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MAXTube comes in three extrusion profiles: 1x1in Tube, 2x1in Tube, and 2x1in Light Tube.
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.
Use Standard 2x1 Tube for a more secure bearing fit and 2x1 Light Tube where weight is a critical factor
Some MAXTube features the MAX Pattern, combination of #10 holes in a 1/2in pitch grid and the MAXSpline bore every 2in. This repeats down the length of channel to mount bearings, MAX Hubs, shafts, brackets, and more.
2x1in MAXTube that features Grid Pattern has three rows of #10 holes on a 1/2in pitch. The Grid Pattern is ideal for rapidly prototyping structures with our 1in brackets.
The flexibility of T-Slot Extrusion makes using it a great option for builds that won’t fit on the pattern 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.
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is compatible with the REV ION System and is a strong extruded aluminum tubing (Aluminum 6061) that features positional hole patterns that make robot structures easier to build.
The has slots on on all four sides that accept standard #10 Hardware, including low-profile nylock nuts. Rather than using a T-nut, which is more expensive, slide a #10 hex head screw along the slot and adjust brackets and other build materials as needed. All holes in the 1in Extrusion can be tapped with a 10-32 tap, consistent with the REV ION Standards. The corners can also accept 1/16in thick flat stock.
Size | Pattern | Position/Length |
1x1in | Grid |
2x1in Light | No Pattern |
2x1in Light | Grid |
2x1in | No Pattern |
2x1in | MAX Pattern | 1-Pos (3in) to 23-Pos (47in) |
REV ION was created to minimize the required tools, hardware, and cost to build a robot. To accomplish this the REV ION System has standardized the following throughout its products:
All hardware is #10-32 sized
Any tapped holes are #10-32
Can use 3/16in rivets
Linear pattern or grid on structural components
Radial pattern on circular components
Some circular components also have the linear pattern for ease of attaching to structure
Combined with MAX Spline to form the MAX Pattern
13.75mm diameter rounded corners for ease of assembly in bearings
Fits standard 1.125in OD Bearings
Components together along a shaft always have a total width on a fractional interval
Competitive Robotics Made Simple
Tackling the challenges of FRC requires rapid iteration, multiple revisions and adaptation to the games challenges. Recognizing that not all teams have access to the same equipment or resources, we created REV ION to enable all teams to be competitive. REV ION is a system of mechanical and electrical components that are perfectly compatible with each other, allowing for complex robot designs without the need for large budgets or extensive manufacturing resources. With just basic tools, teams can build affordable, competitive machines, while preserving the ability to infinitely re-configure and iterate on their designs.
We built the REV ION mechanical system around the MAXSpline shape. This unique shape allows us to do things like combine a bearing support with a torque transfer feature for unrivaled configurability of motion components. We've also created the MAX Pattern, this pattern features the MAXSpline with an array of #10 clearance holes on either side. This 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 belting.
REV ION includes 300+ new and existing products that work within the existing FRC ecosystem, while introducing new features and functionality not currently available to teams. To see how ION can help with your next build, look for the bright blue ION logo next to compatible products on our website.
If you have any questions, please reach out to our support team via email: support@revrobotics.com
With the release of the REV ION Build System, the team at REV Robotics wanted to create a resource that introduces you to some of the basic components and techniques used within the FIRST Robotics Competition. Included in this guide are tips and tricks for building sturdy structures, how to transfer motion, and more!
Check out the guide here!
Threadlocker is an oil-tolerant, removable, medium-strength seal for threaded fasteners. Use on nuts, bolts, and mounting or support screws in high vibration environments.
Perfect for bolting down anything that needs to be secured.
These Low Profile Nylon Lock Nuts are thin enough to fit inside the channel of the REV 1" Extrusion. The embedded nylon ring provides tight vibration resistant hold on the threads of the screw.
Whether you are distributing the load of your bolt, spacing your build evenly, or any of the many other uses for washers, it's always good to have some on hand.
This stretchy latex rubber tubing can be used as a low-tech retraction device for pivot arms or to increase tension in a linear motion kit.
