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feat: sensor head mounts — RPLIDAR, RealSense D435i, 4× IMX219 #48

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seb merged 1 commits from sl-mechanical/sensor-mounts into main 2026-02-28 22:58:43 -05:00
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sl-mechanical commented 2026-02-28 22:53:41 -05:00
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Summary

Phase 2 sensor mount designs for SaltyBot 25 mm OD mast.

Five new files in chassis/:

File Description
sensor_head.scad Split collar (25 mm OD stem, M4 clamping bolts) + octagonal 120 mm platform. RENDER selector: assembly / collar_front / collar_rear / platform_2d
rplidar_mount.scad 4 mm flat ring, Ø58 mm M3 bolt circle, grommet recesses on underside — anti-vibration isolation for RPLIDAR A1M8
realsense_mount.scad Single-piece arm bracket; 2× M4 to platform, 75 mm arm, 10° nose-down tilt, 1/4-20 captured hex nut for D435i
imx219_mount.scad Radial arm, 52 mm reach, 10° tilt, CSI ribbon slot, 4× M2 face holes — print 4×, deploy at 0/90/180/270°
sensor_head_assembly.md ASCII top+side view diagrams, 16-step assembly sequence, fastener table, print settings

Key design decisions

  • No supports — all parts print flat-face-down
  • Anti-vibration — RPLIDAR ring uses same M3 silicone grommets as FC mount
  • Height budget — total sensor stack <90 mm above collar base (fits 100 mm budget)
  • Hole matching — ARM_R = 50 mm, ARM_DY_RS = 18 mm, ARM_DY_CAM = 9 mm are consistent between sensor_head.scad and mount files

Test plan

  • Open each .scad in OpenSCAD, set RENDER="assembly" — verify no geometry errors
  • Set RENDER="collar_front" / "collar_rear" — verify flat print-ready halves
  • Set RENDER="platform_2d" — export DXF, check hole positions
  • Verify M3 hole positions on rplidar_ring match RPLIDAR A1M8 datasheet (58 mm BC)
  • Verify realsense_mount 1/4-20 nut pocket depth ≥ 5.6 mm
  • Print prototype collar half and test fit on 25 mm OD stem

🤖 Generated with Claude Code

## Summary Phase 2 sensor mount designs for SaltyBot 25 mm OD mast. Five new files in `chassis/`: | File | Description | |------|-------------| | `sensor_head.scad` | Split collar (25 mm OD stem, M4 clamping bolts) + octagonal 120 mm platform. RENDER selector: `assembly` / `collar_front` / `collar_rear` / `platform_2d` | | `rplidar_mount.scad` | 4 mm flat ring, Ø58 mm M3 bolt circle, grommet recesses on underside — anti-vibration isolation for RPLIDAR A1M8 | | `realsense_mount.scad` | Single-piece arm bracket; 2× M4 to platform, 75 mm arm, 10° nose-down tilt, 1/4-20 captured hex nut for D435i | | `imx219_mount.scad` | Radial arm, 52 mm reach, 10° tilt, CSI ribbon slot, 4× M2 face holes — print 4×, deploy at 0/90/180/270° | | `sensor_head_assembly.md` | ASCII top+side view diagrams, 16-step assembly sequence, fastener table, print settings | ## Key design decisions - **No supports** — all parts print flat-face-down - **Anti-vibration** — RPLIDAR ring uses same M3 silicone grommets as FC mount - **Height budget** — total sensor stack <90 mm above collar base (fits 100 mm budget) - **Hole matching** — `ARM_R = 50 mm`, `ARM_DY_RS = 18 mm`, `ARM_DY_CAM = 9 mm` are consistent between `sensor_head.scad` and mount files ## Test plan - [ ] Open each `.scad` in OpenSCAD, set `RENDER="assembly"` — verify no geometry errors - [ ] Set `RENDER="collar_front"` / `"collar_rear"` — verify flat print-ready halves - [ ] Set `RENDER="platform_2d"` — export DXF, check hole positions - [ ] Verify M3 hole positions on `rplidar_ring` match RPLIDAR A1M8 datasheet (58 mm BC) - [ ] Verify `realsense_mount` 1/4-20 nut pocket depth ≥ 5.6 mm - [ ] Print prototype collar half and test fit on 25 mm OD stem 🤖 Generated with [Claude Code](https://claude.com/claude-code)
sl-mechanical added 1 commit 2026-02-28 22:53:42 -05:00 
Part of Phase 2 sensor mount designs for SaltyBot 25 mm mast.

Files added:
  chassis/sensor_head.scad        — split collar (25 mm OD stem) + octagonal platform
  chassis/rplidar_mount.scad      — anti-vibration ring for RPLIDAR A1M8 (Ø58 mm BC)
  chassis/realsense_mount.scad    — RealSense D435i arm bracket, 10° tilt, 1/4-20 nut
  chassis/imx219_mount.scad       — 4× IMX219 radial arms, 10° tilt, CSI ribbon slot
  chassis/sensor_head_assembly.md — assembly diagram + fastener BOM + print settings

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
seb merged commit 1c6c5b3c0b into main 2026-02-28 22:58:43 -05:00
seb deleted branch sl-mechanical/sensor-mounts 2026-02-28 22:58:43 -05:00
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Reference: seb/saltylab-firmware#48
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