Surface Mobility Platform A rugged robotic research platform that is agile and easy to maintain Rugged Titanium, Stainless and Aluminum Construction Payload Capacity Exceed *30 Lbs. High Mobility in Rough Terrain Easy Access to Control Box and Electronics Re-Configurable and Scalable Stable Camera Platform Efficient Motors Easy to Repair and Maintain in the Field or in the Shop 105 Webster St. Hanover Massachusetts 02339 Tel. 781 878 1512 Fax 781 878 6708 www.gearseds.
Surface Mobility Platform Illustrated Assembly Guide This is a user customizable platform. There are several ways to configure the control box and differential suspension. Final configurations are left to the user’s discretion. The following guide provides general construction examples.
Surface Mobility Platform The GEARS-SMP is created using three mechanical modules The Chassis and Motor Module Fabricated using 1-1/4” x 0.125” wall 6061-T6 aluminum square tubing. This module includes the chassis structural components, motors, motor mounts and wheel and tire components. Note: The tire tread pattern is show aligned in a unidirectional configuration. This is one of several user selectable tread alignment options. The Control Box Module 0.
Build the Chassis Module(s) Step One: Build the Chassis Module (2 required) Necessary Components Qty. 2 4 8 8 Description 9 Hole Chassis Tube 45 Degree Connector #10-32 x 1-1/2” stainless cap head screws #10-32 stainless nylon lock nuts Fig.1 Procedure Attach the two 45 degree connectors as shown in figures 1, 2 and 3. Fig.3 Fig.2 Step Two: Build Motor Mount Modules (4 required) Necessary Components Qty.
Step Two: Build Motor Mount Modules (continued from previous page) Procedure Caution: The PVC spacer ring has a slit that allows it to be spread apart as it passes over the motor wires. Place a wrap of electrical tape around the end of the motor can and over the wire before attempting to pass the PVC spacer over the motor wires. Take care to spread the split ring spacer so that the split clears the motor power leads while sliding the split ring PVC spacer onto the motor..
Assemble the motor mounts using the #4-40 x 5/8” stainless steel cap screws. Position the upper and lower motor mounts around the motor can, as shown in figures 6 and 7. Place a lock washer under the head of each cap screw. Note that the cap screws are fastened to the motor mounts in an alternating (top/bottom) pattern. Take precautions to keep the seams between the top and bottom motor mounts equal on each side and parallel.
connector and the chase formed by the 3 hole tube. Do not pinch the motor lead wires or pull on them with excessive force. This will damage the wire leads and create a short circuit condition. Use 2 #10-32 x 1-1/2” cap screws and nylon locking nuts , as shown in figure 8, to fasten the motor mount modules to the chassis connector module. Fig.9 Fig.10 105 Webster St. Hanover Massachusetts 02339 Tel. 781 878 1512 Fax 781 878 6708 www.gearseds.
Build the Control Box Module Necessary Components Qty. 8 4 8 2 1 1 6 6 Description #10-32 x ¾” Stainless steel Phillips head machine screws 3/8” x 1 ¼” x #10-32 Round aluminum standoffs #10 Stainless steel lock washers ½” Bore pillow blocks ½” x 10” Titanium axle (6AL4V alloy) 3” x 5” x 12” x 0.
Step Two: Center the pillow blocks and main shaft. Slide (2) ½” shaft collars and washers up against the pillow blocks to secure the main shaft in position as shown in figure 13 below. Fig. 13 Building the Differential Assembly Note: The chassis modules and wheels have been omitted in order to more clearly illustrate the assembly sequence. Step One: Attach the differential shaft bearings and aluminum standoffs Necessary Components Qty.
Attach the Chassis and Control box module Necessary Components Qty. 2 1 4 4 Description Chassis modules (Pages 4-7) Control box module (Pages 8-9) ½” Zinc plated shaft collars ½” Zinc plated flat washers Procedure Step One: Slide a ½” shaft collar and washer onto the main axle. Slide the chassis module onto the main shaft, and follow with a washer and ½” shaft collar. Fig.
Step Two: Make up the tie rods used to support the differential arms Necessary Components Qty. Description 4 2 4 4 #10-32 x 1 ½ ” stainless steel threaded rod #10-32 x 2” aluminum standoffs (round) #10-32 stainless steel hex nuts #10-32 x 0.190” tie rod ends Screw two (2) threaded rod sections approximately ½” into each end of the aluminum standoffs. Screw the hex nut onto the threaded rod so that approximately ½” of threaded rod remains exposed.
Step Three: Assemble the Differential, Axle and Tie Rods Necessary Components Qty. Description 2 1 3 2 2 0/090” x 10” differential arm and bearing assemblies ¼” x 4-1/2” stainless steel axle ¼” shaft collars #10-32 x 1” stainless steel cap head machine screws #10-32 stainless steel nylon lock nuts The ¼” stainless steel axle passes through both differential arms, a ¼” shaft collar and on through the flanged sleeve bearings. Each end of the ¼” axle is secured using a ¼” shaft collar.