Nylon Zip Ties with rounded edges to help prevent snagging. Length of the product linked is ideal for cable management, but Zip Ties are available in many other sizes as well.
Securely attach your robot parts without the need for bulky fasteners with 3M VHB (Very High Bond) Tape. Works with metal and plastics.
Prototype and plan out your designs ahead of time so you can measure twice and cut once with some cardboard.
Easily remove, replace and secure control system components without having to cut and rerun zip ties or refashion nuts and bolts
Used to isolate solder joints and other electrical connections on your robot.
A multipurpose adhesive tape for when you need things to stick together.
Easy to cut, drill and sand smooth plywood is a great material to use as a base to mount control systems or as structural elements.
A material most builders prefer for intakes, polycarbonate is a unique mixture of flex and strength allowing it bend and deflect when hit instead of breaking.
Quickly repair broken plastic, rubber, wood and metal with super glue. And for when you or a team member accidentally glues their fingers together, you may want to pick up a tube of this as well - Super Glue Remover
This is a longer 2 meter length version of the USB-A to USB-C cable included with most of our Control System Components. The added length of this cable becomes extremely handy if you are connecting to a control component that may be buried deep inside your build.
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 together.
Follow through the rest of this section to learn more about brackets.
In the REV ION Build System, motion brackets are referred to as MAXSpline Brackets because within the ION System, the MAXSpline shape is 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.
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. In the REV ION Build System, structure brackets are any bracket that does not have a MAXSpline Bore.
Create a sturdy triangle with our 3-4-5 Brackets to support your robot. When using 3-4-5 Brackets any 3 lengths of tube that make a 3-4-5 triangle will allow the holes to line up with the brackets and for the holes to stay on pitch relative to one another.
There 3-4-5 Brackets come in both external and internal versions. Both brackets form the same structure of a 3-4-5 triangle, it is just secured in different places.
Use External 3-4-5 Brackets for creating a 3-4-5 triangle with 2x1in MAXTube that features the MAXPattern or the Grid Pattern
This section goes over all of the basic structure elements used in FIRST Robotics Competition.
The majority of a robot’s structural elements can be divided into two main categories:
Extrusion
Patterned
T-Slot
Plain Stock
Brackets
Motion
Structure
All REV ION structural components are #10 hardware compatible.
Fixed pitch based systems, like the MAX Pattern on MAXTube, have a set pattern of holes to use for mounting; everything that is attached is spaced on a multiple or a set fraction of the standard pitch.
In contrast, the 1in Extrusion System allows for flexible mounting positions along its slots. Simply slide any brackets that need to be mounted into the appropriate slot and adjust to the desired position. Because there is no fixed pitch, you can have the bracket in an infinite number of positions along your 1in Extrusion.
We believe that the easier it is to adjust your design, the easier it is to iterate and improve that design.
featuring the MAX Pattern: a MAXSpline surrounded by #10 clearance holes on a 1/2in pitch grid. The plates are available in various lengths, with the pattern repeating every 2in.
Plate sizing options are available from 1-Pos (2.48in) to 23-Pos (46.48in) Check out specific sizing options on the product page:
In the REV ION Build System, there are two major groupings of brackets: and . The major distinguishing feature of MAXSpline brackets is a MAXSpline bore or MAX Pattern to support bearings and . Construction brackets are essentially any bracket in the REV ION Build System that does not have a MAXSpline bore. Because the term construction bracket encompasses a broad range of REV ION products, it can be further subdivided as structural brackets and actuator brackets.
Structural brackets act as connectors between structural components. For example, these are the type of brackets you will want to use when connecting and Extrusion elements. Actuator brackets on the other hand are intended to mount and support motors and servos.
are compatible with the REV ION System and are designed to mount to pieces of 2x1in - with MAX Pattern while maintaining proper pattern spacing.
You can also use MAXSpline Brackets to mount motion components such as motors and pulleys, as seen below. A MAXPlanetary Gearbox fits perfectly on the 2in hole pattern of the Offset Mount MAXSpline Bracket ().
A full listing of brackets is located on the product page. Compatible 1in extrusion brackets are also available on the product listing page
1in Inside Corner Bracket () is designed to enable more construction strategies with the REV 1in Extrusion. Designed for #10 hardware, the mounting holes are on a 1in pitch that allows for the creation of complex joints by stacking with other REV 1" Brackets.
