1 Welcome Letter

© REV Robotics LLC, 2023. Version 1.3

 WELCOME!
Welcome to the FIRST ® community! You are joining a great group of people who are all
working to promote and become the next generation of STEM professionals.

We founded REV in 2014 to bring new, innovative products to the educational robotics
community and to promote the next generation of STEM professionals. When designing
products for teams, these experiences are at the forefront of our minds. REV Robotics is
always working to create products that help more teams innovate, compete, and achieve
their goals.

Whether you are a rookie team just starting out, or a veteran team with over a decade
of experience, the FIRST ® Robotics Competition season kickoff brings new and unique
challenges every year. Here at REV Robotics, we understand that adapting to the game’s
challenges requires rapid iteration. We created the REV ION Build System to allow for
complex robot designs without large budgets or extensive manufacturing equipment,
using many of the basic tools that teams are already using for their build season.
While we use REV ION parts within the many examples in this booklet, we try to
present the engineering concepts in a way that is applicable to general robot design,
regardless of the system your team decides to use.

We hope this guide introduces you to some of the basic components and techniques used
within the FIRST Robotics Competition and serves as a great starting point as you begin
to build your robot. For more information or technical assistance, visit our website at
www.revrobotics.com or reach out to us via email at [email protected]

Good luck this season and see you at the competition!

Greg Needel and David Yanoshak

Co-Founders of REV Robotics

Table of Contents 2
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3 hi marcos
© REV Robotics LLC, 2023. Version 1.3
Table of Contents
Categories of Robot Parts 5
Hardware and Tools 6
Structure 7-10
Extrusion 7-9
Brackets 9-10
Structure Application Examples 11-12
Transmitting and Transforming Motion 13-19
Shafts 13-14
Sprockets and Chain 15-17
Belts and Pulleys 18
Gears 18-19
Gearboxes 20
Wheels 21-23
Supporting Motion 24-25
Constraining Motion 25
Drivetrains 26
Actuators 27-28
What’s Next? 29

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4
© REV Robotics LLC, 2023. Version 1.3
 Categories of Robot Parts
A robot is built from many various types of parts. All the parts on a robot can be broken down into the following
categories. This guide will explain each category, as well as provide some suggestions for building sturdy
structures and simple mechanisms.

Hardware and Tools

Hardware refers to the fasteners used to hold the structure together, such as screws, bolts, nuts, rivets, etc.

Structure
Structural parts are the framework to which all other parts are attached.
Strong geometry, like triangles, are a great foundation for a sturdy robot.

Transmitting and Transforming Motion

Sprockets, chain, belts, pulleys, and gears are used to transfer motion on the robot.
Differences in the sizes of gears and sprockets allow for changes to speed and torque.

Wheels
Wheels come in many varieties, each with their own unique features that make them useful not only for
robot propulsion, but also for mechanisms like intakes and manipulators.

Supporting and Constraining Motion

Parts, such as shaft collars and spacers, help restrict or constrain motion to the intended direction.
Unwanted motion hurts the accuracy and repeatability of the robot’s actions.

Drivetrains
Drivetrains are the base of most FIRST Robotics Competition robots. They are generally made of
wheels, gearboxes, motors, and structure. There are many different styles of drivetrains featuring
different components that will affect the maneuverability of the robot.

Actuators
Actuators, like motors, servos, and pneumatic cylinders, create motion on the robot.

There are other types of parts that go into creating a robot that won’t be discussed in this guide.
For more information on those parts, please see the “What’s Next?” section at the end of this guide.

5 Categories of Robot Parts

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Hardware and Tools
Teams participating in the FIRST Robotics Competition use hardware to connect, or fasten, brackets and
structure together on a robot. Different applications require different lengths and/or profiles of screws.
When attaching a bracket to aluminum extrusion, shorter screws with a low-profile head, like a button
head screw, are generally required. Longer screws are used to connect Control System components and
other thicker materials. Locking nyloc nuts are suggested to prevent the screws from loosening due to
vibrations as the robot moves.

