Project

General

Profile

Statistics
| Branch: | Revision:

colonymech / docs / www / colonyscout / internal / assembly_old.php @ f59acf11

History | View | Annotate | Download (9.78 KB)

1
<?php require("includes/internal.php")?>
2

    
3
<!DOCTYPE html PUBLIC "-//W3C//DTD XHTML 1.0 Transitional//EN" "http://www.w3.org/TR/xhtml1/DTD/xhtml1-transitional.dtd"> 
4
<html xmlns="http://www.w3.org/1999/xhtml" xml:lang="en" lang="en"><head> 
5
                <meta http-equiv="Content-Type" content="text/html; charset=iso-8859-1"/>        
6
                <meta name="description" content="FILL IN"/> 
7
                <meta name="keywords" content="FILL IN"/> 
8
<?php include($docRoot."header.php"); ?>
9
                <title>Assembly Instructions | ColonyScout.com</title>
10
<?php include('includes/querybox.php');?>
11
<link href="css/assembly.css" rel="stylesheet" type="text/css" media="screen">
12
<link rel="stylesheet" href="includes/lightbox/lightbox.css" type="text/css" media="screen" />
13
<script type="text/javascript" src="includes/lightbox/lightbox.js"></script> 
14
</head>
15
<body bgcolor="#eeeeee"> 
16

    
17
<div id="general"> 
18
<?php include("includes/nav_internal.php"); ?> 
19
        <div id="body">
20
                <div id="body-boxes">
21
                        <div class="box-row" style="margin-top: 7px;">
22
                                <div class="white-top"></div>
23
                                <div class="white-body text-box">
24
                                        <div id="breadcrumbs">Assembly Instructions&gt;</div>
25
                                        <div id="livesearch"><div id="box0"><!-- livesearch--></div></div>
26
                                        <br/>
27
                                        <div class="hr"></div>
28
                                </div><!--end 'TEMP' collapse-->
29
                                
30
                                <div class="white-body text-box">
31
                                
32
        <div class="box-row">
33
        <h1>Chassis Assembly Preparation</h1>
34
        </div>
35
        
36
                        <div class="box-row">
37
                                <div class="box-3-titles"><h2>Step 0</h2></div>
38
                                <div class="box-3-text"><h2>Gathering parts & tools</h2>
39
                                        <ol>
40
                                        <li>Cut sheet metal parts</li>
41
                                                <li>File sharp edges, countersink all holes (from correct side)</li>
42
                                                <li>Bend to spec, validate with bend check tools CRITICAL</li>
43
                                                <li>Sandblast and clean</li>
44
                                                <li>Powdercoat or primer and paint (use Rustoleum Satin Finish), enamel clearcoat (satin)</li>
45
                                        </ol>
46
                                </div>
47
                                <div class="box-3-pictures">
48
                                        <div class="pic"><a href="" rel="lightbox"><img src="thumbs/assembly/assm.jpg"></a></div>
49
                                </div>
50
                        </div>
51

    
52
        <div class="box-row">
53
        <h1 id="Chassis-Assembly-Front-Half">Chassis Assembly, Front Half<a href="#Chassis-Assembly-Front-Half" class="wiki-anchor">&para;</a></h1>
54
        </div>
55
        