1in BracketsThis is an assortment of Brackets that are all 1in wide and feature #10 clearance holes on a 1/2in pitch. Using these brackets with any of our MAXTube or Extrusion allows for easy construction of robot frames, mechanisms, and structure.
The 1in Bent Universal Motor Bracket V2 () This bracket is designed to work seamlessly with the most popular motors in FRC. The Bent Universal Motor Bracket V2 changes the holes on the 25mm bolt circle from an M4 to an M3 tight fit hole to accommodate 550 style motors, including the . To use a BAG Motor, the holes on the 25mm bolt circle need to be drilled out to a M4 tight fit.
The ION UltraPlanetary Face Mount Bracket () allows for easy mounting of our UltraPlanetary Gearbox to any of our MAXTube products. The plate features 2 x #10-32 tapped inserts for easy mounting on any structure.
The ION Servo Face Mount Bracket () allows for easy integration of Servo Motors into the ION System. Mount a servo motor, such as our Smart Robot Servo (), on a 1/2in pitch and line up perfectly with the MAXPattern on MAXTube.
The REV ION Build System's structural components are comprised of a collection of aluminum extrusions. This includes , a family of rectangular tubes that are available in a variety of sizes, thicknesses, and hole patterns. MAXTube hole patterns are compatible with #10 Hardware and the MAXSpline. Our slotted comes in a 1x1in size and features t-slots that allow for brackets and other items to be adjusted to any position along the rail. is an extrusion with the same outer profile as the MAXSpline that provides a high strength shaft alternative where more torque is needed.
With REV ION, we made it easy to calculate center-to-center distances for standard reductions along the fixed pitch. Gear reductions that add up to 80 teeth and 1-to-1 sprocket/pulley combinations will work by default. For ratios that don't fit on the fixed pitch, we have created that feature an adjusted version of the MAX Pattern.
Transmitting Motion is the act of getting motion from one part of the robot to another using shafts, sprockets, gears, 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).
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 main components in transmitting motion in the REV ION Build System is 1/2in Hex (hexagonal, six sided) shape. 1/2in Hex is featured in components where a MAXSpline is too large or when motion needs to be directly transmitted to a 1/2in Hex shaft. 1/2in Hex shafts are available in a number of different lengths and can be cut to length if needed.
Another important shape for transmitting motion in the REV ION Build System is the MAXSpline. This shape is incorporated into the other main motion components such as: MAXHubs, sprockets, gears, wheels, pulleys, and MAXSpline shaft.
The two primary systems used for transmitting motion in the REV ION Build System are gears and sprockets with chain.
The REV ION build system uses #10 Hardware to connect, or fasten, brackets and structure together on a robot. Different applications require different length screws. When attaching a bracket to extrusion, shorter screws are generally required. Use longer screws to connect Control System components and other thicker materials.
Length is measured from tip to underside of screw head
Length is measured from tip to underside of screw head
Aluminum threaded standoffs (Product Family Page) are an easy way to assemble structural components like plates, brackets and tubes. Tapped on each end with a #10-32 thread and a 3/8in flat to flat dimension similar to a #10-32 nut.
One of the oldest and least 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 hightorque 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.
Convert different output types to 1/2in Hex Shaft to interface with the REV ION Build System using our different 1/2in Hex Shaft Adapters.
MAXHubs provide a way to transfer torque to a MAXSpline pattern from shafts of various shapes and sizes. Other MAXHub variants allow for different bores or structural patterns to populate within an existing MAXSpline. MAXHubs are available in plastic and aluminum.
Dead Axle Tube is compatible with the REV ION System and can be used with 3/4in Needle Bearing Carrier and MAXSpline Shaft as the dead axle in a dead axle roller. Can also be used with custom rollers and as structural support.
3/4in Dead Axle Tube acts as the structural member in this MAXSpline Shaft dead axle application. Supporting the Dead Axle Tube is a Needle Bearing (3/4in ID, 1in OD) that fits into MAXSpline Shaft. Tube nuts ) for the 5/8in ID of the Dead Axle Tube makes mounting your assembly easy. Alternatively you could use a Stepped Bushing to mount your MAXSpline Shaft to your Dead Axle Tube.