Many different build systems, such as the ION Build System, have standardized hardware sizes in order to
cut down on the amount of hardware and tools teams need to keep on hand. Consider picking a standard
for your team, like #10-32, and using it throughout your robot.

See the “Structure Application Examples” section on pages 9-10 of this guide to find some ‘best practice’
tips for working with hardware.

We recommend these tools to start building your team’s toolbox:

• Nut Driver Set
• Drill Bit Set
• Hack Saw
• Hex Key Set
• Tap and Drill Set
• Metal Files
• Combination Wrenches
• Ratcheting Wrenches
• Screw Drivers
• Chain Tool
• Pop Rivets and Handheld Riveter

For more information on recommended tools, check out the Suggested Tools for FIRST Robotics
Competition Teams Guide, which can be found on the technical resources web page:
www.firstinspires.org/resource-library/frc/technical-resources

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 Structure
This section goes over all of the basic structure elements used in FIRST Robotics Competition. Here, we
give a comparison between T-Slot Extrusion and Patterned Extrusions, as well as a few tips and tricks
for anyone choosing to build with REV ION.

The majority of a robot’s structural elements can be divided into two main categories:
• Extrusion
- Patterned
- T-Slot
- Plain Stock
• Brackets
- Motion
- Structure

Extrusion
There are three primary types of structure pieces used when building a robot: T-Slot Extrusion, Patterned
Extrusion, and Plain Extrusion Stock. While they all have a few similar features, they each have
applications best suited for them.

Patterned T-Slot Plain Stock

• A fixed pattern of mounting • Slots allow for brackets to • Available in many
holes be placed anywhere profiles including square/
• Locations for mounting • Adjust design with ease rectangular tube, and
structure, gears, sprockets, • Good for linear motion C-channel
bearings, shafts, motors, • ION 1in Extrusion accepts • Ultimate choice for
and servos standard #10 Nuts and #10 customization, but it
• Good for a robot drivetrain Low-Profile Nyloc Nuts requires precise machining
• MAXTube accepts standard
#10-32 Hardware on 1/2in
pitch

Patterned Extrusion

Using patterned extrusion to build a sturdy drivetrain is a great start to building a robot.
Pre-drilled holes, often in a grid pattern, allow for the rapid iteration of a design without needing to
machine a new part. A wide variety of different patterns exist, each one with its own set of standards.
REV Robotics is just one of many manufacturers of patterned extrusion. Each team should evaluate the
different patterns available and decide which design best suits their robot based on the desired features.
Making sure that any types of patterned extrusion your team uses are compatable with each other will
save you time in the long run.

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The ION Build System has three options for patterned extrusion within the MAXTube line: MAXTube
with no pattern, MAXTube with Grid Pattern, and MAXTube with MAX Pattern. All 1in sides of the
MAXTube extrusion have a nut groove inside to fit #10 nuts, making assembly easier by helping to
retain nuts where a wrench can’t reach.

MAXTube with MAX Pattern features a combination of #10 clearance holes and a MAXSpline
Bore patterned every 2in. The #10 clearance holes are arranged on a common 1/2in pitch grid. MAX
Pattern frees teams from cutting and drilling, with easy installation of bearings for different live axle
applications, as well as correct center-to-center distances for simple 1:1 power transmission with #25
chain or RT25 belts.
MAXSpline is a shape unique to the ION System and is featured on many ION components. Learn
more about power transmission with MAXSpline in the motion section of this guide.

MAXTube’s Grid Pattern is featured on two sizes of MAXTube: 1x1 and 2x1. A grid of #10 clearance
holes are spaced along each side of the MAXTube on a 1/2in pitch.

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 T-Slot Extrusion

The flexibility of T-Slot Extrusion makes using it a great option for builds that won’t fit on the pitch
of your patterned extrusion. Teams are not locked into a pitch, so there are virtually infinite options
for mounting other components. T-Slot Extrusion is also a great option for adding linear motion to
your robot. T-Slot Extrusion is available in many sizes from different manufacturers, including REV
Robotics, 80/20, and Bosch. Each brand of T-Slot Extrusion has different features, such as compatible
hardware sizes, extrusion profiles, and linear motion guides.

