Industrial Robot/Manufacturing Instructions

---

Open Section Fabrication and Assembly

Structure

Foundation

• [2] Main tubes

• [2] Support tubes

• [4] Raising Bars

• • Drill 3 holes in each bar (redone image TBD)

Media:Pillar.jpg

• [1] Plate

• • Drill 13 holes (redone image)

Media:IROverplate.jpg

Fasteners

• [12] Bar Bolts

• [4] Ground Bolts

• [4] Plate Bolts

Main Arm

• [1] Bar
  • Drill 18 holes

Media:MainArm.jpg

• [8] Bolts

• [8] Bolts

Forearm

• Perpendicular Plate
  • Drill 9 holes
  • Weld to tube

Media:ForearmPlate.jpg

• Tube

• Parallel Plate
  • Drill 9 holes
  • Weld to tube

Media:ForearmBar.jpg

• [8] Bolts

• [8] Bolts

Gearbox 1,2

• [2] Hydraulic Motor

• [1] Angle
  • Mark hole centers with a scriber, rule, nipple punch (for torch holes), and center punch (for drill holes)
  • Mark torch holes with a divider
  • Drill holes with 1/2" bit and cordless drill
  • Torch holes with torch cutter
  • Smooth with a file

Media:BaseAngle.jpg

• [2] Input Plate
  • Note: Location of motor mounting holes TBD
  • Mark hole centers with a scriber, rule, nipple punch (for torch holes), and center punch (for drill holes)
  • Mark torch holes with a divider
  • Drill holes with 1/2" bit and cordless drill
  • Torch holes with torch cutter
  • Smooth with a file

Media:IRGearbox12InputPlate.jpg

• [4] Side Plate
  • Mark holes with scriber, rule, and center punch
  • Drill holes with 1/2" bit and cordless drill
  • Smooth with a file

Media:IRGearbox12SidePlate.jpg

• [2] Cover Plates
  • Mark holes with scriber, rule, and center punch
  • Drill holes with 1/2" bit and cordless drill
  • Smooth with a file

Media:IRGearbox12CoverPlate.jpg

• [4] Outer Race Plate
  • Mark drill holes with scriber, rule, and center punch
  • Mark torch hole with scriber, rule, nipple punch, and divider
  • Drill with 1/2" bit and cordless drill
  • Torch with torch cutter
  • Smooth with a file

Media:IRGearbox12OuterRacePlate.jpg

• [2] Round Bar
  • Mark drill holes with scriber, combination set, and center punch
  • Drill with 1/2" bit and cordless drill
  • Tap with 1/2" - 13 taper/intermediate/plug taps and tap wrench

Media:IRGearbox12OutputShaft.jpg

• [4] Inner Race
  • Mark hole with scriber, combination set, nipple punch, and divider
  • Torch with torch cutter
  • Turn with lathe
  • Groove with lathe
  • Smooth with file

Media:IRGearbox12InnerRace.jpg

• [2] Output Hub
  • Mark hole with scriber, combination set, nipple punch, and divider
  • Torch with torch cutter
  • Turn with lathe
  • Groove with lathe
  • Smooth with file

Media:IRGearbox12OutputHub.jpg

• [2] Support Hub
  • Mark hole with scriber, combination set, nipple punch, and divider
  • Torch with torch cutter
  • Turn with lathe
  • Groove with lathe
  • Smooth with file

Media:IRGearbox12SupportHub.jpg

• [1] Loose Ball Bearings

• [12] Side Plate Bolts

• [12] Side Plate Nuts

• [4] Cover Plate Bolts

• [4] Cover Plate Nuts

• [4] O-ring Seal

• [4] Output Shaft Bolts

• [4] Lube Bolts

• [2] Input Gear

• [2] Output Gear

• [2] Key

Gearbox 3,4

Forearm Angle

• As shown below

Media:ForearmAngle.jpg

• As shown below

Media:WristAngle.jpg

• Input Plate

Media:IRGearbox3456InputPlate.jpg

• Note: Location of mounting holes for hydraulic motor unknown

• Side Plate

Media:IRGearbox3456SidePlate.jpg

• Cover Plates

Media:IRGearbox3456CoverPlate.jpg

• Outer Race Plate

Media:IRGearbox3456OuterRacePlate.jpg

• Output Hub

Media:IRGearbox3456OutputHub.jpg

• Output Shaft

Media:IRGearbox3456OutputShaft.jpg

• • Keyed

• Inner Race

Media:IRGearbox3456InnerRace.jpg

Gearbox 5,6

• Wrist Angle

• As shown below

Media:WristAngle.jpg

• Input Plate

Media:IRGearbox3456InputPlate.jpg

• Note: Location of mounting holes for hydraulic motor unknown

• Side Plate

Media:IRGearbox3456SidePlate.jpg

• Cover Plates

Media:IRGearbox3456CoverPlate.jpg

• Outer Race Plate

Media:IRGearbox3456OuterRacePlate.jpg

• Output Hub

Media:IRGearbox3456OutputHub.jpg

• Output Shaft

Media:IRGearbox3456OutputShaft.jpg

• • Keyed

• Inner Race

Media:IRGearbox3456InnerRace.jpg

Encoder Mount

• Encoder Mount Support Angle
  • Mark drill holes with scriber and rule
  • Drill holes with 1/2" bit, 1/4" bit, and cordless drill

Media:IREncoderMountAngleA.jpg

• Encoder Mount Main Angle
  • Mark drill holes with scriber and rule
  • Drill holes with 1/4" bit, 0.15" bit, and cordless drill

Media:IREncoderMountAngleB.jpg

• Encoder Mount Coupling
  • Turn with lathe and cutting tool
  • Mark thru- and mount holes with scriber, combination set, and center punch
  • Mark set hole with box square
  • Drill holes with 1/2" bit, 1/4" bit, and cordless drill

Media:IREncoderMountCoupling.jpg

Stepper Mount

• Stepper Motor Mount Angle
  • Mark holes with scriber, rule, and center punch

Media:StepperMotorMountAngle.jpg

• Stepper Motor Mount Plate
  • Mark holes with scriber, rule, and center punch

Media:StepperMotorMountPlate.jpg

• Shaft Bar
  • Mark thru hole with scriber, combination set, and center punch

Media:ShaftBar.jpg

Assemble Components

Assemble Gearboxes

Assemble Industrial Robot

• As shown below

Assemble Stepper Motor Mount

• As shown below, repeat for a total of 6 mounts

Connect Components

Hydraulic Connections

• 2 Axes Hydraulic Circuit

• Hydraulic Circuit

Electronic Connections

• As shown below