FIRST Tech Challenge. PushBot Build Guide Part II: Building the Robot
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1 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot
2 2 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Revision History Revision Date Description 1 8/15/2014 Initial Release by FTC Team #003 Australia, The Southport School 2 9/1/2014 Replaced MATRIX with TETRIX content by former FTC Team #2843, Under the Son 3 8/6/2015 Updated using the new kit of parts and new programming environment. Contents Contents... 2 Building the Robot... 3 Robot CAD Drawing... 4 Cross Bar Assembly... 5 Phone Holder Assembly... 6 Tower Assembly... 8 Arm Assembly Drive Wheel Assembly Omni Wheel Assembly Right Chassis Rail Assembly Left Chassis Rail Assembly Robot Assembly Install Encoders on Motors Motor Hub and Gear Assembly Drive Motor Assembly Install Drive Motors on Robot... 43
3 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 3 Building the Robot This section will outline the construction of the chassis, sensors, and electronics. The chassis is constructed using the TETRIX Kit of Parts. The standard tools included in the Kit of Parts set will be needed to build the chassis. All parts needed for the construction are listed in the instructions (most are shown below). Make sure that when using an axle hub, motor hub, or axle collar that the set screw is installed. Also, make sure that all assemblies are square. It is hard to drive a crooked Robot straight!
4 4 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Robot CAD Drawing
5 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 5 Cross Bar Assembly Make 2 copies Step 1: 160mm channel (1), 96mm channels (2), 5/16" socket head cap screws (8) keps nuts (8). The second picture shows BOTH completed assemblies.
6 6 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Phone Holder Assembly Step 1: 160mm flats (2), flat bracket (1), button head cap screws (4), keps nuts (4). The second picture shows the completed step. Step 2: assembly from step 1, flat bracket (1), inside C connector (2), button head cap screws (4), and keps nuts (4). The second picture shows the completed step. Note: the inside C connector is below the flat.
7 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 7 Step 3: assembly from step 2, inside corner bracket (2), button head cap screws (4), and keps nuts (4). The second picture shows the completed step. Step 4: assembly from step 3, 1" stand-off posts (2), 1/2" socket head cap screws (4). The second picture shows the completed step. Note: the stand-off posts are not placed symmetrically.
8 8 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Step 5: assembly from step 4, 96mm flats (2), 5/16" socket head cap screws (2), button head cap screws (2), and keps nuts (2). The second picture shows the completed phone holder assembly. Tower Assembly Step 1: 120-tooth gear (1), axle hub (1), 1/2" socket head cap screws (4), axle (1). The second picture shows the completed step.
9 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 9 Step 2: assembly from step 1, 288mm channel, 3/8" axle spacer (1), bronze bushing (2), 1/8" ax axle el spacer (1), 40-tooth gear (1), axle hub (1), and button head cap screws (4). The second picture shows the completed step. Note the order on the axle. 120-tooth gear, axle hub, 3/8" axle spacer, bronze bushing, channel, bronze bushing, 1/8" spacer, 40-tooth gear, and axle hub.
10 10 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Step 3: assembly from step 2, motor mount (1) with included screws (2) and keps nuts (2). The second picture shows the completed step.
11 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 11 Step 4: assembly from step 3, 288mm channel (1), 144mm angle (1), 1/2" socket head cap screws (4), and keps nuts (4). The second picture shows the completed step.
12 12 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Step 5: assembly from step 4, hard point connectors (2), 1/2" socket head cap screws (4), and keps nuts (4). The second picture shows the completed tower assembly.
13 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 13 Arm Assembly Step 1: 416mm channel (1), single standard-scale servo motor mounting bracket (2), button head cap screws (8), and keps nuts (8). The second picture shows the completed step.
14 14 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Step 2: assembly from step 1, 180 O standard-scale HS-485HB servo motor (2), 1/2" socket head cap screws (8), and keps nuts (8). The second picture shows the completed step.