When using ION 1in Extrusion, standard #10 Hex Nuts or #10 Low-Profile Nyloc Nuts will fit in the
slots, allowing teams to use a more commonly available option than specialized T-nuts.

Brackets

Brackets are used to join different parts of the robot together. Most brackets can be divided into two
categories: Motion and Structure. Motion brackets help create strong attachment points for your
motion components and any parts of your robot that move. Structure brackets are designed to hold
pieces of extrusion, flat stock, and other structural material together.

Motion Brackets

Many motion brackets have features specific to the components they are designed to work with,
and they often include special hole patterns for motors or different bores. The motion brackets you
use will heavily depend on the motion components you design into your robot. Be sure to check the
compatibility of your brackets with any other structure or components you are using on your robot.

In the ION Build System, motion brackets are referred to as MAXSpline Brackets. These brackets
feature the ION System’s signature MAXSpline shape, the core to transmitting motion. The major
distinguishing feature of MAXSpline Brackets are a MAXSpline Bore, or a full MAX Pattern to
support bearings and MAXHubs.

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MAXSpline Brackets that feature the MAX Pattern are designed to keep the pattern on pitch.

Structure Brackets

Structure brackets are designed to secure pieces of structure together at varying angles. There are
different hole patterns available to accommodate the different extrusion types and patterns. Within the
ION Build System, structure brackets are any bracket that does not have a MAXSpline Bore. ION 1in
Brackets are hole-aligned to maintain the pitch grid between your MAXTube.

When building a robot with hole-aligned brackets, you may notice an open space between the structure
ends, where they do not touch at the corner. This is expected and will not affect the strength of the joint.

Structure 10
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 Structure Application Examples
Check out the following tips and tricks, so you can quickly become a master robot builder.

3-4-5 Brackets
Triangles are a sturdy structural shape, commonly used on robots to support many types of mechanisms.
Vertical structures are very common and can be supported with a 90 degree, or “right” triangle.

Building a triangle out of patterned extrusion with a fixed pitch hole pattern can be difficult when trying
to ensure the holes remain on pitch across all sides and all angled brackets. For example, a simple right
triangle can be made with a set of 45, 45, and 90 degree brackets. However, the required lengths of
structure to form the triangle sides are irrational numbers, and therefore, the holes of the hypotenuse will
not align with the pattern of the other sides.

The ION Build System features 3-4-5 brackets specifically designed to have the exact angles to make up
a triangle with sides that are multiples of 3, 4, and 5 length units. In other words, the holes on all sides of
a triangle built with 3-4-5 brackets will line up on pitch. Count the number of spaces between holes for
each side of the triangle, and roughly cut the structure to length. In the example, each side is a multiple
of five spaces (1 unit), but that base unit will depend on the overall desired dimensions of the triangle.

How to Bolt Through a Tube

When bolting through a tube, be careful not to over-tighten the bolt. Doing so can cause the tube to
crush or deform. If you need to tighten the bolt for heavy-duty applications, be sure to support the tube
from the inside.

11 Structure Application Examples

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Rivets
Rivets are a popular alternative to nuts and bolts. By using a handheld riveter, you can secure brackets
and other components to a robot with one item.

Nyloc Nuts
Nyloc nuts have a built-in nylon collar that secures a screw with friction. As the nut is tightened, the
nylon collar deforms around the threads, creating a lock that is vibration-resistant. When using nyloc
nuts, make sure to thread the screw through the flat, threaded side first. This ensures that the nylon
collar of the nyloc nut will engage with the threads properly.

Joining Flat Stock or Brackets to Tube

There are three ways to attach flat stock or brackets to tube: (1) bolting through each wall of the tube
separately, (2) using rivets to attach each piece to the tube, or (3) using one bolt to attach all pieces.

Structure Application Examples 12

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 Transmitting and Transforming Motion
Transmitting Motion is the act of getting motion from one part of the robot to another using shafts,
sprockets, gears, belts, pulleys, etc.

