Flatpack

Decided to build something a bit more passive. No large KE weapon I'm afraid.

Flatpack is a 4wd 4 bar lifter which will be competing in the MMM competition in Germany.

Drive: 2x saturn-16 gearboxes with 775 motors
Weapon motor: 4240 sk3 brushless outrunner with a saturn-16 gearbox as the first stage of gearing.
Escs: 2x Tz85a botbitz 1x trackstar 150a
Batteries: 2x 2.25ah 5s Nanotech
Wheels: 2.5"x1.25" colsons with custom hubs
Frame: 5mm 304 stainless steel
Armour: 2mm and 5mm 304 stainless steel


http://i.imgur.com/SOUbtfS.png?1

first bit of design work. Rouging the layout to see what can fit where.

http://i.imgur.com/Ak6mPWT.png?1

more in depth model work happening

http://i.imgur.com/VqcHsEN.png?1

Pretty much done here. It's not even close to being a full detailed model but I'll probably end up working arse backwards and redoing the CAD to be super detailed once the robot is complete.

http://i.imgur.com/JeRlk5d.jpg

Parts began to show up. I'll give you three guesses as to what this was and the first couple don't count.

http://i.imgur.com/GiN220I.jpg

http://i.imgur.com/0IeUhC1.jpg

Here you can see a motor mated to a wheel and a 3d printed timing pulley. I love having a printer. It gets way more use than I thought it would.

http://i.imgur.com/szzQlLP.jpg

the weapon motor and how it mounts onto a the gearbox.

http://i.imgur.com/RZ95CtG.jpg

And here are all the parts for the weapon transmission. The lifter has 4 stages of gearing, 2 planetary by way of the saturn-16 then a spur gear stage and finally a timing belt and pulley stage.

http://i.imgur.com/KkWsHdY.jpg

http://i.imgur.com/Xh6C4xg.jpg

A 12mm bore through the pinion gear for the second stage wouldn't have left enough meat in the gear so i made it a 10mm bore and stepped the shaft down. I had a whole new shaft CNC milled instead of modifying the stock one so I could have a spare for the drive. The pins are machined from the billet, not press fitted. I have no idea if this will make it weaker but it shouldn't really matter. It still runs dead smooth.

http://i.imgur.com/hvntNE0.jpg

The pulley is machined into the lifter arm which is fairly neat. Props to Ellis for helping me draw the tooth profile.

http://i.imgur.com/d7SZieN.jpg

The arm assembly with the bars.

http://i.imgur.com/YE1HO2u.jpg

Bare bones pretendo of the robots internals.

http://i.imgur.com/OEvl9x5.jpg

Pretendo of the steel frame.

http://i.imgur.com/w7hj7zE.jpg

my absolute favorite part is this bent steel wedge. I don't have the facilities to weld so I just went with a bent one for now. Needs grinding and sharpening but should be decent at keeping out some of the nasties.

http://i.imgur.com/jE5uG8W.jpg

lid is 2mm steel. Will have plastic or CF covers underneath the cutouts

http://i.imgur.com/Fy1o5WY.jpg

Mounted the drive motors, machined the front driveshafts and bushings. Small amount of stiffness but it feels like it should wear in nicely.

Got all the holes tapped for the arm and countersunk all the plates for that.

http://i.imgur.com/1RS0Gcr.jpg

beginning to look pimp and like a real robot.

That's so swish mate, i love it

I'm very interested to see the brushless lifter at work, nice work.

Nice!

A wild semi-completed robot appears! Wasn't expecting such juicy build report goodness when I clicked back on to the forum; very nice work man.

Ëxcellent work there. This looks great.

Great work Bud, I love a juicy build

Thanks guys. Appreciate the comments. All being well I should have my lifter bulkheads in hand tomorrow and so I can come closer to finishing it.

http://i.imgur.com/KvYkB7d.jpg

Got the bushings made for the arm mech this evening. Pretendo lift time

'Harry uses Design. Its super effective!'