Check out our for an Onshape example.
This Stepped Bushing () in conjunction with the MAXSpline Shaft and the 3/4in tube can be used to build robust and effective rollers and intakes for your FRC robot. It can also be used as a pivot point when combined with a MAXTube and 3/4in dead axle.
This MAXSpline Shaft Endcap () enables you to convert MAXSpline Shaft into a live axle driven by a 1/2in Hex shaft.
MAXSpline Shaft () is compatible with the REV ION System and is an extruded aluminum MAXSpline that provides a high strength alternative to 1/2in hex shaft that can interface with any REV ION system components. The inner diameter is 1in and can fit a Needle Bearing for dead axle applications.
The 1/2in Rounded Hex Shafts () are a ready-to-use hex shaft that have been cut to length and have the ends tapped #10-32 in order to accept a screw and washer or a shaft collar. We've rounded the corners to form a 13.75mm circle that allows the shaft to pilot inside our Flanged Bearings () resulting in an exceptionally smooth assembly and driving experience. Additionally, an untapped 36in shaft is available if you need to create a custom cut length.
Easily attach the UltraPlanetary 1/2in Hex Adapter to the output of your UltraPlanetary Gearbox to provide a convenient 1/2in hex output shaft
With the 8mm to 1/2in Hex Adapter you can convert 8mm keyed shafts to drive 1/2in hex bore wheels, sprockets, gears, and more! Use these with any motors that have a 8mm round keyed output shaft, like the NEO Brushless Motor .
MAXSpline Spacers are compatible with the REV ION System and can be used on the shaft as a spacer for wheels and sprockets as well as an in-between spacer for bearings.
Primarily used with ION wheels and sprockets, the MAXSpline Spacer with MAX Pattern features a 2in bolt circle pattern allowing it to be bolted directly to structural members like MAXTubes and the bolt circle allows it to be mounted to motion components as well.
1/2in Hex Shaft Spacers are primarily used with a hex shaft as a spacer between components with 1/16in, 1/8in, 1/4in, 1/2in widths available.
The 8mm Shaft Spacer is compatible with the REV ION System and is a convenient way to space pinions and gears along the shaft of the NEO Brushless Motor.
Compatible with the REV ION System and are an accurate way to space structural components like plates, brackets, or tubes apart on #10 screws. Our #10 Spacers can also be used to to space motion components like gearboxes away from their mounting surface. Mix and match various spacer lengths to adjust spacing in increments as small as 1/8in.
#10-32 Shaft End Screw ION 1/2in Rounded Hex Shafts come tapped with a 10-32 hole. Use this special screw to retain things on any of our hex shafts instead of shaft collars. The integrated flange is larger than the outside diameter of the shaft and will keep motion components from sliding off the end of the shaft and a nylon patch helps keep it secured in high vibration environments.
MAXSpline Shaft Collar - 2 Piece - Aluminum The MAXSpline Shaft Collar provides a simple way to retain items in place on the MAXSpline Shaft. The shaft collar can also be bolted to structure to constrain the axial alignment of MAXSpline Shaft when used in a structural method.
2 Piece Shaft Collar - 1/2in Hex Bore The 2-Piece 1/2in Hex Plastic Shaft Collar is used to prevent gears, sprockets, wheels, and other parts from sliding out of place on a 1/2in hex shaft. The two-piece design allows you to install the shaft collar onto a shaft without having to remove other parts or having access to the ends of the shaft. Tighten the two screws to secure the shaft collar onto the shaft. Screws require a 5/32in hex driver (not included).
