From 4bd66c73b1440822832fa9eed5cefbe16bc83d25 Mon Sep 17 00:00:00 2001 From: daniel watson Date: Sat, 4 Mar 2017 23:40:55 -0800 Subject: [PATCH] create mechanical checklist --- mechanical-checklist.org | 298 +++++++++++++++++++++++++++++++++++++++ 1 file changed, 298 insertions(+) create mode 100644 mechanical-checklist.org diff --git a/mechanical-checklist.org b/mechanical-checklist.org new file mode 100644 index 0000000..53cad17 --- /dev/null +++ b/mechanical-checklist.org @@ -0,0 +1,298 @@ +* attach arduino to deck + - [ ] locate materials + - [ ] 1x arduino + - [ ] 1x deck + - [ ] 4x spacers + - [ ] 4x 6-32x5/8 inch bolt + - [ ] 1x 6-32 nut + - [ ] locate tools + - [ ] safety goggles + - [ ] magnetic tray + - [ ] 5/64 inch hex wrench + - [ ] pliers + - [ ] drill + - [ ] drill bit + - [ ] drill 1 hole, put in 1 bolt + - [ ] drill second hole, furthest away from first hole, put in 2nd bolt + - [ ] drill 2 remaining holes + - [ ] loosen first 2 bolts until arduino comes off + - [ ] put in all 4 bolts just enough to place spacers on them + - [ ] put arduino on top and tighten all but bottom right bolt + - [ ] hold locking nut with pliers, shiny side toward arduino, while + tightening last bolt into it. +* make sonar cables + - [ ] locate materials + - [ ] 2x 220mm red stiff wire, solid core 22 awg + - [ ] 2x 220mm blue stiff wire, solid core 22 awg + - [ ] 2x 220mm yellow stiff wire, solid core 22 awg + - [ ] 2x 220mm black stiff wire, solid core 22 awg + - [ ] 4x zip tie + - [ ] 8x terminal + - [ ] 2x white housing, 4 positions + - [ ] locate tools + - [ ] magnetic tray + - [ ] 1x crimper + - [ ] 1x wire stripper + - [ ] 1x wire cutter (or reuse wire stripper) + - [ ] prepare wires + - [ ] strip 1 end of all 8 wires by about 3mm (3/16 inch). + the terminal will crimp onto this end + - [ ] crimp terminals onto exposed end of wires + - [ ] strip other end of all 8 wires by about 2cm (1/2 inch). + this end will plug into the breadboard or arduino header + - [ ] finish cables + - [ ] put crimped ends into housing in the order: + black, yellow, blue, red + such that the probe points face towards the arduino on + the finished robot. + - [ ] put 2 zip ties about 2 cm down from the white housing. + this will spread any pulling stress across all terminals. + - [ ] repeat process to make the other sonar cable, + with wire colors in the same order as the first +* make sonar assemblies + - [ ] locate materials + - [ ] 2x sonar + - [ ] 2x sonar holder + - [ ] 2x 6-32 lock nut + - [ ] 2x 6-32x5/8 inch bolt + - [ ] 2x #6 washer + - [ ] locate tools + - [ ] magnetic tray + - [ ] socket wrench + - [ ] 5/16 inch socket + - [ ] 5/64 hex wrench + - [ ] attach binder clip arm to sonar holder + - [ ] fold binder clip arms back as if to open binder clip + - [ ] put #6 washer on 6-32x5/8 inch bolt + - [ ] put bolt through binder clip arm from the inside out + so bolt head will be between opened binder clip arms + - [ ] put sonar holder onto 6-32 bolt + - [ ] finger tighten 6-32 bolt with shiny side toward bolt head + - [ ] use socket, socket wrench and hex wrench to tighten + - [ ] repeat for other sonar holder + - [ ] attach sonars to deck + - [ ] attach sonar holders to deck by clamping binder clip to the deck + - [ ] put a sonar into left holder with sonar cans facing down, + and pins facing right, toward robot center + - [ ] repeat for other sonar, but face pins left, toward robot center +* attach wires to motor + - [ ] locate materials + - [ ] 2x motor + - [ ] 2x 220mm yellow wire + - [ ] 2x 220mm green wire + - [ ] 2x zip tie + - [ ] hot glue + - [ ] electrical tape + - [ ] locate tools + - [ ] got glue gun + - [ ] soldering iron + - [ ] scissors (or wire cutters) + - [ ] prepare wires + - [ ] strip one side of all 4 wires by about 2mm (1/8 inch) + - [ ] strip other side of all 4 wires by about 2cm (about 1/2 inch) + - [ ] temporarily attach wires to motor + - [ ] orient motor such that metal tabs are at the top, facing you + - [ ] put green wire's short exposed side through motor's right + side metal tab, + running wire down towards shaft + - [ ] wrap wire around shaft and body to keep it oriented and + still during soldering + - [ ] do the same for yellow wire, except put wire through + motor's left side metal