written by: openrov (sofar) - amazon web services · 2019-10-01 · step 1 — battery adapters...

OpenROV

Guide 5 - Battery TubesWe will now build the battery tubes for the ROV.

Written By: OpenROV (Sofar)

Guide 5 - Battery Tubes Draft: 2016-02-11Guide ID: 67 -

This document was generated on 2019-10-01 02:14:06 AM (MST).

© 2019 openrov.dozuki.com/ of 16

INTRODUCTION

You will be using many of the skills you have learned throughout the build process so far.

TOOLS:Acrylic Cement (1)Applicator for Acrylic Cement (1)Disposable Rubber Glove (1)Super Glue (1)Soldering Iron and Solder (1)Sand Paper (around 150 grit) (1)Helping Hands (1)Flush Cutter (1)Wire Strippers (1)Safety Glasses (1)2-Ton Epoxy 'Flowmix' (1)




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Step 1 — Battery Adapters

Next we will build the polyfuse adapter for the battery tubes.

Start by removing the paper backing from both sides of the acrylic pieces.

Super glue one of the positive battery terminals to the acrylic piece.

Be sure the smaller hole is in alignment with the gap in the piece. This will ensure the polyfuse fitswell.

When working with cyanoacrylate (super glue) it is recommended that you wear gloves, safetyglasses, and work in a ventilated area.




Step 2

Bend the leads of the polyfuse perpendicular to the fuse in opposite directions.

Place the polyfuse into the gap in the acrylic piece. The fuse leads should fit easily through theholes on each side of the adapter.

Place the other button terminal on the acrylic with the lead of the polyfuse going through the smallhole.

Make sure that the metal battery terminals aren't off center enough to keep the adapter from fittingin the battery tubes. Test fit them if you are unsure.

Use superglue to hold this button terminal in place.

Ensure that the polyfuse leads are not touching each other when packed into the gap!




Step 3

Bend the polyfuse leads onto the battery terminal and solder the terminals. It important that theterminals lay flat and the solder is not higher than the center off the terminal which could make thebattery connection intermittent.

Be careful when soldering the battery terminal as it will be very hot.

Repeat this process for the other battery adapter.




Step 4 — Battery Terminals

Sand down the top of the base of the spring terminal. Do a corner that is adjacent to the smaller ofthe holes.

Solder on a glob of solder on the sanded portion of the spring terminal.

Do this for both battery terminals.




Step 5

Place the internal structure into the shell.

This is for measurement and alignment purposes for the following steps. Do not place your shellpermanently onto the motor structure just yet.




Step 6 — Rear Battery Endcap

Align the round irregular shaped piece with the holes in the square piece.

Cement together and set aside, the rest will not be cemented until the battery wires are routed.

When working with acrylic cement it is recommended that you wear gloves, safety glasses, andwork in a ventilated area.




Step 7

Grab your end cap piece and slide the starboard side wires through the hole. Make sure you slidethe piece on the wires, square piece first.

Slide the acrylic piece on with the wires going through the holes.




Step 8

Make sure your end cap is flushed against the shell and is next to the slit marked in image 1. Pullany slack from behind the end cap so it's a comfortable length without it being too taut.

Also make sure the acrylic is oriented as shown in image 1 with wires coming from bottom.

Hold that end cap piece at its designated length and drag along the circular pieces to it. Make sureit is concentric.

Acrylic cement the pieces together.




Step 9

Clip the negative wire around 1cm away from the acrylic piece.

Strip the negative wires.

Step 10

Slide on the spring terminal, with green wire through the larger hole.

Thread the spring terminal all the way to the acrylic pieces, threading the negative wire through thesmaller hole.

Bend the wires over the glob and solder it on.




Step 11

Grab one of your battery tubes and put an endcap on one end with the green wire going through.

Seal the end caps by cementing around the edge.

If the fit is tight, you can use sandpaper to sand the inside edge of the battery tube to bevel it (justlike you did for the main electronics tube).

Do the same steps for the port side battery tube.

Step 12

Sand one of the corners of the top of the button terminal.

On the topside of the terminal, solder a glob on the corner you sanded earlier.




Step 13

Apply two drops of super glue on opposite corners. This is important for making the potting stepeasier.

Then place the button terminal on the front end cap.

Step 14

Next, prepare the frame and batterytubes for epoxy. Hang the batterytubes over a table edge and withyour Tenda box, place the end capon top of it as shown.




Step 15

Begin epoxying the end caps, makesure the epoxy flows through theentire end cap where it is slightlyoozing up the wires.

When working with epoxy it isrecommended that you wear gloves,safety glasses, and work in aventilated area.

Allow the epoxy to cure for 4-6hours before working with it again.Allow the epoxy to cure for 24 hoursbefore using your OpenROV inwater.

Step 16

Next, we'll also fill the back side ofthe main endcaps around theprotruding parts of the syringesections.

Be careful not to allow epoxy toover-flow into the hole of the syringeas this will need to be clear for thesyringe plunger (which acts as apressure relief valve).




Step 17

Epoxy the other endcap at this timeas well.

Step 18

Apply epoxy to both front batteryend caps till it fills the concavespace of the button terminal.

If the epoxy is shooting back up onyou it's because there is no wherefor the air to escape because toomuch super glue was applied whengluing the terminal to the front endcap. Use a tooth pick to push theepoxy in and allow air to escape theenclosed space.

Allow the epoxy to cure for 4-6hours.




Step 19

Continue your build by progressingto Guide 6.




https://openrov.dozuki.com/Guide/Guide+6+-+Finishing/68

written by: openrov (sofar) - amazon web services · 2019-10-01 · step 1 — battery adapters...

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