VersaBot- Material Custimaziton Robot

                                                                                  Thinking Ahead
The dimensions of your batteries need to be taken into consideration for space, weight, and placement. Especially for the 1-A and 1-B sides. Always have a system to hold the batteries in. The last thing you want is the batteries bouncing out.
If using an antenna provide a piece for the antenna to protrude from so that the remote control can have better signal.
A covering for the electronics and chain is needed to keep snow, rain, and other debris out of the robot. The cover should also help protect the electronics in case of a chain slipping or breaking.


                                                                             Table of Contents
Finished VersaBot
Pre-Planing
Mechanical Components
Chassis Frame Construction
External Piece Construction
Chassis and External Construction
Electronic Components
Electronic Diagram
Electronic Wiring



                                    Mechanical Components:
   Part                             Amount          Size                Part Number

Sprockets                          2       16-teeth/Pitch .75     2299K67  http://www.mcmaster.com/#catalog/118/1044/=hld36s
Sprockets                          2        30-teeth                   2299K78  http://www.mcmaster.com/#catalog/118/1044/=hld3en
Axel                                   2        1.00 in” ø
Pillow Block Bearing         2        1.00 in” ø                 6244k56   http://www.mcmaster.com/#catalog/118/1154/=hld3on
Square Bearings               2        1.00 in” ø                 5967k84   http://www.mcmaster.com/#catalog/118/1154/=hld416
Motor Chains                     2
Silver Lock Collars             4         1.00 in” ø
Suggested Material  (Carbon Steel, Wood, Aluminum) Pieces           16 x 24 in”
Pneumatic Wheels             2      12” Diameter
Swivel Wheels                    2       8” Diameter
Pneumatic Swivel Caster  2      For 8” Wheels                           http://www.harborfreight.com/8-inch-pneumatic-swivel-caster-42485.html

VersaBot Chassis in Autodesk Inventor 2012. *All Pictures are listed in the order of the instructions. We have an actual booklet, the format on here was different than our book setup.

VersaBot Chassis completed in workshop.

1-A  Side
1) Begin cutting this Panel by rough cutting the basic shape with a Vertical Saw.
2)   Clean Up sharp edges and burs.
3)   Hole location and size will vary depending on bearing.
4) Then drill four holes each ½”
1-A  Side for mounting square bearings.

1-B  Side

1)  Begin cutting this Panel by rough cutting the basic shape with a Vertical Saw.
2)  Clean Up sharp edges and burs.
3)  Hole location and size will vary depending on bearing.
4) Then drill four holes each ½”
1-B  Side for mounting square bearings. 

2-B Motor Panel

1.) Cut the basic shape with a Vertical Saw.
2.)  Then clean up the edges Front Panel with a CNC machine.
3.)  Layout hole coordinates.
4.)  Drill holes using a drill press.                                
2-B Motor Panel (1) for mounting the motors.

3-C Bottom Panel A

1.)  Cut the basic shape out with a Vertical Saw.
2.)  CNC the finish edges.
3-C Bottom Panel A (1) for motors.

       4-D Bottom Panel B
1.)  Rough cut Panel basic shape with a Vertical Saw.
2.)  CNC the finish edges.
        4-D Bottom Panel B (1) for Pillow Risers and Pillow Blocks.

G-Code Used on HASS 101 Milling Machine(Optional to do)
%
O07777
G17 G20 G40 G49 G80
T1 M06
G00 G90 G54 X-1. Y-0.25
S800 M03
G43 H01 Z2.
Z0.1
G01 Z-0.175 F5.
G41 D01
X0. Y0.
Y6.
X16.
Y0.
X0.
X-1.
G40 X-2.
G0. Z2.
G91 G28 Z0.
G91 G28 Y0.
M30
%

