Motor mount from
McMaster Carr
Gearboxes and motors from the
“Team Nightmare” site
Material Selection
•Light
•Strong
•Easy to fabricate
•Easy to integrate
Polycarbonate Sheets
Polycarbonate is a very tough thermoplastic material used in police riot shields,
bulletproof windows, as armor and even structural material in combat robots.
Polycarbonate plastic may also be found as the walls of the BattleBots arena (Lexan),
as well as the high-strength walls of other robot arenas around the world.
Polycarbonate used in robots have many advantages:
1. It is very lightweight compared to other material choices. About five to six times less
dense than steel!
2. It is quite durable and has a tendancy to spring back into position when bent. It will
not form to a bend as many metals will.
3. It is see-thru, making it a great choice for robot armor where you need to be able to
see into the robot.
4. It does not conduct electricity and makes a great insulator for electrical systems.
5. Polycarbonate plastic is easy to work with. Cutting, drilling and even machining and
tapping it is a breeze.
You can find Polycarbonate plastic on many of the top robots in the sport of robotic
combat.
COMPOSITE MATERIALS CARBON FIBER
"Composite" is a general term which means an assembly of
dissimilar materials used together. They are carefully
engineered and are uniquely suited to be extremely strong
and surprisingly light weight. These materials consist of a
resin matrix and a fiber reinforcement. As a result, Carbon
Fiber is a fantastic material to use for robot armor, interior
component mounting, and any situation where you want
rigidity but do not want to add much weight. Carbon fiber is
even lighter than Polycarbonate Plastic
80/20 Extrusions
Limit different sizes and types of
threads of nuts and bolts
Limit the different styles of
head you select
Limit the different styles
of drives you use
McMaster Carr has a large selection
of spacers and standoffs
Attaching Wheels etc.
As the wheels get bigger your robot
•Moves faster
•May have more friction, therefore drawing
more amperage
•Will need more initial power to begin to
make it turn
Wheels from “Team Nightmare” site
Multi-Purpose Hubs
This is a great solution to hold various high-stress items
that you'd like to spin, such as a sawblade. Depending on
your particular application, this may also work quite nicely
as a drive wheel hub.
It is made especially for Robotic Combat standards of high
quality, lightweight 6061 Aluminum on one of the finest of
commercial lathes by some of the best makers in the USA.
We chose 6061 Aluminum as the ideal material for this
task at a reasonable price. It is much stronger than many
of the other aluminum hubs you will find, with many times
the shatter resistance of any kind of plastic hub.
This hub comes with 6 black, 3/8" long, 1/4"-20 hex-socket
head bolts to attach through the sawblade (or wheel) face
and into the hub itself, so nuts should not be necessary.
Bore
WH1
3/4"
WH2
3/4"
WH3
5/8"
WH4
5/8"
WH5
5/8"
WH6
1/2"
WH7
1/2"
Thickness
Keyway
Weight
O.D.
1/2"
1/4"
1.9oz
2"
1/2"
3/16"
1.9oz
2"
1/2"
3/16"
1.9oz
2"
1/2"
3/16"
??oz
1.5"
3/8"
3/16"
??oz
1.5"
1/2"
1/8"
2.1oz
2"
3/8"
1/8"
??oz
1.5"
Colson Bore Reducers
from Team Nightmare site
So you want to use one of the big
Colson wheels with the large bore,
but you don't want to use a
monster shaft. This is what you
need to reduce the large bore
down to something more
manageable. These are custom
built 6061 Aluminum bore
reducers that were made to fit the
Colson Performa wheels. These
reducers are made especially for
Robotic Combat standards.
Keyway
size
1/4x1.25" 1/4x1.25"
Weight
11.40oz 11.40oz
Hardware
Included Pack A* Pack A*
3/16x1.25
"
1/4x1.25" 1/4x1.25"
11.40oz 11.40oz 11.40oz
Pack A*
Pack A*
Pack A*
Model
Fits
Colson
Wheels
CH6
WC23
WC24
Length
Bore
Outer
Diameter
Flange
Diameter
Flange
Width
Keyway
size
Weight
Hardware
Included
3 1/4"
3/4"
CH7
WC10
WC11
WC15
WC16
WC18
WC19
WC21
WC22
2 7/16"
1/2"
CH8
WC10
WC11
WC15
WC16
WC18
WC19
WC21
WC22
2 7/16"
1/2"
CH9
WC10
WC11
WC15
WC16
WC18
WC19
WC21
WC22
2 7/16"
1/2"
CH10
WC10
WC11
WC15
WC16
WC18
WC19
WC21
WC22
2 7/16"
5/8"
1 15/16"
1 3/16"
1 3/16"
1 3/16"
1 3/16"
3 1/8"
2 1/8"
2 1/8"
2 1/8"
2 1/8"
.40"
.40"
3/16x1.25
"
1/8X1.25"
11.40oz 4.75oz
.40"
.40"
.40"
3/16X1.25
"
1/4X1.25" 1/8x1.25"
4.75oz
4.75oz
4.75oz
Pack A*
Pack B*
Pack B*
Pack B*
Pack B*
Couplers
Coupler from
McMaster Carr
O'all
Bore
Bore
Max.