Transforming Motion is the act of changing the turning force (torque) and speed. Torque and speed
are inverse to each other, meaning when one increases, the other decreases. Several of the same
components that transmit motion are also used to transform motion (sprockets and chain, belts and
pulleys, and gears).

Shafts
The core component to transmitting motion on a robot is a shaft. They come in many shapes and styles,
but the goal of each shaft is to transmit motion to other components.

One of the oldest and least commonly used shaft types is a D-shaft - a round shaft with one flat side that
makes a D shape. To transmit motion with a D-shaft, shaft collars and motion components are secured
to the flat side of the shaft using a set screw. Transferring torque through a set screw can cause failure
in high-torque applications, and the set screws require re-tightening under the best of circumstances, so
this method is generally not recommended.

Another shaft type commonly found on motors and gearboxes are Keyed Shafts. These consist of two
parts: a round shaft with a groove called a keyway, and a key that fits into that groove. Components
attached to keyed shafts will also have a keyway, as the key is how torque is transferred from the shaft.

A 1/2in Hex Shaft is the most common way to transmit motion in the FIRST Robotics Competition. The
six-sided shape provides reliable torque transfer and is commonly used with wheels, gears, sprockets,
and more.

13 Transmitting and Transforming Motion

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Sometimes when building with 1/2in hex shaft, it can be difficult to line up the shape within hex bore
elements because the corners must be perfectly aligned. 1/2in Rounded Hex Shaft is a popular variation
of 1/2in hex shaft. With the corners rounded to form a 13.75mm circle, 1/2in rounded hex shaft pilots
smoothly inside 1/2in hex bore components as well as standard 1.125in flanged bearings for an easy
assembly experience.

The last common style of shaft is the splined shaft. Splined shafts are identified by the shape of their
spline, often consisting of grooves or teeth that run down the length of the shaft and interlock with other
motion pieces. An example of a spline is the MAXSpline from the ION Build System. This hex-like
spline is incorporated into various motion components in the ION System; sprockets, gears, wheels,
shafts, etc. This unique spline shape combines bearing support with a torque transfer feature for added
configurability of motion components.

Transmitting and Transforming Motion 14

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 Motion Transmission Systems

The three primary motion systems used to transmit motion are: sprockets and chain, belts and pulleys,
and gears. Additionally, these systems are often configured in ways that simultaneously transmit and
transform motion.

Sprockets and Chain Belts and Pulleys Gears

• Good for transmitting • Smooth and efficient • Can be used for changing
motion over long distances • Can be lighter than gears rotation direction
• Changing sprocket sizes or sprockets that are • Compact
requires changing the chain traditionally made of metal • Flexible in adjusting speed
length and/or spacing • Changing pulley size and/ and torque
• Chain is forgiving in or spacing needs a new belt • Gear spacing is important
construction accuracy length
• Chain tension and wrap are • Belt tension and wrap are
important important

Sprockets and Chain

Sprockets and Chain are ideal for transmitting motion over long distances. A chain consists of a
continuous set of links that ride on the sprockets to transmit motion. The two most commonly used sizes
of chain in the FIRST Robotics Competition are #25 and #35. When choosing between chain sizes, it
is important to consider the pitch of the chain and the weight and forces that your mechanism will be
experiencing. The ION System is designed around #25 chain using compatible #25 sprockets.

15 Transmitting and Transforming Motion

© REV Robotics LLC, 2023. Version 1.3
Creating a loop of chain requires breaking off the correct number of links by removing a specific chain
pin and joining the ends together. Chain can be broken using many methods, including a chain tool or
various steel cutting devices, like a rotary tool. Once you have counted the number of links necessary
for your application, the chain can be joined using a master link or by replacing a pin. The diagram
below shows how a master link is assembled to replace an outer link joining two inner links.

Instead of using a master link, a #25 Chain Tool can be used to push out a pin and then push the pin
back in once the link has been formed for a stronger, but more difficult, joining method. For instructions
on how to break and reassemble the chain using this method, see the Chain Tool User’s Manual and
‘How-To’ video found on its product page on our website.

