sl-mechanical
23f2daa3cd
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>
158 lines
6.1 KiB
Markdown
158 lines
6.1 KiB
Markdown
# SaltyBot Sensor Head — Assembly Diagram
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**Rev A — 2026-02-28 — sl-mechanical**
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---
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## Overview
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The sensor head mounts on top of the 25 mm OD vertical stem.
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Five printed/machined parts stack on a split collar platform.
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---
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## TOP VIEW (schematic)
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```
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FRONT (+X)
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↑
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[IMX219 arm] | [IMX219 arm]
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90° | 0°
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↑ +---------+ ↑
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| | | |
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[IMX219]←----[•]---| RPLIDAR |---[•]----→[IMX219]
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270° | | Ø70mm | | 90°
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↓ | | ↓
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+---------+
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| PLAT |
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| Ø120mm |
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| (octag) |
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+---------+
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↑ | | ↑
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[RS arm]---[•]---| COLLAR |---[•]
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| Ø52mm |
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+---------+
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25mm stem
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↓
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```
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---
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## SIDE VIEW (section through front, to scale)
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```
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Z
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↑
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│
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│ RPLIDAR A1M8 (Ø70 × 30 mm)
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│ ┌────────────────────┐ ← Z ≈ 52 mm (top of RPLIDAR)
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│ │ ██████████████ │
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│ │ ██ A1M8 ██ │ ← Z ≈ 22 mm (bottom of RPLIDAR)
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│ └────────────────────┘
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│ │ │ │ │ ← M3×30 bolts (4 off)
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│ ┌────┴────┴────┴────┐
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│ │ rplidar_ring.scad│ ← Z = 14..18 mm (4 mm ring)
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│ │ [silicone gromm]│ ← grommets 8 mm below ring
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│ └───────────────────┘
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│ ┌───────────────────┐
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│ │ P L A T F O R M │ ← Z = 36..44 mm
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│ │ (octag, Ø120mm) │
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│ └───────────────────┘
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│ │ COLLAR │
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│ ┌────┴────────┴────┐
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│ │ COLLAR FRONT │ ← Z = 0..36 mm
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│ │ │ stem bore │ │
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│ │ COLLAR REAR │
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│ └──────────────────┘
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│ │
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│ 25 mm STEM
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└─────────────────────────────────────── X
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```
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> **Note on Z references:** Z=0 is the bottom of the collar.
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> Stem clamp bolts lock the sensor head at chosen height on the mast.
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---
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## IMX219 Arm (side view — one arm shown)
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```
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Platform edge Camera PCB
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│ │
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─────┤══════════════════════════════════════╗
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│ ←── 52 mm arm ──────────────────► ║ IMX219
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─────┤══════════════════════════════════════╝ ← 10° nose down
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│ 2× M4 4× M2
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│ base bolts PCB bolts
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│ [slot: CSI ribbon through arm length]
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```
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---
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## RealSense Arm (side view)
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```
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Platform edge
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│ 2× M4
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─────┤
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│ Base ←── 75 mm arm ──────────────────►
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─────┤ plate
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│ (flat) ══════════════════════════════════╗
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║ ← 10° nose down
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║ D435i
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║ 90×25×25
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1/4-20 nut (captured)
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```
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---
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## Assembly Sequence
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| Step | Action |
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|------|--------|
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| 1 | Print 2× `collar_half` (flat-face-down; mirror one in slicer) |
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| 2 | Print 1× `platform` |
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| 3 | Print 1× `rplidar_ring` |
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| 4 | Print 1× `realsense_bracket` |
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| 5 | Print 4× `imx219_arm` (one per direction) |
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| 6 | Seat 4× M3 silicone anti-vibration grommets in platform holes |
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| 7 | Place rplidar_ring on grommets; pass 4× M3×30 SHCS from platform bottom up through ring |
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| 8 | Set RPLIDAR A1M8 on ring; tighten M3×30 into RPLIDAR tapped holes (fingertight) |
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| 9 | Thread 1/4-20 hex nut into realsense_bracket pocket; bolt D435i onto bracket |
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| 10 | Bolt realsense_bracket to platform front with 2× M4×16 SHCS |
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| 11 | Bolt 4× imx219_arm to platform with 2× M4×16 SHCS each |
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| 12 | Snap IMX219 PCBs onto arm face plates with 4× M2×6 BHCS each |
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| 13 | Route CSI ribbon cables through arm slots toward platform centre |
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| 14 | Assemble collar halves around stem (flat faces mating); tighten M4×30 clamping bolts |
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| 15 | Tighten M4 set screw in front collar half to lock height |
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| 16 | Torque RPLIDAR M3 bolts: 0.5 N·m |
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---
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## Fastener Summary
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| Qty | Size | Use |
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|-----|------|-----|
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| 2 | M4×30 SHCS | Collar clamping bolts |
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| 1 | M4×10 set screw | Collar height / rotation lock |
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| 2 | M4×16 SHCS | RealSense bracket to platform |
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| 8 | M4×16 SHCS | IMX219 arms to platform (2 per arm) |
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| 4 | M2×6 BHCS | IMX219 PCB to face plate (per arm; ×4 arms = 16 total) |
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| 4 | M3×30 SHCS | RPLIDAR ring to platform (through grommet) |
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| 4 | M3 anti-vibration grommet | Silicone, M3, Ø6 | Between platform and RPLIDAR ring |
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| 1 | 1/4-20 hex nut | Captured in RealSense bracket |
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| 2 | M4 hex nut | Captured in collar rear half |
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| 8 | M4 flat washer | Under head of all M4 bolts |
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---
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## Print Settings
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| Part | Material | Infill | Perimeters | Notes |
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|------|----------|--------|-----------|-------|
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| collar_half (×2) | PETG | 40% | 5 | Flat-face-down; print support-free |
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| platform | PETG or PLA | 30% | 4 | Top-face-up |
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| rplidar_ring | PETG | 30% | 3 | Flat |
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| realsense_bracket | PETG | 35% | 4 | Base on bed; arm horizontal |
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| imx219_arm (×4) | PETG or PLA | 30% | 3 | Flat, arm along X |
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