Day #16 – 1/18/2015 – Shiny Metal Parts

Lab opening time: 12:30pm

The whirl of the Haas Mini Mill greeted the students as the walked into the lab today. Mr. Hoard and Mr. Black worked ceaselessly on the swerve tube today. Each of the seven tubes took about 40 minutes to make, not including the time to re-position the tube through all six setups, and clear the chips. The blanks cut from 3.5″ round bar stock weighed 996 grams prior to machining and weighted 99 grams after machining.  Approximately 90% of the material was turned to chips.  A picture of all the CNC parts made to date is shown below.

Swerve drive parts manufactured as of closing time today.  Axles and spacers not shown.
Swerve drive parts manufactured as of closing time today. Axles and spacers not shown.

The prototyping team started on a new frame that is the actual dimensions of the robot. They are not completely abandoning the previous prototype but are using it at as a model for how to build a better, stronger model.

The beginning of the new prototype frame.
The beginning of the new prototype frame.

The CAD team worked on the frame and how to mount the electronics. Shay worked on improving the forks for the elevator and he hopes to have the forks ready to be cut on the Techno Router by tomorrow.

The business team worked on finding more sponsorship to help balance the cost of building a robot and competing in two regionals.

Lauren worked on photographing some of the manufactured parts.

Lauren taking pictures of the manufactured parts.
Lauren taking pictures of the manufactured parts.

Media team has been working on a time-lapse of the lab and continued editing some of the footage and also worked on creating posters for the Clark Expo next Saturday.

Sipan has been working on creating a fully 3D printed swerve module. The hardest part has been creating 3D printed bearings and getting them to the exact size so that the swerve module move.

On the programming side, Daniel worked on swerve tracking which basically allows us to see how many degrees the wheels have turned even though we are using absolute encoders. Alexandr worked on a way to figure out the robots angle using odometry numbers so that are robot does not need a gyro. John has programmed 2012’s and 2013’s robots and is now learning how to programming for autonomous using state machines which is autonomous decision making. Daniel has been working on many different programs that will enhance the data received from the encoders

The CAM team worked on getting the 84 tooth gear and the top plates ready for manufacturing as soon as the swerve tube is done.

Mr. Widholm and Bhavin working on OneCNC.
Mr. Widholm and Bhavin working on OneCNC.

The Lathe team worked on creating the shafts for the swerve model and Alexander Luke started working on the VersaPlanetary gearboxes by cutting the output shafts shorter and drilling and tapping the end 10-32 to hold on the miter gear.  A picture of the six modified and assembled VersaPlanetaries is shown below:

VexPro VersaPlanetary gearboxes, to be used for steering the swerve modules.  These are assembled with BaneBots 550 motors and two 7:1 stages of gearing, for an overall ratio of 49:1. The overall steering gear ratio to the module will be 171.5:1, through a final reduction of 84:24.
VexPro VersaPlanetary gearboxes, to be used for steering the swerve modules. These are assembled with BaneBots 550 motors and two 7:1 stages of gearing, for an overall ratio of 49:1. The overall steering gear ratio to the module will be 171.5:1, through a final reduction of 84:24.

The web team worked on website designs and layouts and has come up with a design that they are going to use a template for the rest of the website. For the title they will use a black background with white text and for long passages, a white background with black text.

Finally, we took a look at the overall layout of the frame and electronics, in a conceptual 2D CAD sketch.  A screen capture is shown below.  In this picture, the frame is 40.5 inches wide, and 27.5inches long.

Frame layout including electronics as viewed from the top.  40.5 inches wide.  27.5 inches long.  The separate panel will be mounted to the elevator support structure.
Frame layout including electronics as viewed from the top. 40.5 inches wide. 27.5 inches long. The separate panel will be mounted to the elevator support structure.

Lab closing time: 10:45 PM