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feat: SaltyRover chassis Rev 2 — 4-wheel rover with spring suspension (#109) #116

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sl-jetson merged 1 commits from sl-mechanical/issue-109-rover-chassis into main 2026-03-02 09:03:13 -05:00
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sl-mechanical commented 2026-03-02 08:43:09 -05:00
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Summary

  • saltyrover_chassis_r2.scad — Deck plate (500×480×6 mm Al, DXF export), 4× M3-adjustable pivot brackets, 4× CSI corner camera mounts (45° outward, 20° tilt), D435i front bracket (8° nose-down tilt), stem collar. Shared FC/Jetson SaltyLab pattern.
  • rover_spring_arm.scad — Trailing-arm spring suspension (×4). M8 pivot, 14 mm OD compression spring (50 mm free, ~5 N/mm). 25 mm bump + 15 mm droop travel. Caliper-verified 37.8 mm bearing-seat recess.
  • rover_electronics_bay.scad — PETG bay (240×200×80 mm). FC 30.5×30.5 M3 + Jetson Orin 58×49 M3 standoffs (shared SaltyLab swappable pattern). Ventilation all walls + lid. Lid integrates 100 mm RPLIDAR tower (58 mm BC, matches rplidar_mount.scad). Split-print halves for 220 mm beds.
  • rover_chassis_r2_BOM.md — Full BOM, mass estimate (~2.15 kg frame; reduce to <2 kg by setting DECK_T=5), assembly sequence, export commands.

Sensor positions

  • RPLIDAR A1M8: top-centre on electronics bay lid tower
  • D435i: front deck bracket, 8° nose-down
  • 4× IMX219/CSI: deck corners, 45° outward, 20° downward

Test plan

  • Open saltyrover_chassis_r2.scad in OpenSCAD 2021.01+, render assembly preview
  • Verify pivot bracket M3 slots align with deck holes
  • Export deck_2d DXF and confirm geometry in DXF viewer
  • Open rover_spring_arm.scad, render arm + retainer assembly
  • Verify RPLIDAR BC=58mm pattern matches rplidar_mount.scad
  • Print 1× pivot bracket + 1× spring arm prototype; test-fit with M8 pivot bolt + 14mm OD spring
  • Confirm FC 30.5mm and Jetson 58×49mm patterns match SaltyLab bay

🤖 Generated with Claude Code

## Summary - **`saltyrover_chassis_r2.scad`** — Deck plate (500×480×6 mm Al, DXF export), 4× M3-adjustable pivot brackets, 4× CSI corner camera mounts (45° outward, 20° tilt), D435i front bracket (8° nose-down tilt), stem collar. Shared FC/Jetson SaltyLab pattern. - **`rover_spring_arm.scad`** — Trailing-arm spring suspension (×4). M8 pivot, 14 mm OD compression spring (50 mm free, ~5 N/mm). 25 mm bump + 15 mm droop travel. Caliper-verified 37.8 mm bearing-seat recess. - **`rover_electronics_bay.scad`** — PETG bay (240×200×80 mm). FC 30.5×30.5 M3 + Jetson Orin 58×49 M3 standoffs (shared SaltyLab swappable pattern). Ventilation all walls + lid. Lid integrates 100 mm RPLIDAR tower (58 mm BC, matches `rplidar_mount.scad`). Split-print halves for 220 mm beds. - **`rover_chassis_r2_BOM.md`** — Full BOM, mass estimate (~2.15 kg frame; reduce to <2 kg by setting `DECK_T=5`), assembly sequence, export commands. ## Sensor positions - RPLIDAR A1M8: top-centre on electronics bay lid tower - D435i: front deck bracket, 8° nose-down - 4× IMX219/CSI: deck corners, 45° outward, 20° downward ## Test plan - [ ] Open `saltyrover_chassis_r2.scad` in OpenSCAD 2021.01+, render assembly preview - [ ] Verify pivot bracket M3 slots align with deck holes - [ ] Export `deck_2d` DXF and confirm geometry in DXF viewer - [ ] Open `rover_spring_arm.scad`, render arm + retainer assembly - [ ] Verify RPLIDAR BC=58mm pattern matches `rplidar_mount.scad` - [ ] Print 1× pivot bracket + 1× spring arm prototype; test-fit with M8 pivot bolt + 14mm OD spring - [ ] Confirm FC 30.5mm and Jetson 58×49mm patterns match SaltyLab bay 🤖 Generated with [Claude Code](https://claude.com/claude-code)
sl-mechanical added 1 commit 2026-03-02 08:43:10 -05:00 
New chassis design files for the SaltyRover rough-terrain variant:

• saltyrover_chassis_r2.scad — Deck plate (500×480×6mm Al, laser-cut DXF),
  4× M3-adjustable pivot brackets, 4× CSI corner camera mounts (45° outward,
  20° down), D435i front bracket (8° tilt), stem collar. All RENDER modes
  for STL and DXF export included.

• rover_spring_arm.scad — Trailing-arm spring suspension (×4). Pivot on M8
  bolt; captured 14mm OD compression spring (50mm free, ~5 N/mm); open-end
  axle dropout slot with retainer cap. Provides 25mm bump + 15mm droop travel.
  Bearing-seat recess for caliper-verified 37.8mm collar OD.

• rover_electronics_bay.scad — PETG electronics bay (240×200×80mm internal).
  FC standoffs 30.5×30.5mm M3 and Jetson Orin 58×49mm M3 — shared SaltyLab
  swappable pattern. Ventilation slots all 4 walls + lid. Lid integrates
  100mm RPLIDAR A1M8 tower (58mm BC, matched to rplidar_mount.scad).
  Split-print halves for 220mm beds included.

• rover_chassis_r2_BOM.md — Full BOM, mass estimate (frame ~2.15kg; reduce
  to <2kg by setting DECK_T=5), assembly sequence, critical dimensions.

Sensor positions: RPLIDAR top-centre on bay lid, D435i front, 4× IMX219 at
deck corners. Shares 30.5mm FC + 58mm Jetson + Ø25mm stem patterns with
SaltyLab for swappable electronics.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
sl-jetson merged commit 5bb1ec6d3e into main 2026-03-02 09:03:13 -05:00
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Reference: seb/saltylab-firmware#116
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