Objectives

Review “Base” Design

– Chassis
• Structure
• Geometry
• Material
• Examples
– Drivetrain
• Wheels
• Motors
• Transmissions
• Examples

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Lovely Professional University
 Chassis Design
• Review principles of chassis design
• Examine trade-offs
• Material
• Weight

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Lovely Professional University
 Chassis Function
• Provide platform for everything
– Strong
– Stable
– Well laid out and accessible
– Light
• Resist, defend against shock

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Lovely Professional University
 Weight
• Develop a weight budget and stick to it!
• Start coarse: chassis = 60 lbs, tower = 60 lbs
• Tip: parts far from the floor should be the lightest
• Refine:
– ie Chassis
• Frame
• Wheels
• Gearbox
• Controls
– Trade-off
• How many ½ inch diameter holes in .100 Al are needed for 1
pound?

200!
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Lovely Professional University
 CG
• Keep it Low!!
d
spread
sheet

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Lovely Professional University
Given the will, any configuration can
workSandeep Duran
Lovely Professional University
 Geometry
• Strength
• Space
• Accessibility

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Lovely Professional University
 Kit Chassis
(pictures available at www.innovationfirst.org)

• Advantages: lightweight, quick to build, uses standard parts

• Disadvantages: may not fit your design, requires added structure (that will most likely be put on
anyway)

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Lovely Professional University
 T-slot style

• Advantages: quick to build, standard parts, easy to create tension and to

add fastening points
• Disadvantages: heavy, expensive
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Lovely Professional University
 Welded Aluminum Tube & Plate

• Advantages: lightweight, strength, fits your design

• Disadvantages: takes time, requires skill, non standard parts

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Lovely Professional University
 Unique Drive Bases

• Advantages: fits your design, unique

• Disadvantages: takes much time, requires
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Lovely Professional University
 Chassis Materials
• Aluminum Extrusion
– 1/16” – 1/8”: usable but will dent and bend
– T-slot: use 1” sized profiles or higher
• Aluminum plates and bars
– 3/16” – ¼” used often
• Plastic Sheet
– Spans structures, provides bracing
– Polycarbonate (LEXAN, etc.) NOT Acrylic (Plexiglas, etc.)
• Wood
– Lightweight and easy to use
– Will splinter and fail but can be fixed
• Steel Tube and Angle
– Strong, but heavy, 1/16” wall thickness is plenty strong

Sandeep Duran
Lovely Professional University