1 Piece Shaft Collar - 1/2in Hex Bore The 1-Piece 1/2in Hex Plastic Shaft Collar is used to prevent gears, sprockets, wheels, and other parts from sliding out of place on a 1/2in hex shaft. Tighten the screw to secure the shaft collar onto the shaft. Screw requires a 5/32in hex driver (not included)
Screw Size
Outside Diameter
Threads Per Inch
Tool
0.190in
32
1/8in Hex
0.190in
32
1/8in Hex
0.190in
32
1/8in Hex
Nut Size
Height
Threads Per Inch
Tool
#10-32
11/64in
32
3/8in Wrench
Screw Size
Outside Diameter
Threads Per Inch
Tool
#10-32 3/8in
0.190in
32
5/32in Hex
#10-32 1/2in
0.190in
32
5/32in Hex
#10-32 5/8in
0.190in
32
5/32in Hex
#10-32 3/4in
0.190in
32
5/32in Hex
#10-32 1in
0.190in
32
5/32in Hex
#10-32 1-1/4in
0.190in
32
5/32in Hex
#10-32 1-1/2in
0.190in
32
5/32in Hex
#10-32 1-3/4in
0.190in
32
5/32in Hex
#10-32 2in
0.190in
32
5/32in Hex
#10-32 2-1/2in
0.190in
32
5/32in Hex
#10-32 3in
0.190in
32
5/32in Hex
#10-32 3-1/2in
0.190in
32
5/32in Hex
#10-32 4in
0.190in
32
5/32in Hex
Size
Outside Diameter: Flange
Thread Per Inch
Tool
#10-32 1/2in
0.63in
32
1/8in Hex
Diameter
Length
Tapped
5.5mm Hex
3/4in
#10-32
5.5mm Hex
1in
#10-32
5.5mm Hex
1-1/2in
#10-32
5.5mm Hex
2in
#10-32
5.5mm Hex
3in
#10-32
5.5mm Hex
36in
#10-32
Diameter | Length | Tapped |
1/2in Rounded Hex | 1.0-8.0in | #10-32 tapped |
1/2in Rounded Hex | 36in | Not Tapped |
Diameter | Length |
1/2in Rounded Hex | 1/16in |
1/2in Rounded Hex | 1/8in |
1/2in Rounded Hex | 1/4in |
1/2in Rounded Hex | 1/2in |
Outside Diameter | Length |
3/8in | 1/8in |
3/8in | 1/4in |
3/8in | 3/8in |
3/8in | 1/2in |
3/8in | 3/4in |
3/8in | 1in |
3/8in | 1-1/8in |
3/8in | 1-1/2in |
3/8in | 2in |
The ION Pivot Joint (REV-21-2395-PK2) can be used in numerous ways within the ION Build System. One example is a Pivot Joint being used as a bearing for a shaft to support a wheel, like in the picture below. Another example is a Pivot Joint being used as a hinge for a pivoting mechanism.
The Flanged Bearing (REV-21-1916) for 1/2in Rounded Hex is compatible with the REV ION System and provides a way of locating and supporting a 1/2in Rounded Hex Shaft while it rotates. The flange on the outer space of the bearing allows the bearing to be installed in a hole or MAXSpline with no other means of retention.
The Needle Bearing (REV-21-2386) with 3/4in ID and 1in OD, fits into MAXSpline Shaft (REV-21-2520) and is used for dead axle applications. Hold it in place securely using a 3/4in Needle Bearing Carrier (REV-21-2385).
Needle Bearings should be lightly greased and not run dry on shafts. We recommend red tacky or other Lithium based grease.
Documentation Coming Soon!
Gears are one common way to transmit power and change the output torque or speed of a mechanical system. Understanding these basic concepts is required to make optimized design decisions which consider the trade-off between torque and speed for a system with a given power.
Speed is the measure of how fast an object is moving. The speed of an object is how far it will travel in a given amount of time. For rotating parts like gears and wheels, speed is expressed in how many revolutions are made in a given amount of time. Under ideal conditions, the rotation of a wheel is converted into linear speed and can be calculated by multiplying the diameter of the wheel by the rotations for a given time. The SI unit for speed is meters per second (m/s), but speed is also commonly expressed in feet per second (ft/s).
Torque is roughly the measure of the turning force on an object like a gear or a wheel. Mathematically, torque is defined as the rate of change of the angular momentum of an object. This can also be stated as a force that acts normal (at 90 degrees) to a radial lever arm which causes the object to rotate. A common example of torque is the use of a wrench in order to tighten or loosen a bolt. In that example, using a longer wrench can produce more torque on the bolt than using a shorter wrench. Torque is commonly expressed in Nâ‹…m or inâ‹…lbs.
