# Details Motor Shaft Preparation
<img src="../images/motor_shaft_preparation_1_1.jpg" width="350"> <br>*Starting Point: Components for the motor shaft assembly.*

<img src="../images/motor_shaft_preparation_18.jpg" width="300"> <br>*End Result: Motor shaft, pulley and codewheel fully assembled.*

## Description
* this page describes how to prepare the the motor shaft assembly for the brushless actuator modules
* the aluminum motor pulley and the stainless steel motor shaft are bonded with Loctite 648<br>  [-> Bonding the Pulley to the Motor Shaft](#bonding-the-pulley-to-the-motor-shaft)
* the code wheel mount is installed and the code wheel is bonded to the mount<br> [-> Bonding the Codewheel](#bonding-the-codewheel)  

### More Information
* More information on the 3d printing: [Details 3d Printed Parts](details_3d_printed_parts.md#details-3d-printed-parts)  
* More information on the machined part: [Details Machined Parts](details_machined_parts.md#details-machined-parts)
* [PDF Drawing - Motor Shaft](../drawings/motor_shaft.PDF)
* [PDF Drawing Motor Pulley](../drawings/motor_pulley_at3_t10.PDF)
* [STL File - Codewheel mount for code wheel ordered from PWB](../stl_files/encoder_codewheel_pwb_mount.STL)
* [STL File - Codewheel mount for code wheel from kit](../stl_files/encoder_codewheel_kit_mount.STL)
* [STL File - Tool Motor Shaft Pulley Bonding](../stl_files/tool_motor_shaft_pulley_bonding.STL)
* [STL File - Tool Code Wheel Bonding](../stl_files/tool_code_wheel_bonding.STL)

## Bonding the Pulley to the Motor Shaft

<img src="../images/motor_shaft_preparation_1.jpg" width="300"> <br>*Motor shaft, motor pulley and tool for motor shaft bonding.*

<img src="../images/motor_shaft_preparation_1.png" width="300"> <br>*Make sure that the tool supports the pulley in the right position before bonding.*

<img src="../images/motor_shaft_preparation_1_2.jpg" width="300"> <br>*Measure the depth of the tool using the depth gauge of a digital caliper.<br>The depth should be around 6,6mm.*

<img src="../images/motor_shaft_preparation_1_3.jpg" width="300"> <br>*The distance between the tool and the end of the motor shaft should be about 26,8mm.*

<img src="../images/motor_shaft_preparation_1_4.jpg" width="300"> <br>*Clean the bonding surfaces with a cotton swab and ethanol.*

<img src="../images/motor_shaft_preparation_1_5.jpg" width="300"> <br>*Prepare some Locitite 648, tooth picks and cotton swabs.<br>Wear gloves to protect your skin.*

<img src="../images/motor_shaft_preparation_2.jpg" width="300"> <br>*Apply a thin layer of Locitite 648 onto the bonding surfaces.*

<img src="../images/motor_shaft_preparation_2_1.jpg" width="300"> <br>*Insert the motor shaft into the pulley and rotate it a bit.<br>Remove the excess Loctite from the bottom using a cotton swab.*

<img src="../images/motor_shaft_preparation_2_2.jpg" width="300"> <br>*Place the motor shaft and pulley on the bonding tool.<br>Make sure that the flats on the motor shaft are pointing upwards.<br>Remove the excess Loctite from the top using a cotton swab.*

<img src="../images/motor_shaft_preparation_3.jpg" width="300"> <br>*Make sure that the motor shaft vertical and fully inserted into the tool.<br>Let the parts cure at room temperature for a couple of hours.*

<img src="../images/motor_shaft_preparation_4.jpg" width="300"> <br>*Leave the parts on the tool, put them in an oven.<br>
Cure the bond for another couple of hours for full strength.*

<img src="../images/motor_shaft_preparation_5.jpg" width="300"> <br>*We cure the parts at 70 degrees celcius for about 3 hours.*

<img src="../images/motor_shaft_preparation_6.jpg" width="300"> <br>*The motor shaft and pulley assemblies are now ready and can be used for the next step.*

## Bonding the Codewheel
<img src="../images/motor_shaft_preparation_9.jpg" width="300"> <br>*Code wheel, code wheel mount, motor shaft with pulley and bonding tool.*

<img src="../images/motor_shaft_preparation_7.jpg" width="300"> <br>*There are two different sources for the code wheel. <br> A: Code wheel ordered from PWB / B: Code wheel from encoder kit. <br> Make sure to use the corresponding code wheel mount stl file.<br>[A: Codewheel mount for code wheel ordered from PWB](../stl_files/encoder_codewheel_pwb_mount.STL)<br>[B: Codewheel mount for code wheel from encoder kit](../stl_files/encoder_codewheel_kit_mount.STL)<br>All the other assembly steps are identical.*

<img src="../images/motor_shaft_preparation_8.jpg" width="300"> <br>*Place the code wheel on the code wheel mount and make sure it fits before you apply glue.*

<img src="../images/motor_shaft_preparation_8_2.jpg" width="300"> <br>*Make sure that the code wheel is fully seated, flat and doesn't wobble when you turn it.*

<img src="../images/motor_shaft_preparation_8_1.jpg" width="300"> <br>*Sometimes the codewheel doesn't sit flat on the surface because of residue from the 3d printing.<br> Use a flat screw driver to scratch off the residue from the corner of the part.*