15 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 15 Step 3: servo horn - metal (2), flat bracket (2), button head cap screws (8), and keps nuts (8). The second picture shows the completed step. Step 4: assembly from step 3, 96mm flats (2), L bracket (2), 5/16" socket head cap screws (8), 1/2" socket head cap screws (4), and keps nuts (12). The second picture shows the completed step.
16 16 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Step 5: assembly from step 2, assemblies from step 4. Remove the black screw from the center of the plastic servo horn. Use this screw to attach the grippers. To set the position of the grippers, rotate the servo to the fully open position and install the gripper so that it is opened just past vertical. This should get the servo in approximately the correct position. The second picture shows the completed step.
17 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 17 Step 6: assembly from step 5, 80-tooth gear (1), gear hub spacer (1) with included screws (4), and axle hub (1). The second picture shows the completed arm.
18 18 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Drive Wheel Assembly Make 2 copies Step 1: 4" wheel (1), gear hub spacer (1) with included screws (4), axle hub (1), and axle (1). The order is wheel, gear hub spacer, gear then axle hub. The second picture shows the two completed assemblies. Omni Wheel Assembly Make 2 copies These are assembled as per the instructions that come in the omni wheel pack. Step 1: 4" omni wheel half (2), joining ring (1) with included screws (4). The order is omni wheel, joining ring, omni wheel. The second picture shows the two completed assemblies.
19 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 19 Step 2: assemblies from prior step and bronze bushings (4). The second picture shows the two completed assemblies. Right Chassis Rail Assembly Step 1: 32mm channel (1), 160mm channel (1), 288mm channel (1), 5/16" socket head cap screws (4), 1/2" socket head cap screws (2), and keps nuts (6). The second picture shows the completed step.
20 20 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Step 2: assembly from step 1, drive wheel assembly (1), 1/8" axle spacer (2), axle collar (1), and bronze bushing (2). Note: assembly order is drive wheel assembly, 1/8" spacer, bronze bushing, channel, bronze bushing, 1/8" spacer, and axle collar. The second picture shows the completed step.
21 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 21 Step 3: assembly from step 2, omni wheel assembly (1), 1/8" axle spacer (2), 3/8" axle spacer, axle collar (2), bronze bushing (2), and axle (1). Note: assembly order is axle collar, 1/8" spacer, omni wheel assembly, 1/8" spacer, bronze bushing, channel, bronze bushing, 3/8" spacer, and axle collar. The second picture shows the completed step.
22 22 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Step 4: assembly from step 3, motor mount (1) with included screws (2), and keps nuts (2). The second picture shows the completed right chassis rail.
23 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 23 Left Chassis Rail Assembly This is built as a mirror image to the right chassis rail assembly. Step 1: 32mm channel (1), 160mm channel (1), 288mm channel (1), 5/16" socket head cap screws (4), 1/2" socket head cap screws (2), and keps nuts (6). The second picture shows the completed step.
24 24 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Step 2: assembly from step 1, drive wheel assembly (1), 1/8" axle spacer (2), axle collar (1), and bronze bushing (2). Note: assembly order is drive wheel assembly, 1/8" spacer, bronze bushing, channel, bronze bushing, 1/8" spacer, and axle collar. The second picture shows the completed step.
25 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 25 Step 3: assembly from step 2, omni wheel assembly (1), 1/8" axle spacer (2), 3/8" axle spacer, axle collar (2), bronze bushing (2), and axle (1). Note: assembly order is axle collar, 1/8" spacer, omni wheel assembly, 1/8" spacer, bronze bushing, channel, bronze bushing, 3/8" spacer, and axle collar. The second picture shows the completed step.
26 26 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Step 4: assembly from step 3, motor mount (1) with included screws (2), and keps nuts (2). The second picture shows the completed left chassis rail.
27 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 27 Robot Assembly Step 1: left chassis rail assembly (1), cross bar assembly (1), 5/16" socket head cap screws (4), and keps nuts (4). The second picture shows the completed step.
