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Bruder MAN Truck RC Conversion w/embedded PC

Discussion in 'Highway Trucks & Trailers' started by SteinHDan, Feb 9, 2015.

  1. SteinHDan

    SteinHDan Active Member

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    This goal of this project is to build a low-cost but functional tip-up truck to go with my Delta Loader:
    - http://www.rcsparks.com/forum/threads/bruder-delta-loader-rc-conversion-w-embedded-pc.36063/

    I'll use an embedded PC for this RC conversion too. Some of the benefits I hope to accomplish with this:
    1. Low cost
    2. Realistic sound
    With an embedded PC, you can use a standard wireless gamepad for the controls. Also, you can add internet connection, webcam, and whatever other standard USB-connected device.
    The options for the embedded PC was either Raspberry PI or the BeagleBone Black.
    (Edited) I've chosen the Raspberry PI, because it can drive one servos directly, it has a 3.5mm audio Jack and it has two USB ports (that I'll use for the GamePad and the WiFi).
    I also wanted to try to create the parts I needed on a 3D printer, because I love the accuracy of the parts produces on such machines.

    I bought a Bruder MAN Tip-up Truck for the build:
    - Bruder MAN Tip-up Truck

    [​IMG]
     
    #1 SteinHDan, Feb 9, 2015
    Last edited: Mar 18, 2015
  2. SteinHDan

    SteinHDan Active Member

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    The teardown. This model came apart quite easily, compared to some of the other Bruder models:

    [​IMG]
     
  3. SteinHDan

    SteinHDan Active Member

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    For the drive, I'm using one gear motor for each of the back wheels in a simple pivoting bogie configuration.

    The gear motors are quite powerful, but also quite long. I wanted 12mm hex mounts for the wheels, and the length of the gear motor made me have to remake the rims to be able to get the hex mount far enough out into the rim.

    I cut out the rims from the original wheels:

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    Then I copied the design of the rims into 123D Design and printed them with gray ABS plastic on the 3D printer (25% infill):

    [​IMG]

    Finally, I put the new rim with the 12mm hex mount into the original tire:

    [​IMG]

    [​IMG]
     
  4. SteinHDan

    SteinHDan Active Member

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  5. SteinHDan

    SteinHDan Active Member

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    The two bogies are put on a mount with a 8mm aluminum tube. The mount is also printed on the 3D printer (black ABS, 25% infill):

    [​IMG]

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  6. SteinHDan

    SteinHDan Active Member

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    I cut away some plastic on the chassis to make room for the mount. I tried to keep the mount as short (in height) as I could, because I want to have the lift mechanism for the truck bed as low as possible to get a good angle on the lift. A very narrow angle will put a lot of stress on the lift mechanism.

    I also made a 3D-printed stencil to help guide where the screw holes needed to be drilled:

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  7. Antho11

    Antho11 Studio Forums Elite
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    Awesome build coming along! It must be pretty powerful with 4 motors. I really want a 3d printer!
     
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  8. SteinHDan

    SteinHDan Active Member

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    Thanks, Antho11! :) It's quite powerful, yes. I'm thinking it probably doesn't have enough weight on the rear (yet) to get the full benefit of the torque, but it's easy to add weight later when all the mechanisms are in place (in contrast to removing it later ;-) )
    To keep it simple, I've not plannet to add motors to the front wheels initially. We'll see how that works out.

    Best regards,
    Stein :)
     
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  9. SteinHDan

    SteinHDan Active Member

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    The 3D printer that I'm using:
    - MakerBot Replicator 2X

    There is a lot of good and cheaper alternatives out now. I'm printing with ABS for the strength. For printing with ABS, it's good to have a heated table, otherwise it's difficult to get the build to stick to the table. Other than that, most ABS 3D printers will do fine for RC work.
    The good ting about the Replicator 2X, is that it's very little trouble printing parts. which leaves more time to the actual design of the parts and the build.

    Stein :)
     
  10. SteinHDan

    SteinHDan Active Member

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  11. Antho11

    Antho11 Studio Forums Elite
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    It's a great printer but I think I'm going to wait. I want to get a resin 3d printer when they become cheaper and better.
     
  12. inthepit

    inthepit Studio Forums Elite
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    Looking good!! Must be awesome to have a 3D printer. :haveaniceday:
     
  13. Bubba J

    Bubba J Studio Forums Elite
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    awesome job
     
  14. SteinHDan

    SteinHDan Active Member

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    I got the steering in place. It's a very simple pivoting-axle design:

    [​IMG]


    When using a Fused-Filament 3D printer like I am, the prints will typically be very strong in two out of three dimensions. To counter this, I've added some bolts that go through the whole mount (probably overkill):

    [​IMG]

    I'm using a very cheap but powerful servo:
    - TowerPro MG946R

    [​IMG]

    The pivot arm sits on an aluminum tube that connects it to the mount:

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    The aluminum tube is held in place with a small screw through a hole:

    [​IMG]



    For the front wheels, I did the same as for the rear wheels. I opted to add the ball bearing to the rim rather than the axle.
    So I cut out the original rims, copied the design and printed new ones, and added the ball bearing:

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    The wheels are mounted on a horn with two M6 bolts:

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    The wheels with horns are added to the pivot with 5mm bolts:

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    I use an M3 threaded rod with some typical RC servo linkages for connection the servo horn to the wheel horns:

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    Cut away some plastic on the chassis to allow the steering module to slide into place:

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    I use four self-tapping screws to fix the mount to the chassis:

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    Ready for a test drive! :)
     
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  15. SteinHDan

    SteinHDan Active Member

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    First test drive:




    And with a trailer:

     
  16. Antho11

    Antho11 Studio Forums Elite
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    It has some nice flex, I think the test drive went well! Subscribed to your channel!
     
  17. inthepit

    inthepit Studio Forums Elite
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    Lookin good! :)
     
  18. drzoo2

    drzoo2 Studio Forums Elite
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    Holy sweet mother that is fantastic. The part that stands out is the quality of the work and the thought that went into the details. I would bet most people would be happy just getting it moving, but the added articulation in the suspension adds so much to the quality and detail of your build.

    This alone for me makes the whole build, on top of the "coolness" of it being a 3D printed part....
    [​IMG]
    Awesome work. Next level thinking....
     
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  19. SteinHDan

    SteinHDan Active Member

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    Thanks all! :)
     
  20. SteinHDan

    SteinHDan Active Member

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    I've added the truck bed tipping mechanism now. Initiallly I was thinking about doing a sliding mechanism. But then I had this 3rpm gear motor, and I thought the gear-motor appraoch would be very much simpler than a sliding mechanism.

    So I put in this motor:
    - Tsiny 3rpm gear motor (55kg/cm)

    With this motor, I've got a bit too much weight on the back, so I have to balance this with putting the batteries in the very front of the truck later.

    Anyways, here are the pictures:


    Milled down two 8mm-axle mounting hubs on a CNC machine to copy the profile of the truck bed rails:

    [​IMG]

    I got the hubs from here:
    - 8mm set screw hubs

    Milled the same profile on some L-shaped aluminum profiles:

    [​IMG]

    Mounted the aluminum profiles to the truck bed with two screws in the front, and drilled holes in the back for bolts that will go through all the three layers:

    [​IMG]


    3D-printed a mount for the motor:

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