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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.
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.
6” adjustable wrench
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.
*Caution should be taken as Threadlocker is toxic and contact with skin, eyes or mouth should be
avoided.
ENGR466 Integrated Design Project 4
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).
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.
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.
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.
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)
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.
7. Once the Holder (01-0006) is mounted tighten the 10-32X3/4 SHCS at the bottom of each Pivot
Tower (01-0001B).
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.
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.
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.
12. See Electronic Procedures for Wiring of the Solenoid and control of the Robot Drummer (01).