28 28 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Step 2: assembly from step 1, right chassis rail assembly (1), 5/16" socket head cap screws (4), and keps nuts (4). The second picture shows the completed step.
29 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 29 Step 3: assembly from step 2, cross bar assembly (1), 5/16" socket head cap screws (8), and keps nuts (8). The second picture shows the completed step.
30 30 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Step 4: assembly from step 3, 288mm angle (1), 1/2" socket head cap screws (4), and keps nuts (4). The second picture shows the completed step.
31 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 31 Step 5: assembly from step 4, tower assembly, 1/2" socket head cap screws (6), and keps nuts (6). The second picture shows the completed step.
32 32 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Step 6: assembly from step 5, arm assembly, bronze bushing (3), 1/8" axle spacer (2), axle (1), and flat spacer (1). Note: order of assembly is tower channel with hardpoint connector, bronze bushing, axle spacer, bronze bushing, flat spacer, arm, axle spacer, bronze bushing, tower channel with gears. The second picture shows the completed step.
33 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 33 Step 7: assembly from step 6, inside corner bracket (2), 1/2" socket head cap screw (8), and keps nut (8). The second picture shows the completed step.
34 34 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Step 8: assembly from step 7, 160mm flat (1), 5/16" socket head cap screw (4), and keps nut (4). The second picture shows the completed step.
35 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 35 Step 9: assembly from step 8, 160mm flat (1), 1" stand-off posts (4), and 5/16" socket head cap screw (4). The second picture shows the completed step.
36 36 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Step 9: assembly from step 8, battery clip (2), 5/16" socket head cap screw (4). The second picture shows the completed step.
37 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 37 Step 10: assembly from step 9, flat building plate (1), 5/16" socket head cap screw (7), and keps nut (7). The second picture shows the completed step.
38 38 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Step 11: assembly from step 10, phone mounting assembly (1), 1/2" socket head cap screw (4), and keps nut (4). The second picture shows the completed step.
39 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 39 Step 12: flat building plate (2), flat bracket (1), 5/16" socket head cap screw (8), and keps nut (8). The second picture shows the completed step. Step 13: Robot from step 11, assembly from step 12, L bracket (1), 5/16" socket head cap screw (7), 1/2" socket head cap screw (2), and keps nut (9). The second picture shows the completed step.
40 40 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Install Encoders on Motors Make 2 copies These are assembled as per the instructions that come in the encoder pack. Step 1: encoder kit (1) and TETRIX DC motor (1). The second picture shows the separate encoder parts. Step 2: install the encoder printed circuit board assembly to the motor with the provided screws.
41 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 41 Step 3: install the encoder disk on the motor shaft using the provided spacer tool. The first photo shows the spacer tool on the motor shaft setting the disk position. The second photo shows it without the spacer tool. Step 4: snap the encoder cover onto the motor encoder.
42 42 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot Motor Hub and Gear Assembly Make 3 copies Step 1: 40-tooth gear (1), motor shaft hub (1), and button head cap screws (4). The second picture shows the completed assemblies. Drive Motor Assembly Step 1: motor and encoder assembly (2) and motor hub and gear assembly (2). The second picture shows the completed assemblies. Note: install the hub as close as possible to the encoder without touching.
43 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot 43 Install Drive Motors on Robot Step 1: drive motor assembly (2) and Robot (1) The picture shows the completed assembly for the left chassis rail. The right chassis rail will be similar. Note: rotate the motor in the motor mount until the gears mesh well but not too tight. If they are too tight, they will bind, if they are too loose, they will slip.
44 44 FIRST Tech Challenge PushBot Build Guide Part II: Building the Robot The following pictures show examples of meshing the gears. The first is too loose, the second is too tight, the third is a good mesh. To test, rotate the mechanism by hand. If the gear teeth slip, then it is too loose, if the mechanism binds, then it is too tight We will finish the final assembly after the Robot is programmed and we have determined which motor controller will be operating the drive motors and which will be operating the arm motor.
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