sl-mechanical
3e4764b3eb
Add parametric OpenSCAD designs for the SaltyRover stable 4-wheel variant. Reuses existing 25mm stem, sensor head, and all SaltyLab sensor mounts without modification. Files: - saltyrover_chassis.scad 480×500mm deck, stem collar, FC+Orin standoffs, motor attachment holes, battery tray opening; RENDER deck_2d for waterjet/CNC DXF - rover_motor_mount.scad L-bracket + axle clamp plate per motor; uses caliper-verified axle dims from BOM.md; dropout slot for tool-free motor swap; RENDER bracket_2d for CNC DXF - rover_battery_tray.scad Slide-out tray for 2-4 × 420×88×56mm packs laid flat (low CG); T-slot rails, spring latch - rover_stem_adapter.scad Flange + split clamp locks 25mm stem to deck collar; 550mm stem option for rover height - rover_BOM.md Assembly sequence, fastener table, mass estimate (~13.4kg), height stack diagram Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
241 lines
9.8 KiB
OpenSCAD
241 lines
9.8 KiB
OpenSCAD
// ============================================================
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// rover_motor_mount.scad — SaltyRover Drive Motor Brackets
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// Rev A 2026-03-01 sl-mechanical
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// ============================================================
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// L-bracket that bolts to the deck edge and positions the drive
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// motor axle at the correct height. Print or CNC 4×.
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//
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// Default values from BOM.md (caliper-verified hoverboard motor):
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// Axle base OD: 16.11 mm
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// D-cut OD: 15.95 mm (flat chord 13.00 mm)
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// Bearing seat OD: 37.80 mm
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// Axle CL above gnd: 127 mm
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// Tire OD: 254 mm (10×2.125")
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//
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// Bracket geometry (all dims in mm):
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// Vertical flange — bolts to deck edge (2× M5 SHCS)
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// Horizontal arm — extends BRKT_REACH beyond deck edge
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// to position axle CL at TRACK_W/2
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// Axle channel — open-bottom dropout slot for easy
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// motor install/removal; retained by
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// a separate clamping plate (×1 per bracket)
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// Bearing recess — 37.8 mm recess on inboard face
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//
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// ⚠ VERIFY before printing / CNC:
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// AXLE_D, AXLE_FLAT, BEARING_OD from caliper measurement.
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// DECK_BOT_H = GND_CLR + BATT_FLOOR_T + BATT_PACK_H.
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// Adjust BRKT_REACH so TRACK_W matches chassis layout.
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//
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// Print orientation: flange face flat on bed.
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// Material: PETG or PC, 5 perims, 60% infill.
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// Alternative: CNC-routed 10mm 6061-T6 aluminium plate.
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//
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// RENDER options:
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// "assembly" bracket + clamp plate + phantom motor axle
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// "bracket" main L-bracket for printing/CNC
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// "clamp_plate" axle retention clamp plate (print 4×)
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// "bracket_2d" bracket floor projection → DXF
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// ============================================================
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RENDER = "assembly";
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// ── Axle / motor (BOM.md caliper-verified) ────────────────
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AXLE_D = 16.11; // axle base section OD (round)
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AXLE_FLAT = 13.00; // D-cut flat chord width
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AXLE_D_DCUT = 15.95; // D-cut section OD
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BEARING_OD = 37.80; // bearing seat collar OD
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BEARING_D = BEARING_OD + 1.0; // bore clearance for bearing seat
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BEARING_H = 8.0; // bearing recess depth on inboard face
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AXLE_H = 127.0; // axle CL above ground
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TIRE_OD = 254.0; // 10×2.125" tire outer diameter
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// Dropout slot dims
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DROP_W = AXLE_D + 2.0; // slot width (axle + 1 mm each side)
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DROP_D = AXLE_H; // slot depth from bracket bottom (full height)
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// ── Bracket geometry ─────────────────────────────────────
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// Deck geometry (must match saltyrover_chassis.scad)
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GND_CLR = 50.0;
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BATT_FLOOR_T = 3.0;
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BATT_PACK_H = 56.0;
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DECK_T = 8.0;
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DECK_BOT_H = GND_CLR + BATT_FLOOR_T + BATT_PACK_H; // 109 mm