Torque,
OD
Lg.
(A)
(B)
in.-lbs.
1 1/4"
1 7/8"
1/2"
0.235"
60
Aug-32 3084K31
$21.72
1 1/2"
2 1/4"
5/8"
0.235"
90
Oct-32 3084K32
22.47
1 3/4"
2 5/8"
3/4"
0.235"
190 1/4"-28
3084K33
28.25
1 7/8"
2 7/8"
7/8"
0.235"
190 1/4"-28
3084K47
29.81
2"
3"
1"
0.360"
190 1/4"-28
3084K34
29.79
2 1/8"
3 1/4"
1 1/8"
0.360"
190 1/4"-28
3084K48
33.26
2 1/4"
3 3/8"
1 1/4"
0.360"
190 1/4"-28
3084K35
33.31
2 3/8"
3 5/8"
1 3/8"
0.360"
190 1/4"-28
3084K49
35.09
2 1/2"
3 3/4"
1 1/2"
0.485"
190 1/4"-28
3084K36
36.04
3"
4 1/2"
1 3/4"
0.485"
435 5/16"-24
3084K51
42.13
3 1/4"
4 7/8"
2"
0.485"
435 5/16"-24
3084K52
49.23
Screw
Size
Each
Couplers from McMaster
Carr
Couplings connect two shafts and
transfer motion from one shaft to
another. They attach via cap
screws, set screws, a combination
of keyways and set screws, or
bushings.
ANSI Keyways- Couplings
with keyways give you a more
secure hold and are especially
good for alternating-motion
applications. Keyways follow
standard ANSI dimensions listed in
the chart at right.
Torque Ratings- Couplings are rated
by the maximum torque they can carry,
and sometimes by a limiting or maximum
rpm. Maximum torque can be used to
determine horsepower (or vice versa) by
the following formula:
Pinhole Disk Couplers from McMaster Carr
Also known as Schmidt couplings, these couplings handle
three times more angular misalignment than the slotteddisc couplings above. Great for use with encoders, they
allow zero backlash (they will not slip) and never need
lubrication. For a complete coupling, you need to order two
hubs and one disc from the same line in the listing below
(for example, two 60635K1 hubs are designed to work
with one 60635K86 disc).
Hubs are aluminum and have an internal clamp-style
collar with socket-head cap screw for a strong, nonmarring
grip. Bore sizes smaller than 1/2" do not have
keyways; 1/2" and larger have ANSI keyways.
To Order: Please specify bore size from those available
below. Note: You can use two hubs with different bore sizes
in one coupling as long as the hub ODs are the same.
Discs are Delrin. Temp. range is -30° to +150° F.
COUPLING
HUBS
COUPLING
DISCS
M ax.
Hub
OD
47/64"
O'all
Lg.
5/8"
Bore
Available
Bore Siz De pth
1/8", 1/4"
0.219"
Scre w
Size
Each
Feb-56
60635K1
$10.48
Torque ,
M ax.
in.-lbs .
rpm
4
M axim um M is alignm e nt
Paralle l
5000 0.013"
Angular
1.5°
Axial
0.010"
$10.77
0.014"
60635K8
7
10.77
13.55
1/8", 1/4",
63/64"
1"
3/8", 1/2"
0.375"
Apr-40
60635K2
10.48
9
4600 0.019"
1.5°
Each
60635K8
6
3/16", 1/4",
60635K3
13.79
31
4200 0.028"
1.5°
0.021"
60635K8
8
3/8", 1/2",
1 31/64"
1 1/8"
5/8"
0.375"
Aug-32
3/8", 1/2",
0.563"
1/4"-20
60635K4
22.06
106
3700 0.041"
1.5°
0.031"
60635K6
9
21.86
0.75"
5/16"-24
60635K5
25.92
250
3200 0.055"
1.5°
0.042"
60635K7
5
32.79
5/8", 3/4",
2 1/4"
1 11/16"
7/8"
3/8", 1/2",
5/8", 3/4",
3"
2 1/4"
7/8",
1"
Acetal Helical Beam Couplings
Three beams, or cuts, in these lightweight,
corrosion resistant couplings provide flexibility for
parallel and angular misalignment. Excellent for
motion-control applications that require precise
positioning for frequent starts and stops, they allow
zero backlash (they will not slip) and never need
lubrication. Couplings connect to shafts via integral
shaft collars-no marring as with set-screw mounted
couplings. Two socket-head cap screws are included.
