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feat: bumper + frame crash protection (roll cage, base bumper, stem sleeves) #56

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seb merged 1 commits from sl-mechanical/bumper-protection into main 2026-03-01 00:21:13 -05:00
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sl-mechanical commented 2026-02-28 23:30:22 -05:00
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Summary

Crash protection system for SaltyBot — 4 new files in chassis/.

Layer File Protects
Sensor head roll cage bumper_frame.scad RPLIDAR, RealSense, 4× IMX219
Base plate bumper ring base_bumper.scad FC, electronics, wheels
Stem impact sleeves stem_protector.scad 25 mm stem tube
Assembly notes + BOM bumper_BOM.md —

Key design decisions

  • RPLIDAR FOV preserved: roll cage posts at 45°/135°/225°/315° (between cameras). At RPLIDAR scan-plane height (~105 mm), posts are ~78 mm from CL, outside RPLIDAR body. Crown ring at Z=148 mm, 18 mm above RPLIDAR top — no scan-plane obstruction.
  • FC LEDs visible: base bumper clips below plate edge only; does not cover plate top face.
  • Fully removable: collar clamps, plate edge clips, stem snap-fit — no permanent fixings.
  • No print supports: all parts flat-face-down or naturally horizontal.
  • ~500 g total: symmetric about robot axes — negligible CG shift.

Test plan

  • OpenSCAD RENDER="assembly" on each file — check for geometry errors
  • Print one collar_front + collar_rear — verify snap around 25 mm stem tube
  • Print one cage_post — verify M4 hole spacing matches collar boss
  • Print one corner bracket — verify clip slot grips 6 mm Al plate edge
  • Print one stem_protector front+rear pair in TPU — verify snap closes flush
  • Check cage crown Z clearance ≥ 15 mm above RPLIDAR top in assembled stack

🤖 Generated with Claude Code

## Summary Crash protection system for SaltyBot — 4 new files in `chassis/`. | Layer | File | Protects | |-------|------|----------| | Sensor head roll cage | `bumper_frame.scad` | RPLIDAR, RealSense, 4× IMX219 | | Base plate bumper ring | `base_bumper.scad` | FC, electronics, wheels | | Stem impact sleeves | `stem_protector.scad` | 25 mm stem tube | | Assembly notes + BOM | `bumper_BOM.md` | — | ## Key design decisions - **RPLIDAR FOV preserved**: roll cage posts at 45°/135°/225°/315° (between cameras). At RPLIDAR scan-plane height (~105 mm), posts are ~78 mm from CL, outside RPLIDAR body. Crown ring at Z=148 mm, 18 mm above RPLIDAR top — no scan-plane obstruction. - **FC LEDs visible**: base bumper clips below plate edge only; does not cover plate top face. - **Fully removable**: collar clamps, plate edge clips, stem snap-fit — no permanent fixings. - **No print supports**: all parts flat-face-down or naturally horizontal. - **~500 g total**: symmetric about robot axes — negligible CG shift. ## Test plan - [ ] OpenSCAD `RENDER="assembly"` on each file — check for geometry errors - [ ] Print one `collar_front` + `collar_rear` — verify snap around 25 mm stem tube - [ ] Print one `cage_post` — verify M4 hole spacing matches collar boss - [ ] Print one `corner` bracket — verify clip slot grips 6 mm Al plate edge - [ ] Print one `stem_protector front`+`rear` pair in TPU — verify snap closes flush - [ ] Check cage crown Z clearance ≥ 15 mm above RPLIDAR top in assembled stack 🤖 Generated with [Claude Code](https://claude.com/claude-code)
sl-mechanical added 1 commit 2026-02-28 23:30:23 -05:00 
Protects expensive sensors when robot tips over during testing.

Files added:
  chassis/bumper_frame.scad   — roll cage (25 mm stem collar + 4 inclined
                                posts + crown ring + TPU snap pad). Posts at
                                45/135/225/315° between cameras. Crown at
                                Z=148 mm above cage collar, 18 mm above RPLIDAR
                                top. RPLIDAR FOV unobstructed.
  chassis/base_bumper.scad    — clip-on bumper ring for 270×240 mm base plate.
                                50 mm tall, 15 mm standoff, rounded corners.
                                4× corner + 4× side clip brackets. TPU snap
                                edge caps. FC status LEDs remain visible.
  chassis/stem_protector.scad — split TPU sleeve for 25 mm stem. Snap-fit
                                closure (no hardware). Install 3–4 sleeves
                                along stem at ~200 mm intervals.
  chassis/bumper_BOM.md       — full BOM, print settings, install heights,
                                mass estimate (~500 g total, balanced).

All parts print without supports. Fully removable (clip/snap/clamp).

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
seb merged commit 3d2d317431 into main 2026-03-01 00:21:13 -05:00
seb deleted branch sl-mechanical/bumper-protection 2026-03-01 00:21:14 -05:00
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Reference: seb/saltylab-firmware#56
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