Robot Assembly Guide
When 15mm links (F) or 30mm links (G) are assembled to an aluminium profile, always fit with the flat side outwards and the round side in the groove.
Be careful with the orientation of the 15mm and 30mm blocks - both are used to later fit the motors and ball caster. The orientation of the slot at the bottom of the block is important as it will allow the mounting screws (and axles) to fit to the frame. If you get the orientation wrong you will need to disassemble the robot to correct it.
You will need:
| Quantity | Description | Ref. |
|---|---|---|
| 1 | 90mm Aluminium Profile | * |
| 2 | 30mm Block | A |
| 2 | 15mm Link | F |
| 2 | Small Hinge | M |
| 2 | Mini-Switch | W |
Assemble 2 15mm links (F) into the rear groove of the aluminium profile with the flat edge of the link outermost.
Assemble 2 small hinges (M) into the front groove of the aluminium profile, so that the moveable flap of the hinge pivots at the top. (See diagram below).
Assemble the 30mm block (A) into the centre of the upper groove The groove across the bottom of block (A) should be at right angles to the aluminium profile as in the diagram below.
Assemble the two Mini-switches (N) length-ways into the lower groove, with the red switch actuators facing forwards
Diagram: Lower front cross member (front):
Diagram: Lower front cross member (back):
You will need:
| Quantity | Description | Ref. |
|---|---|---|
| 2 | 120mm Aluminium Profile | * |
| 2 | 5mm Block | E |
| 2 | 15mm Link | F |
| 2 | 30mm Link | G |
Assemble 1 15mm link (F) towards the rear of upper groove of each aluminium profile.
Assemble 1 30mm link (G) towards the front of the same groove in each aluminum profile.
Assemble 1 5mm block (E) into the front of inner groove of the aluminium profile so that the groove in the 5mm block is at right angles to the section.
See the diagram below to check if this is done correctly.
Diagram: Lower side members, left and right hand:
You will need:
| Quantity | Description | Ref. |
|---|---|---|
| 2 | 90mm Aluminium Profile | * |
| 2 | Small Hinge | M |
| 4 | 15mm Block | B |
Assemble 1 15mm block (B) into the bottom end of the rear groove of each aluminium profile, so that the groove in the end of the block is at right angles to the profile. This groove will hold the wheel axle.
Assemble 1 15mm block (B) to the inner side of the first 15mm block on each profile, making the bottom groove in the block parallel with the aluminium profile. This will ensure that the groove for the axle is of maximum length.
Assemble 1 small hinge (M) into the bottom end of the front groove of the aluminium profile, so that the moveable flap pivots at the top of the hinge.
Check the assembly with the diagram below to ensure it is correct. Pay care attention to the orientation of the 15mm blocks, they must be aligned so the wheel axle can slide through (on the opposite side from the hinges).
Diagram: Front vertical legs, left and right hand:
You will need:
| Quantity | Description | Ref. |
|---|---|---|
| 2 | 90mm Aluminium Profile | * |
| 3 | 5mm Block | E |
| 2 | 15mm Block | B |
| 1 | 30mm Block | A |
Assemble 1 5mm block (E) into the bottom end of the front groove of each aluminium profile so that the groove on the block is at right angles to the section.
Assemble 1 15mm block (B) into each 5mm block (E) already in position. The groove at the end of the block should again be at right angles to the aluminium profile.
Assemble the 30mm block (A) into the bottom end of the inner groove of the left vertical leg, so that the groove in the end of the block is parallel with the aluminium profile.
Assemble the remaining 5mm block (E) into the bottom end of the inner groove of the right vertical leg, making the groove in the block parallel with the aluminium profile.
Pay careful attention to the orientation of the 15mm blocks, they must be aligned so the motor mounting screws can go through parallel to the 30mm block. The 30mm block must be orientated so the ball caster mounting screw can go through parallel to the aluminium profile.
Diagram: Rear vertical legs, left and right hand:
You will need:
| Quantity | Description | Ref. |
|---|---|---|
| 2 | 90mm Aluminium Profile | * |
| 2 | 15x90mm Single Row Plate | J |
| 2 | 30mm Block | A |
| 2 | 30mm Link | G |
Assemble 1 15x90mm single row plate (J) into top groove of each aluminium profile. Assemble 1 30mm link (G) into front of lower groove of each section.
Assemble 1 30mm block (A) into the 30mm link (G) at one end of the aluminium profile with the groove in the end of the block aligned across the width of the profile and facing away from the end. (See diagram).
Pay careful attention to the orientation of the 30mm blocks, they must be aligned so the motor mounting screws can go through perpendicular to the aluminum profile.