This looks amazing!!! Is this intended for full combat or not? Some bits look spinner proof while other bits don't.

Nice.

It's designed for MMM. So not massive spinners due to the arena spec.

Which bits do you see as not being spinner proof out of interest.

Valkiri should be allowed to run after improvements.

Quote:

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Originally Posted by harry hills

It's designed for MMM. So not massive spinners due to the arena spec.

Which bits do you see as not being spinner proof out of interest.

---

Conker 3 and Binky are both going to MMM.

The front blade looks vulnerable to horizontals if its caught on the edges. And (this is a guess) since the front wheels look to be supported by the inner and outer bulkheads, if those get bent then it could jam up the drive.

Edit: Harry, how and when are you getting to MMM, we are driving past you on the way down and we have space in the car for another person if you want to tag along. And I have the stuff from Matt to deliver anyway.

I've actually got a flight and train booked, hadn't realised you were going otherwise i'd take you up on that offer. However if you could transport a few bits for me that would be fantastic. I'll send you a message later on.

So much double posting

http://i.imgur.com/3YMPb3I.jpg

Gear thinned down to size, bored and keyed. Slightly odd finish but that might be user incompetence or tooling quality.

Doesn't look like I've done much but all the belts and pulleys are in stalled and 85% of the shafts are done and all of the nylon bushes are in place.

http://i.imgur.com/xXgqipc.jpg

And another unnecessary lifterpose

http://i.imgur.com/8Rl39F8.jpg

Looking Swish!

Let me know ASAP if you need anything carrying. Can't you cancel your train? It would be much cheaper for you to travel with us (probably).

It's a shame I can't make it to Germany.
For this is getting interesting.

One tip, try bringing a table along or be early to claim one.
There aren't that many tables available at the 'rollerhalle'

Quote:

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Originally Posted by Niels - Team K.a.L.M.

try bringing a table along

---

Good idea! Consider it done!

Its got to the stage where I spend all of my time taking the damn thing apart and putting it back together again. Progress continues in fairly substantial chunks. Only major bit is I'm waiting on a new pinion gear for my weapon and I've not had a chance to grind the wedge flat and sharpen it due to pissing rain.

http://i.imgur.com/42t1owE.jpg

^working out the wiring paths and stuff. Wiring always takes much longer than I think. Whole robot was done in about 3 hours.

http://i.imgur.com/R4tf3nu.jpg

Look upon my link/fuse and power light mount and weep puny mortals! Super happy with how this came out. I slightly neglected that I did need this part and ended up designing it and ramming the print settings together in about 5-10 minutes.

http://i.imgur.com/1GvpbIg.jpg

works super nice. If anyone wants the files for some reason let us know. You have to strip the maxi fuse holder down to the bare bare bones.

oh and have a random photo from a few days ago.

http://i.imgur.com/BNbSgkQ.jpg

Raptorweight wedge. All handmade to offset the lasercut fustercluck that is Flatpack. This is now done it just needs putting together.

Damn! I'm loving all of this! That link is amazing!

You decided if I am carrying anything to MMM yet? Time is running out :-P

http://i.imgur.com/pOZAdbH.jpg

go go gadget speedbuild. Its as done as its going to be. It drives fairly nicely although I will probably have to fine tune the wedge sharpness depending on the arena floor. It drives much better upside down than right way up due to general incompetence.

https://www.youtube.com/watch?v=P4G1FFHMP4E

video of the lifter on 3s, it could really do with troubleshooting and simonk firmware but meh. It moves kinda.

Weight on my scales is 12.55kg

Flight is tomorrow so I'll go back to filling my suitcase full of PJ tips and grab some sleep.

Much robot. Such legit. Very win.

Such a nice job! I'm keen to see how it gets on

Thanks guys. I've made it to Bochum in one peice. I love german trains! Quick, clean and simple. Take note Brittish Fail.

My robot was kindly picked up by the Botwrights this morning (shout out to Alex & Ian for being a massive help)

Have fun, and keep us posted.

do some good work man it looks awsome