Path to Motorama 2K16: Work Begins!

Welcome to the first post in a series of posts detailing the construction of the two beetleweight entries into the NERC's Motroama Robot Conflict 2016. We first begin with Play'n Krazy v2...

CAD rendering of Play'n Krazy v2

Play 'n Krazy's frame rails mid construction

 Since we here at Bone Dead Robotics currently only have access to a drill press, bandsaw, table grinder, and a hand Dremel tool, these parts don't have extreme precision. However, using a trick where we attach a 1:1 drawing generated by Solidworks to the material. We then simply follow the markings; cut around the outline and punch out all the holes. It seems to work fairly well.

The final priducts

The weapon motor and drive are sooo tight together!

 In the picture above we see all the parts fit together with drive system and weapon system in the machine. The original CAD design showed everything being tight, but I never truly understood it until I see it now. The weapon mount actually had to be cut down to make sure the weapon teeth wouldn't whack it by accident.

Spaghetti monster problems

 As you can see, there are soo many wires literally gushing out of the sides of the robot. Its gonna take a bit dancing to get everything together.

Wiring: mastered

 The robot looks pretty now, but their is still some work to be done. Those frame rails look good, but I don't think they will remain since they are basically spare parts just floating around.

Ti: 14 Cut-off Disks:0

The construction of the .06" Grade 5 Titanium Wedge takes forever because there is so much friction generated that it basically chews up the disks. That little container used to be full of disks and after about 14 of them were killed only about 6 remain.

Tiii looks niiice

The completed wedge! It looks sweet and I still have enough to make another wedge for our other beetleweight: Wedge of Destruction v3.

CAD rendering of Wedge of Destruction v3

These are the first bushings/pulley/hub combos whipped up for WOD v3. The wheels are actually glued directly onto the pulley meaning that the only way to get spares is to make a whole new combo

 These wonderful pieces here are the front pulleys to WOD v3's drive train. Essentially, these are 30T pulleys from Fingertech Robotics bored out to about 3/8" then pressed the 1/4" bushings from Servo City then used red Loctite 242 to bond them together. Whilst they sit, we took some 6061 Aluminum spacers at cut them to length. They were then lightly sanded down by the table grinder and mounted. They can be seen inside the bushing in the picture and will be used as both a dead shaft and as a support for the outer frame rail.

Parts from Fingertech Robotics!

 Some spare pulleys, drive belts and nutstrip arrive courtesy of Fingertech. Thanks Kurtis!

Machining for WOD begins 

Here is the first part being made for WOD v3. This part here is the central cross brace which braces the robot from horizontal attacks. This part and all other frame pieces are made of 5/16" 7075 Aluminum from Midwest Steel and Aluminum Supply. Through the use of the bandsaw, I was able to make some of the notches in the chassis and then use the drill press to punch each of the weight reducing holes. The purpose of those notches on the sides is to interlock the frame pieces and create intra-frame strength.

Bare Aluminum is so shiny!

One of the benefits of cutting out material are the nice Al washers

Looking good for weight

Central frame rail cutting begins

And all that brings us to this point where the frame rail pieces are being machined from a single piece via the bandsaw. Will they be finished on time? Will they be overweight? Find out on the next update of Path to Motorama 2K16!