AndyMark User Guide

System Overview

The 2012 AndyMark Drive System is designed for use in the 2012 FIRST Robotics Competition (FRC). This Drive System includes standard AndyMark products:

• 2012 C-Base Drive Chassis (am-0938)
• CIMple Box gearbox (am-0734)
• 6" HiGrip FIRST Wheels (am-0940)
• 3/8" bore wheel bearings (am-0209)
• #35 ANSI Roller Chain (am-0367) and masterlinks (am-0368)
• 26-tooth Sprocket (am-0737) and mounting screws (am-1123)
• 12-tooth Double Sprocket (am-0736) w/ spacers (am-0947, am-1181)

All of these parts are provided in kit form. Assembly instructions can be found in this manual, and online. CAD files and more detailed layout drawings can be found at www.andymark.com.

AndyMark also offers additional parts for FRC teams. Please see the website for more details:

• Battery Plugs (am-0122)
• 9015 Motor (am-0912) - www.andymark.com/product-p/am-0912.htm
• PG71 Gearmotor (am-0914) - www.andymark.com/product-p/am-0914.htm

AndyMark, Inc. Background

AndyMark was founded in 2004 by Andy Baker and Mark Koors to design and sell unique mechanical parts for the competition and educational robotics community. Recognizing the difficulty teams faced in sourcing fabrication resources, AndyMark grew to serve all 50 states and over 30 countries.

AndyMark is committed to supporting FIRST, having been an FRC program supplier since 2005 and its owners serving as FRC mentors since 1998. Understanding the demands of build season and competition, AndyMark works to meet customer needs and volunteers at FRC events.

For product information, visit www.andymark.com or email sales@andymark.com. While phone calls (877-868-4770) are welcome, emails are preferred during the busy January and February build season to improve efficiency. AndyMark wishes participants success in the 2012 FRC season.

2012 C-Base (am-0938) Bill of Material and Part Photos

Sprocket and Wheel Bill of Materials

2012 AndyMark Drive System Layout Drawing

The drive system can be configured in two main ways: NARROW (~27" wide) and WIDE (~37" wide).

The diagram shows the placement of various components on the C-Base chassis. Key components labeled include:

• C-Channels (am-0202) forming the base frame.
• Corner Connects (am-0212) used to join C-Channels.
• Spacers (am-0243, am-0244) used for wheel axle alignment.
• Cross Hex Tubes (am-0756) providing structural support.
• Nuts (am-1015, am-1054) and Screws (am-1053, am-1055, am-1058, am-1182) for assembly.
• CIM Motors (am-0255) mounted to the CIMple Boxes.
• CIMple Boxes (am-0734) which house the gearboxes.
• Sprockets (am-0736, am-0737) for chain drive.
• Wheels (am-0940) and Bearings (am-0209) for locomotion.
• Machine Keys (am-1121, am-1043) for shaft alignment.

Tip: The 2012 C-Base can be configured in a NARROW or WIDE setup.

Tip: If configuring the drive system for chain drive on all wheels, spacers can be installed in reversed positions to align chain with the double sprocket on the CIMple Box output shaft.

Tip: Ensure the double sprocket aligns with the wheel sprockets when wheels are placed with proper spacer locations.

CIMple Box Overview and Specifications

The AndyMark CIMple Box (am-0734) is a single-stage spur gearbox. Each FRC team receives two unassembled CIMple Boxes. Assembly instructions are available in this manual and online at www.andymark.com/product-p/am-0734.htm. Each box supports two 2.5" CIM Motors.

Specifications:

• Gear Profile: AGMA 6
• Gear specifics: 20 dp, 14.5 deg. pressure angle
• Gear material: cold-formed 4140 steel
• CIM Gear: 12 tooth (0.314” inside diameter with 2mm keyway)
• Large Output Gear: 56 tooth (1/2" hex bore)
• Gear Ratio: 4.67:1 (56/12)
• Output Shaft: 1/2" diameter 4140 steel shaft, 1/8" keyway
• 1/4-20 x 1/2" deep threaded hole at end
• Includes 1 machine key, washer, and 1/4-20 screw to capture shaft items.
• Housing material: Nylon 6/6 with Long Fiberglass Fill
• Shaft plate material: 5052 aluminum