Diagram: Upper side members, left and right hand:
You will need:
| Quantity | Description | Ref. |
|---|---|---|
| 2 | 90mm Aluminium Profile | * |
| 2 | 15x90mm Single Row Plate | J |
Assemble 1 15x90mm single row plate (J) into top groove of each aluminium profile.
Diagram: Upper front and rear cross members:
You will need:
| Quantity | Description | Ref. |
|---|---|---|
| 1 | 90mm Aluminium Profile | * |
NOTE: This member holds the pen assembly when fitted.
Diagram: Rear lower member:
You will need:
| Quantity | Description | Ref. |
|---|---|---|
| 1 | 30mm Block | A |
| 2 | 15mm Link | F |
| 2 | V15 Block | E |
| 1 | 15x90mm Single Row Plate | J |
| 1 | Ball Caster holder | U |
| 2 | 10mm Clip | P |
| 2 | M4x35mm Screws | * |
| 2 | M4 Nuts | * |
| 2 | M4 Washers | * |
Assemble the 30mm block (A) into the 15x90mm single row plate (J) with the 30mm block at one end of the plate and the groove in the end of the 30mm block aligned across the width of the plate, and facing away from the end. See diagram below to check assembly.
Pay careful attention to the orientation of the 30mm block, it must be aligned so the ball caster mounting screw can go through parallel to the plate.
The other parts in this sub-assembly step will be added to the main frame assembly later.
Diagram: Rear Castor Support (pre-assembly):
You will need:
| Quantity | Description | Ref. |
|---|---|---|
| 1 | 80mm Steel axle | N |
| 2 | 10mm Clip | P |
| 2 | Gear Wheel | T |
| 4 | Hub (top) | Q |
| 4 | Hub (bottom) | Q |
| 4 | Locking washer | L |
| 6 | M4 Washers | * |
| 6 | V-Axle | K |
| 12 | Grey axle | * |
| 2 | Large pulley wheel | R |
| 2 | O-Ring | * |
Assemble the grey axles into the radial slots in the large pulley wheels (R), pushing firmly home. Fit the O-rings as tyres on to the wheels, making sure the rings do not become twisted (you will need to stretch the O-Rings over the edge of the tyres and make sure they are correctly in the groove around the wheel).
The hubs (Q) are in two parts which you will sometimes find screwed together. Unscrew and fit them to the large pulley wheels (R) and gear wheels (T) by screwing them together through the centre of the part. Assemble loosely at this stage (just enough to hold them in place).
Fit the large pulley wheels to one end of each axle (N) so that the top of the hub (the wing-nut) are towards the outside end of the axles. Leave a maximum of one or two millimetres of axle protruding.
Fit two locking washers (L) to each axle and then the gear wheel so that the flat sides of the large pulley wheel hub and gear hub face each other. Fix the large pulley wheels to the gear wheels by pushing the V-axles (K) through the holes provided. Tighten the large pulley wheels and gear wheels to the axles by grasping the top of both hubs (wing nuts) in opposite hands and tightening against each other.
The following diagram shows a close up of the correct assembly as described above:
The remaining 10mm clips (P) and washers will be assembled later.
Diagram: Driving wheels assembly:
Slide the lower front cross member (sub-assembly 1) into the side grooves of the front vertical legs (sub-assembly 3) from the top. Do not push it to the bottom yet. Make sure that all four hinges are facing the front and the blocks on the vertical legs (sub-assembly 3) are facing inwards. Note that the mini-switches should not be attached to the vertical legs at this stage.
Slide the bottom ends of the front vertical legs (sub-assembly 3) into the front of the upper groove on the lower side members (sub-assembly 2). then push the lower front cross member (sub-assembly 1) down to the bottom or the vertical legs, engaging the ends of the mini-switches in the red building blocks (E). If the building blocks (B) on the vertical legs foul the downward movement, they can be moved slightly towards the rear.
Make sure that the vertical legs are flush with the ends of the black inserts in the lower side members. All four lower corners of the Buggy frame should be checked in this way as they are built.
Slide the links (F) on the lower front cross member into the blocks attached to the vertical legs. Slide the links (G) on the lower side members into the blocks attached to the vertical legs. The corners should now be firmly locked.
Assemble the lower end of the rear vertical legs (sub-assembly 4) into the upper grooves of the lower side members, so that the building blocks (B) rest on the lower side members. Slide the red links (F) into the building blocks (B) to lock the corners.
Fit the upper side members (sub-assembly 5) between the front and rear vertical legs, with building blocks (A) also slid into the front legs. The red building plates (J) should be uppermost and should be positioned slightly lower than the ends of the vertical legs.
