feat(mechanical): universal sensor mount rail system (Issue #138) #151

sl-mechanical · 2026-03-02T09:46:48-05:00

sl-mechanical commented

2026-03-02 09:46:48 -05:00

Summary

sensor_rail.scad: 2020 T-slot rail profile (DXF spec), printable T-nut, thumbscrew wheel, end caps, index pins, and 3 cross-variant base adapters (stem / square post / tank flat-plate clamp)
sensor_rail_brackets.scad: universal T-nut base + 4 sensor-specific quick-swap brackets (RPLIDAR A1M8, D435i RealSense, IMX219 CSI, UWB MaUWB ESP32-S3) + cable management clip
sensor_rail_BOM.md: purchased hardware list, print settings, mass estimate (~255 g), export commands

Key design decisions

Rail profile matches OpenBuilds V-Slot 2020 / MISUMI HFS5-2020 — off-the-shelf extrusion preferred; printable prototype sections also provided
Tool-free M3 thumbscrew (¼ turn) clamps printed T-nut against T-groove walls
Height-adjustable stepless + optional 25 mm indexed grid via cross-hole pins
Shared base adapter interfaces across all three robot variants

Test plan

Open sensor_rail.scad in OpenSCAD, verify assembly preview renders cleanly
Open sensor_rail_brackets.scad, verify all 5 bracket RENDER modes produce valid geometry
Export sensor_rail_profile.dxf and confirm 20×20 T-slot cross-section matches extrusion spec
Print T-nut base + cable clip in PETG, verify fit in spare 2020 extrusion
Verify RPLIDAR M3 bolt holes align to Ø58 mm BC
Verify D435i 1/4-20 nut pocket matches tripod standard

Closes #138

🤖 Generated with Claude Code

## Summary - `sensor_rail.scad`: 2020 T-slot rail profile (DXF spec), printable T-nut, thumbscrew wheel, end caps, index pins, and 3 cross-variant base adapters (stem / square post / tank flat-plate clamp) - `sensor_rail_brackets.scad`: universal T-nut base + 4 sensor-specific quick-swap brackets (RPLIDAR A1M8, D435i RealSense, IMX219 CSI, UWB MaUWB ESP32-S3) + cable management clip - `sensor_rail_BOM.md`: purchased hardware list, print settings, mass estimate (~255 g), export commands ## Key design decisions - Rail profile matches OpenBuilds V-Slot 2020 / MISUMI HFS5-2020 — off-the-shelf extrusion preferred; printable prototype sections also provided - Tool-free M3 thumbscrew (¼ turn) clamps printed T-nut against T-groove walls - Height-adjustable stepless + optional 25 mm indexed grid via cross-hole pins - Shared base adapter interfaces across all three robot variants ## Test plan - [ ] Open `sensor_rail.scad` in OpenSCAD, verify assembly preview renders cleanly - [ ] Open `sensor_rail_brackets.scad`, verify all 5 bracket RENDER modes produce valid geometry - [ ] Export `sensor_rail_profile.dxf` and confirm 20×20 T-slot cross-section matches extrusion spec - [ ] Print T-nut base + cable clip in PETG, verify fit in spare 2020 extrusion - [ ] Verify RPLIDAR M3 bolt holes align to Ø58 mm BC - [ ] Verify D435i 1/4-20 nut pocket matches tripod standard Closes #138 🤖 Generated with [Claude Code](https://claude.com/claude-code)

sl-mechanical added 1 commit 2026-03-02 09:46:48 -05:00

feat(mechanical): universal sensor mount rail system (Issue #138 ) 3992b80bcb

Add 2020 T-slot quick-swap sensor rail for SaltyLab/Rover/Tank variants:
- sensor_rail.scad: 2020 T-slot profile, T-nut, thumbscrew, end cap, index
  pins, stem/post/tank clamp adapters
- sensor_rail_brackets.scad: universal T-nut base + RPLIDAR A1M8, D435i,
  IMX219, UWB anchor, cable clip brackets (tool-free M3 thumbscrew retention)
- sensor_rail_BOM.md: purchased hardware, print settings, export commands

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

sl-jetson merged commit 07b4edaa2d into main

2026-03-02 09:51:31 -05:00

sl-jetson referenced this issue from a commit

2026-03-02 09:51:32 -05:00

Merge pull request 'feat(mechanical): universal sensor mount rail system (Issue #138)' (#151) from sl-mechanical/issue-138-sensor-rail into main

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Reference: seb/saltylab-firmware#151