56
                        <div class="box-row">
57
                                <div class="box-3-titles"><h2>Step 1</h2></div>
58
                                <div class="box-3-text"><h2>Install Pivot block</h2>
59
                                        <ol>
60
                                        <li>Using #4-40 CSK hardware, tighten pivot block into position</li>
61
                                                <li>Ensure perpendicularity with long axis of robot (otherwise robot halves will collide and robot will not drive straight)</li>
62
                                        </ol>
63
                                </div>
64
                                <div class="box-3-pictures">
65
                                        <div class="pic"><a href="" rel="lightbox"><img src="thumbs/assembly/assm.jpg"></a></div>
66
                                </div>
67
                        </div>
68
                        <div class="box-row">
69
                                <div class="box-3-titles"><h2>Step 2</h2></div>
70
                                <div class="box-3-text"><h2>Install return springs</h2>
71
                                        <ol>
72
                                        <li>Slide spring onto bent tab, ensuring parallelism with vertical plane</li>
73
                                                <li>Install wire retainer from (outside) of front half, aka space between the halves</li>
74
                                                <li>Twist the retaining wire tightly over the spring, clip neatly</li>
75
                                        </ol>
76
                                </div>
77
                                <div class="box-3-pictures">
78
                                </div>
79
                        </div>
80
                        <div class="box-row">
81
                                <div class="box-3-titles"><h2>Step 3</h2></div>
82
                                <div class="box-3-text"><h2>Front Cliff Sensor</h2>
83
                                        <ol>
84
                                        <li>Solder wires according to wiring diagram (link?)</li>
85
                                                <li>Install on front mounting tab using #2-56 SHCS, lock washer, and nut, or nylock</li>
86
                                                <li>Be careful not to distort mounting tab</li>
87
                                        </ol>
88
                                </div>
89
                                <div class="box-3-pictures">
90
                                </div>
91
                        </div>
92
                        <div class="box-row">
93
                                <div class="box-3-titles"><h2>Step 4</h2></div>
94
                                <div class="box-3-text"><h2>Front Drivetrain</h2>
95
                                        <ol>
96
                                        <li>Solder capacitor and attach wires according to wiring diagram</li>
97
                                                <li>Solder 0.1" pitch vertical standoffs (4pins each) to encoder pcb</li>
98
                                                <li>Using long #2-56 screws and provided nuts (in motor bracket), install spacer plate, encoder pcb, motor, and motor bracket.</li>
99
                                                <li>Wheels can remain off for time-being, or can optionally be installed.</li>
100
                                        </ol>
101
                                </div>
102
                                <div class="box-3-pictures">
103
                                </div>
104
                        </div>
105
                        <div class="box-row">
106
                                <div class="box-3-titles"><h2>Step 5</h2></div>
107
                                <div class="box-3-text"><h2>Install Air Filters on Side Panels</h2>
108
                                        <ol>
109
                                        <li>Adhere (6) custom bent polypropylene clips following placement guide (link?) to side panels</li>
110
                                                <li>Use XXXX epoxy, taking care to use only the amount necessary. Do NOT touch other parts of the panels as this will mar the paint job</li>
111
                                                <li>After epoxy is dried, custom cut air filter panels can be slid into place. They should be constrained on three sides (left, right, bottom).</li>
112
                                                <li>Ensure no visible gaps from outside of front assembly.</li>
113
                                                <li><strong>NOTE:</strong> This step can be done in parallel with parts 1-4</li>
114
                                        </ol>
115
                                </div>
116
                                <div class="box-3-pictures">
117
                                </div>
118
                        </div>
119
                        <div class="box-row">
120
                                <div class="box-3-titles"><h2>Step 6</h2></div>
121
                                <div class="box-3-text"><h2>Front undercarriage plate</h2>
122
                                        <ol>
123
                                        <li>Affix diamond plate film to plate, covering entire exposed surface</li>
124
                                                <li>Trim neatly with a SHARP razor blade, ensure no visible snags are present</li>
125
                                                <li>Loosen the two frontmost motor bolts (#2-56) and slide the front undercarriage plate under these bolt heads).</li>
126
                                                <li>Use of washers is recommended if bolt length still protrudes past nuts in motor brackets</li>
127
                                                <li>Re-tighten bolts. The front undercarriage should now be secure</li>
128
                                        </ol>
129
                                </div>
130
                                <div class="box-3-pictures">
131
                                </div>
132
                        </div>                        
133

