FW Electric hammer - Robo Challenge (no name yet)

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Originally Posted by shakesc

I presume a show that gets made in Digbeth

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No it's a different one. I got the lower snail cams machined out last night so more pics to follow!

Who did the machining? The pics don't match your workshop.

lol proves how much machining u did when u were there :P

Kane and Ant machined the bulkheads for me as they're just a tad too big for my small mill. All the rest and all te pics are done by me at our workshop. Gears on the rotary table in the Bridgeport and the rest on the CNC and manual lathe.

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Originally Posted by grant_ploughbot

No problem at all! The whole point of a build thread is to show others how we do things and pass on info or learn things ourself!
But yes, my preferred choice for bulkheads would be these materials as the tensile strength is close to that of steel, but with very little weight difference compared to other aluminiums. That means certain sections can be thinner and held a lot of force.

The other difference is that they are very hard in comparison to the 6000 series, they don't bend so much as snap, not good for armour or plates that need bending. Also, machining these materials is soooo much easier as they chip off nicely and don't clog up the cutters like softer aluminiums do. Makes things a lot easier.

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Thanks! Do appreciate the help, I'm definitely no engineer so it's a lot to figure out otherwise haha!
It definitely sounds like those are the ideal for bulkheads then, best of both worlds! Going to have a look at getting some of that in then and machined into some decent bulkheads for HardWired when I can. Definitely a lot better than the 3mm aluminium I'm using at the minute, I'll say that much!

Really like this build, looks great!

Can you explain how the cam system works? Looks really interesting and im guessing its something to do with saving switching the motor back and forth?

I spent abit of time yesterday machining out the lower cams. I think they came out quite nicely.
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Its taken a reasonable amount of manual machining aswell, and the modification of a cutter to finish them off. When the cylindrical grinder doesn't work - gaffa tape an angle grinder to the lathe :)
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Grinders and gaffa tape, my kind of engineering!

Looking great man, how you're going to build this in time I have no idea but I wish you luck!

Dave, I machined once... with you... remember? All trying to put a hole in the centre of that steering column.

I've been doing a little more work on my robot and managed to get it working in time for filming on Thursday.
The only material I could get for the axe handle itself was a 3m long, 71mm x 44mm price of 7075 aluminium. It added a fair amount of time having to mill it down to the 40mmx30mm size I needed.

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I spent a number of hours lightening the axe and machining it to fit nicely :)
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Most the components are machined ready for assembly.
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And a picture of the weapon mech mostly assembled.
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I had to make a very bodged base, drive and armour for it intime for filming, so excuse the bad looks!
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I've got a video I posted on Facebook that I will try posting on here of the testing. I ran it on 5S lipos and only 1kg on the axe head and I'm quite happy with the results :)

Looking very nice, look forward to seeing this in competition

I know you said the mag is pulling over 100A on 24v, what's it pulling on the 5S (18.5v) test? My plans for Hell's angel may have changed and it involves a mag motor, hence my asking.

I'm not too sure on this setup, I would need to stick a meter on and check. As the axe head is only 1kg and not 2 it doesn't seem to be pulling a lot. After it's first fight on Thursday with lots of fires the mag was barely warm which is good.

Any footage of that fight, or is it TV-only for now?

http://m.youtube.com/watch?v=Mm1UaraxD7E
Here's the first test vid on only 5S.

Impressive :)

How are you controlling the axe? Beefy relays and quick reactions on the controller?

From Grant, when I inquired:

To fire it at the moment I'm using an Albright contactor for motor reversing ( DC88-556PL, Albright 24v DC, motor reversing solenoid, intermittent, 100A, IP66)

Thanks

Looking really impressive Grant.
Engineering on the axe mech looks awesome - look forward to seeing it in action in competition.

I have started too look at Killer Joule again now so that I can get it fully working and reliable for the World Championships in April. There's quite alot I haven't updated on here such as the drive units etc so I will get some pics up shortly.

The biggest thing I need to test is the custom ESC. We had to build a 200A dual direction ESC for it a few days before the champs which had a couple of bugs causing it not to fire at times and stuck at full power in reverse. It may be due to the wires between the main control side of the board and the FETs passing directly under the main motor. Hopefully have that sorted ready for a test this weekend at RL's small show at the NEC.

How did you get on with competing? Is there any footage?