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PhysicalBuild.adoc

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PhysicalBuild

Tiger Motor Flame 60A ESC programing cable removal mod

Using a 1.5mm hex tool unscrew the 4 bolts

ESCUnScrew
ESCUnScrewed

The housing should pull apart smoothly, and then carefully pick off the indicated epoxy.

ESCCoverRemoved
ESCGoopRemoved

Use a soldering iron to reflow and remove the indicated wires, then cover the pads with hotglue.

ESCWiresRemoved

While the hotglue is still got place the back cover back on firmly and hold for a few seconds to cool.

ESCBackPlate

Flip back over and reinstall the bolts.

ESCScrewsLoose

Arms

Solder motors to ESCs

  • 2 motors straight wired, 2 motors with 2 wires swapped. This supports the motor orientation to hard-wire their rotation. Make sure to add heat shrink around each solder joint.

ESCdiagram
ESCtoMotor

Extend power wires from ESCs

  • Add heat shrink around each solder joint

ESCpower

Attach Motor to motor mounts

  • Make sure to attach metal brackets prior to attaching motors

  • Loctite motor bolts and arm bracket bolds

Slide the plastic onto the bolt

BoltPlastic
MotorMount
MotorMountUpsidedown
4xMotorMounts

@TODO update image

motormount2
Note
Wear respiration PPE when cutting or drilling carbon fiber.

Cut arm to 18 inches:

armCut

Drill a hole to attach the hinge to arm. This hole should align with the hinge mounting holes - to align in, you can put the hinge in place and mark a drill point.

armDrill

Prepare the arm hinge 3D print by adding the brass inserts. Note the shorter brass insert is used to secure the long bolt through the arm, all the other brass inserts are the longer inserts.

armHingeBrassInsert1
armHingeBrassInsert2

Remove the bolt from the kit arms:

armHingeBoltRemove

Attach the prepared arm hinge using the long bolt to the end of the arm:

armHingeBolt

Attach mounted motors to end of arms

armAttach

Zip tie ESCs to the bottom of the arm and the wires against the arms:

armZipTie

Result 4x of these, 2 with swapped ESC / Motor wires:

@TODO image of finished arms

Body

Legs

Cut the thicker carbon fiber tube to match the length of the provided ones in the kit. Make sure the setscrews are installed if not look for them in a small plastic bag. Install the tube and tighten till the tubes won’t move/pullout.

legSetScrew
legSetScrew2
legSetScrewLower

Mount Legs

Unscrew leg brackets and attach them to the body

legBracket1

Reattach legs to brackets and connect set screw

legBracket2
legReattach1
legReattach2

Mount Arms

Prepare 3D printed arm clasps by inserting long brass inserts into mounting holes:

armClaspBrassInsert
  • Replace stock tarot frame arm locks with larger 3D printed arm clasps.

armMount

Attach built arms to attachment points in the body frame.

armBuiltAttach

@TODO missing image built arm attach

Keep in mind motor orientation. Motors A and C (1 and 2) should be using crossed ESC to motor wiring orientation, motors B and D should be straight. (See Quad motor letter example figure for arm labels).

armOrientation

Solder Hall Effect sensor (Mauch voltage sensor) to XT90 plug Verify hall effect sensor orientation. Arrow should be pointing away from the battery in, towards the quad

@TODO missing image hall effect sensor

Wire power to main power Route wires into permanent locations and make sure you have enough slack Hall Effect

wireRoute
wireRoute2

5 power and 5 ground into 1 power 1 ground → PL-Sensor → Anti-spark connectors. Add heavyduty heat shrink around joints and stow wires

wireStow

Result:

wireResult

Battery Tray

Add Battery Tray Attach tray hangers to body (metal payload brackets go inside of 3D printed parts): @TODO need image

Add payload rails. The long bracket end should face towards the back of the quad (weight offsets the payload)

@TODO need image

Attach left and right battery brackets using axils and crossbeams to stabilize separation between tray hangers. Use a battery to ensure that the mounting separation is correct. The battery should be fixed (not tight or loose) within the battery hangers and brackets.

BatteryTrayAttach

Add glue to axils and crossbeams

BatteryTrayGlue
BatteryTrayGlue2

@TODO need image of adding glue to axils

Mount top plate to body Top plate should face forward with mourning fins on the left and right side of the quad. The forward orientation of the plate has a notch for GPS mast clearance.

Make sure Mauch has enough slack

@TODO missing image Mauch slack check

Widen holes in body to accept bolt

WidenHoles

Screw top plate to body with rubber dampeners sandwich between top plate and body

screwTopPlate
screwTopPlate2

Mount pixhawk Tape Pixhawk down to secondary top plate in corners

TapePixhawk

Glue secondary top plate to top plate with vibration gel

@TODO need image

Assemble Raspberry pi

pi

Solder in mounting leads

piHatSolder

Wire indicator LED to hat (LED should have note facing forward)

PiLedResistor

Solder power jumpers

piHatJumper

Attach to Raspperry PI using plastic standoffs

PiStandoff

Ziptie down Raspberry pi Use large ziptie as “belt”, second small ziptie in corner

piZiptie

Ziptie down mauch power supply Small zip ties in 4 corners

mauchPowerZiptie

Wire mauch to pixhawk power 1 and power 2

mauchPixhawkPower

@TODO double check this image

Mount power button and wire to Mauch

powerButton

Wire hall effect sensor (voltage sensor) to Mauch

@TODO need image

Run ESC control lines to pixhawk The motor orientation shoudl already be set, but wiring the control lines tot he pixhawk must be done in the specified order: [A,C,D,B] → [1,2,3,4]

motorLayout

Wire telemetry and radio control to pixhawk, velcro to the bottom

@TODO need image

radio
telemetry

GPS

@TODO update images for new GPS MAST

Assemble GPS stand and mount to front corner of frame Glue together GPS stand structure. Verify length will fold down accommodating GPS wire length.

@TODO need image for GPS wire length

Attach stand structure to the bottom bracket (add tightener before screwing together):

Mount bottom bracket to the frame. Keep in mind the orientation of the bolt and angle of the GPS arm. The arm should tilt in towards the center but face forward and the bolt should face outward for accessibility. Be sure to add Loctite

Mount GPS device

Wire to Pixhawk GPS, lidar, etc

Wire to raspberry pi pixhawk uart, sba5 usb

Wire in LiDAR

LiDAR1
LiDAR2
LiDAR3
I2C 1
I2C