    
134
                        <div class="box-row">
135
                                <div class="box-3-titles"><h2>Step 7</h2></div>
136
                                <div class="box-3-text"><h2>Side panel/Scoutfly mounting blocks</h2>
137
                                        <ol>
138
                                        <li>Using 1 front right side (long) 1 front left side (short), and 2 front vertical mounting blocks</li>
139
                                                <li>Thread all to accept #2-56 hardware WITH THE EXCEPTION of the ciruit board mounting holes, which require #4-40 SHCS hardware</li>
140
                                                <li>Secure appropriate parts to front undercarriage and baseplate</li>
141
                                        </ol>
142
                                </div>
143
                                <div class="box-3-pictures">
144
                                </div>
145
                        </div>
146
                        <div class="box-row">
147
                                <div class="box-3-titles"><h2>Step 8</h2></div>
148
                                <div class="box-3-text"><h2>Install Side panels</h2>
149
                                        <ol>
150
                                        <li>Side panels with installed air filters can now be bolted into mounting blocks using #2-56 CSK hardware.</li>
151
                                                <li>One bolt on left side will be nutted into place (nylock) as the short mounting block does not reach this hole</li>
152
                                                <li>Shortened for Scoutfly underside connector clearance - Nut this bolt in place to plug hole for aesthetics and intrusion prevention (dust, water, etc).</li>
153
                                        </ol>
154
                                </div>
155
                                <div class="box-3-pictures">
156
                                </div>
157
                        </div>
158
                        <div class="box-row">
159
                                <div class="box-3-titles"><h2>Step 9</h2></div>
160
                                <div class="box-3-text"><h2>Hood Assembly</h2>
161
                                <ol>
162
                                <li>Bolt hinge strut in place on side of hood using #2-56 CSK hardware. Bolts should NOT protrude beneath strut</li>
163
                                        <li>Bolt rear air filter to strut using #2-56 CSK hardware.</li>
164
                                        <li>Heat and bend front headlight assemblies according to spec. Should have 1 left and 1 right side bent from same cutout</li>
165
                                        <li>Apply pre-cut diamond to inside of each headlight cover as per spec sheet (link?)</li>
166
                                        <li>Apply adhesive (cyanoacrylate/super glue) around perimeter of headlight that will be in contact with hood</li>
167
                                        <li>CRITICAL: do not apply extra glue or smear on visible portion of headlight assembly. More can be added later once headlight cover is in place</li>
168
                                        <li>Align (center) over headlight cutout, ensuring bolting hole is aligned. Press into place and hold for 30+ seconds.</li>
169
                                        <li>More adhesive (clear epxoy) can carefully be applied around perimeter to ensure solid contact. This will be important since headlight assembly is part of hood clasp</li>
170
                                        <li>Install front BOM components and tactile switch into mounting block</li>
171
                                        <li>Using epoxy and #2-56 CSK hardware to attach front BOM/bumper switch mounting block. Again ensure epoxy is not visible on exterior, and has a clean look inside</li>
172
                                        <li>The hood is perhaps the most visible component, and both inside and outside will be viewed frequently, so take the time to do a nice job on this.</li>
173
                                </ol>
174
                                </div>
175
                                <div class="box-3-pictures">
176
                                </div>
177
                        </div>
178
                        <div class="box-row">
179
                                <div class="box-3-titles"><h2>Step 10</h2></div>
180
                                <div class="box-3-text"><h2>Install Hood on Front Half</h2>
181
                                        <ol> 
182
                                        <li>Bolt hood to side panels using #2-56 CSK hardware. Remember this is a moving hinge, so do not over-tighten.</li> 
183
                                                <li>If installed properly the rear air filter should "seal" off the rear hatch when the lid is closed.</li> 
184
                                                <li>Once Scoutfly and grounding strap are mounted, magnet clasp assembly will be installed.</li> 
185
                                        </ol>
186
                                </div>
187
                                <div class="box-3-pictures">
188
                                </div>
189
                        </div>        
190
                        <div class="box-row">
191
                                <div class="box-3-titles"><h2>Step 11</h2></div>
192
                                <div class="box-3-text"><h2>Grounding strap</h2>
193
                                        <ol> 
194
                                        <li>Prepare grounding strap with (2) ring terminals per wiring diagram</li> 
195
                                                <li>Attach one end to front pivot block using #4-40 SHCS hardware</li> 
196
                                        </ol>
197
                                </div>
198
                                <div class="box-3-pictures">
199
                                </div>
200
                        </div>                                                
201

    
202
        <div class="box-row">
203
        <h1>Rear Half Assembly</h1>
204
        </div>
205

    
206
                        <div class="box-row">
207
                                <div class="box-3-titles"><h2>Step 1</h2></div>
208
                                <div class="box-3-text"><h2>Step Title</h2>
209
                                        Step Content
210
                                </div>
211
                                <div class="box-3-pictures">
212
                                </div>
213
                        </div>        
214

    
215

    
216

    
217
                                </div>
218
                                <div class="white-bottom"></div>
219
                        </div>                                        
220
                        
221
                        
222
                </div>        
223
        </div> <!--BODY!--> 
224

    
225
<?php include($docRoot."footer.php"); ?>
226

    
227
</div><!--GENERAL!--> 
228
</body></html>
229

    
230
<?php                
231
        mysqli_close($mysqli);
232
?>