AndyMark Climber in a Box

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Summary

Assemble Hook

Align Hook Plates and Spacers

Align hook plates and spacers, using the hook as a drill guide for subsequent steps.

Secure Hook Plates

Insert and secure screws through plates and spacers with nuts.

Pre-Assemble Winch Plates

Align Winch Plates and Spacers

Align winch plates and spacers on the outer-most box tube.

Secure Winch Plate Assembly

Loosely attach winch plates with screws and nuts.

Pre-Assemble Bearing Plates

1.5 Bearing Plate Assembly

Align 1.5" bearing plates and spacers, then loosely secure with screws and nuts.

2.0 Bearing Plate Assembly

Align 2.0" bearing plates and spacers, then loosely secure with screws and nuts.

Drill 2.0 Box Tubes (2 Stage Only)

Prepare and Secure Bearing Plate

Align bearing plate with box tube edge and tighten screws.

Drill Holes for Winch Plate

Drill holes for winch plate alignment on both sides and opposite face.

Enlarge Rope Hole

Use a step drill bit to enlarge the hole for the rope.

Drill 1.5 Box Tubes

Initial Tube Drilling

Align bearing plate, tighten screws, and drill initial holes.

2-Stage Climber Specific Drilling

Drill additional holes for the 2-stage climber bearing plate.

1-Stage Climber Specific Drilling

Drill additional holes for the 1-stage climber winch plate.

Drill 1.0 Box Tubes

Align and Secure Hook Assembly

Align hook assembly with box tube edge and secure.

Drill Hook Assembly Holes

Drill holes for hook assembly on both sides and adjacent faces.

Main Assembly Steps

Install Springs and Clamp Blocks

Screw springs into 1.0" tube and attach clamp blocks to 1.5" tube.

Secure Rope and Attach Blocks

Tie rope securely and attach spring/clamp blocks to the 1.5" tube.

Connect Bearing Plates and Tubes

Attach bearing plate assembly and connect 1.0" tube to 1.5" tube.

Assembly Continued

Install Slider Blocks

Insert slider blocks into pockets and secure with screws.

Assemble Bearings and Secure

Assemble spacers, bearings, and secure the assembly with a nut.

Connect 2-Stage Climber Components

Connect 1.5" tube assembly into the 2.0" tube for 2-stage climbers.

Winch and Bearing Assembly

Attach Winch Plate Assembly

Attach the winch plate assembly to the outer stage tube.

Install Rope Guide

Insert screw and spacers to guide the rope through the hole.

Install Bearing into Plate

Press bearing into bearing plate and secure with screws.

Final Assembly Steps

Secure Rope and Gearbox

Secure the rope to the spool and add the gearbox.

Attach Hook Assembly

Add remaining spacers and screws to complete the hook assembly.

The provided document is an assembly guide for the "Climber in a Box" product from AndyMark, designed for use in robotics, likely for the FIRST Robotics Competition (FRC). This guide details the components and steps required to assemble both 1-Stage (am-4667) and 2-Stage (am-4668) versions of the climber.

Function Description

The AndyMark "Climber in a Box" is a modular and customizable climbing mechanism for robots. Its primary function is to enable a robot to ascend a vertical or angled structure, typically a "rung" or "bar" in a competition game. The system utilizes a winch-and-rope mechanism to pull the robot upwards, with a hook assembly engaging the climbing structure. The modular design allows for either a single-stage or a two-stage extension, providing flexibility in reach and climbing height. The constant force springs assist in the extension and retraction of the stages, while slider blocks and bearing plates guide the movement of the telescoping tubes. The winch system, powered by a gearbox (not included but mentioned for selection guidance), winds a Dyneema rope, lifting the robot. The design emphasizes ease of assembly and adaptability, with components serving dual purposes as drill guides to simplify fabrication.

Important Technical Specifications

The "Climber in a Box" system is built around telescoping square aluminum tubes of varying dimensions:

