Dexter v1
(Assembly Manual)

Contents

Proper Assembly Area: ...................................... 3

Supplied Tools: .................................................... 3

I Base Assemble: ................................................ 4

Base Assembly Parts List: ............................... 4

Base Assembly Tool List: ................................. 4

A: Dry fit the parts in the following manner: ................................................................................ 6

B: Gluing .............................................................. 8

II Arm Body......................................................... 11

Arm Body Parts List: ....................................... 11

Arm Body Tools List:....................................................................................................................................................................... 11

A: Dry fit the parts in the following manner: ........................................................................................... 13

B. Attach the bearings ................................................................................................................................... 19

C. Gluing the strakes ..................................................................................................................................... 20

D. Attaching the 2 stepper motors to the assembly. ............................................................................ 21

III. Pivot ............................................................................................................................................................. 24

Pivot Parts List: ............................................................................................................................................... 24

Pivot Tools List: ............................................................................................................................................... 24

A: Dry fit the parts in the following manner: ........................................................................................... 26

B: Glue the parts in the following manner: .............................................................................................. 29

C: Mounting the Code Disk .......................................................................................................................... 32

E: Mounting the Arm Body motor and harmonic drive component. ................................................... 34

D: Mounting the Base motor and harmonic drive component. ............................................................ 37

F: Gluing the Pivot Assembly. ...................................................................................................................... 40

F: Glue Rig for the Pivot Assembly. ............................................................................................................ 45

IV. End Arm Hub Assembly ........................................................................................................................... 50

End Arm Hub Parts List: ............................................................................................................................... 50

End Arm Hub Tools: ........................................................................................................................................ 52

A: New Belt Pulley A & B: ............................................................................................................................. 53

B: Dry fit the parts in the following manner ............................................................................................ 55

C: Glue the parts in the following manner .............................................................................................. 60

D: Prepping the All-Thread Bolts ................................................................................................................ 77

E: Final End Arm Hub Assembly .................................................................................................................. 79

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V. External Gear Assembly ........................................................................................................................... 90

External Gear Parts List: ............................................................................................................................... 90

External Gear Tools: ....................................................................................................................................... 90

A: Finishing Nails and Strakes Insertion ................................................................................................... 92

B: Glue Strakes and Motor End Cap (G02A). .......................................................................................... 93

B: Motor Placement ........................................................................................................................................ 98

C: Attaching the External Gear to the Arm Body ................................................................................ 103

D: Attaching the Stator Gear to the External Gear ............................................................................ 104

VI. Differential ............................................................................................................................................... 106

Differential Parts List:................................................................................................................................... 106

Differential Tools:........................................................................................................................................... 107

A: Dry Fit components ................................................................................................................................. 108

VII. Attaching Arm Body and End Arm Hub ............................................................................................ 148

VIII. Attaching PIVOT to Base. ................................................................................................................... 154

IX. Attaching PIVOT to Arm Body. ............................................................................................................ 169

X. Attaching Differential and End Arm Hub ........................................................................................... 175

XI. Attaching Belts ........................................................................................................................................ 177

XII. Attaching Wire and First Light (open loop) .................................................................................... 182

XIII. Attaching the Wire Harness and Optical Encoders (closed loop) ........................................... 182

XIV. Connecting to DDE .............................................................................................................................. 182

XV. Fine Tuning the Optical Encoders ..................................................................................................... 182