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Jolt & friends - Team Overkill - NSW
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MoonSet416



Joined: 25 Sep 2016
Posts: 297
Location: Sydney


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Yeah having a thin frame definitely saves a whole lot of weight. Can't wait to see your new bot! Very Happy

Post Sun Sep 03, 2017 7:50 pm 
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Nick
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Joined: 16 Jun 2004
Posts: 11713
Location: Sydney, NSW


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Mr Mangle:

I weighed some alternate parts today; the smaller weapon motor is 120 grams lighter than the flame-out motor, while the 32mm wide self-levelling wheels are only 60 grams heavier than the Colsons. Swapping less fire for more traction is a definite win in my books! Smile

Boom Stick

The under-cutter spinner is taking shape but already has some weight issues. I am trying out a new Scorpion 2025 drive motor to help with that:



Its smaller & lighter than an NTM motor and rated for 6S so it should run cooler than a 4S rated NTM. Build quality is fantastic and the cost is mid way between an NTM and the sensored out-runners I was using in Mr Mangle. these Scorpions came from New Zealand, with the lowest on-line price in the world Cool.
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Post Mon Sep 04, 2017 9:24 pm 
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Nick
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Joined: 16 Jun 2004
Posts: 11713
Location: Sydney, NSW


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Boom Stick:

A huge 50 x 500mm round of titanium arrived last week and now its being turned into new shafts for the weapon motor and bearing block. Parting off the Ti was a nightmare; it had extreme chatter despite using the lathe's lowest speed, the fixed steady support and a live centre:



The chatter was so bad it looked like I was knurling rather than parting:



Once the short off-cut was back in the lathe it was a different story; the Ti cuts very smoothly with a great finish. That's lucky because the 50mm stock has to be turned down to a much smaller diameter for most of it's length. In the photo below, the flange is 38mm and everything else is 19mm or less.

Here is the interior of the Neu 8019 motor:



The original shaft will be changed to extend at the front of the motor and end at the flange. That let's the motor drive the weapon shaft from underneath the bot, very much like Neon. It saves a ton of weight & space by reducing the hight of the frame by 20mm.

Once the motor shaft is complete, I want to make a test-bed for the weapon; with so much power on tap, its risky to just design something without knowing how it will perform (or if it will just destroy ESCs).
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Post Mon Sep 11, 2017 6:17 pm 
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shakesc



Joined: 14 May 2012
Posts: 60
Location: UK


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Nick

I ha a local machine shop make my Neumotor shafts the other way around.
Neumotor can supply them ready made but the output was a bit short for the pinion

Havent decided whether to epoxy the magnets or not. They seem held in ok but strange things happen in combat. Were you epoxying?

Post Tue Sep 12, 2017 3:11 am 
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Nick
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Joined: 16 Jun 2004
Posts: 11713
Location: Sydney, NSW


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Thanks for the info, how are your motors working out for heavyweight drive? I need quite a long shaft with a keyway and I definitely need to save weight so the Ti shaft is a must. The magnets and the motor back shell are well made but as you said, odd things can happen so more epoxy can't hurt. Will definitely be doing my magnets.
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Post Tue Sep 12, 2017 6:51 am 
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Nick
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Joined: 16 Jun 2004
Posts: 11713
Location: Sydney, NSW


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The motor shaft is working out really well so far; all the turning is done and now its off to the mill for a key way and a bolt circle. I don't have the right cutter for the key yet, so that's a job for next week.



The weight saving with the Ti shaft is substantial; with a thicker flange and no bolt holes or key way, its still 68 grams lighter. Very Happy
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Post Tue Sep 12, 2017 9:58 am 
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Nick
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Joined: 16 Jun 2004
Posts: 11713
Location: Sydney, NSW


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I added some storage for the lathe, it gets tons of stuff off the bench and keeps it handy:



I'm pissed with Hare & Forbes though; the pegboard at the back of the draws didn't come with any tool hangers, even though they were shown in the catalogue.

Its time to put most of the bot projects away and get cracking on the CNC mill(s). The enclosure became a storage shelf while I worked on bots for the last two events:



That needs cleaning up so the remaining panels can be installed. After the panels are in and painted, I can move the old manual mill in and get a few parts completed. The CNC mill still needs much work and its going to be a top priority once I have a bit more space in the shed.
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Post Thu Sep 14, 2017 10:35 am 
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Nick
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Joined: 16 Jun 2004
Posts: 11713
Location: Sydney, NSW


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Boom Stick

The weapon testing set-up is getting closer; I tried out laser-cut part to check that everything fits:



Now that checks out, its time for a new output shaft and some pulleys. With the movable bearing block, I can try out different pulley ratios to get the current draw and speed right.

CNC

I put in some work on the gantry router; the router is mounted, the electronics is about 2/3rds finished and there is a new Ikea cabinet hacked into a workstation:



The back of the control box houses the PC and PSUs, while the front has the breakout board and stepper controllers:



The router fits on top of the cabinet with enough room for a monitor & keyboard:



And there is just enough room inside for a dust collection system:


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Post Mon Sep 18, 2017 11:12 pm 
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