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.

AndyMark Climber in a Box - Page 5