<img src="../images/motor_shaft_preparation_10.jpg" width="300"> <br>*I find it easiest to bond the code wheel on the stator. <br> Insert the motor shaft with the flats downwards into the bearings of the stator.*

<img src="../images/motor_shaft_preparation_11.jpg" width="300"> <br>*Adjust the inner diameter of the codewheel mount with a 4mm reamer.*

<img src="../images/motor_shaft_preparation_12.jpg" width="300"> <br>*Place the code wheel mount on the motor shaft and align the teeth of the pulley and the mount.<br> Push the code wheel mount all the way down.*

<img src="../images/motor_shaft_preparation_12_1.jpg" width="300"> <br>*Check the distance between the end of the motor shaft and the mount.<br> The distance  should be around 2mm - it's fine if it's off by 0,1 or 0,2mm.*

<img src="../images/motor_shaft_preparation_13.jpg" width="300"> <br>*Prepare your code wheel with the print facing upwards. <br> Prepare the superglue, tooth pick, q-tipps and the bonding tool.<br>Use gloves to protect your skin from the superglue.*

<img src="../images/motor_shaft_preparation_8.jpg" width="300"> <br>***Important: The code wheel has to be mounted in the correct orientation.<br> The print on the code wheel has to be readable from the top as shown in the picture.***

<img src="../images/motor_shaft_preparation_14.jpg" width="300"> <br>*Apply a thin layer of superglue to the code wheel mount.<br> We use Loctite 406.*

<img src="../images/motor_shaft_preparation_15.jpg" width="350"> <br>*Place the code wheel on the mount and push it all the way down using the tool.<br> Hold for 30 seconds, gently remve the tool and wait a couple of minutes for the glue to cure.*

<img src="../images/motor_shaft_preparation_16.jpg" width="300"> <br>*Code wheel bonded to the code wheel mount.*

<img src="../images/motor_shaft_preparation_17.jpg" width="300"> <br>*Rotate the motor shaft and make sure that the code wheel is horizontal and doesn't wobble.<br> Remove the motor shaft assembly from the stator.*

<img src="../images/motor_shaft_preparation_18.jpg" width="300"> <br>*The motor shaft assembly is now ready for installation.*

---
## Step-by-Step Instructions

| Motor Preparation  | Motor Shaft Preparation | Encoder Preparation |Center Pulley Preparation|
| --- | --- | --- | --- |
| <a href="details_motor_preparation.md#details-motor-preparation"><img src="../images/motor_mod_1_1.jpg" width="200"></a>| <a href="details_motor_shaft_preparation.md#details-motor-shaft-preparation"><img src="../images/motor_shaft_preparation_18.jpg" width="200"></a>  | <a href="details_encoder_preparation.md#details-encoder-preparation"><img src="../images/encoder_1.jpg" width="200"></a>  |<a href="details_center_pulley_preparation.md#details-center-pulley-preparation"><img src="../images/pulley_preparation_1_1.jpg" width="200"></a> |

| Output Pulley Preparation | Shell Preparation | Actuator Module Assembly |Actuator Module Testing|
| --- | --- | --- | --- |
| <a href="details_output_pulley_preparation.md#details-output-pulley-preparation"><img src="../images/output_pulley_preparation_9.jpg" width="200"></a>| <a href="details_shell_preparation.md#details-shell-preparation"><img src="../../leg_2dof_v1/images/shells_1.jpg" width="200"></a>  | <a href="details_actuator_module_assembly.md#details-actuator-module-assembly"><img src="../images/actuator_module_open_1.jpg" width="200"></a>  |<a href="details_actuator_module_testing.md#details-actuator-module-testing"><img src="../images/actuator_module_1.png" width="200"></a> |

---
## More Details
| Details 3d Printed Parts | Details Machined Parts | Mechanical Tools and Consumables |Electronic Components and Tools|
| --- | --- | --- | --- |
|<a href="details_3d_printed_parts.md#details-3d-printed-parts"><img src="../images/3d_printed_parts_2.jpg" width="200"></a>|<a href="details_machined_parts.md#details-machined-parts"><img src="../images/machined_parts_1.jpg" width="200"></a>|<a href="details_tools.md#details-mechanical-tools-and-consumables"><img src="../images/tools_1.jpg" width="200"></a>|<a href="../../../electronics/details/details_components.md#details-electronic-components-and-tools"><img src="../../../electronics/images/components_tools_1.jpg" width="200"></a>|

---
## More Information
[Open Dynamic Robot Initiative - Webpage](https://open-dynamic-robot-initiative.github.io)  
[Open Dynamic Robot Initiative - YouTube Channel](https://www.youtube.com/channel/UCx32JW2oIrax47Gjq8zNI-w)   
[Open Dynamic Robot Initiative - Forum](https://odri.discourse.group/categories)  
[Open Dynamic Robot Initiative - Paper](https://arxiv.org/pdf/1910.00093.pdf)  
[Hardware Overview](../../../README.md#open-robot-actuator-hardware)  
[Software Overview](https://github.com/open-dynamic-robot-initiative/open-dynamic-robot-initiative.github.io/wiki)  
[Back to Actuator Module](../README.md)  
[Back to Top of Page](#details-motor-shaft-preparation)

---
## Authors
Felix Grimminger

## License
BSD 3-Clause License

## Copyright
Copyright (c) 2019-2020, Max Planck Gesellschaft and New York University