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2009

Isidore’s Revenge: Robot


Drummer – Manufacturing
Procedures

Daniel Partridge
ENGR466 Integrated Design Project
1/1/2009
ENGR466 Integrated Design Project 2
Isidore’s Revenge: Robot Drummer – Manufacturing Procedures

Objective
To outline the procedure to proper manufacturing of the mechanical components for “Isidore’s
Revenge” the robot drummer designed for George Tzanatakis as part of the ENGR466 Integrated Design
Project.

Parts
The following list of parts contains all the machined and purchased parts, along with the fasteners
required to construct the robot drummer.

Name Part Number Supplier Qty.


Main Base 01-0001A Machined 1
Pivot Tower 01-0001B Machined 2
Solenoid Tower 01-0001C Machined 2
Spring Tower 01-0001D Machined 1
Solenoid 01-0002 Digikey 1
Solenoid Connector 01-0003 Machined 1
Holder 01-0006 Machined 1
Spring Return Cap 01-0010 Machined 1
Delrin Shim 01-0014 Machined 1
1/4-20X3 Shoulder Bolt 01-0015 McMaster-Carr 1
M6 Fender 01-0016 McMaster-Carr 2
M6 Nut 01-0017 McMaster-Carr 3
Spring 3-1/8 ext. 01-0018 Canadian Tire (046-2084-0) 1
6-32X1/2 SHCS* 01-0019 McMaster-Carr 4
8-32X3/4 SHCS* 01-0020 McMaster-Carr 4
#8 Washer 01-0021 McMaster-Carr 8
10-32X3/4 SCHC* 01-0022 McMaster-Carr 5
#10 Internal Star-lock 01-0023 McMaster-Carr 5
Cymbal Stand 01-0024 McMaster-Carr 1
*SHCS – Socket Head Cap Screw
ENGR466 Integrated Design Project 3
Isidore’s Revenge: Robot Drummer – Manufacturing Procedures

Tools Required
The following tools are required for assembly of the robot drummer based on the fasteners used and
the conditions of the robot drummer’s use.

Medium Strength Threadlocker

Allen keys (Imperial)

9/64, 5/32, 3/16

6” adjustable wrench

Phillips (cross) head screw driver

Needle nose pliers

Hot glue gun

Special Instructions
All fasteners are to be attached using Medium Strength THREADLOCKER. Proper use of Threadlocker
requires a small amount of Threadlocker being applied to the threads of the fastener as shown in the
image below prior to insertion.

Figure 1: Application of Threadlocker on a Bolt

*Caution should be taken as Threadlocker is toxic and contact with skin, eyes or mouth should be
avoided.
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Isidore’s Revenge: Robot Drummer – Manufacturing Procedures

Procedure
1. Connect Spring Tower (01-0001D) to the Main Base (01-0001A) using one (1) 10-32X3/4 SHCS,
Socket Head Cap Screw, (01-0022) and one (1) internal star-lock washer (01-0023). Prior to
tightening fasteners ensure that the position of the spring mounting hole is perpendicular to the
length of the Base plate (shown in Figure 2).

Figure 2: Spring Tower (with Spring) and Main Base

2. Mount the two (2) Pivot Tower (01-0001B) to the Main Base (01-0001A) as shown in Figure 3,
using one (1) 10-32X3/4 SHCS (01-0022) and one (1) internal Star-lock washer (01-0023) each.
Keep fasteners loose until the pivot and pivot support bolt are attached. This will ensure proper
alignment of the pivot with the solenoid.

Figure 3: Pivot Towers and Main Base


ENGR466 Integrated Design Project 5
Isidore’s Revenge: Robot Drummer – Manufacturing Procedures

3. Mount the two (2) Solenoid Tower (01-0001C) to the Base Plate (01-0001A) as shown in Figure
4, using one (1) 10-32X3/4 SHCS (01-0022) and one (1) internal star-lock washer (01-0023) each.
Position the solenoid mounting holes on each of the Solenoid Towers (01-0001C) co-linearly.

Figure 4: Solenoid Towers on Main Base

4. Install the Solenoid (01-0002) as shown in Figure 5, using four (4) 8-32X3/4 SHCS (01-0020) and
various #8 washers (01-0021) as spacers to center the solenoid.
*Do not over tighten the fasteners as this will damage the solenoid. And ensure that Solenoid
wires are not caught between the Supports and the solenoid body.

Figure 5: Solenoid mounted to Solenoid Towers


ENGR466 Integrated Design Project 6
Isidore’s Revenge: Robot Drummer – Manufacturing Procedures

5. Prepare the Holder (01-0006) for installation by ‘press fitting’ the Delrin Shim (01-0013) through
the pivot hole using a manual press. Ensure alignment is straight to prevent damage to the
Delrin Shim (01-0013)

Figure 6: Holder with Delrin Insert

6. Attach the Holder (01-0006) to the Pivot Towers (01-0001B) using a 1/4-20X3 shoulder bolt (01-
0015) and a 1/4-20 Nylock nut (01-0016) by sliding the bolt through one of the Pivot Tower(01-
0001B) followed by passing the bolt through the Holder (01-0006) and then the final Pivot
Tower (01-0001-X) before adding the Nylock Nut (01-0016) *No Threadlocker required for this
application. The images Below (Figure 7) show the steps for assembling this portion of the
assembly.

Figure 7: Holder Assembly


ENGR466 Integrated Design Project 7
Isidore’s Revenge: Robot Drummer – Manufacturing Procedures

7. Once the Holder (01-0006) is mounted tighten the 10-32X3/4 SHCS at the bottom of each Pivot
Tower (01-0001B).

Figure 8: Tightening Fasteners after Installation

8. Attach the Spring (01-0018) to the Spring Tower (01-0001D) by first widening the loop at one
end of the Spring (01-0018) the needle nose pliers. This is done by grasping the loop in the
pliers and bending it so the end of the spring can pass through the hole in the Spring Tower (01-
0001D) once the end of the spring has been passes through spring return use the pliers to bend
the end. This will prevent the spring from sliding back out.

(a) Before (b) After

Figure 9: Spring Adjustments for Installation


ENGR466 Integrated Design Project 8
Isidore’s Revenge: Robot Drummer – Manufacturing Procedures

9. Attach the Spring (01-0018) to the Spring Return Cap (01-0010) this is done in the same manner
as mentioned above for the Spring Tower (01-0001D).
10. Once both ends of the spring are in place use glue, from the hot glue gun, to fill the holes in the
Spring Return Cap (01-0010) and the Pivot Tower (01-0001D). This will prevent the spring from
rattling at high speeds.

Figure 10: Hot Glue in Spring Mounting Hole

11. Attach the Robot Drummer (01) to the cymbal stand (01-0024) using three M6 (01-0017) nuts
and two M6 fenders (01-0016). First thread one M6 nut (01-0017) the entire length of the
thread on the cymbal stand (01-0024) and place one M6 Fender (01-0016) on top of it. Position
the Robot Drummer (01) on the Cymbal Stand (01-0024) through the mounting hole in the Main
Base (01-0001A) and placing the remaining Fender (01-00160 over the thread, and locking it in
place with the two remaining M6 nuts (01-0017). * No Threadlocker is required for this
application.

Figure 11: Underside of Main Base


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Isidore’s Revenge: Robot Drummer – Manufacturing Procedures

Figure 12: Top Side of Main Base

12. See Electronic Procedures for Wiring of the Solenoid and control of the Robot Drummer (01).

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