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DECK_TOP_H = DECK_BOT_H + DECK_T; // 117 mm
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// Axle height relative to deck top:
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AXLE_ABOVE_DECK = AXLE_H - DECK_TOP_H; // ~10 mm
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// Bracket reach beyond deck edge to motor axle CL
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BRKT_REACH = 40.0; // motor CL is BRKT_REACH mm outside deck edge
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// (TRACK_W/2 - ROVER_W/2 = 270 - 240 = 30 mm +
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// bearing housing clearance margin = 40 mm)
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// Bracket plate dimensions
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BRKT_T = 10.0; // bracket plate thickness
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BRKT_H_ABOVE = AXLE_ABOVE_DECK + BEARING_OD/2 + 8.0; // above deck top
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BRKT_H_BELOW = DECK_T + 12.0; // below deck bottom
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BRKT_TOTAL_H = BRKT_H_ABOVE + BRKT_H_BELOW; // full height
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// Width of bracket arm (fore-aft direction)
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BRKT_W = 60.0; // covers motor fore-aft attachment bolts
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// Flange for deck attachment
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FLANGE_T = 8.0; // flange plate thickness
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FLANGE_DEPTH = 20.0; // how deep flange sits on deck face (Y direction)
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// M5 bolt holes: 2× through flange (deck attachment)
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M5_D = 5.3;
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MOT_BOLT_SPC = 30.0; // matches saltyrover_chassis.scad MOT_BOLT_SPC
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// Clamping plate (retains axle in dropout slot)
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CLAMP_T = 6.0; // clamp plate thickness
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CLAMP_W = DROP_W + 12.0;
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CLAMP_H = BEARING_D + 12.0;
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CLAMP_BOLT_D= 4.3; // M4 clearance
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CLAMP_BOLT_SPC = CLAMP_W - 10.0;
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// Gusset (triangular fillet between flange and arm)
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GUSSET_T = 8.0;
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$fn = 64;
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e = 0.01;
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// ─────────────────────────────────────────────────────────
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// motor_bracket()
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// Main L-bracket. Coordinate: Z=0 at deck top.
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// Bracket outboard face at X=0 (deck edge).
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// Bracket arm extends +X toward motor.
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// ─────────────────────────────────────────────────────────
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module motor_bracket() {
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axle_z = AXLE_ABOVE_DECK; // axle CL in bracket coords
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difference() {
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union() {
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// ── Vertical arm (extends +X from deck edge) ──
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translate([0, -BRKT_W/2, -BRKT_H_BELOW])
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cube([BRKT_REACH + BRKT_T, BRKT_W, BRKT_TOTAL_H]);
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// ── Vertical flange (sits against deck edge, -X side) ──
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translate([-FLANGE_DEPTH, -BRKT_W/2, -BRKT_H_BELOW])
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cube([FLANGE_DEPTH, BRKT_W, BRKT_TOTAL_H]);
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// ── Gusset (arm to flange transition) ──
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translate([0, -BRKT_W/2, axle_z - GUSSET_T/2])
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linear_extrude(GUSSET_T)
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polygon([
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[0, 0],
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[BRKT_REACH/2, 0],
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[0, BRKT_W]
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]);
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}
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// ── Axle dropout slot (open at bottom, centered on arm tip) ──
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translate([BRKT_REACH, -DROP_W/2, -BRKT_H_BELOW - e])
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cube([BRKT_T + e, DROP_W, AXLE_H + 2*e]);
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// ── Axle round bore at slot top ──
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translate([BRKT_REACH, 0, axle_z])
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rotate([0, 90, 0])
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cylinder(d=AXLE_D + 1.0, h=BRKT_T + 2*e);
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// ── D-cut anti-rotation flat (matches axle flat chord) ──
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translate([BRKT_REACH - e, -AXLE_FLAT/2, axle_z - AXLE_D/2 - e])
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cube([BRKT_T + 2*e, AXLE_FLAT, AXLE_D/2 + e]);
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// ── Bearing seat recess (inboard face, X=BRKT_T) ──
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translate([BRKT_REACH + BRKT_T - BEARING_H, 0, axle_z])
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rotate([0, 90, 0])
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cylinder(d=BEARING_D, h=BEARING_H + e);
