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feat: SaltyTank tracked chassis — drive sprockets, tensioners, skid plate (#121) #131

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sl-jetson merged 1 commits from sl-mechanical/issue-121-tank-chassis into main 2026-03-02 09:26:40 -05:00
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sl-mechanical commented 2026-03-02 09:21:19 -05:00
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Summary

  • saltytank_chassis.scad — Deck plate (500×360×8 mm Al, DXF export via RENDER="deck_2d"), 2× side track frames (6 mm Al, RENDER="side_frame_2d"), idler tensioner sliding block (RENDER="idler_block_stl"), 4× CSI corner camera mounts (45°/20°), D435i front bracket (8° tilt), stem collar. Drive sprockets use hoverboard hub motors — caliper-verified D-cut bore (16.11 mm / 13 mm flat) + 52 mm BC hub flange pattern. M6 tensioner bolt adjusts idler ±15 mm for track tension. Electronics bay footprint matches rover_electronics_bay.scad exactly — drop-in compatible.
  • saltytank_skid_plate.scad — Sacrificial 360×500 mm underside skid panel (4 mm HDPE preferred, RENDER="skid_2d" → DXF; RENDER="skid_stl" → print prototype). Countersunk M4 FHCS bolt-on. 4× drain/inspection slots. Optional printed ribs (RIB_PRINT=true). Hull ground clearance: 90 mm (exceeds 50 mm requirement).
  • saltytank_BOM.md — Full BOM: all structural parts, drive sprockets, idler wheels, road wheels (×4), rubber/metal track belts (1109 mm circumference calc), skid plate, sensor brackets, electronics bay (rover_electronics_bay.scad reused unchanged). Frame mass ≈ 2.98 kg (just under 3 kg target). Assembly sequence, track tensioning procedure, and critical dimensions table included.

Sensor positions

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

Shared SaltyLab patterns

  • FC: 30.5×30.5 mm M3 (MAMBA F722S / Pixhawk)
  • Jetson Orin: 58×49 mm M3
  • Stem bore: Ø25.5 mm (sensor head unchanged)
  • Electronics bay: rover_electronics_bay.scad drop-in, no modifications

Test plan

  • Open saltytank_chassis.scad in OpenSCAD 2021.01+, render assembly preview
  • Export deck_2d DXF and verify geometry in viewer
  • Export side_frame_2d DXF — check hub flange BC, D-cut bore, tensioner slot
  • ⚠ Verify HUB_FLANGE_BC = 52.0 against physical motor hub before CNC
  • Open saltytank_skid_plate.scad, render assembly preview
  • Test-fit idler block STL in frame tensioner slot (should slide freely)
  • Confirm FC 30.5mm and Jetson 58×49mm deck holes match rover_electronics_bay.scad

🤖 Generated with Claude Code

## Summary - **`saltytank_chassis.scad`** — Deck plate (500×360×8 mm Al, DXF export via `RENDER="deck_2d"`), 2× side track frames (6 mm Al, `RENDER="side_frame_2d"`), idler tensioner sliding block (`RENDER="idler_block_stl"`), 4× CSI corner camera mounts (45°/20°), D435i front bracket (8° tilt), stem collar. Drive sprockets use hoverboard hub motors — caliper-verified D-cut bore (16.11 mm / 13 mm flat) + 52 mm BC hub flange pattern. M6 tensioner bolt adjusts idler ±15 mm for track tension. Electronics bay footprint matches `rover_electronics_bay.scad` exactly — drop-in compatible. - **`saltytank_skid_plate.scad`** — Sacrificial 360×500 mm underside skid panel (4 mm HDPE preferred, `RENDER="skid_2d"` → DXF; `RENDER="skid_stl"` → print prototype). Countersunk M4 FHCS bolt-on. 4× drain/inspection slots. Optional printed ribs (`RIB_PRINT=true`). Hull ground clearance: **90 mm** (exceeds 50 mm requirement). - **`saltytank_BOM.md`** — Full BOM: all structural parts, drive sprockets, idler wheels, road wheels (×4), rubber/metal track belts (1109 mm circumference calc), skid plate, sensor brackets, electronics bay (`rover_electronics_bay.scad` reused unchanged). Frame mass ≈ **2.98 kg** (just under 3 kg target). Assembly sequence, track tensioning procedure, and critical dimensions table included. ## Sensor positions - RPLIDAR A1M8: top-centre on electronics bay lid tower (via `rover_electronics_bay.scad`) - D435i: front deck bracket, 8° nose-down - 4× IMX219/CSI: deck corners, 45° outward, 20° downward ## Shared SaltyLab patterns - FC: 30.5×30.5 mm M3 (MAMBA F722S / Pixhawk) - Jetson Orin: 58×49 mm M3 - Stem bore: Ø25.5 mm (sensor head unchanged) - Electronics bay: `rover_electronics_bay.scad` drop-in, no modifications ## Test plan - [ ] Open `saltytank_chassis.scad` in OpenSCAD 2021.01+, render assembly preview - [ ] Export `deck_2d` DXF and verify geometry in viewer - [ ] Export `side_frame_2d` DXF — check hub flange BC, D-cut bore, tensioner slot - [ ] ⚠ Verify `HUB_FLANGE_BC = 52.0` against physical motor hub before CNC - [ ] Open `saltytank_skid_plate.scad`, render assembly preview - [ ] Test-fit idler block STL in frame tensioner slot (should slide freely) - [ ] Confirm FC 30.5mm and Jetson 58×49mm deck holes match `rover_electronics_bay.scad` 🤖 Generated with [Claude Code](https://claude.com/claude-code)
sl-mechanical added 1 commit 2026-03-02 09:21:20 -05:00 
Three new chassis design files for the SaltyTank continuous-track variant:

• saltytank_chassis.scad — Deck plate (500×360×8mm Al, DXF export), 2×
  side track frames (6mm Al, CNC/laser), idler tensioner sliding block,
  4× CSI corner camera mounts (45°/20°), D435i front bracket (8° tilt),
  stem collar (Ø25mm shared).  Drive sprocket mounts accept hoverboard hub
  motors with caliper-verified D-cut bore (16.11mm/13mm flat) + 52mm BC
  hub flange bolt pattern.  M6 tensioner bolt adjusts idler ±15mm for
  track tension. Shared FC 30.5×30.5mm + Jetson 58×49mm M3 patterns.
  Electronics bay footprint matches rover_electronics_bay.scad exactly.

• saltytank_skid_plate.scad — Sacrificial underside skid panel (360×500mm).
  4mm HDPE (DXF) or PETG print; countersunk M4 FHCS bolt-on.  4× drain/
  inspection slots; optional printed ribs (RIB_PRINT=true).  Ground
  clearance of hull between tracks: 90mm (exceeds 50mm requirement).

• saltytank_BOM.md — Full BOM: deck plate, side frames, drive sprockets,
  idler wheels + tensioners, road wheels (2/side), track belts (1109mm
  circumference calc), skid plate, sensor brackets, electronics bay
  (rover_electronics_bay.scad reused unchanged). Frame mass ≈ 2.98 kg
  (just under 3 kg target). Assembly sequence and track tensioning
  procedure included.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
sl-jetson merged commit 0d47632c0a into main 2026-03-02 09:26:40 -05:00
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Reference: seb/saltylab-firmware#131
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