CIMple Box (am-0734) Bill of Material and Part Photos

CIMple Box Assembly Instructions

1. Step 1: Press R6ZZ bearing (am-0516) into Housing (am-0739). Then, insert Output Shaft (am-0740) into bearing. Tip: Use an arbor press or tap with a wood block to avoid damaging the bearing.
2. Step 2: Insert 56 Tooth Output Gear (am-0742) onto Output Shaft (am-0740). Tip: The 1/2" hex hole in the gear should align with the 1/2" hex portion of the Output Shaft.
3. Step 3: Insert FR8ZZ Bearing (am-0030) into Shaft Plate (am-0738). Tip: Ensure the FR8ZZ flange is inside the housing. If it is on the outside of the plate, the bearing may fall out.
4. Step 4: Slide the Shaft Plate and FR8ZZ Bearing onto the Output Shaft. Align the four locating nubs on the Housing with the holes on the Shaft Plate.
5. Step 5: Attach the CIMple Box Housing to the Shaft Plate.
6. Step 6: Install 4 Nylock Nuts (am-1042) into the hex pockets on the back of the Housing. Screw a 10-32 x 5/8" screw (am-1120) into each nut. Tip: Hold the nut with a finger while driving the screw with a 5/32" allen driver.
7. Step 7: Insert the 2x2x10mm Machine Key (am-1121) into the CIM Motor keyway. Slide the 12x520 CIM Gear (am-0741) onto the motor shaft, almost touching the motor. Press the 5/16" Retaining Ring (am-0033) onto the motor shaft to secure the gear. Tip: Align the retaining clip's tongs with the keyway. Use a 3/8" socket driver to push the retaining ring into position.
8. Step 8: Slide the CIM Motor into one of the two motor locations on the Housing. Secure with two 10-32x5/8" Screws (am-1120). Tip: No additional thread-locking material is needed; the screws have pre-applied adhesive.
9. Step 9: Insert the 1/8x1/8x0.7" Machine Key (am-1043) into the Output Shaft keyway. Use a 1/2" Washer (am-1027) and Button Head Screw (am-1039) to capture the sprocket on the shaft. Tip: Use thread-locking adhesive on the screw to prevent it from backing out.

Drive System Assembly Instructions

1. Step 1: Decide whether to use the C-Base in a NARROW (~27" wide) or WIDE (~37" wide) setup.
2. Step 2: Build the C-Base frame by measuring and cutting C-Channel pieces (am-0202) to the desired length. If undecided, build a 37"x37" square chassis, noting it will be too wide for the 2012 FRC game but allows time for decision.
3. Step 3: Assemble Corner Connects (am-0212) onto C-Channels (am-0202) using 1/4-20 x 1.75 screws (am-1058) and 1/4-20 nylock nuts (am-1015). For NARROW, use 4 long C-Channels with 2 Corner Connects each. For WIDE, use 4 short C-Channels with 2 Corner Connects each.
4. Step 4: Assemble the frame. Insert 7" screws (am-1055) and spacers. One long spacer (am-0244) and one short spacer (am-0243) are installed on each axle to locate wheels. Lightly fasten the 3/8" nut (am-1054) on each 7" screw; this nut will be removed later. Tip: Position the middle axle hole lower than outside holes for better turning. For WIDE bases, ensure C-Channels are cut and installed so axle holes align.
5. Step 5: Prepare the Wheels. Press two bearings (am-0209) into each HiGrip wheel (am-0940). For a 4-wheel drive (WIDE base), all wheels use 26-tooth sprockets (am-0737), attached with 6 self-threading screws (am-1123). For a 6-wheel drive (NARROW base), four wheels have sprockets, and two do not. Tip: If configuring for chain drive on all wheels, spacers can be reversed to align chain with the CIMple Box output sprocket. Tip: Ensure the double sprocket aligns with wheel sprockets once wheels are in place with correct spacers.
6. Step 6: Install the wheels onto the C-Base as shown in previous steps.
7. Step 7: Attach CIMple Boxes (am-0734) to the C-Base.
8. Step 8: Install Cross Hex tubes (am-0756) using 1/4-20 x 1" Thread Forming Screws (am-1182). Tip: Use a 3/8" socket driver or wrench to drive the screws.
9. Step 9: Install 1/2" id Shoulder Washer (am-0947) and Machine Key (am-1043).
10. Step 10: Install the S35-12DHE Sprocket (am-0736) and 188x500 Spacer (am-1181). Use a 1/4" washer (am-1027) and 1/4-20 BHCS (am-1039) to hold the sprocket on the shaft. Tip: Use thread-locking adhesive on the screw to prevent it from backing out.

Chain Installation Tips

This kit includes #35 series roller chain (am-0367), which differs from bike chain in pitch. Bike sprockets are not compatible with #35 roller chain.

Step 1: Cut the chain to the required length, accounting for the masterlink (am-0368). Use a chain breaker, Dremel tool, or grinder for cutting. Ensure safety during cutting.

Step 2: Wrap the chain around the two sprockets on the robot. Position the chain ends for easy masterlink insertion. Tip: The example chain length is 19-7/8" (excluding masterlink), but your length may vary.

Step 3: Slide the masterlink into position, then place the flat plate and retaining clip. Ensure masterlink posts protrude past the retaining clip for proper function. Tip: If difficult, install the masterlink without the chain on the robot, then adjust CIMple Box position.

Additional chain and masterlinks are included for driving two wheels per CIMple Box.

Battery Plug Usage

Four plastic battery plugs (am-0122) are included in the 2012 AndyMark Drive System kit. These plugs serve as visual indicators for charged batteries and should not be used on uncharged batteries.

Procedure for using battery plugs:

1. Remove a charged battery from the charger.
2. Insert the battery plug into the charged battery's red connector.
3. Place the battery on a shelf; the plug indicates it is charged.
4. Remove the battery plug before installing the battery on the robot.
5. When removing an uncharged battery from the robot, do not re-insert the plug into it, to avoid confusion.

The plugs help distinguish between charged and uncharged batteries, preventing accidental use of depleted power sources.