When torque is turning an object like a spur gear, the gear will create a straight line (linear) force at the point where the teeth contact the other gear. The magnitude of the torque created is the product of the rotational force applied and the length of the lever arm ,which in the case of a gear, is half of the pitch diameter (the radius).
Power (P) is the rate of work over time. The concept of power includes both a physical change and a time period in which the change occurs. This is different from the concept of work which only measures a physical change. The difference in these two concepts is that it takes the same amount of work to carry a brick up a mountain whether you walk or run, but running takes more power because the work is done in a shorter amount of time. The SI unit for power is the Watt (W) which is equivalent to one joule per second (J/s).
In competitive robotics, the total amount of available power is determined by the motors and batteries allowed to be used. The maximum speed at which an arm can lift a certain load is dictated by the maximum system power.
Meshing two or more gears together is known as a gear train. Selecting the gears in the gear train as larger or smaller relative to the input gear can either increase the output speed or increase the output torque, but the total power is not affected.
When a larger gear drives a smaller one, for one rotation of the larger gear the small gear must complete more revolutions - so the output will be faster than the input. If the situation is reversed, and aa smaller gear drives a larger output gear, then for one rotation of the input the output will complete less than one revolution – so the output will be slower than the input. The ratio of the sizes of the two gears is proportional to the speed and torque changes between them.
The ratio in size from the input (driving) gear to the output (driven) gear determines if the output is faster (less torque) or has more torque (slower). To calculate exactly how the gear ratio effects the relationship from input to output, find the ratio for the number of teeth between the two gears. In the image below, the ratio of the number of teeth from the input gear to the output gear is 72T:15T which means the input needs to turn 4.8 rotations for the output to complete one rotation.
What happens when a 45 tooth idler gear is inserted into the gear example? An idler gear is any intermediate (between input and output) gear which does not drive any output (work) shaft. Idler gears are used to transmit torque over longer distances than would be practical by using just a single pair of gears. Idler gears are also used to reverse the direction of the rotation of the final gear.
Regardless of the number or size of idler gears in the chain, only the first and last gear determine the reduction. Since idler gears do not change the gear reduction, the reduction in the example remains 72:15, but the direction of the output stage is now reversed from the previous example.
Idler gears are a good way to transmit power across distances in your robot. A common example of this is an all gear drivetrain. In this example the gears on the end are linked to the drive wheels and one of the center gears would be driven by a motor (not shown). The orange arrows indicate the relative rotation of each of the gears showing that the two wheels are mechanically linked and will always rotate in the same direction.
Because idler gears reverse the direction of rotation, it is important to pay attention to the number of gears in the drivetrain. In the picture below there is an even number of gears, and because of this the wheels will always spin in the opposite direction.
Some designs may require more reduction than is practical in a single stage. The ratio from the smallest gear available to the largest in the REV ION Build System is 80:10, so if a greater reduction than 8 is required, multiple reduction stages can be used in the same mechanism, and this is called a compound gear reduction. There are multiple gear pairs in a compound reduction with each pair of gears linked by a shared shaft. Below is an example of a two-stage reduction. The driving gear (input) of each pair is highlighted in orange.
Reduction is the concept of lowering input speed to reduce overall output speed.
To calculate the total reduction of a compound reduction, identify the reduction of each stage and then multiply each reduction together.
​Where:
CR is the total Compound Reduction
Rn is the total reduction of each stage
Using the image above as an example, the compound reduction is 12:1.
​For any gear system, there are a limited number of gear sizes available, so in addition to being able to create greater reductions using compound reductions, it is also possible to create a wider range of reduction values, or the same reduction of a single stage, but with smaller diameter 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).
PD = M Ă— N
PD = (OD Ă— N) / (N + 2)
PD = OD - (2 Ă— M)
Then, use the pitch diameters to calculate the center-to-center distance (CCD).
CCD = ((PD1) / 2) + ((PD2) / 2)
Any two REV 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
Documentation Coming Soon!