To Order: Where applicable, please specify bore size
(A) and bore size (B) from those available below.For
more information about couplings, see page 1029 .
Note: You can choose any available bore size (A) and
any available bore size (B) for a given hub OD.
Max.
Maxim um
O'all
O'all
Available Bore Sizes
Bore
Torque,
Max.
Misalignm ent
Screw
OD
Lg.
(A)
(B)
Depth
in.-lbs.
rpm
Parallel
Angular
Size
1/2"
3/4"
1/8, 3/16"
1/8", 3/16"
0.24"
2.12
5000 0.005"
5°
M3
2505K11
$17.38
3/4"
29/32"
3/16", 1/4"
1/4"
0.26"
5.66
5000 0.005"
5°
M4
2505K12
20.68
1"
1 1/4"
1/4", 3/8"
1/4", 3/8"
0.35"
12.39
5000 0.005"
5°
M5
2505K13
22.58
1 1/4"
1 3/4"
1/2"
0.47"
22.12
5000 0.005"
5°
M6
2505K14
27.66
Each
1/4", 3/8",
1/2"
Gears
About Gears
In order to mesh, gears must have the
same pitch (ratio of number of teeth to
pitch dia.) and pressure angle (angle
between contact points of meshing teeth).
Pitch dia. is the dia. of the circle formed
at the contact point of meshing teeth.
Gears with 14 1/2° pressure angle are the
original AGMA (American Gear
Manufacturers' Association) standard.
They provide smooth, quiet meshing and
are good for replacements in existing
designs. Gears with 20° pressure angle
are the most recent AGMA standard, with
stronger teeth and higher load capacities.
If you need a gauge to help determine
gear pitch and pressure angle, see 2069A
on page 2048 .
There are three types of gear pitch:
Coarse (up to 20 pitch) for heavy duty
power transmission; medium (20 to 64
pitch) for general purpose power
transmission; and fine (more than 64
pitch) for light duty power transmission
and instrumentation applications.
Helical gears
Right hand
helical
Left hand
helical
Bevel gears
Teeth are set at a 45° helix angle which, in parallel shaft applications, gives you more
constant tooth contact for smoother, quieter operation and the ability to handle higher
horsepower than comparable-size spur gears. Hubless design allows use in tight spots.
Parallel-shaft applications require one right- and one left-hand gear.
These gears can also be used with shafts at 90° angles; however, they are 50% less
efficient due to reduced tooth contact area. Use gears with the same hand (two righthand gears or two left-hand gears).
All have a finished bore with keyway unless noted. To Order: Please specify right- or
left-hand helix angle.
Timing belt gears
Hubless spur gears
Also called change gears, these gears
feature a space-saving hubless design
that makes it easier to mount two or
more gears side-by-side. Gears have a
finished bore with two keyways spaced
180° apart. You can attach gears to your
shaft with a bushing, sold separately
below. Bushings are steel, can be
press-fit, and have two integral keys that
match the hubless gear's keyways.
Worm Gears
Worm gears and worms produce a
high speed-reduction ratio in a
minimal amount of space. They're
designed for use on shafts that
intersect at a 90° angle.
Worm gears are cast iron and
have a plain bore (no set screws or
keyway). Worms are steel and have
a keyway and right-hand thread.
Note: Speed-reduction ratio is
determined by number of teeth. For
example, a 20-tooth worm gear and
its mating worm will give you a 20:1
ratio; a 30-tooth worm gear and its
mating worm will give you a 30:1
ratio.
Sprockets
In order for sprocket and chain to properly mesh,
select a sprocket that matches your specific chain
number and pitch. Pitch is the distance from one
tooth valley to the next; this is where the centers
of chain pins mesh with the sprocket.
Finished Bore Steel Sprockets
Bores are finished so these sprockets are ready
to mount. They have a standard keyway,
except 3/8" and 1/2" bore sizes. Keyways are
on the centerline of tooth. All include two set
screws. Use sprockets with ANSI single-strand
chain. Made of steel.
To Order: Please specify bore size. Standard
bore sizes are: 3/8", 1/2", 5/8", 3/4" , 7/8",
1", 1 1/8", 1 3/16", 1 1/4", 1 3/8", 1 7/16"
1 1/2", 1 5/8", 1 3/4", 1 15/16", 2", 2 3/16",
2 7/16", and 2 15/16".
Plain Bore Sprocket
Sprocket accessories
Hubless
plain bore
sprocket
Just like the plain bore
sprockets, except these don't
have a hub which makes them
excellent for use in confined
spaces. Sprockets do not include
keyways or set screws. Use with
ANSI single-strand chain.
