Nuisance V1 - Construction

I knew that I wanted to use the following parameters to give me an easy to build platform that would still be very flexible.

• Differential drive
• DC motors w/ integrated gearing
• R/C Monster truck tires and wheels
  
• Omniwheel rear wheel
• 2 levels. One for sensors and servos. One for power and electronics
• Plexiglas construction

Before building anything, I used Google SketchUp to do some CAD drawings to make sure everything would fit together the way I expected. It was good that I did this since it pointed out some places where I did not have enough room.

Much of this was drawn before I had the parts, so I based the drawings on whatever documentation I could find. Once the actual parts arrived, I had to adjust a few things.

• Swapped position of Axon and R/C receiver to give better access to Axon USB port.
• Replace slide switches with lever switches and added LEDs for indication
• Left off back bumper
• Moved standoffs supporting upper deck back from front edge so if a 3rd deck is added, the next layer of standoffs won't interfere with the sensor servos.
• Added a bolt-on front bumper that could extend out to the sides to cover the tires as well as the chasis.
• Added two power bus terminal near the front. One for common ground, and one for unregulated 6V.

I used Plexiglas since it was cheap and easy to work with. I cut the basic shapes on my tablesaw, and they used a drill press and coping saw to create the mounting holes for servos, electronics, and other hardware. The lower level is made with 5/16" Plexiglas, and the upper deck is made with 1/8". For the bolt-on bumper, I used 3/16". I got all the Plexiglas from the scrap bin of the local plastics fabricator for very little cost.

Everything is connected using 4-40 hardware wherever possible. The breadboard is attached with velcro so it can be removed easily to access the Omniwheel mounting underneath. Batteries are also attached with velcro. Anywhere that wires need to pass through a layer, I used rubber grommets in the holes to protect the wires.

The Omniwheel is attached with 1/4" threaded rod and brackets made from steel strapping. The brackets are attached to the Plexiglas with 4-40 bolts and locknuts that are countersunk into the top of the Plexiglas so as not to interfere with the breadboard.

The R/C receiver did not have any holes or attachment points, so I built a strap out of brass and bolted it down with that.

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