacers



Figure 1: Figure Showing all the components needed for the assembly of the Parker01 motor/encoder assembly




1) Cover the air flow holes of the motor with removable tape (such as electrical tape). This prevents any unwanted particles/pieces from getting into the motor and spoiling it)

2) Attach the connector plate to the motor. Click on the image below to see how to attach the plate to the motor
 

Figure 2: Assembly of the connector plate to the motor (Note: the motor used here has the Hall Effect Encoder already mounted at the rear of the motor)


2) Attach the assembled connector plate/motor to the body of Parker01
    The robot might either have a box plate attached to the body of Parker01 (Figure 1 shows this assembly)
or
    The assembled connector plate/motor can be directly attached to the body of Parker01

       To attach the connector plate to the robot body we must make sure that the motor itself is "floating"
to do this follow the instructions given below:



If the TAMUbot motors plates are to be attached directly to the body of the robot it needs the assembly as shown in the left picture in Figure 3. If the motor is attached to the an aluminum housing the robot can use a simpler assembly.
The aluminum housing method is more stronger and robust than directly attaching the motor plates directly to the body of the robot. The added rigidity of the aluminum housing also is beneficial in terms of coping oscillations occurring due to the the rotating motion of the wheels. We shall refer to these two mounting methods separately in the following steps.

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Mounting with Aluminum housing:

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1) Attach the aluminum housing onto the body of the TAMUbot
2) Orient the connector plate to the holes in the housing of the TAMUbot V3.0
3) Insert all four screws into the mounting holes of the connector plate along with a steel washer, an ordinary steel washer or a teethed steeled
     washer as shown in Figure 3 below may be used.

4) Add a plastic spacer to each of the four screws attached along with a hexagonal nut.
5) Screw the hexagonal nut (HEX1) until 2 threads are left between the connector and the spacer.
    This is important as the motor must be free floating
6) Insert the assembly into the mounting holes in the housing of the TAMUbot V3.0
7) First assemble the bottom two screws. Add a pressure washer, followed by a steel washer and a hexagonal nut(HEX2)
    to connect the motor/connector plate to the housing
8) Hold HEX1 in place while tightening HEX2.
9) Tighten HEX2  until the pressure washer has flattened out
10) Assemble the top to screws in the same manner
11) Assemble all four motors in the same manner.



                          Figure 3: The two mounting methods for the TAMUBot V3.0. On the left we see the the assembly for mounting the motor directly onto the body of the TAMUbot. On the right the motor is mounted onto a aluminum housing holding the motor assembly

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Mounting directly onto the Body:

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 Note: Due to the length of the motor the mounting method is changed slightly. Since two motors are mounted inline it is difficult to get the second one in place. Follow the procedure below for mounting the motors

1) Orient the connector plate to the holes in the housing of the TAMUbot V3.0
3) Insert bottom two into the mounting holes of the connector plate along with a steel washer, an ordinary steel washer or a teethed steeled
     washer.

4) Add a rubber spacer to each of the screws attached along with a hexagonal nut.
5) Add a washer followed by a teethed washer and a hexagonal nut.
5) Screw the hexagonal nut (HEX1) until two threads can be seen between the mounting plate and the rubber spacer
6) Insert the assembly into the mounting holes in the housing of the TAMUbot V3.0
7) First assemble the bottom two screws. Add a pressure washer, followed by a steel washer and a hexagonal nut (HEX2) to connect the motor/connector plate to the body of the robot
8) Hold HEX1 in place while tightening HEX2.
9) Tighten HEX2  until the pressure washer has flattened out
10) Assemble the top to screws in the same manner
11) Assemble all four motors in the same manner.


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Assembling the drive shaft, encoder and wheel

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Once the motor is in place and is "floating" we can go ahead and assemble the wheel, driveshaft and encoder

Parts:
1) Spacer 1 [Aluminum spacer with screw to attach motor and driveshaft
2) Spacer 2 [Aluminum spacer with screw to attach to driveshaft]
3) Gear 2 and teethed belt
4) DriveShaft
5) Wheel and Screw



Steps:
1) Insert Spacer 1 in the space between the Hard Mount Plate
2) Place teethed belt onto Gear2. Put this assembly inside the boxed section
3) Insert Driveshaft while holding Spacer 2 in place
4) Allow Driveshaft to go though Spacer 2, then Gear 2, then Spacer1
5) Allign hole of on driveshaft with flattened portion of motor end
6) Screw Spacer1 into the hold of driveshaft
7) Push Spacer2 to push against the end of the aluminum housing
8) Tighten Spacer2 screw to make sure it does not move
9) Attach wheel to the end of the Drive Shaft
10) Check if the assembly rotates without a problem
11) Check that the motor moves when the wheel is rotated and that there are no snags during one full rotation
12) If snags exist check if all the screws mounting the free floating plate to the Hard Mount Plate
      are loose enough to allow oscillations
13) If everything moves smoothly (should be able to rotate wheel with one finger) screw the wheel into
      the driveshaft
14) The optical encoder can now be mounted according to the steps in the Encoder section.

If the encoder is already attached to the robot the mounting process much easier
we can just attach the two spacers to the driveshaft at the appropriate location
.
The video below shows the "floating" motors configuration at work


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