(G17-Circular Motion XY, G20-Verify Inch Coordinates, G40-Cutter Comp Cancel, G49-Tool Length Compensation Cancel, G80-Cancel Canned Cycle)
(T1- Number of Teeth in Cutter, M06-Tool Change)
(G00-Rapid Positioning Motion, G90-Absolute Positioning Command, G54-Work Offset Positioning Coordinate #1, Y-.25- Y-Axis Direction)
(s800- Spindle Speed, M03-Spindle On Clockwise)
(G43-Tool Length Compensation-(H01,Z2)
(Z0.1-Direction in the Z-Axis)
(G01-Linear Interpolation Motion, Z-0.175 Depth Down, F5-)
(G41-2D Cutter Compensation,D01-)
(X0. Y0.-Home)
(Y6- Direction in Y-Axis)
(X16- Direction in X-Axis)
(Y0.- Direction in Y-Axis)
(X0.- Direction in X-Axis)
(X-1.-Direction in X-Axis)
(G40-Cutter Comp Cancel(X-2,Y0))
(G0-Rapid Positioning Motion(Z2))
(G91-Incremental Positioning Command, G28-Machine Zero Turn Through Ref Point(Z0))

(G91-Incremental Positioning Command, G28-Machine Zero Turn Through Ref Point(Y0))
(M30-Program End and Reset)




5-E Bottom Panel C

1.) Rough cut basic shape with a Vertical Saw.
2.) Then clean up any sharp edges and burrs.         

5-E Bottom Panel C Panel for batteries.





6-F Back Panel

1.) Rough cut basic shape with a Vertical Saw
2.)  Then CNC the finish edges.


Back of Chassis 

Wheel Hub Tube 1-A *All Pictures are listed in the order of the instructions. We have an actual booklet, the format on here was different than our book setup.

Wheel Hub Tube 1-B

1.)  Hollow cylinder with inner diameter of the axel.
2.)  Cut cylinder length to 2.75” in.
3.) Then plot the distance to your hole on the tube.
4.)  Bore a ¼” hole through each side.



Round Sheet 1-A

1.)  Rough cut the circular shape with a Vertical Saw.
2.)  Then clean up sharp edges or burrs.
3.)  Then bore 23/64” holes to match the wheel.


Wheel Hub 1-A mounted on Right Axel 1-A and Tire 1-A.


Wheel Hub Tube 1-B

1.) Hollow cylinder with inner diameter of the axel.
2.) Cut cylinder length to 2.75” in.
3.) Then plot the distance to your hole on the tube.
4.) Bore a ¼” hole through each side.

Round Sheet 1-B

1.)  Rough cut the circular shape with a Vertical Saw.
2.)  Then clean up sharp edges or burrs.
3.)  Then bore 23/64” holes to match the wheel.

Wheel Hub 1-B mounted on Left Axel 1-B and Tire 1-B.



12” Pneumatic Tires

Axel is connected to wheel hub.


8” Swivel Wheels

Two of these for the back for Swivel Casters.



Trailer Hitch Z-3

1.)  Rough cut the shape with a Vertical Saw.
2.)  Then clean up sharp edges or burrs.


Trailer Hitch Z-2

1.) Rough cut the shape with a Vertical Saw.
2.)  Then clean up sharp edges or burrs.


Trailer Hitch Z-1

1.) Rough cut the shape with a Vertical Saw.
2.)  Then clean up sharp edges or burrs.

Trailer Hitch Z-2 piece and Trailer Hitch Z-1.

Axel 1-A


1.) 1” Steel Rod (Diameter needs to be close to I.D. of Pillow Bearings and Square Bearings).
2.)  Cut with a Horizontal Saw to a length of 12”.



Axel 1-B


1.) 1” Steel Rod (Diameter needs to be close to I.D. of Pillow Bearings and Square Bearings).
2.)  Cut with a Horizontal Saw to a length of 12”.




Pillow Riser 1-A

1.)  Measure pillow bearing mount length and hole diameter.
2.) Cut block to mirror those dimensions.
3.) Then bore holes.
  Pillow Riser 1-A for the left side axel.


Pillow Riser 1-B

1.)  Measure pillow bearing mount length and hole diameter.
2.) Cut block to mirror those dimensions.
3.) Then bore holes.




  Pillow Riser 1-A for the left side axel.



Balance Wheels

Caster Swivel Wheels

These Swivel Mounts are attached to Tire Bracing 1-A and 1-B pieces.



Tire Bracing 1-A

1.) Rough cut the rectangular shape with a Vertical Saw.
2.)  Then clean up sharp edges or burrs.
3.)  Then bore 1/4 holes to match the Zero Turn Mounts.
Triangle Set of holes is to attach to the Wheel Bracing Cross.
The four holes closest to the triangle add support and assist bend resistance.

