Front Sensor Array

This subassembly contains the main, forward-facing sensors used by the car for object and environmental detection.

I. Requirements

Tools

	Description
	2.0mm Hex Driver, 2.5mm Hex Driver, 3.0mm Hex Driver, 3/8" Hex Driver
	Soldering Iron
	Cyanoacrilate, Two-part Epoxy or Silicon Glue

Parts

Hardware

	Description	Qty			Description	Qty
	M2.5x16 CBR Screws	2			M3 Nyloc Nuts	2
	M3x8 CSK Screws	16			M4 Nuts	4
	M3x12 CSK Screws	2			M4 Nyloc Nuts	4
	M3x16 CSK Screws	2			M4x6 T-Nuts	8
	M4x10 CBR Screws	17
	1/4"-20x1/2" CBR Screws	3

Custom Parts

	Description	Qty			Description	Qty
	Sensor Vertical Rail	2			Hand Knob	2
	Rail Horizontal Brace	2			Sick Bracket	1
	Left Brace	1			Camera Bracket	2
	Right Brace	1			Camera Bracket Back Support	2
	Brace Nut	2			Vive Bracket	1

Commercial Components

	Description	Qty
	Sick TIM55x Ranging Laser Scanner	1
	ZED Stereo camera	1
	Intel RealSense Depth Camera D435i	1
	HTC Vive Tracker	1

II. Assembly Steps

II.1 Array Screws

1. Insert one M4 Nut on one end of the M4x270 and use another M4 Nut to jam it in place so as to prevent them moving. Up to 5mm of thread can be left after the nuts. Repeat this step for the second screw.

   

2. Attach the Hand Knob to the threaded rod using some glue, preferrably two-part epoxy, but silicone or cyanoacrylate based ones should work as well. Make sure that the hexagonal faces of the outermost nut engage properly with those in the Hand Knob and that it is seated as deeply as possible. Repeat this step for the second screw.

   

3. Final assembly. Let the glue fully cure according to the manufacturer's instructions before applying any forces to the screws.

   

II.2 Mounting Bracket

1. Insert two M4 Nyloc Nuts into the respective holes as shown in the picture. Use some form of glue to preventing from falling out when attaching or removing the screws.

   

2. Insert two M3 Nyloc Nuts into the respective holes as shown in the picture. Optionally, use glue to affix them in place, though it is less likely that they will fall out.

   

3. Insert the GR8LE's Body Columns into their respective square bosses. Screw them in place using the car's original M2.5x16 CBR screws using the bottom holes from the columns.

   

4. Final assembly. Let the glue fully cure according to the manufacturer's instructions before applying any forces to the assembly.

   

II.3 Vertical Rails

1. Using a soldering iron, place the M3 Brass Threaded Inserts into the Sensor Vertical Rail, leaving it flush with the top surface. Repeat for the second rail.

   

2. Fasten the Horizontal Rail Braces to one of the Vertical Sensor Rails using four M4x10 Socket Head screws.

   

3. Using another four M4x10 Socket Head screws, fasten the second Vertical Sensor Rail to the previous subassembly.

   

4. Attach the Left and Right Braces to the subassembly using two M3x8 Countersunk screws.

   

5. Insert the Brace Nuts into the Braces, making sure that the hexagonal faces are aligned, and secure them using two M3x12 Countersunk screws. Leave a gap between the bottom face of the brace and the flange of the nut of about 3.5mm for an easier installation on the PC Case later.

   

6. Final assembly.

   

II.4 Vive Tracker Bracket

1. Attach two M4x10 Socket Head Screws and two M4x6 Tee Nuts to the Vive Tracker Bracket, leaving them loose for easy insertion and removal from the Rail Subassembly.

   

2. Screw an M4x10 Socket Head Screw into any of the six holes of the Vive Tracker Bracket. The purpose of this screw is to prevent the rotation of the Tracker, and its position determines the angular orientation of the tracker with respect to the rest of the car. The recommended position shown in the picture is so that the z axis of the Tracker is pointing towards the front of the car.

   

3. Secure the Vive Tracker to the Bracket using a 1/2"-20x0.500" Socket Head Screw, making sure to also align the screw from the previous step with the Stabilizing Pin Recess on the bottom of the Tracker*.

   

4. Final assembly.

   

II.5 Intel Camera Bracket

1. Attach two M4x10 Socket Head Screws and two M4x6 Tee Nuts to the Camera Bracket, leaving them loose for easy insertion and removal from the Rail Subassembly.

   

2. Mount the Camera Bracket Back Support to the Camera Bracket's front holes using two M3x8 Countersunk Screws.

   

3. Secure the Intel RealSense Camera to the Bracket using a 1/2"-20x0.500" Socket Head Screw.

   

4. Optionally, secure the Camera to the Back Support using two M3x8 Countersunk screws.

   

5. Final assembly.

   

II.6 ZED Camera Bracket

1. Attach two M4x10 Socket Head Screws and two M4x6 Tee Nuts to the Camera Bracket, leaving them loose for easy insertion and removal from the Rail Subassembly.

   

2. Mount the Camera Bracket Back Support to the Camera Bracket's rear holes using two M3x8 Countersunk Screws.

   

3. Secure the ZED Camera to the Bracket using a 1/2"-20x0.500" Socket Head Screw.

   

4. Final assembly.

   

II.7 SICK Scanner Bracket

1. Attach two M4x10 Socket Head Screws and two M4x6 Tee Nuts to the SICK Bracket, leaving them loose for easy insertion and removal from the Rail Subassembly.

   

2. Mount the Sick Ranging Laser Scanner to the Bracket using two M3x8 Countersunk screws.

   

3. Final Assembly.

   

II.8 Final Assembly

1. Slide each of the sensor brackets into their desired position, making sure that the Tee Nuts are engaging properly with the T-Slots. Once satisfied with their positioning, tighten all of the M4x8 Socket Head screws holding them in place.

   

2. Final –proposed– assembly.

   

III. Exploded View

III.1 Mounting Bracket

BOM

ID	Description	Qty
1	Front Sensor Bracket	1
2	Body Columns	2
3	M2.5x16 CBR Screws	2
4	M3x16 CSK Screws	2
5	M3 Nyloc Nuts	2
6	M4 Nyloc Nuts	2

III.2 Sensor Array

BOM

ID	Description	Qty		ID	Description	Qty
1	Sensor Vertical Rail	2		13	Intel RealSense Depth Camera D435i	1
2	Horizontal Rail Brace	2		14	Vive Tracker Bracket	1
3	Left Brace	1		15	HTC Vive Tracker	1
4	Right Brace	1		16	M3x8 CSK Screws	16
5	Brace Nut	2		17	M3x12 CSK Screws	2
6	Hand Knob	2		18	M4x10 CBR Screws	17
7	M3x270 Threaded Rod	2		19	1/4"-20x1/2" CBR Screws	3
8	Sick Bracket	1		20	M3 Nuts	4
9	Sick TIM55x Ranging Laser Scanner	1		21	M4 Nuts	4
10	Camera Bracket	2		22	M4x6 Tee Nuts	8
11	Camera Bracket Back Support	2		23	M4 Brass Threaded Insert	2
12	ZED Stereo Camera	1