Gears have teeth that mesh with other gears in order to transmit torque. Gears can be used to change the speed, torque (turning force), or direction of a motor’s original output. For gears to be compatible with each other, the meshing teeth must have the same shape (size and pitch). Gears are ideal for use in more compact spaces and are also used for changing the direction of rotation.
Gears offer more flexibility in transforming motion than sprockets and chain because there are a larger variety of gear sizes available.
There are many different types of gears; one of the simplest and most commonly used is a spur gear, and that is the gear type used in the REV ION System. Spur gears consist of a disk with straight teeth projecting radially (outward from the center) and these gears will only mesh correctly with other gears if they are on parallel shafts.
Documentation Coming Soon!
DP stands for Diametral Pitch. The diametral pitch of a gear is the number of teeth in the gear for each inch of pitch diameter. So, a 20DP gear has 20 teeth per inch.
Sometimes in a design it may be desirable to stack together multiples of the same gear on a shaft to increase the load carrying capacity of the gears. In the case where the number of teeth on the gear is not divisible by six, because of how they are oriented when put onto the hex shaft, the teeth may not be aligned between the two gears. To ensure all of the gears are clocked the same way, use the alignment shaft notch to put all the gears on the shaft with the same orientation.
Meshing two or more gears together is known as a gear train. Selecting the gears in the gear train as larger or smaller relative to the input gear can either increase the output speed, or increase the output torque but the total power is not affected.
A gear ratio is the ratio of the sizes of two gears. For instance, in the image below, the input gear is a 15 tooth gear and the output gear is a 72 tooth gear. So, the gear ratio is 72T:15T. The ratio in size from the input (driving) gear to the output (driven) gear determines if the output is faster (less torque) or has more torque (slower). The gear ratio is proportional to the speed and torque changes between them.
In the image above, the 15 tooth input gear is rotating clockwise. As the input gear rotates, it pushes down on the output gear where the teeth are meshed. This action transmits the motion to the output gear, but forces the output gear to rotate in the opposite direction of the input gear.
In order for gears to work effectively, and not become damaged, it’s important that the center-to-center distance is correctly adjusted. The gears in DETAIL A of the figure below may work under very light load, but they will certainly not work and will skip under any significant loading. The gears in that example are too far apart, and the teeth of each gear barely contact each other. The gears in DETAIL B are correctly spaced and will provide smooth and reliable operation.
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 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 REV ION Build System is designed around #25 chain using compatible #25 sprockets.
Sprockets are rotating parts that have teeth and can be used with a chain and another sprocket to transmit torque. Sprockets and chain can be used to change the speed, torque or direction of a motor. For sprockets and chain to be compatible with each other, they must have the same thickness and pitch.
Sprocket and chain is a very efficient way to transmit torque over long distances.
The most common and important features of a sprocket are called out in the figure below.
Number of Teeth is the total count of the number of teeth (projections) around the whole circumference of a sprocket. For sprockets with very few teeth this number is easily physically counted, but for high tooth counts this may not be isn’t very practical.
Pitch Diameter (PD) is an imaginary circle which is traced by the center of the chain pins when the sprocket rotates while meshed with a chain. The ratio of the pitch diameter between sprockets can be used to calculate the gear ratio, but more commonly and much more simply the ratio of the number of teeth is used for this calculation.
Pitch represents the amount of pitch diameter in inches per tooth. Sprockets with a larger pitch will have bigger teeth. Common pitches are 0.25”, known as #25, and 0.375” (#35). The REV Robotics building system uses #25 chain.
Outside Diameter (OD) will always be larger than the pitch diameter but smaller than the chain clearance diameter. The outside diameter does not account for the additional diameter added by the chain, so it should not be used to check for assembly interference.
Chain Clearance Diameter is the outside diameter of a sprocket with chain wrapped around it. The chain clearance diameter will always be larger than the pitch diameter and the outside diameter. The chain clearance diameter should be used when checking for interference when placing sprockets very close to other structures.
Roller chain is used to connect two sprockets together and transfer torque. Roller chain is made up of a series of inner and outer links connected together which forms a flexible strand.
