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>
203 lines
8.3 KiB
OpenSCAD
203 lines
8.3 KiB
OpenSCAD
// ============================================================
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// rover_stem_adapter.scad — SaltyRover Vertical Stem Adapter
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// Rev A 2026-03-01 sl-mechanical
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// ============================================================
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// Secures the 25 mm OD vertical stem to the rover deck.
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//
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// Two-part system:
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// base_flange() — annular flange plate bolts to deck top
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// (4× M4 SHCS into deck; deck already has
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// 25 mm stem bore through its centre collar)
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// stem_clamp() — split collar clamps on stem above the
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// deck collar; two M4 clamping bolts
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// lock stem position / rotation
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//
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// Reuses the existing sensor head, RPLIDAR, camera mounts, and
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// roll cage from SaltyLab — stem OD 25 mm is unchanged.
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//
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// Stem length options:
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// SaltyLab 1000 mm (balance robot — tall for CG)
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// SaltyRover 550 mm (rover — sensors visible, compact)
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// The adapter is identical; only the purchased tube differs.
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//
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// ⚠ Ensure the deck stem collar (saltyrover_chassis.scad,
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// STEM_COLLAR_OD=50 mm, H=22 mm) is the primary lateral
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// support. The flange + clamp provide torque/axial lock.
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//
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// RENDER options:
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// "assembly" flange + clamp + stem stub
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// "base_flange" flange plate for printing
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// "clamp_front" clamp front half for printing
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// "clamp_rear" clamp rear half for printing
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// "flange_2d" flange projection → DXF
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// ============================================================
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RENDER = "assembly";
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// ── Stem ─────────────────────────────────────────────────
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STEM_OD = 25.0;
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STEM_BORE = 25.4; // +0.4 clearance (same as sensor mounts)
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STEM_L_ROVER = 550; // recommended rover stem length (mm)
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// ── Base flange ───────────────────────────────────────────
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// Sits on deck collar top. 4× M4 bolt through flange into deck.
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FLANGE_OD = 80.0; // outer diameter
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FLANGE_T = 6.0; // plate thickness
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FLANGE_BOLT_BC = 65.0; // M4 bolt circle diameter
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FLANGE_BOLT_D = 4.3; // M4 clearance
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FLANGE_BOLT_N = 4; // number of bolts (at 90°)
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// Deck collar height (must match saltyrover_chassis.scad STEM_COLLAR_H)
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DECK_COLLAR_H = 22.0;
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// ── Split stem clamp ─────────────────────────────────────
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// Sits on top of flange; clamped M4 bolts lock stem.
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COL_OD = 52.0; // clamp outer diameter
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COL_H = 28.0; // clamp height (above flange)
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COL_BOLT_X = 19.0; // M4 clamping bolt CL from stem axis
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COL_BOLT_D = 4.5; // M4 clearance hole
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COL_NUT_W = 7.0; // M4 hex nut across-flats
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COL_NUT_H = 3.4; // hex nut height
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// Set screw for rotation lock (front half)
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SET_SCREW_D = 4.5; // M4 set screw
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// ── Fasteners ─────────────────────────────────────────────
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M4_D = 4.3;
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$fn = 64;
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e = 0.01;
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// ─────────────────────────────────────────────────────────
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// base_flange()
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// Sits on top of the deck stem collar.
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// Z=0 at deck top (collar rises from here).
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// ─────────────────────────────────────────────────────────
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module base_flange() {
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difference() {
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union() {
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// Annular flange plate (sits on collar top)
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translate([0, 0, DECK_COLLAR_H])
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cylinder(d=FLANGE_OD, h=FLANGE_T);
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// Short skirt that drops inside/over collar
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translate([0, 0, DECK_COLLAR_H - 4])
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cylinder(d=FLANGE_OD - 8, h=4);
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}
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// Stem bore
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translate([0, 0, DECK_COLLAR_H - 4 - e])
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cylinder(d=STEM_BORE, h=FLANGE_T + 4 + 2*e);
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// M4 bolts through flange + down into deck (×4)
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for (ang=[0, 90, 180, 270])
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rotate([0, 0, ang])
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translate([FLANGE_BOLT_BC/2, 0, DECK_COLLAR_H - e])
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cylinder(d=FLANGE_BOLT_D, h=FLANGE_T + 2*e);
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// Countersink on top face
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for (ang=[0, 90, 180, 270])
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rotate([0, 0, ang])
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translate([FLANGE_BOLT_BC/2, 0, DECK_COLLAR_H + FLANGE_T - 3.5])
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cylinder(d1=FLANGE_BOLT_D, d2=8.5, h=3.5 + e);
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}
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}
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// ─────────────────────────────────────────────────────────
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// stem_clamp_half(side)
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// Split collar clamps on stem above the flange.
