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builds:invisible_jet [2018/10/22 15:30]
prysk
builds:invisible_jet [2019/01/27 14:22] (current)
prysk
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 For 2018, the team consisted of myself, my friends Amanda and Max, and my brother David. We started on the kart right after the FRC and Battlebots seasons wrapped up (RIP Brutus). The only thing that changed for 2018 was the theme: we decided to build Wonder Woman'​s Invisible Jet plane. I think we're going all in on the airplane theme, expect an airplane themed cart every season from now on! (suggestions always appreciated). For 2018, the team consisted of myself, my friends Amanda and Max, and my brother David. We started on the kart right after the FRC and Battlebots seasons wrapped up (RIP Brutus). The only thing that changed for 2018 was the theme: we decided to build Wonder Woman'​s Invisible Jet plane. I think we're going all in on the airplane theme, expect an airplane themed cart every season from now on! (suggestions always appreciated).
 +
 +{{:​builds:​36064318_10214351866922867_3464131023917285376_n.png?​600|}}
 +
 +Final Conceptual stage before assembly.
 +
 +{{:​builds:​42603568_562654254153672_245132166042746880_n.jpg?​600|}}
 +
 +As it sat in the pit at Maker Faire NY
  
 **Construction** **Construction**
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   * Ground clearance: ugh   * Ground clearance: ugh
   * Going 15mph in something you built is both fun and terrifying   * Going 15mph in something you built is both fun and terrifying
 +  * Worry about all the things breaking, not just the steering, or the frame
  
 The biggest issue we ran in to was that the gearbox was still the bench test prototype: the gearbox plates were 1/8" 6061, and the jack shaft bearing blocks were Markforged plastic.[[https://​www.youtube.com/​watch?​v=WXhJ0nLqzSs|This led to multiple chain issues and ended with a bearing block melting into a bearing.]] The biggest issue we ran in to was that the gearbox was still the bench test prototype: the gearbox plates were 1/8" 6061, and the jack shaft bearing blocks were Markforged plastic.[[https://​www.youtube.com/​watch?​v=WXhJ0nLqzSs|This led to multiple chain issues and ended with a bearing block melting into a bearing.]]
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 Gearbox work. Replaced the Markforged plastic bearing blocks with CNC'd aluminum blocks, and a longer output shaft. Immediate improvement,​ much less flex in output. With properly spaced output shaft, no longer have issues with bolts coming out.[[https://​www.youtube.com/​watch?​v=5VCEGFOLO5A|Noticeable difference in testing.]] Gearbox work. Replaced the Markforged plastic bearing blocks with CNC'd aluminum blocks, and a longer output shaft. Immediate improvement,​ much less flex in output. With properly spaced output shaft, no longer have issues with bolts coming out.[[https://​www.youtube.com/​watch?​v=5VCEGFOLO5A|Noticeable difference in testing.]]
  
-{{ :​builds:​42796945_1180676058750765_3239628900057219072_n.jpg |}}+{{:​builds:​42796945_1180676058750765_3239628900057219072_n.jpg?600 |}} 
 +{{:​builds:​42833646_255946574998243_5609846614270148608_n.jpg?​600|}}
  
 __**October 6-7**__ __**October 6-7**__
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 Steering work. Replaced column with solid shaft. Replaced Markforged bushings with oil-infused brass bushings. Took apart and inspected/​greased/​oiled all the components. New shoulder bolts for the tie rod ends that go into the knuckles, to limit steering slop/play. Additionally,​ 10" slicks installed. Better ground clearance, though skids a lot in the school hallways. Will have to test on asphalt.[[https://​www.youtube.com/​watch?​v=y08IqKmj6aQ|Noticeable improvement in steering.]] Steering work. Replaced column with solid shaft. Replaced Markforged bushings with oil-infused brass bushings. Took apart and inspected/​greased/​oiled all the components. New shoulder bolts for the tie rod ends that go into the knuckles, to limit steering slop/play. Additionally,​ 10" slicks installed. Better ground clearance, though skids a lot in the school hallways. Will have to test on asphalt.[[https://​www.youtube.com/​watch?​v=y08IqKmj6aQ|Noticeable improvement in steering.]]
  
