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mecanical_assembly.md

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Mechanical Assembly Guide

This project consists of five main subsystems that must be assembled to complete the system:

  • 4 pulleys
  • 4 winches
  • 1 frame
  • 1 payload
  • 1 homing tool

Once assembled, your build should look like the image below:

Table of Contents

  1. Bill of Materials (BOM)
  2. Frame Assembly
  3. Winch Subsystem
  4. Pulley Subsystem
  5. Completing the Frame
  6. Electrical Box
  7. Homing Tool
  8. Payload
  9. Final Assembly

1. Bill of Materials (BOM)

This project uses a combination of 3D printed parts, laser-cut plywood, and off-the-shelf components.

  • A 3D printer with a minimum bed size of 20cm x 20cm is required, capable of printing in PLA and TPU.
  • A laser cutter is needed for some parts.
Description Quantity Link
20mm x 1000mm aluminium extrusion 6
20mm x 1220mm aluminium extrusion 2
90° 3-way aluminium extrusion connector 4 Amazon
M5 x 5mm set screw 16
M5 T-nuts for 20mm extrusion 62
M5 x 10mm socket head screw 62
M3 x 6mm x 5mm brass insert 20
M3 x 10mm countersunk screw 4
M3 x 10mm socket head screw 20
M3 x 20mm socket head screw 6
M3 x 30mm socket head screw 2
M4 x 16mm socket head screw 4
M3 nut 8
M2 x 10mm socket head screw 4
M2 washer 4
6-32 x 1" machine screw 16
Aluminium hub for 6mm D-shaft 4 link
8lb braided fishing line 1 roll
Super glue small amount

File Resources

  • STL files for 3D printing: /doc/STL
  • STEP files for laser cutting or modification if you don't own a laser cutter : /doc/STEP

Access the full CAD model via Onshape:
Onshape Link

2. Frame Assembly

You will need to 3D print the parts in /doc/STL/Frame and laser cut the parts in /doc/STEP/Frame.

Required Parts

3D Printed

Name Quantity
Top_Frame1 2
Top_Frame2 2
Top_Middle1 1
Top_Middle2 1
Triangle1 4
Triangle2 4

Hardware

Name Quantity
M3 x 6mm x 5mm brass insert 16
M5 x 5mm set screw 12
M3 x 10mm socket head screw 4

Step-by-Step

Step 1

Assemble the 6 aluminium extrusions (1000mm) using the 4 corner connectors as shown below:

empty

You should now have a basic frame like this:

empty

Secure the extrusions in place with the M5 set screws.

Step 2

Install the triangle brackets using M5 x 10mm screws and loosely attached T-nuts. Align the T-nuts with the extrusion slots, insert, and tighten.

Each corner should look like this:

empty

3. Winch Subsystem

3D print all the files in /doc/STL/Winch 4 times, but print the motor support variants only once each.

Required Components

Name Quantity
M3 x 6mm x 5mm brass insert 16
M3 x 10mm screw 16
M5 x 10mm screw 12
M5 T-nuts 12
6-32 x 1" screw 16
Aluminium hub for 6mm shaft 4

Step-by-Step

Step 1

Insert the brass inserts into the underside of the motor casing.

Step 2

Assemble the winch following this exploded diagram:

empty

Step 3

Attach each winch to the frame using M5 screws and T-nuts. Align with the slots and tighten at the desired height.

Final result:

empty

4. Pulley Subsystem

3D print each file in /doc/STL/Pulley 4 times.

Required Components

Name Quantity
M5 x 10mm screw 16
M5 T-nuts 16
M3 x 10mm countersunk screw 4
M2 x 10mm socket head screw 4

Step-by-Step

Step 1

Assemble each pulley using the exploded view:

empty

Note: Screws are driven directly into plastic; apply firm pressure if needed.

Step 2

Mount pulleys on the frame using M5 screws and T-nuts.

Final result:

empty

5. Completing the Frame

Steps

  1. Attach a Top_Frame1 to each side of a 1220mm extrusion.

  2. Repeat with Top_Frame2.

  3. Assemble as shown below:

    empty

  4. Insert brass inserts into Top_Middle1.

  5. Attach Top_Middle2 using M3 x 10mm screws.

Final frame:

empty

6. Electrical Box

Print each part in /doc/STL/Electrical_box. Modify as needed to fit your electronics.

Required Components

  • 2 M3 x 30mm screws

Steps

  1. Secure electronics using screws.
  2. Wire according to the diagram in /doc/Electrical.
  3. Mount the E-stop button on the cover.
  4. Insert two M3 x 30mm screws into each hinge side of the box.

7. Homing Tool

Print the parts from:

Laser print the parts from:

Step

Glue the 3D printed part onto the part labeled homing3.

Final result:

empty

8. Payload

The payload houses the Raspberry Pi, Pi-camera, and battery.

Files available here: /doc/STL/Payload

Recommended:

Print attachment parts in TPU for better flexibility (PLA is acceptable).

Required Components

Name Quantity
M3 x 6mm x 5mm brass insert 2
M3 nut 8
M3 x 20mm socket head screw 6
M4 x 16mm socket head screw 4

Steps

  1. Insert brass inserts into the top of the payload body.
  2. Slide the Pi camera into its holder and connect the cable.
  3. Assemble the payload using the exploded view:

empty

  1. Insert the battery into the upper compartment.
  2. Connect the Raspberry Pi to the battery and camera.

9. Final Assembly

You're now ready to string the fishing line.

Required Components

Name Quantity
Fishing line 1 roll
M2 washer 4

Step-by-Step

Step 1

Pass the fishing line through the winch pulley’s small hole. Use tweezers if needed. Tie a knot around a M2 washer to prevent slippage and wind ~2–3m of line onto the pulley. Repeat for all winches.

Step 2

Route the line through the pulleys and attachment holes. Tie knots and test their strength.

Congratulations

You’ve completed the full mechanical assembly.