tab + - [ ] repeat this process for other motor + - [ ] solder wires to tabs using soldering iron and solder + - [ ] protect motor's metal tabs in the solder joints + - [ ] from electrically connecting to motor's metal band + - [ ] cut strip of about 10cm (4 inches) of electrical tape + - [ ] slide center of tape under wires, sticky side toward motor. + be careful to bend the tabs as little as possible, + to prevent them from snapping + - [ ] wrap tape around motor + - [ ] from breaking + - [ ] place a zip tie around the wires and motor on motor's + round portion, just under square portion + - [ ] put hot glue all over the solder joint and wires to protect + from making accidental electrical connections with stray wires, + and to hold wires mechanically. +* battery solid core wire leads + - [ ] locate materials + - [ ] 1x black battery pack to power arduino, 9v + - [ ] 1x clear battery pack to power motor, 4xAA 6v + - [ ] 2x 35mm black stiff (solid core) wire + - [ ] 2x 35mm red stiff (solid core) wire + - [ ] 2x 35mm black (or clear) heat shrink + - [ ] 2x 35mm red (or clear) heat shrink + - [ ] solder + - [ ] locate tools + - [ ] soldering iron + - [ ] wire stripper + - [ ] heat gun + - [ ] helping hands + - [ ] prep wires for soldering + - [ ] put heat shrink on all battery wires. + match heat shrink color to battery lead + color (unless heat shrink is clear) + - [ ] strip all 4 battery pack leads to about 2cm (1/2 inch) + - [ ] strip in really short segments, about 1mm (1/16 inch) + - [ ] strip both ends of all stiff wires about 1cm (1/4 inch) + - [ ] solder stiff red wire onto clear battery pack red wire + - [ ] grip stiff red wire by one helping hand + - [ ] grip battery red wire by the other helping hand + - [ ] wrap exposed battery wire around exposed stiff wire + - [ ] apply heat from soldering iron, + melt solder with wires, forming solder joint + - [ ] wait for 10 seconds for solder joint to cool + - [ ] unclamp wires from helping hands + - [ ] solder remaining 3 wires on clear and black battery packs: + 2 black, 1 red + - [ ] cover solder joints with heat shrink + - [ ] slide heat shrink so solder joint is in middle of heat shrink. + the purpose of the heat shrink is to keep the solder joint + electrically isolated, and to make a strong mechanical connection. + - [ ] shrink heat shrink with heat gun, starting at end of + wire furthest away from battery pack, working toward battery pack. +* attach breadboard and batteries to top of deck + - [ ] locate materials + - [ ] 1x clear battery pack for powering motors, 4xAA 6v + - [ ] 1x black battery pack for powering arduino, 9v + - [ ] 1x breadboard + - [ ] 10x glue dot + - [ ] locate tools + - [ ] short stubby philips head screw driver + - [ ] attach breadboard + - [ ] 4 glue dots + - [ ] if breadboard has silvery heat spreader + - [ ] remove sticky backing on underside + - [ ] place silvery heat spreader on sticky underside of breadboard + - [ ] attach sticky dots + - [ ] break off 1 glue dot + - [ ] peel paper away from clear. glue dot will stick to clear side + - [ ] place glue dot by holding clear backing into a corner of the + underside of the breadboard. leave clear backing on glue dot. + - [ ] press down firmly on clear backing to make sure sticky dot + stays stuck to breadboard. still leave clear backing on glue dot. + - [ ] repeat this process for all 4 corners of breadboard. + - [ ] now that all 4 corners have a sticky dot with clear backing + - [ ] remove clear backing from all glue dots + - [ ] place breadboard down on deck, just under arduino + - [ ] make sure chip is on right + - [ ] attach clear battery pack for powering motor, 4xAA 6v + - [ ] 4 glue dots + - [ ] short stub screw driver + - [ ] attach glue dots to all 4 corners + - [ ] put short stub philips screw driver through hole 3,2 in deck grid + - [ ] place battery pack with screw hold on screw driver + - [ ] lower battery pack, using screw driver to make sure battery + pack's screw hole lines up with hole 3,2 on the deck + - [ ] attach black battery pack for powering arduino, 9v + - [ ] 2 glue dots + - [ ] short stub screw driver + - [ ] attach a glue dot to each end of the black battery pack + on the side of the battery pack with a screw and without a + switch. + - [ ] use short stub screw driver to guide battery pack so battery + screw hole lines up with grid hole 6, 1 +* make motor assembly + - [ ] put motor mounts on motors + - [ ] locate materials + - [ ] 2x motor + - [ ] 2x motor mount + - [ ] 4x 4-40x1 inch bolt + - [ ] 4x 4-40 lock nut + - [ ] locate tools + - [ ] magnetic tray + - [ ] 1x socket wrench + - [ ] 1x 1/4 inch socket + - [ ] 1x stub screw driver + - [ ] attach motor mount to left motor + - [ ] orient motor mount so that motor nub goes through motor + mount nose, and angle bracket holes are off to left when + looking at motor mount face upright in front of motor + - [ ] put 4-40 bolt through left eye of motor mount face, + then into motor + - [ ] finger tighten 4-40 locking nut onto 4-40 bolt, + put shiny side down, so nylon part of nut is still visible + - [ ] repeat for right eye + - [ ] tighten both bolts with socket wrench and screw driver, + but only after both bolts are through their holes + - [ ] repeat for right motor, but this time, angle bracket holes + will go off to the right when looking at upright motor mount face. + - [ ] put angle brackets on motor mounts + - [ ] locate materials + - [ ] 4x angle bracket + - [ ] 4x 6-32x3/8 inch bolt + - [ ] locate tools + - [ ] magnetic tray + - [ ] 5/64 inch hex wrench + - [ ] face left motor's mount face upright, angle bracket holes on left + - [ ] put 6-32 bolt through upper hole on motor mount + - [ ] bring angle bracket toward bolt from side of motor mount that + has the motor, and nuts on the 4-40 bolts + - [ ] use long arm of hex wrench to spin bolt while bringing angle + bracket's hole closer to the bolt. eventually, the bolt will + catch on the angle bracket hole and pull it in. tighten only a + few turns. the angle bracket will be completly tightened later. + - [ ] put wheels on motors + - [ ] locate materials + - [ ] 2x 2-20x3/8 screw + - [ ] 2x wheel + - [ ] 2x hair tie + - [ ] locate tools + - [ ] magnetic tray + - [ ] stub philip's head screw driver + - [ ] put hair ties on both wheel, it will act as a tire and provide grip + - [ ] put wheel on motor shaft + - [ ] use stub philips screw driver to tighten 2-20 + screw into wheel shaft. + push wheel firmly into motor shaft while tightening. + - [ ] repeat for other wheel +* attach motor assembly to deck + - [ ] make motor assemblies + - [ ] locate materials + - [ ] 4x #6 washer + - [ ] 4x 6-32x3/8 inch bolt + - [ ] 1x left motor assembly + - [ ] 1x right motor assembly + - [ ] locate tools + - [ ] magnetic tray + - [ ] 5/64 inch hex wrench + - [ ] attach left motor assembly to left side of robot + - [ ] put #6 washer on 6-32 bolt + - [ ] put bolt through hole 6,1 on deck + - [ ] use long arm of hex wrench to spin bolt tightening (clockwise) + while bringing left motor assembly angle bracket towards it. + orient assembly so that other angle bracket is on deck grid hole 5,1. + leave it a little loose so motor assembly can pivot second bracket + to line up with hole 5,1 on deck grid. + - [ ] put #6 washer on 6-32 bolt + - [ ] put bolt through hole 5,1 on deck + - [ ] use long arm of hex wrench to spin bolt tightening (clockwise) + while bringing second angle bracket towards it. + - [ ] push motor assembly to the left, out from robot center and + tighten up all 4 of the 6-32 bolts. + pushing out gives the wheel room to spin without rubbing the deck. + - [ ] repeat this process with right motor assembly and + holes 8,5 and 8,6. +* attach caster to deck + - [ ] locate materials + - [ ] 3x 6-32x5/8 inch bolt + - [ ] 3x 6-32 lock nut + - [ ] 3x #6 washer + - [ ] caster holder + - [ ] caster ball + - [ ] locate tools + - [ ] magnetic tray + - [ ] socket wrench + - [ ] 5/16 inch socket + - [ ] 5/64 inch hex wrench + - [ ] attach first bolt + - [ ] put #6 washer on 6-32 bolt + - [ ] put bolt through hole 4,1 on deck grid from top + - [ ] bring middle hole of caster holder towards that bolt + - [ ] finger tighten a locking nut onto the bolt + it will be tightened more after getting all the bolts through the + caster holder + - [ ] put a washer on another bolt, put that bolt through hole + 4,2 on deck and finger tighten nut to it + - [ ] do the same through hole 5,1 + - [ ] use socket, socket wrench and hex wrench to tighten all 3 bolts -- 2.30.2