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// ── Clamping plate bolt holes (×2, retain axle) ──
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for (dz=[-CLAMP_BOLT_SPC/2, CLAMP_BOLT_SPC/2])
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translate([BRKT_REACH - e, 0, axle_z + dz])
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rotate([0, 90, 0])
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cylinder(d=CLAMP_BOLT_D, h=BRKT_T + 2*e);
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// ── Deck attachment holes through flange (M5 × 2) ──
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for (bz=[-MOT_BOLT_SPC/2, MOT_BOLT_SPC/2])
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translate([-FLANGE_DEPTH - e, 0, bz])
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rotate([0, 90, 0])
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cylinder(d=M5_D, h=FLANGE_DEPTH + 2*e);
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// ── Lightening pocket on arm (inboard face) ──
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translate([BRKT_T, -BRKT_W/2 + 8, -BRKT_H_BELOW/2])
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cube([BRKT_REACH - BRKT_T - 8,
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BRKT_W - 16,
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BRKT_H_BELOW/2 - 4]);
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}
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}
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// ─────────────────────────────────────────────────────────
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// axle_clamp_plate()
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// Bolts to bracket outboard face to close dropout slot.
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// Print flat face down. 1× per bracket.
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// ─────────────────────────────────────────────────────────
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module axle_clamp_plate() {
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axle_z = AXLE_ABOVE_DECK;
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difference() {
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translate([-CLAMP_W/2, 0, axle_z - CLAMP_H/2])
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cube([CLAMP_W, CLAMP_T, CLAMP_H]);
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// Axle bore
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translate([0, -e, axle_z])
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rotate([-90, 0, 0])
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cylinder(d=AXLE_D + 0.5, h=CLAMP_T + 2*e);
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// Bearing seat relief
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translate([0, CLAMP_T - BEARING_H + e, axle_z])
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rotate([-90, 0, 0])
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cylinder(d=BEARING_D, h=BEARING_H + e);
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// M4 bolt holes (×2)
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for (dz=[-CLAMP_BOLT_SPC/2, CLAMP_BOLT_SPC/2])
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translate([0, -e, axle_z + dz])
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rotate([-90, 0, 0])
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cylinder(d=CLAMP_BOLT_D, h=CLAMP_T + 2*e);
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}
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}
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// ─────────────────────────────────────────────────────────
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// Render selector
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// ─────────────────────────────────────────────────────────
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if (RENDER == "assembly") {
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color("DimGray", 0.90) motor_bracket();
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color("SteelBlue", 0.85)
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translate([BRKT_REACH + BRKT_T, 0, 0])
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axle_clamp_plate();
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// Phantom axle stub
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color("Silver", 0.4)
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translate([BRKT_REACH, 0, AXLE_ABOVE_DECK])
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rotate([0, 90, 0])
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cylinder(d=AXLE_D, h=80);
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// Phantom tire (semi-transparent outline)
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color("Black", 0.12)
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translate([BRKT_REACH + 40, 0, AXLE_ABOVE_DECK])
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rotate([0, 90, 0])
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cylinder(d=TIRE_OD, h=54);
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// Reference deck edge
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color("Gold", 0.25)
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translate([-FLANGE_DEPTH - 20, -BRKT_W/2, -BRKT_H_BELOW])
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cube([20, BRKT_W, BRKT_TOTAL_H]);
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} else if (RENDER == "bracket") {
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motor_bracket();
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} else if (RENDER == "clamp_plate") {
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// Orient for printing: lay flat, rotate upright
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translate([0, CLAMP_T, -AXLE_ABOVE_DECK])
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rotate([90, 0, 0])
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axle_clamp_plate();
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} else if (RENDER == "bracket_2d") {
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projection(cut=true)
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translate([0, 0, -BRKT_H_BELOW - BRKT_T/2])
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motor_bracket();
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}
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