When creating your loop of chain, remember that properly tensioned chains should not be tight. If the
chain is too tight on your sprockets, it can waste energy, making your actuators work harder while causing
premature wear and damage. If the chain is too loose, it can slip off or skip teeth on the sprockets.

Transmitting and Transforming Motion 16

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 Transforming the torque and speed of motion with sprockets and chain is accomplished by changing the
size of the sprockets.

Chain Loops can be used with ION Sprockets and structure featuring the MAX Pattern. Any 1:1 ratio
will have the correct center-to-center distance for a properly tensioned chain, without the need for
tensioning bushings. To calculate how many links you will need, multiply the center-to-center distance
by eight, and add the number of teeth on one sprocket.
Links of #25 chain = (Center-to-Center Distance x 8) + Teeth in one sprocket

ION Ratio Plates are available as a part of the ION Build System to accomodate ratios other than 1:1
that would not usually fit on pitch. The ION Ratio Plates provide an offset from the standard MAX
Pattern that creates the correct center-to-center distance.

17 Transmitting and Transforming Motion

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Belts and Pulleys
Belts and pulleys are a great, lightweight option for building a smooth-running mechanism. They are
very similar to chain and sprockets, with the belt replacing chain and pulleys replacing sprockets.

The biggest difference is that belts are a set size and cannot be adjusted. If you want to change the
spacing of your pulleys or use a different size pulley to increase speed, you will likely need a different
sized belt.

In the ION Build System, we created a new standard of belt called RT25. Unlike many common metric
belt standards, RT25 Belts haves a 1/4in pitch just like #25 chain. With this pitch, both RT25 Belts and
#25 chain work natively within the ION Build System. The matching 1/4in pitch allows both systems
to be swapped out 1:1 for rapid prototyping and iteration of designs. The pitch compatibility with MAX
Pattern also makes it easier to swap in different belt lengths when you want to make changes. These belts
are comparable in strength to the belts that teams are accustomed to using while working on the same
pitch as the ION Build System.

Gears

Gears have teeth that mesh together in order to transmit motion. Gears offer more flexibility in
transforming motion than sprockets and chain or pulleys and belts because there are a larger variety of
gear sizes available.

Gears are ideal for use in more compact spaces and are also used for changing the direction of rotation.

Transmitting and Transforming Motion 18

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 Transforming the torque and speed of motion can be accomplished by changing the size of the gears.

To ensure that you have a proper amount of gear teeth mesh, it is important to calculate the center-to-
center distance in between your gears. You can do this by first calculating the pitch diameter (PD) of
each gear using some combination of module (M), number of teeth (N), or outside diameter (OD).
You can usually find these parameters in documentation specific to the manufacturer and type of gear.
• PD = M × N
• PD = (OD × N) / (N + 2)
• PD = OD - (2 × M)
Then, use the pitch diameters to calculate the center-to-center distance (CCD)
• CCD = ((PD1) / 2) + ((PD2) / 2)
Any two ION Gears that add up to 80 teeth will fit center-to-center on structure elements featuring the
MAX Pattern and have a center-to-center distance of 2in.

19 Transmitting and Transforming Motion

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Gearboxes

Gearboxes are a very common way to transform motion in the FIRST Robotics Competition. They are
generally compact and modular, able to be mounted on your robot wherever they’re needed. Some have
fixed gear ratios, and some can be easily changed for the needed application. A popular style of gearbox
is the adjustable, modular, planetary gearbox. In this style of planetary gearbox, cartridges of different
gear ratios are stacked to create an overall reduction. This is a fantastic option for teams to prototype
with because they can quickly change the gear ratio without needing to redesign the entire mechanism.

One example of this kind of planetary gearbox is the MAXPlanetary Gearbox. The MAXPlanetary
System consists of pre-assembled and lubricated gear cartridges, available in 3:1, 4:1, and 5:1 gear
ratios. Teams can easily adjust torque and speed for different applications by configuring different
combinations of cartridges. When assembling the MAXPlanetary Gearbox or any other planetary
gearbox, it is important to place the highest gear ratio cartridge next to the motor. Additional cartridges
should then be mounted in descending order.

