Team Eventorizon: Build Diary

[typhoon_driver]

Welcome to combat robots

[Eventorizon]

I am going to order my Banebots parts soon and I was wondering what I should get in the way of spares.

I was going to get 4 motors and 3 gearbox's but I just wonder if I should get 4 of each so I have a total replacement set.

Has anyone ever had on of their gearbox's fail through general combat? I mean getting smacked by NST on the shaft will obviously break it but what experience have people got with them?

Oh and does anyone have an accurate density for Hardox 400? Ellis and i have been looking and it can swing from 7650kg/m^3 to 9345kg/m^3.

[maddox10]

Hardox 400 is a tad heavier than normal steel, but not that much. For a fast calculation I just use 8kg/dm³.

[Mouldy]

Not had a failure yet, but I carry a complete spare drive unit - motor/gearbox/hub/wheels just incase...

[Eventorizon]

This happened yesterday but I have ordered...

4X Banebots 7nn, 16:1 gearbox's
4x RS775 18V Motors
8x 1 Wide, 1/2 inch bore Wheel Hubs.

Still not got time at the moment to finish the CAD but it is looking good at 13kg without many changes.

If it is over weight I can see myself milling pockets into the Bulkheads/Hardox/Ti where I am not in need of as much material.

[typhoon_driver]

What was delivery like on that order? I'll be placing a similar order myself soon so would be a good idea to have a heads up on postage costs

[Eventorizon]

It is $65 standard delivery to anywhere in the world or $75 express. That's all the options you get. Mine totalled at $413 with standard delivery.

[Eventorizon]

Off the subject of robots, I came across this...
http://www.youtube.com/watch?v=cPV5Ufs0emM
... and something about just seems a little odd.

The material is said to be Toolox 44 but at the speed it is cutting it, with no coolant, I cant see how? It isn't sped up it just jumps to key points. And the way the machine is behaving in how it cuts seems unusual as well. Its not doing the typical layer by layer pattern. Is this common for CNC mills these days or is this a special/new type?

[daliad100]

Good tool path generation algorithm (which we unfortunately have to pay for)

Essentially they use the side of the end mill to take off lots of material at once and step inwards and upwards from the bottom of the work piece. They also have something to stop it from cutting air as much.

Manufacturers specs (second to last page) for machining toolox 44 say nothing about lubricants for milling and that it can be cut at very high speeds (100-150 meters/minute cutting speed) which make it similar to brass except carbide tooling is needed to deal with the hardness.

[Eventorizon]

Getting ever closer! Conker 3.12.3
Conker 3.12.3 Render 01.JPG
Conker 3.12.3 Render 02.JPG
Conker 3.12.3 Render 03.JPG
Current weight in CAD is 12.86kg! Still has 4mm Hardox around the edges and the sides, 3mm Ti on the top and bottom and the monstrous 16:1 RS775 Banebots drive. If if cant spin... it will just slam!

[Liftoff]

Looking really good there, I'm sure it will perform well...just like its shape and style of weapon, have to come over to see it when you're done building it!

[Eventorizon]

My degree is over!!! Surprisingly I decided to relax by giving Binky some TLC.
In short she is fine electronically but has taken quite a lot of physical damage. The main one was to the armour when we landed from LF3 in the Melee.
20130522_121523.jpg
First thing I did was blast down the armours welds ready to have them beefed up/redone entirely. The welds that we paid for on Binky were weaker than the ones that we had done for free at Un for Conker 2. Go figure.
20130522_150427.jpg
I need to show how shiny the wheels look now but this is the state they were in before I washed them. Now they are grippy and shiny and free of grease from the GR02's which have been leaking; I don't think they are supposed to drip grease.
20130522_122937.jpg
The pulley cut a grove into the weapon motor shaft which took some effort to remove... very carefully. I filed down the grove and then gently sanded it so the pulley now goes back on without catching.
20130522_140916.jpg
The broken Cir-clip was a pain to replace but I got it off. Took the opportunity to look inside the HK-40. It's been balanced with this blue paste which I found slightly amusing.
20130522_143008.jpg
Got an issue with the bulkheads where, despite putting in the steel spacers that they come with, they are slowly eating the flanges. I need to solve this quickly before it fails during a fight and the disc goes flying. One of the bearing had also ceased up totally and the other was pretty stiff. Both had lost a lot of grease which I think is probably the reason why they have both basically failed. They were like £12 each from RS too so not exactly cheap-o's. Maybe I will have to get the £40 ones.
20130522_151131.jpg
Also blasted down the disc in preparation for hutting off the inner teeth. They do little for the inertia and are really sharp so I would prefer to use the 150g elsewhere.
20130522_172011.jpg
The next phase after this is to start planning exactly what improvements we are going to make. The main ones I think are to reshape the front to better expose the disc and also do what is done on LH3 and link the armour to the base with a lip of metal and bolts round the bottom. This will drastically stiffen the machine up and mean that the disc will be the first thing to hit another robot rather than the wedge.
There are also plans to make a alternative weapon head, basically a vertical version of NST's bar. The disc has a 12mm gap under it to reach the base plate so the new bar can be slightly wider and spin faster which would give it better engagement.

[typhoon_driver]

Nothing too horrific. I would recommend removing the shaft from the brushless and replacing it with a full diameter shaft right the way through. A small spacer such as a washer should handle the rubbing issue

[shakesc]

On replacing the shaft - is this easy to do (e.g. a vice and some care) or does it require a press and other none garage things?

[Eventorizon]

It requires an arbour press and a few other things we don't have.
I personally don't feel comfortable replacing the shaft, but I don't see the need on Binky. You need it in situations where the motor is attached to a different bulkhead or mount to that of the weapon so that the shaft wont bend if the two twist. If Binky ever twists to that point... that will be the least of our worries as the motor and weapon are attached to the same body.
The shaft is 6mm all the way down anyway. if we go up to 8mm then I doubt the pulley will have enough material left to put the grub screw in anyway.