Minimum bore size is the
furnished size; you can enlarge
bore to the maximum bore size.
Double strand plain
bore sprocket
Roller chain
lubricator
Double drive plain bore sprocket
Roller chain idler sprockets
The bearings or bushings in these sprockets
allow them to rotate freely while controlling
chain slack to maintain proper tension and
prevent whip.
Steel sprockets have precision-cut teeth
for longer chain life. Teeth on steel
sprockets with plain bronze bearings and
with needle bearings are also hardened to
reduce sprocket wear. Steel sprockets with
plain bronze bearings also have two plain
washers and a hardened steel sleeve to
protect the bearings.
UHMW polyethylene sprockets are selflubricating, flexible, and resistant to
abrasion and impact.
Bearing/Bushing Sprockets: Ball
bearings are double-sealed and lubricated;
bronze bearings/bushings are oilimpregnated; needle bearings have
retainers separating the needle rollers to
minimize internal friction and wear.
Chain & links
Roller chain consists of alternating pin links (two
pins supported by side plates) and roller links (two
rollers on bushings, also supported by side plates).
The pins (all of which are riveted, except where
noted) pivot inside the bushings. The rollers are
free-turning to provide rolling contact with
sprocket teeth. Chain sizes are distinguished by
pitch, the distance between pin centers. Some
smaller-pitched roller chain is actually rollerless,
and is constructed of pins and bushings only. Use
roller chain and sprockets with the same ANSI No.
Connecting link
Roller
single link
Offset
single link
Connecting Link- A special pin link that's easily disassembled; use to join the ends of a
length of chain to make a continuous strand and to splice lengths together.
Roller Link- Add to chain to lengthen it. Note: Roller links for multistrand chain are single
links placed side-by-side.
Offset Link- A combination of a pin link and roller link. Standard chain has an even number
of pitches; use an offset link to make a strand with an odd number of pitches.
Chain tools
Use one tool to break and rivet roller chain.
This tool can break ANSI 50 ( 3/8"- 5/8"
pitch) and 60 ( 1/2"- 3/4" pitch) roller chain.
Rivets #40-#60. You can bolt it to a
workbench (using two 3/8"-24 bolts, not
included), support it in a vise, or use it by
hand (with included removable handle). Also
includes rivet set, rivet anvil, and press
plate. All attachments are made of 86L20
steel and are heat treated for strength and
durability.
Chain holders work like a
third hand to help you
insert and fasten
connecting links. Just
hook the jaws into each
end of your chain and
turn the handle on top (a
knurled screw knob on
Style A and a T-handle on
Style B) until chain ends
almost meet. Insert the
connecting link and
fasten. Made of carbon
steel.
Alligator®
Conveyor Belt
Lacing
Roller chain tensioner
These tensioners ride on chain, compressing it
axially to control tension. They don't need to be
mounted to a structure. They require no tools,
lubrication, idler sprockets, or bearings. Saddle
blocks ride on chain midway between the drive
sprocket and driven sprocket and are joined by
adjustable straps which take up the slack.
Tensioners are made of UHMW polyethylene
(FDA and USDA compliant for food contact) with
stainless steel housing and zinc-plated steel
screws and wing nuts. Max. temp. is 200° F.
Tension force not rated.
Ball Bearings
Steel semi precision ball bearings
The unground inner raceways in these bearings give you good performance at moderate
speeds and loads. Inner and outer sleeves are hardened carbon steel. Temperature range is
-20° to +250° F.
Standard Bearings- Tolerance for open bearings: +.005" to -0" for shaft dia., +0" to .005" for OD, and ±.010" for width. For double- shielded and double-sealed bearings:
+.005" to -0" for shaft dia., +0" to -.0005" for OD, and ±.005" for width.
Flanged Bearings- Allow precise positioning during installation, so you don't need snap
rings or to counterbore the housing. Tolerance: +.005" to -0" for shaft dia.; +.005" to -0"
for OD, and ±.010" for width on open bearings; ±.005" for width on double-sealed.
Radial load track rollers
Also known as cam followers, track rollers
guide linear motion in a variety of machine tool
and material handling applications. In addition,
they resist shock loads.
Radial-Load Track Rollers- Support loads
perpendicular to their axis of rotation. They
usually contain needle roller bearings,
cylindrical roller bearings, or sleeve bearings.
Needle roller bearings offer higher load carrying
capacity than sleeve bearings. Cylindrical roller
bearings also offer high load carrying capacity,
as well as the ability to run at higher speeds
without forcing the roller out of alignment.
Sleeve bearings have no rolling element-loads
are supported through sliding motion between
two low-friction surfaces. Sleeve bearings are
designed for light loads and low speeds. Some
radial-load rollers have a hex-socket head or a
slotted head for ease of fastening.