A wide range of gear ratios are possible with the three available cartridges. When combining up to
three cartridges, just multiply each cartridge gear ratio to find the overall gear ratio. For example, a
combination of the 4:1 and 5:1 cartridges make a 20:1 overall gear ratio. The table below shows the
common use cases for all possible ratios that can be created with the MAXPlanetary Gearbox.

While this table is a good starting point, please take a look at the MAXPlanetary Gearbox User’s
Manual on our website before configuring the gearbox. The guide contains detailed information
about the system features and limitations that are very useful when designing a robot. The online
documentation also has information about how the type of motor used will affect what ratios are
effective for different mechanisms.

Transmitting and Transforming Motion 20

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 Wheels
Most wheels used in the FIRST Robotics Competition can be divided into four categories; Standard,
Omni, Compliant, and Mecanum. Each manufacturer makes slightly different wheels, with varying
materials, sizes, durometers, and colors. One element to consider when choosing a wheel is the bore
size, and if you will need any additional hubs to convert your wheel to the needed input or output.

Most sizes of ION Wheels feature a MAXSpline Bore that can fit standard 1.125in OD bearings or
easily be adapted to other bores using MAXHubs. Smaller wheels feature 1/2in hex bore. Larger
sizes of ION Traction, Grip, and Omni Wheels have spokes with a bolt circle of #10 clearance holes
patterned outward at 1/2in pitch. They also have a 3/8in-wide nut groove that eliminates the need for a
wrench when utilizing the holes on the spokes.

Standard Wheels

Standard wheels feature smooth or grip-textured tread. These wheels are versatile, being a great option
for drivetrains, as well as intakes or flywheels. Standard wheels without a tread pattern are designed
for optimal grip in situations where the material the wheel is interacting with is compliant, like carpet,
foam objects, and squishy game pieces.

Standard wheels that have a tread pattern are designed for increased traction. They are good for
drivetrains when you need a lot of pushing force.

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Omni Wheels

Omni wheels have smaller rollers around the circumference of the wheel. These rollers can passively
roll perpendicularly to the direction the wheel is driven. Using omni wheels in conjunction with each
other can create more maneuverable robots in advanced drivetrain applications. This wheel makes it
easier for a robot with a differential drivetrain to turn.

Compliant Wheels

Compliant wheels are ideal for intakes and conveyor systems where a bit of “give” is needed. These
wheels come in many sizes and are available in multiple durometers. As the tread durometer increases,
the compliant wheel gets harder, which will change the wheel’s traction, wear, and compliance. Many
compliant wheels feature “hurricane” or other shaped cutouts to ensure even compliance across the rotation
of the wheel.

Mecanum Wheels

Mecanum wheels, when properly setup on a drivetrain, allow for omni-directional movement. A set
of mecanum wheels used in a drivetrain include two left wheels and two right wheels each made up
of rollers that are angled at 45 degrees. Mecanum wheels can also be used to create vectored intakes.
By using the 45-degree angle of the rollers to your advantage, you can funnel game pieces towards a
specific point on your robot, such as the opening of a conveyor.

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 Mounting Wheels

The two main methods of attaching wheels to a robot are to create Live and Dead Axles.

A Live Axle is an axle that transmits torque to a wheel. This can be done through a 1/2in hex hub, gear,
pulley, or sprocket. In a live axle assembly, the axle will rotate along with the wheel. Live axles are
commonly used in drivetrains or as a flywheel.

A Dead Axle is an axle that only supports the wheels and does not move. Generally, bearings are used
to support the wheel on the dead axle so it can spin freely. Dead axles remain stationary while the
supported wheel is in motion. Some applications include free-spinning intake rollers and non-powered
drivetrain wheels.

In the ION Build System, MAXHubs provide a way to transfer torque to a MAXSpline Bore from
shafts of various shapes and sizes. MAXHub variants allow for other bores or mount holes to populate
within an existing MAXSpline Bore.

The MAXSpline Bore can also accept standard 1.125in bearings directly. This allows teams to quickly
switch between live and dead axles while prototyping.