Tube Sizes:
- 1 x 1 x .063 30IN Square Tube (am-4203-30)
- 1.5 x 1.5 x 0.063 30IN Square Tube (am-4669-30)
- 2.0 x 2.0 x 0.063 30IN Square Tube (am-4670-30) These tubes form the telescoping stages of the climber. The 1-stage version likely uses the 1.5" tube, while the 2-stage version incorporates the 2.0" tube as the outer stage and the 1.5" tube as the inner stage.
Hook Assembly (am-4660): Consists of two "Climber In A Box Hook Plates" (am-4654) and multiple 1IN 3/8 OD .192ID Aluminum Spacers (am-3876). Secured with 10-32 x 1.500 SHCS (am-1014) and 10-32 Nylock Jam Nuts (am-1063). This assembly is designed to be installed on the 1.0" box tube.
Bearing Assemblies:
- 1.5" to 1" Bearing Assembly (am-4661): Utilizes 1.5" Bearing Plates (am-4644), 1.5" 3/8 OD Round Spacers (am-1599), Plastic Spacers (am-1611), and 5/16 OD 1.5" long #10 Aluminum Spacers (am-1503). Features "Climber In A Box Inside Slider Block" (am-4629) and "Climber In A Box 1x1 Clamp Slider Block" (am-4630) for guiding the 1.0" tube within the 1.5" tube.
- 2.0" to 1.5" Bearing Assembly (am-4662): Utilizes 2.0" Bearing Plates (am-4645), 2.0" 3/8 OD Round Spacers (am-1600), Plastic Spacers (am-1610), and 5/16 OD 2.0" long #10 Aluminum Spacers (am-1582). Features "Climber In A Box Inside Slider Block" (am-4629) and "Climber In A Box 1.5x1.5 Clamp Slider Block" (am-4631) for guiding the 1.5" tube within the 2.0" tube.
Bearings: Primarily 608 Bearings (am-4456) are used in the bearing plate assemblies, with a 500 Hex HD Bearing (am-2986) for the winch spool.
Fasteners: A variety of 10-32 screws (SHCS, BHCS, FHCS) and nuts (Nylock Jam Nut, Jam Nut) are used throughout the assembly. Washers (#10 Washer, 5/16" Hardened Steel Washer) are also specified.
Springs: Constant force springs (am-4657) are crucial for the extension and retraction mechanism, ensuring smooth movement of the telescoping stages.
Winch Assembly (am-4663): Includes "Climber In A Box Winch Plate" (am-4646), 1.125IN Bearing Plate (am-3722), 1.5" or 2.0" 3/8 OD Round Spacers (am-1599/am-1600), and 10' Silver Dyneema Rope (am-4559). The winch spool is made of "Climber In A Box Winch Spool Half" (ip-4647). Spacers of various lengths (.250 long, 1.313 long) are used to guide the rope.

Usage Features

Modular Design: The "Climber in a Box" can be configured as a 1-stage or 2-stage climber, allowing teams to choose the appropriate reach for their specific competition needs. The 1-stage version uses 1.5" tubes, while the 2-stage version adds 2.0" tubes as the outer stage.
Telescoping Action: The system utilizes telescoping square aluminum tubes, guided by slider blocks and bearing plates, to extend and retract.
Spring-Assisted Movement: Constant force springs are integrated to assist in the extension and retraction of the stages, providing a controlled and potentially faster deployment/retraction.
Winch-and-Rope System: A Dyneema rope is wound onto a winch spool, which is driven by a gearbox (user-supplied). This mechanism provides the lifting force for the robot.
Integrated Drill Guides: A key feature for ease of assembly is that several components, such as the hook plates and bearing plate assemblies, double as drill guides. This eliminates the need for complex measurements and specialized jigs, simplifying the drilling process for the box tubes.
Customizable Gearbox Integration: The guide mentions the need to choose a gearbox, indicating that the winch system is designed to be compatible with various motor and gearbox combinations, allowing teams to optimize for speed, torque, and weight.
Rope Management: Specific spacers are used in the winch assembly to guide the Dyneema rope, ensuring smooth winding and preventing tangles. The 2-stage climber uses an additional 0.5" spacer to accommodate a longer rope.
Secure Hook Engagement: The hook assembly is robustly constructed with multiple spacers and fasteners, designed to securely engage climbing structures.

Maintenance Features

While the document primarily focuses on assembly, some aspects imply maintenance considerations:

Dyneema Rope: Dyneema rope is known for its strength and durability, but like any rope, it will experience wear and tear. Regular inspection for fraying or damage would be necessary, and replacement of the 10' Silver Dyneema Rope (am-4559) would be a straightforward process.
Bearings: The system uses multiple 608 Bearings (am-4456) and a 500 Hex HD Bearing (am-2986). Bearings are wear items and may require periodic inspection for smooth operation. Replacement of these standard bearings is generally simple.
Fasteners: The extensive use of Nylock Jam Nuts (am-1063) suggests a design intent for vibration resistance and secure connections, reducing the likelihood of fasteners loosening during operation. However, routine checks of all fasteners for tightness would be good practice.
Slider Blocks and Bearing Plates: These components guide the telescoping tubes. Inspection for wear, damage, or excessive friction would be important to ensure smooth operation of the stages. The modular nature of these parts means individual components could be replaced if damaged.
Tube Inspection: The aluminum box tubes should be inspected for dents, bends, or other damage that could impede the telescoping action. The drilling tips emphasize removing all chips and burrs, which is crucial for long-term smooth operation and preventing premature wear.
Springs: Constant force springs (am-4657) are critical for the climber's action. They should be inspected for deformation or damage. The warning about springs being sharp during uncoiling and handling also implies careful handling during any maintenance or replacement.
Gearbox and Motor: Although not included, the user-supplied gearbox and motor would require their own maintenance, as per the manufacturer's guidelines for those specific components. The guide's mention of choosing a gearbox suggests that the interface is designed to be adaptable, making gearbox replacement feasible if needed.