-{{:​builds:​43480485_889522587919447_6198155575025467392_n.jpg?​300|}}{{:​builds:​43299324_164731067784911_2039308020407599104_n.jpg?​300|}}{{:​builds:​43467035_1861453097266179_8918564869351931904_n.jpg?​300|}}+{{:​builds:​43480485_889522587919447_6198155575025467392_n.jpg?​600|}}{{:​builds:​43299324_164731067784911_2039308020407599104_n.jpg?​600|}}{{:​builds:​43467035_1861453097266179_8918564869351931904_n.jpg?​600|}}
  
 __**October 13-14**__ __**October 13-14**__
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 New VESC's came in. Replaced the e-bike controllers,​ additional noticeable difference. Regenerative braking is a nice plus to have: I like being able to let off the accelerator pedal and get quickly to a desired speed. Blew the fuse after turning regeneration on though, will have to install a diode to protect the fuse from the back current. The acceleration is brutal though. Will need better brakes as well. Neat-ified the wiring. More power poles, but much better run: less chance of catching fire or coming apart. [[https://​www.youtube.com/​watch?​v=d1wQODyQTKQ|Noticeable improvement in testing.]] New VESC's came in. Replaced the e-bike controllers,​ additional noticeable difference. Regenerative braking is a nice plus to have: I like being able to let off the accelerator pedal and get quickly to a desired speed. Blew the fuse after turning regeneration on though, will have to install a diode to protect the fuse from the back current. The acceleration is brutal though. Will need better brakes as well. Neat-ified the wiring. More power poles, but much better run: less chance of catching fire or coming apart. [[https://​www.youtube.com/​watch?​v=d1wQODyQTKQ|Noticeable improvement in testing.]]
  
-{{:​builds:​43951962_314718855974771_727734620069560320_n.jpg?​300|}}{{:​builds:​44027586_281460745828650_2761882284515655680_n.jpg?​300|}}+{{:​builds:​43951962_314718855974771_727734620069560320_n.jpg?​600|}}{{:​builds:​44027586_281460745828650_2761882284515655680_n.jpg?​600|}} 
 + 
 +(This is how David gets to work in the morning) 
 + 
 +__**October 20-21**__ 
 + 
 +No work 
 + 
 +__**October 27-28**__ 
 + 
 +Replaced the centrifugal clutch with a straight sprocket: wanted to get some testing in on difference between a centrifugal clutch and a direct connection. There'​s a lot more cogging than we'd like, but this might be due to not having the controller parameters right. 
 + 
 +In testing, we also came across another issue: mainly that we forgot to put a ground lead in the CAN cable between controllers,​ and the back EMF from one managed to blow the CAN chips on both up when trying to manually push it backwards. New controller chips have been ordered, and a ground lead has been installed. This is also a good excuse for me to just make the heatsink I've been planning for the VESC's for 3 weeks now. 
 + 
 +{{:​builds:​img_8156.jpeg?​600|}} 
 + 
 +__**November 3-4**__ 
 + 
 +No Work 
 + 
 +__**November 10-11**__ 
 + 
 +Finally got the motor controllers fixed and back in. Took the time to make the heatsink, it seems to be working nicely! Going to have to figure out a better retention method, a bit of VHB tape right now to hold it down for testing. 
 + 
 +{{:​builds:​img_8259.jpeg?​600|}} 
 +{{:​builds:​img_8264.jpeg?​600|}} 
 +{{:​builds:​img_8266.jpeg?​600|}} 
 + 
 +__**November 17-18**__ 
 + 
 +No Work 
 + 
 +__**November 24-25**__ 
 + 
 +New body concept and design work 
 + 
 +__**December 1-2**__ 
 + 
 +More concept and design work with some bodywork manufacturing starting 
 + 
 +__**Build on hold until end of FRC season**__ 
 + 
 +Good luck to all the teams! 
 + 
 +{{:​builds:​kart_2018_hopefully_not_broken_v11.png?​600|}}
builds/invisible_jet.1540240226.txt.gz · Last modified: 2018/10/22 15:30 by prysk