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Supporting Motion
Supporting the mechanisms that move on the robot is very important. Without planning proper
supports, shafts may not be able to spin and your mechanisms and actuators could be damaged.

Forces, or “loads”, that are at a right angle, or “normal” to the shaft, are the most important forces to
counteract. The floor pushing on a wheel or two gears pushing against each other are two examples of
normal forces.

A shaft should be supported with two points of contact. Without two support points, the shaft can pivot
in the direction of the force. Ideally, those two points of contact should “capture” the mechanism under
load. In other words, the support points are on either side of the mechanism. If a mechanism can’t be
captured, it is important to keep the load as close to the two support points as possible.
Below are some examples of the three major supported load configurations: Captured, Near, and Far.

Additionally, the further apart the two support points are from each other, the better it can resist effects
of a normal force. As the supports move closer together, they begin to act more like a single support.

Supporting a shaft is important, but adding more than two support points can have diminishing returns.
Each bearing that the shaft passes through adds a constraint to that shaft. You need to balance having
the appropriate amount of constraints to keep the shaft from moving due to normal forces, but not
so many that the shaft becomes “overconstrained.” Overconstrained mechanisms can bind and make
rotation difficult, causing stress on the actuators and even damaging components of your robot.

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 The diagram below gives an overview of how bearing quantity and arrangement can impact the stability
of load configuration (Captured, Near, and Far).

Constraining Motion
Robots need movement to accomplish goals; arms must pivot, wheels must turn, etc. However,
movement that isn’t directly related to those actions can affect the accuracy and precision of the robot
mechanisms. This unintended motion must be properly restricted, or “constrained.”

Long and thin structures can flex and deform, making it difficult to interact with objects and operate in a
repeatable manner. Strengthen and constrain these structures by making use of brackets and extrusion.

Gears and sprockets must stay aligned to work properly. For example, if two sprockets are not perfectly
aligned with each other, the chain between them will run off the sprockets. Keeping parts aligned on a
shaft and keeping the shaft itself from sliding out is critical for reliably working robot mechanisms. Use a
combination of spacers and shaft collars to align and constrain these parts into place.

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Drivetrains
One of the first considerations when designing a robot is identifying what kind of drivetrain will be built.
A good starting point for most drivetrain styles is the Drive Base Kit, available in the FRC Kit of Parts.
In this section, we will focus on drivetrain styles, not drivetrain kits.

Differential Drivetrain
Differential drivetrains, also known as West Coast or Tank drivetrains, control the left and right sides
individually. This simple type of drivetrain is easy to design and build but can be less maneuverable
than other types. To help improve maneuverability, omni wheels can be used on the front or back, so
wheels slide across the floor while turning. If your design uses six or more wheels, lowering the middle
wheel of the drivetrain will cause less friction because not all wheels are touching the floor at one time.

Mecanum Drivetrain
Mecanum drivetrains require four motors and a full set of mecanum wheels for operation. When the
mecanum wheels are set up to create an “X” pattern from above, you can program the drivetrain to
strafe side-to-side, move diagonally, and drive like a differential drive would. This maneuverability
is of great benefit to teams. However, because your wheels are made of rollers, your robot is more
susceptible to being pushed.

Swerve Drivetrain
Swerve drivetrains use standard wheels mounted on their own pivoting mechanisms. Most swerve
drivetrains require two motors per wheel; one to rotate the wheel, and one to control the direction the
wheel points. Your robot can move in any direction because the drive wheels pivot without changing
the orientation of the drivetrain, but this type of drivetrain is very technically complex.

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 Actuators
Actuators, such as motors, servos, and pneumatic cylinders, are devices used to create movement on the
robot. When designing a robot, selecting the correct actuator for the application is important.

DC Motors

DC Motors consist of two major parts, the part that rotates, or the “rotor”, and the part that is stationary,
or the “stator”. A DC motor uses these parts to convert electrical energy into rotational mechanical
energy using electricity and permanent magnets.

Two types of DC motors are used in the FIRST Robotics Competition: Brushed DC Motors and
Brushless DC motors. Both types are useful in various robot applications, and both have their trade-offs.