Fit the upper front and rear cross members (sub-assembly 6) between the left and right vertical legs, so that the red building plates (J) are uppermost and slightly lower than the ends of the vertical legs.
Fit the rear lower member (sub-assembly 7) between the left and right lower side members. Slide it forward a few centimetres.
Slide the building block (A) on the left rear vertical leg upwards a couple of centimetres. Slide the free end of building plate (J) from sub assembly 8 into the rear groove of the building block. This can be done by bending the building plate (J) slightly backwards.
Slide the building blocks (A) and building plate (J) down again, engaging the end of the right hand block in the red building block (E) which should be at the bottom of the right rear vertical leg. See the diagram below for the correct assembly of the ball caster.
Diagram: Ball caster assembly:
Assemble the corner blocks (C) into the rear inside grooves of the left and right lower side members and lock to the building blocks above them using the links (F).
Insert the two M4x35mm bolts upwards through the outside holes of the caster holder (U). (The ball faces downwards.) Fix the clips (P) onto the bolts close against the upper side of the caster holder.
Insert the bolts through the grooves in the ends of the building blocks at the rear of the Buggy and fix in position using M4 washers and nuts. The nuts should be firm, but do not over-tighten or damage may result to the clips.
Fit 2 washers on each axle (sub assembly 9) and insert the wheel sub assemblies into the axle holes which are located at the junction of the front vertical legs and the lower side members. Fit one more washer on each axle and fix in position using the remaining clips (P) from sub assembly 9. This completes the main chassis assembly.
The wheel track width (centre to centre) should be approximately 164mm. If it is very different from this figure, you have probably assembled the Buggy incorrectly. Finer adjustments can be made when the Buggy is tested.
Note: The wheels should turn with just a little resistance. If the wheels are stiff, use a 4mm drill bit (either by hand or using pliers) and twist it through the axle mounts to clear out any unwanted material.
You will need:
| Quantity | Description | Ref. |
|---|---|---|
| 2 | Cog wheel | S |
| 4 | Drive chain | V |
| 4 | M4x25mm screw | * |
| 4 | M4 Nut | * |
| 8 | M4 Washers | * |
| 2 | 30x90mm Single row plate | H |
| 2 | 7.5mm Block | D |
| 4 | 5mm Block | E |
Loosely assemble a screw and nut with two washers in the hole in the building block (B) at the junction of the rear vertical legs and the lower side members, one on each side of the Buggy. Make sure that one washer is on each side of the building block.
Insert one of the slotted motor flanges on to the screw between the outside washer and the building block, so that the motor power lead goes diagonally upwards and out through the rear of the Buggy and the motor spindle is pointing outwards. Fix the motor in position with the other screw, nut and washers, and tighten the screws firmly.
Snap the chain links (M) together to make 2 chains of 40 links. Make sure the chain links are all assembled the same way round.
Fit the cog wheels to the motor spindles with the knurled knob to the outside. Tighten the knob when the cog is level with the gear wheel.
Diagram: Motor mounts:
Fit the chains round both gear wheels and cogs and join the ends of the chains together with the open side of the chain links facing outwards. The drive chains should not be tight but there should be no visible slack.
Assembling the bumpers can be a tittle tricky - make sure you assemble the bumpers in the correct order - or you will not be able to fit them. Put the Buggy upside down with the ball caster towards you and the wheels away from you. Fit the right bumper first (on the left as you look at it). The pegs on the building plate go towards the top of the Buggy (now underneath). Fit the inside hinge to the end peg of the building plate, best done by bending the building plate slightly backwards. Fit the outside hinge to the third peg from the other end of the building plate.
The left bumper can now be assembled (on lhe right as you look at it). Fit the inside hinge to the first peg on the building plate. then slide the hinge to your right in order to attach the remaining hinge to the third peg from the end. This is best done by squeezing the building plate and hinge together until the peg can be inserted.
Fit the building blocks (D) on to one of the pegs between the hinges on each bumper so that when the bumper is pressed, the mini-switch operates.
Assembly of the bumpers is complete when the building plates (H) are level with each other with a slight gap in the centre so that each bumper can operate independently.
Diagram: Bumpers (top):
Diagram: Bumpers (bottom):
Fit the building blocks (E) to the tops of the vertical legs so that they slide forwards and backwards. These blocks are used to secure the control PCB in place (by sliding them slightly over the PCB edges).
The Buggy is now complete mechanically.
Diagram: Completed buggy (Front):
Diagram: Completed buggy (Back):
Diagram: Completed buggy (Side):