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// Print flat-face-down. side = "front" | "rear"
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// ─────────────────────────────────────────────────────────
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module stem_clamp_half(side="front") {
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y_front = (side == "front");
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// Clamp Z origin: on top of flange
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clamp_z0 = DECK_COLLAR_H + FLANGE_T;
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difference() {
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// D-shaped half
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intersection() {
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translate([0, 0, clamp_z0])
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cylinder(d=COL_OD, h=COL_H);
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translate([-COL_OD/2,
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y_front ? 0 : -COL_OD/2,
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clamp_z0])
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cube([COL_OD, COL_OD/2, COL_H]);
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}
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// Stem bore
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translate([0, 0, clamp_z0 - e])
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cylinder(d=STEM_BORE, h=COL_H + 2*e);
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// M4 clamping bolt holes (Y direction, through front half)
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for (bx=[-COL_BOLT_X, COL_BOLT_X])
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translate([bx,
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y_front ? COL_OD/2 : 0,
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clamp_z0 + COL_H/2])
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rotate([90, 0, 0])
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cylinder(d=COL_BOLT_D, h=COL_OD/2 + e);
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// M4 hex nut pockets in rear half
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if (!y_front)
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for (bx=[-COL_BOLT_X, COL_BOLT_X])
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translate([bx,
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-(COL_OD/4 + e),
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clamp_z0 + COL_H/2])
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rotate([90, 0, 0])
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cylinder(d=COL_NUT_W/cos(30),
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h=COL_NUT_H + e, $fn=6);
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// M4 set screw hole (front half, mid-height, horizontal)
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if (y_front)
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translate([0, COL_OD/2,
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clamp_z0 + COL_H * 0.65])
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rotate([90, 0, 0])
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cylinder(d=SET_SCREW_D,
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h=COL_OD/2 - STEM_BORE/2 + e);
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// Mating face chamfer (0.2 mm, prevents elephant-foot binding)
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translate([0, 0, clamp_z0 - e])
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rotate([0, 0, y_front ? 0 : 180])
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translate([-COL_OD/2, -0.2, 0])
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cube([COL_OD, 0.2, COL_H + 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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// Phantom deck collar reference
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color("Gray", 0.15)
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difference() {
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cylinder(d=50, h=DECK_COLLAR_H);
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translate([0,0,-e]) cylinder(d=STEM_BORE, h=DECK_COLLAR_H+2*e);
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}
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color("SteelBlue", 0.90) base_flange();
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color("CornflowerBlue", 0.90) stem_clamp_half("front");
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color("SlateBlue", 0.90)
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mirror([0,1,0]) stem_clamp_half("rear");
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// Phantom stem stub
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color("Silver", 0.30)
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translate([0, 0, DECK_COLLAR_H + FLANGE_T + COL_H])
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cylinder(d=STEM_OD, h=STEM_L_ROVER);
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} else if (RENDER == "base_flange") {
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// Print flat; rotate flange down
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translate([0, 0, -(DECK_COLLAR_H - 4)])
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base_flange();
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} else if (RENDER == "clamp_front") {
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translate([0, 0, -(DECK_COLLAR_H + FLANGE_T)])
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stem_clamp_half("front");
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} else if (RENDER == "clamp_rear") {
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translate([0, 0, -(DECK_COLLAR_H + FLANGE_T)])
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stem_clamp_half("rear");
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} else if (RENDER == "flange_2d") {
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projection(cut=true)
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translate([0, 0, -(DECK_COLLAR_H + FLANGE_T/2)])
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base_flange();
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}
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