Tire Bracing 1-B

1.) Rough cut the rectangular shape with a Vertical Saw.
2.)  Then clean up sharp edges or burrs.
3.)  Then bore 1/4 holes to match the Swivel Mounts.
Triangle Set of holes is to attach to the Wheel Bracing Cross.
The four holes closest to the triangle add support and assist bend resistance.

Tire Bracing Side 1-A

1.) Cut right angle to 9 ¾”
2.) Drill 1/4” holes at locations. (Determined by Zero Turn Mount and Wheel Bracing Cross)



Tire Bracing Side 1-B

1.) Cut right angle to 9 ¾”
2.) Drill 1/4” holes at locations. (Determined by Zero Turn Mount and Wheel Bracing Cross)


Tire Bracing and Tire Bracing Side Assembled


Wheel Bracing Cross

1.)  Cut 3x3” right angle to 23” long.
2.) Drill 1/4” holes to match Zero Turn Mounts.
3.) Drill ¼” holes to match Tire Bracing and Tire Bracing Side
4.) Cut a hole to allow room for the hitch.

1.) In completion to manufacturing frame all components are assembled as shown below.*All Pictures are listed in the order of the instructions. We have an actual booklet, the format on here was different than our book setup.

Placement diagram for chassis pieces.

2.)  Install Servo motors on 2-B Motor Panel

3.) Install square bearings on both Sides 1-A and 1-B
4.) Pillow Bearing Placement will vary according to axel length. Secure Pillow Bearing and Pillow Block by running a bolt through. 

5.)  Install sprockets on Servo Motor.

6.) Place axel through the Square Bearing and Pillow Bearing.

7.)  Install the wheel hub on the tire.

8.) Place Assembled Hitch on the back of 6-F Back Panel.

*We welded the Hitch because we used steel.

9.)  Place Wheel Bracing Cross next to 6-F Back Panel and line up over Hitch.

*We welded theWheel Bracing Cross because we used steel.

10.) Bolt Tire Bracing and Tire Bracing Side on to  Wheel Bracing Cross

11.) Bolt Tire Bracing and Tire Bracing Side on Wheel Bracing Cross.

*All Pictures are listed in the order of the instructions. We have an actual booklet, the format on here was different than our book setup.
Servo Motors

 Antenna


 VEX Robot Convertor controller

VEX Robot Handheld controller

20 amp fuse

30 amp fuse

12 volt deep wet battery 
Placed in 5-E Bottom Panel C

12 Volt Wheel Chair Motor
Placed in 2-B Motor Panel

7.2  volt battery for vex

*The electronics can be different. The setup would still be similar though.
1. Cut three pieces of wires down to the right length you would like depending on how far apart you have the batteries sitting.

2. Hook up one of your negative with the positive exactly across from it on the other battery.

3. Attach your leads to the positive and negative posts that are left.
You have now done the first step to making your robot move.

We will start with your positive power first.
1. You will take the lead from your battery and will attach it to your on, off toggle switch.

2. With another wire you will go to the opposite side and hook it to the toggle switch.
Here is where you will decide which side on your fan control is power and which side is for the motors once that is done continue on to the next step.

3. On the fan control there is a spot for positive and negative hook up you will hook a wire to the positive post.

4. On the second fan control you will hook up your wire to the positive post that you’ve decided the power will be hooked up to.

5. The lead from the toggle switch one of the wires from the fan control and you will put a third wire in and put those three wires into a wire nut.

6. The third lead attaches to an inline fuse and the wire on the other end of that fuse goes to a wire nut which will hold the other lead from the other fan control.
Next would be the negative lead from the battery and work the way from there

1. On the fan controllers there is two spots left for the power, both spots should be negative make to leads on the negative posts long enough to reach the negative power lead from the battery.

2. Next you need to wrap those three wires together and put them into a wire nut.

The power is now completed for this stage of wiring.
From here it matters on whether or not you are programming it or using the vex remote control system.

1. For the RC controller you will take your wires with the male parts and plug them into the two fan controllers there are two spots that stick up that go with it.

2. You will then plug the other end into the motor section on the controller in motor 1 and motor 3. 

3. From there you will hook up the antenna and battery like normal.


PLC Unit:

1. Hook the wires that are connecting the PLC unit to the fan controllers up.

2. The wiring on the PLC unit will depend on what is being done with it.

3. Program.