Brushed vs. Brushless

Operating a brushed DC motor is simple; provide DC electrical power and the motor spins. In a brushed
motor, the rotor consists of electrical winding wires and the stator consists of permanent magnets.
Since the electrical part is spinning, there needs to be a way to connect the external power wires to the
spinning rotor. This is accomplished through conductive “brushes” that make contact with the stator,
automatically sequencing the power to make the rotor spin. Brushes make it easy on us, but they
produce extra friction which reduces the efficiency of the motor.

Brushless DC motors don’t have brushes. They still have both electrical winding wires and permanent
magnets, but the locations are flipped. The stator now consists of the electrical parts, and the spinning
rotor consists of the magnets. This means there is no more brush friction within the motor, making a
brushless motor more power-efficient. However, you can’t just provide DC power and expect the motor
to spin. Without the brushes doing the sequencing for us, you must use a specialized motor controller
that is designed for brushless motors to properly sequence the power and get the rotor spinning.

Power Classes

Traditionally in the FIRST Robotics Competition, there are two major power classes of motors:
Workhorse and Racehorse.

Workhorse class motors are well-suited for applications that require a lot of torque or speed. They are
not only high-power, but are resilient in high-load situations. This makes workhorse class motors ideal
for drivetrains, flywheels, and arms. Common workhorse motors include the CIM, NEO, Falcon 500,
and RS-775 style motors, but the available motors can change from season to season.

Racehorse class motors are generally smaller and more lightweight than workhorse class motors.
Great for intakes, conveyors, and tight spaces, these motors are very versatile. Common racehorse class
motors include the NEO 550, BAG Motor, RS-550 style motors, and several other lower power motors.

Be sure to check out the game manual for a list of legal motors this season!

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Servo Motors

Servo Motors are a specialized kind of motor that can be controlled to move to a specific angle, instead
of continuously rotating like a DC motor. Some servo motors can be programmed to run continuously
as well, but not all servo motors have this function. Servos have an output spline and are often paired
with servo horns to transmit motion to mechanisms like camera gimbals or small grippers.

Linear Actuators

There are two main types of linear actuators used in the FIRST Robotics Competition: Motor Powered
Linear Actuators and Pneumatic Cylinders.

Motor Powered Linear Actuators

Linear actuators that convert rotational motion into linear motion are generally known as motor
powered linear actuators. These linear actuators come in many different sizes and often have both DC
motor and servo motor versions. Motor powered linear actuators are great for mechanisms where the
linear motion needs to be varied, like raising or lowering the angle of a launcher.

Pneumatic Cylinders

Pneumatic cylinders are actuated by moving pressurized air through a closed system. They can either
be retracted or extended- the output is binary with no in-between. These are ideal for when you need to
extend part of your robot to the same length repeatedly, like deploying an intake.

For more information on Pneumatics, check out the Pneumatics Manual which can be found on
FIRST’s technical resources webpage:
https://www.firstinspires.org/resource-library/frc/technical-resources.

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 What’s Next?
The methods outlined here in our FIRST Robotics Competition Robot Basics Guidebook are a great way
to start building a robot that is ready to drive.

So, what’s next? Check out the following websites for information on how to get your robot moving by
wiring and programming your control system.

FIRST Robotics Competition Resource Library

Technical resources to help with building, programming, and wiring a robot, as well as tips on running
a FIRST Robotics Competition team.
www.firstinspires.org/resource-library/frc/technical-resources

Control System and Programming Documentation (WPILib)

Resources to help with wiring your control system and programming your robot.
docs.wpilib.org

REV Robotics Documentation

Resources for help using REV products, including the REV Power Distribution Hub, SPARK MAX,
NEO Brushless Motors, REV ION Build System, and more.
www.docs.revrobotics.com

Have a question for us?

The best way to get answers about REV Robotics products is to email us at:
[email protected]

For questions about FIRST Robotics Competition within your area visit:
www.firstinspires.org/find-local-support
Or, contact FIRST directly at:
[email protected]

29 What’s Next?
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