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3.6 Fasteners
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Once you have decided upon the materials used to build your robot, you will now be left with the task of deciding how to hold them together. What do you think is the number one problem most robots have when they are brought out for a competition Most people would think of things like dead batteries or codes that can t work in the actual environment (problems with light background noise or the running surface), but it is very common for robots to fall apart or break because the different parts are not held together very well. Part of the problem is the use of an unsuitable material for the structure (like one that breaks during use), but the overwhelming problem is the use of inappropriate adhesives (glues) and fasteners for the robot s structural parts.
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FIGURE 3-3 Some of the different mechanical fasteners that can be used to hold different pieces of a robot s structure together.
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Fasteners is the generic term used to describe the miscellaneous nuts and bolts, nails, screws, and other devices that have been developed over the years to hold things together. Fig. 3-3 shows the operation of some common fasteners, and the more commonly used items are listed in the following sections.
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3.6.1 NUTS AND BOLTS
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Number 6, 8, and 10 nuts and pan-head stove bolts (6 32, 8 32, and 10 24, respectively) are good for all-around construction. Get a variety of bolts in 1 2, 3 4, 1, 11 4, and 11 2 in lengths. You may also want to get some 2 and 3-in-long bolts for special applications. Motor shafts and other heavy-duty applications require 1 4-in 20 or 5 16-in hardware. Panhead stove bolts are the best choice; you don t need hex-head carriage bolts unless you have a specific requirement for them. You can use number 6 (6 32) nuts and bolts for small, lightweight applications. Or for even smaller work, use the miniature hardware available at hobby stores, where you can get screws in standard 5 56, 4 40, and 2 20 sizes.
3.6.2 WASHERS
While you re at the store, stock up on flat washers, fender washers (large washers with small holes), tooth lock washers, and split lock washers. Get an assortment so you have a variety of nut and bolt sizes. Split lock washers are good for heavy-duty applications because they provide more compression locking power. You usually use them with bolt sizes of 1 4 in and above.
3.6.3 ALL-THREAD ROD
All-thread comes in varying lengths of stock. It comes in standard thread sizes and pitches. All-thread is good for shafts and linear motion actuators. Get one of each in 8 32, 10 24, and
3.6 FASTENERS
1 4-in 20 threads to start. If you need small sizes, hobby stores provide all-thread rod (typically used for push-pull rods in model airplanes) in a variety of diameters and threads.
3.6.4 SPECIAL NUTS
Coupling nuts are just like regular nuts except that they have been stretched out. They are designed to couple two bolts or pieces of all-thread together, end to end. In robotics, you might use them for everything from linear motion actuators to grippers. Locking nuts have a piece of nylon built into them that provides a locking bite when threaded onto a bolt. It is preferable to use locking nuts over two nuts tightened together.
3.6.5 RIVETS
An often overlooked method of fastening structures together is the blind or pop rivet. This fastener consists of a flanged aluminum tube with a steel rod running through it and a ball at the end. When the ball is pulled into the tube, the tube distorts and flares outward, providing two wide ends to hold together pieces of material. When a certain amount of tension has been placed on the steel rod, it pops off, leaving a permanent fastener that is quite a bit shorter over the surface of the material than nuts and bolts. Rivets are quite vibration resistant, and despite being labeled as permanent, they can be drilled out in a few seconds.
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