Step 4: Attach the bottom tie rod ends to the chassis modules Necessary Components Qty. Description 2 2 2 0.190” dia x ¼” nylon spacers #10-32 x 2” stainless steel cap head machine screws #10-32 stainless steel nylon lock nuts The bottom tie rod ends are attached to the chassis module using 10-32 x 2” long stainless steel cap head screws and nylon locking nuts. The ¼” nylon spacers are used to position the tie rod end outboard of the chassis module.
Caution: Do not restrict the free movement of the tie rod ends by over tightening them. They should be just tight enough to remove any looseness or “play” in the connection. Secure the Control Box Cover Fig. 27 Step 1: Attach the control box cover to the control box Necessary Components Qty. Description 1 4 ¾” x 5.25” x 12” control box cover #12 self tapping phillips head screws Note: Attach the wheels before securing the cover. Fit the cover to the control box.
Step Five: Mount the Wheels and Tires Necessary Components Qty. 4 4 4 4 Description ¼” Bore Threaded Hex Adapters Wheel and Tire Assemblies (See page 24 for assembly instructions) 12mm Jamb Nuts 12mm Washers Procedure Slide the hex adapters onto the motor shaft. (In some cases these are pre-assembled). The set screw should slide as far onto the shaft as possible while remaining on the flat of the shaft. Tighten the setscrew on the hex adapters.
Electrical Assembly Step One: Gather the components listed below. Cut eight (8) three quarter inch long pieces of 1/8” diameter heat shrink. Cut four (4) three quarter inch long pieces of 1/4” diameter heat shrink. Cut Two (2) one inch long pieces of 3/8” diameter heat shrink. Cut Two (1) lengths of the 3 conductor cable, 9” long. Necessary Electrical Components Qty. Description 2 1 2 1 2 2 4 1 1 1 1 1 1 2 GEARS-IDS™ 12 ampere ESC’s SPST Toggle switch 5/8” x 3/8” x 0.
Step Two: Solder the ¼” phono plug to the three conductor cable. Prepare the 3 Conductor Cable Strip the black rubber insulation back , 1” to 1-1/4”. This will expose the three conductors, black, white and green. We use a razor knife to strip away the rubber insulation, being very careful to NOT cut through the green, white or black wire insulation. This could possibly create a short circuit situation, should the white and black conductors touch during operation.
Slide the ¼” Phone plug cover onto the three conductor cable. Unscrew the phone plug cover from the phone plug. Slide the phone plug cover over the black rubber jacket of the three conductor cable as shown above. The plug fits tight but it will go on. It is best to use a screwing motion as you push the cover onto the cable. A little liquid soap helps, but it is not necessary. Wipe it off completely after sliding the plug cover onto the cable. Solder the ¼” phone plug onto the cable wires exactly as shown.
Complete the cable assembly by sliding two lengths of ¾” x 1/8” heat shrink over the black and white conductors, and one rubber grommet and one, 1” length of ½” heat shrink over the black cable jacket as shown above. Do not shrink the heat shrink at this point. The (2) yellow wires on the speed controllers are the motor leads. Refer to the Speed controller wiring instructions supplied with the kit of parts.
Strip 3/4” of insulation from each of the black and red leads on both speed controllers. Twist the two red leads together and crimp a ¼” insulated spade connector onto the end of the black leads. Repeat this step for the red leads. The finished assembly is shown above. Remember: Black to black and red to red! Failure to observe this instruction will damage the speed controllers and void the warranty.
Fasten the phone jacks to the center hole in the side of the control box as shown below. Wire the ESC’s, battery and switch per the instructions that come with ESC’s. Use small square tabs of Velcro to secure the battery to the floor of the control box. Secure the ESC’s to the battery (shown) or to the side wall of the control box using velcro squares cut from the strip provided in the kit. Snake the front and rear motor leads through the chassis tube hole as shown.
Slide the rubber grommet down the cable and force it firmly into the chassis tube hole using a dulled table knife or similar dull object. Make certain the grommet is evenly seated in the hole. If necessary, push the cable into the grommet hole and secure it with a few drops of Cyanoacrylate glue. Insert the phone plug into the jack. Repeat for the other side. 105 Webster St. Hanover Massachusetts 02339 Tel. 781 878 1512 Fax 781 878 6708 www.gearseds.
Complete the wiring of the receiver, battery and ESC’s per the instructions provided with the ESC’s. Turn on the transmitter and the robot when you are sure the wiring is completed correctly. It may be necessary at this point to configure the transmitter in order to customize the steering and vehicle performance. Read the instructions that came with the transmitter carefully in order to correctly configure the RC controls. Instructions differ for each brand of transmitter. 105 Webster St.
Illustrated Assembly Tips Mounting the Tires and Rims The tires used on the GEARS-SMP are made from a medium soft rubber compound. These tires can support the weight of batteries, sensors and cameras. In addition, the tires can be partially filled with sand or lead shot in order to gain additional traction. Partially filling the tires with ballast will lower the SMP’s overall center of gravity and provides additional stability over rough terrain.
