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You can easily shape wood using rasps and files. If the shaping you need to do is extensive like creating a circle in the middle of a large plank you may want to consider getting a rasp
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118 BUILDING A BASIC WOODEN PLATFORM
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for your drill motor. They come in various sizes and shapes. You ll want the shaped wood to be as smooth as possible, both for appearance s sake and so it s easier to attach other wood pieces or components of the robot to it. A medium-grit sandpaper is fine for the job. Add a coat of paint to the wood when you re done. Silver, gloss black, or some other high-tech opaque color are good choices. The paint also serves to protect the wood against the effects of moisture and aging.
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Building a Wooden Motorized Platform
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Figures 9.1 and 9.2 show approaches for constructing a basic square and round motorized wooden platform, respectively. See Table 9.1 for a list of the parts you ll need. To make the square plywood platform shown in Fig. 9.1, cut a piece of 3/8- or 1/2-inch plywood to 10 by 10 inches (the thinner 3/8-inch material is acceptable if the plywood is the heavy-duty hardwood variety, such as that used for model ships). Make sure the cut is square. Notch the wood as shown to make room for the robot s wheels. The notch should be large enough to accommodate the width and diameter of the wheels, with a little breathing room to spare. For example, if the wheels are 6 inches in diameter and 1.5 inches wide, the notch should be about 6.5 by 1.75 inches. To make a motor control switch for this platform, see the parts list given in Table 8.3 of in Chap. 8. Figure 9.2 shows the same 10-inch-square piece of 3/8- or 1/2-inch plywood cut into a circle. Use a scroll saw and circle attachment for cutting. As you did for the square platform, make a notch in the center beam of the circle to allow room for the wheels the larger the wheel, the larger the notch.
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FIGURE 9.1
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Cutting plan for a square plywood base.
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BUILDING A WOODEN MOTORIZED PLATFORM
Cut circle
Center hole
FIGURE 9.2 Cutting plan for a round plywood base.
TABLE 9.1
PARTS LIST FOR WOOD BASE
Robot Base: 1 Misc 10-inch-by-10-inch plywood (3/8- or 1/2-inch thickness) 1-inch-by-10/24 stove bolts, 10/24 nuts, flat washers
Motor/drive: 2 2 1 2 1 Misc DC gear motors 5- to 7-inch rubber wheels 1 1/4-inch caster 2-by-4-inch lumber (cut to length to fit motor) Four-cell D battery holder 3-inch-by-10/24 stove bolts, 10/24 nuts, flat washers (for motor mount) 1 1/4-inch-by-8/32 stove bolts, 8/32 nuts, flat washers, lock washers (for caster mount)
ATTACHING THE MOTORS
The wooden platform you have constructed so far is perfect for a fairly sturdy robot, so the motor you choose should be too. Use heavy-duty motors, geared down to a top speed of no more than about 75 rpm; 30 to 40 rpm is even better. Anything faster than 75 rpm will cause the robot to dash about at speeds exceeding a few miles per hour, which is unacceptable unless you plan on entering your creation in the Robot Olympics.
120 BUILDING A BASIC WOODEN PLATFORM
Note: You can use electronic controls to reduce the speed of the gear motor by 15 or 20 percent without losing much torque, but you should not slow the motor too much, or you ll lose power. The closer the motor operates at its rated speed, the better results you ll have. If the motors have mounting flanges and holes on them attach them using corner brackets. Some motors do not have mounting holes or hardware, so you must fashion a holddown plate for them. You can make an effective hold-down plate, as shown in Fig. 9.3, out of wood. Round out the plate to match the cylindrical body of the motor casing. Then secure the plate to the platform. Last, attach the wheels to the motor shafts. You may need to thread the shafts with a die so you can secure the wheels. Use the proper size nuts and washers on either side of the hub to keep the wheel in place. You ll make your life much easier if you install wheels that have a setscrew. Once they are attached to the shaft, tighten the setscrew to screw the wheels in place.
8/32 nut (Length determined by thickness of wood block)
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