2009:Mechanical 4.16.2009

Pre Atlanta work:

1.  Rebuilt all conveyor banebot reducers including spares.  Disassemble all parts, deburr mating surfaces.  Removed endplay from output shaft assembly by shiming bearings apart to get about .005" end play max.  Wash all components in solvent, dry.  Reassembly with EP type grease.  Used Exxon Romex MP.  

2.  All motor and speed reducer transmissions are Identified using a number and letter combination.  A runnig log sheet is kept up in the box with the spare motor / transmissions and rebuild tools.  We now have a history of the service duty and what has been done to the units.  Also the units on the robot have been identified as well.  Example: A-1, B-2, C-3, etc.

3.  Two 1/4" re-enforcing side plates were added to the shooter motor transmission to hold it together.  This unit was almost completely apart at Maryland.  Maybe due to extra vibration on top or that unit may not have been tightened correctly or lock washers left off?

4.  We had to gusset the left lower weldment at Maryland due to a weld seam failure.  New parts were made, including a a 1/4" oversized plate (1.25 x 2") to overlap the weld seam and give a surface to lay an encircleing weld beam.  Parts got welded by Dave Vadas' friend Greg Speckler - nice job.  Got painted black and packed for Atlanta in the withholding box.  Drill and tap the two holes in Atlanta.

5.  Worked with design guys to come up with shooter hood design concepts.  Two most likely are either a aluminum bar structure over top or a 1/16" plexiglass hood on ~30 degrees.  Both ideas should help control the ball spread when shooting.  This should be a good addition to the spring steel side bands that got added in Maryland as well.  We are packing aluminum 3/4 light gage angle to fab in Atlanta for option one, and we bent up a piece of 1/16" plexi 24" wide with 12"  legs for mounting flexibility.  Both designs can mount to the frame uprights.

6.  Packing heavy gage .093" 1 x 1 angle if needed to re-enforce the chassis angle that is bending slightly.  This is giving us some wheel toe in.

 List for Atlanta  - Discussed at Wednesday night meeting on 15th 

1.  Replace left front weldment - 10-15 mins tops.

2.  Mock up shooter hood and or bar concept - in between other activities.  Actual mounting will take 10-15 minutes.

3.  Re-do center top rear divider - string and zip ties don't look like it was well thought out.

4.  Re-do ball hopper top edge fastening - velcro is loose, etc.

5.  Grease bearings and chains, check sprocket alignment and cahin tension.

6.  Evaluate more pluckers for shooter.

7.  Verify rotations of spare motors.  Fix wiring or make short cross over leads.

8.  Check out chassis lower angle piece - replace or re-inforce as required.

9.  C'Sink mouse pivot bolt and replace with flat head screw.

Priority at Atlanta - set Thursday Morning on 16th 

1.  Mouse - hanging up.  Made new plastic washer, lube pivot and adjust clamp load.  -  Done.  Did not c'sink the pivot screw.

2.  Weldment swap out. - Done

3a.  Drive train chassis bent angle - OK as is, just monitor.

3b.  Grease and oil got done first.  Then alignment and tension - done

4.  Evaluate shooter hoods and bars.  Went with bar construction.

5.  Verify motor rotations - Done

6.  Hopper fastening - went with inverted "V" across back and short angle pieces on the rear corners - Done.

7.  Add more pluckers to shooter to fill in the gaps.  One each from the outside in and the inside out total of 4 - got started and put on hold.  A couple of pilot holes were drilled.

Added at the end of the day.

8.  Replace front conveyor transmission- inspect for wear, etc.  Unit was replaced.  Unit that was removed was tore down and inspected - only slight wear, cleaned, adjusted endplay, and repacked with fresh grease.  Complete description with unit numbers on motor log sheet.  

9.  Discussion on replacing worn top pluckers - not done, leave as is.

At Atlanta Friday 17th 

1.  Took some hard hits in the front, bent lower plucker shaft bracket and pushed shaft in about 3/4" on left side.

2.  Next match front drive chain came off.  REadjust lower shaft and chain drive chain tension for front shaft.

3.  End of the day - noticed one of the center belts had a little slit in it.  Cut it out and rejoined it on the robot.  Also made a spare belt at same time.

4.  Cart handle quick release block did fracture.  Installed spare - maybe should make it out of aluminum or steel or machine nylon.

At Atlanta Saturday 18th

1.  First thing early AM, we washed all the belts and roller shafts to remove aluminum smut and dirt, using shampoo and water on a rag.  Belts seems to have better grip and track better also.