Boner

[typhoon_driver]

Re: Boner

Update time!

Photos to follow but thought I would post a few updates. Things are certainly getting interesting.

The off center issue with the hex hubs on the gimson shafts was really bugging me so I looked at my options. Best option was to shim the inside annulus between the shaft and hub. Bought some 0.3mm copper sheet off ebay. A few reasons I went for it, it was cheap as chips, it was available in the rough thickness I required (would have preferred 0.35mm but beggars can't be choosers) and being copper it was easy as hell to bend into shape with my hands and squeeze into position. Seems to have worked well and reduced the wobble a good deal. Also got some keystock off ebay to properly secure the hubs to the shafts. Again was only a couple quid.

Lipo batteries arrived the other day. I will have to do a few modifications to make to the battery box I had previously but it's very doable and they fit in nicely. Might have to skim a bit of material off the hardox bum to get an extra hundred grams or so but it shouldn't be tricky.

Going to do the programming on the turnigy 85a controllers this weekend so fingers crossed there.

Biggest and baddest news is the new motor I'm planning on putting on the drum, a scorpion 4530-540 LE. If you do a search on this motor you will see it peaks at 11KW power. Although that is likely on 12s. Either way i'm going to be running some serious power behind the drum on boner

[Eventorizon]

Re: Boner

And when they say the might Motor they reacted with Awe!

Awwwwwww...

I said Awe. A.W.E.

Oooooooooo...

Thats better.

[Name the film!]

[typhoon_driver]

Re: Boner

Photo time.



Copper shim placement



Keyway and copper in place



Reprogramming turnigy 85a controllers



3 programmed controllers

If anyone is thinking of using the banebots hubs with the gimsons I would heavily recommend shimming with copper or something similar as it completely removes the wobble on the wheel.

Got 540 out of the basement and I'll need to give it a clean down before working out how best to mount either a brushless or speed 900 motor to the beater for the whiteboards.

[typhoon_driver]

Re: Boner

Small update but it put a big smile on my face.

Just arrived, a scorpion 4530 motor. 11KW peak of power in a package not much bigger than my last 4035 motor. I also was running the last motor at only half it's rated voltage so not only will boner have twice the power from the upped voltage, it's going to be a more powerful motor. The drum should now be spinning at around the 8000rpm mark give or take.

[typhoon_driver]

Re: Boner

Back down to my parents place in Edinburgh today to do some work in their garage whilst i'm still getting my own workshop in order in Aberdeen.

With the increase in weight going to the larger motor and needing a small lipo pack for the drive as the converted turnigy can only handle 6s I needed to find a good few hundred grams of weight. The ideal place to find this was the 22mm nylon bulkheads. Each one weighed around 300g a piece and didn't provide much in the way of structural support. So I decided to replace these with 2mm titanium welded to the base. This makes a whole lot more space internally and saves around 400g in weight. Got the gimsons mounted and the shafts shortened. They give me more space than the old drill motor gearboxes.





The new motor fits in nicely and those observant will also notice I put the timing pulley on the lathe and took the teeth off it to act as a clutch. Should hopefully help reduce the stress on the motor and esc.

Got my replacement castle creations on the way back from the states as well after burning it out in yeovil last year.

[typhoon_driver]

Re: Boner

Quick update.

Got a bunch of bits and pieces arrived,

- 6mm gold connectors for brushless motors
- A bunch of EC5 connectors to redo the wiring in boner
- Two new Nimh transmitter batteries as the old ones were nicads around the 600mah mark (new ones are 2400mah) and I had to keep charging between fights previously
- A mini lipo, 6s 1300mah for the drive motors

[archie2000]

Re: Boner

is 1300mah enough for GR-02s?
what nominal voltage have you gone for on the gimsons?

[typhoon_driver]

Re: Boner

The gimsons are 24v. Yes it should be but I wouldn't advise it if you haven't used lipos and understand them.

[typhoon_driver]

Re: Boner

Post 10 000 in this part of the forum!!

[typhoon_driver]

Re: Boner

Back from a week long training course in London with work to spend the final 3 and a half days before heading south again for the featherweight champs.

Jobs still to do on boner,

- Thread axle for drum at ends
- Make nuts for axle threads
- Redrill new hole for the changed position of the weapon batteries/titanium battery holder
- Make a box or bracket to mount the drive batteries
- Make a mount for the weapon motor
- Mount the castle creations esc
- Wire it all up
- Test

Gonna be a long few days ahead of me!

[daveimi]

Re: Boner

This will be one of those robots that comes back each year 30% scarier and more developed till it ends up pretty much unbeatable.

[typhoon_driver]

Re: Boner

Well this is the last time the current design will be at competition and it's been running for a good 6 or 7 years now. I'm planning on taking the best parts of the design and jacking up the diameter of the drum from 3 inch to 4 or 5 inch and making a new precision chassis around it.

Had a very productive day today although I didn't get many pictures taken so this update will be text based.

Started the day off frustratingly by breaking my bench vice. Seems it didn't like taking my full weight to tighten up on the 17mm silver steel bar used as an axle.



Bought another from B&Q.

Got both ends of the bar threaded to an 11/16 thread. I would have gone for an M17 thread however it's a rare thread to find a tap and die for and so expensive. 11/16 of an inch is essentially around the same ball park and I was able to pick up a tap and die for a tenner off ebay. Happy days.

Threaded some ali plates, screwed them on the ends and screwed them into the bulkheads. No way those are coming loose!

Wired up the drive and ran it around. Initially had issues with channels etc but I noticed that odd noises were coming from one of the motors. Need to have a look inside it and see what's going wrong.

Positioned and mounted both sets of batteries and the three esc.

I left it this evening having cut out the titanium for the weapon motor mount and drilled out the mounting holes on the mill. Need to get it placed tomorrow and then look at a new bearing mount on the front to give additional support for for the motor shaft.

Hoping to get boner finished tomorrow then do the bit of work I need to on 540 for whiteboards.

[typhoon_driver]

It's half 11 and I'm done for the night. Wow that was a long day!

Boner is now wired up with the new motor in place and an additional bearing support on the main shaft as I've had twisting issues in the past. Did a spin up test earlier today and boy was it a cracker. Looking back on the data logger on the castle creations esc, the drum got up to 9000rpm and at that speed was only drawing 3amps, yes that's right, 3amps! Spin up time is basically as fast as I can turn the knob on the transmitter.

Swapped out the unusual noise drive motor for a fresh one. Need to speak to Ewan about that as it's only been run in under no load for 15minutes but i'm much happier with the drive.

Started to look at 540 at around half 9 this evening. At 10 I fired up the mill and made a motor mount from nylon. It's not tidy and it's not clever but it works and that's what I'm happy about. Rest of machine isn't an issue. Should have some fun in the whiteboards with it!

Pictures and videos below.

http://youtu.be/OpIda_RfRWQ - 540 spin up
http://youtu.be/Lb03My8P_oY - boner spin up (yes that's my foot to stop it dancing off the crate)

http://i.imgur.com/5asNVR0.jpg - boner bulkhead showing smooth pulley and threaded axle
http://i.imgur.com/WmFiaDx.jpg - quick glimpse of the workshop as it stands atm
http://i.imgur.com/lJ7yFVo.jpg - close up of boner

[Ellis]

Boner was pretty rad at Yeovil last year... can't begin to understand what it must be like at 9000 RPM!? Can't wait to see it go. 540 too.

[TeamPsyclone]

Wow, they are two truly fearsome machines... I doubt a box of steel would stand up to them for long. Lucky I'm not entering, I think I'd faint to see them in the flesh-Metal-plastic. Yeah.