Outside Links consist of two outside plates which are connected by two pins that are pressed into each plate. The pins in the outside link go through the inside of the hollow bushings when the inner and outer links are assembled. The pins can freely rotate on the inside of the bushings.
Inside Link consist of two inside plates that are connected by two hollow bushings which are pressed into each plate. The teeth of the sprocket contact the surface of the bushings when the chain is wrapped around a sprocket.
Pitch is the distance between the centers of two adjacent pins. Common pitches are 0.25”, known as #25, and 0.375” (#35). The REV 15mm Building System uses #25 chain.
Transforming the torque and speed of the motion is accomplished by changing the size of the sprockets.
A sprocket size ratio is the relationship between the number of teeth of two sprockets (input and output). In the image below, the input sprocket is a 15 tooth sprocket and the output is a 20 tooth. The sprocket size ratio for the example is 20T:15T. The ratio in size from the input (driving) sprocket to the output (driven) sprocket determines if the output is faster (less torque) or has more torque (slower).
In order for sprockets to work effectively, it’s important that the center-to-center distance is correctly adjusted. The sprocket and chain example with the red 'X', in the image below, may work under very light loads, but they will certainly not work and will skip under any significant loading. The sprockets in this example are too close together so chain is loose enough that it can skip on the sprocket teeth. The sprockets, with the green check mark, are correctly spaced which will provide smooth reliable operation.
All REV ION Gears are 20DP, made of 4140 Steel, and pocketed to reduce weight. Our REV ION 20DP Gears come in a wide range of sizes and bores including MAXSpline, 1/2in Hex, and 1/2in Rounded Hex. Larger gears include #10 clearance hole patterns, 2in bolt circle, and MAXTube mounting pattern.
When assembling the gear train we recommend adding grease during assembly and re-applying as needed for the maintenance of your mechanism. For most applications, using or will provide sufficient lubrication.
To learn more about calculating center-to-center distance for Gears visit the .
Sprockets consist of a disk with straight teeth projecting radially. Sprockets will only work correctly with chain and other sprockets if they are on parallel shafts and the teeth are in the same plane. A chain consists of a continuous set of links that ride on the sprockets to transmit motion. The REV ION Build System is designed around #25 Roller Chain () using compatible #25 Sprockets.
Our are compatible with the REV ION system and designed for use with These sprockets are flat and feature a MAXSpline and a 2in bolt circle that patterns outward radially, allow for bolting to structure easily. #25 Hub Sprockets feature a 1/2in hex bore or MAXSpline and transfer torque through a shaft. 1/2in Hex - 16 Tooth - Double sprockets available for chain in tube applications.
To learn more about ratio calculations for sprockets, check out the section on our Advanced Page!
To learn more about calculating center-to-center distance for sprockets visit the section on the Advanced Sprockets and Chain Page.
The first step to getting ideal chain tension is to manipulate, or cut the chain to the correct size. Using the center-to-center distance calculation is one of the most accurate ways to find the chain size needed. Once sizing is approximated, use the Chain Tool () or Master Link () to break and reform the chain.
To learn more about using the Chain Tool and Master Link, check out the section.
Sprockets are one common way to transmit power and change the output torque or speed of a mechanical system. Understanding these basic concepts is required to make optimized design decisions. This section will briefly cover the definition of these concepts and then explain them in relationship to basic sprocket and chain designs.
Speed is the measure of how fast an object is moving. The speed of an object is how far it will travel in a given amount of time. The SI unit for speed is meters per second but speed is also commonly expressed in feet per second.
Torque is roughly the measure of the turning force on an object like a sprocket or a wheel. Mathematically, torque is defined as the rate of change of the angular momentum of an object. A common example of torque is a wrench attached to a bolt produces a torque to tighten or loosen it. Torque is commonly expressed in Nâ‹…m or inâ‹…lbs.
When torque is turning an object, like a sprocket, the sprocket will create a straight line (linear) force at the point where the teeth contact the chain. The magnitude of the torque created is the product of the rotational force applied and the length of the lever arm, which in the case of a sprocket, is half of the pitch diameter (the radius).
Power (P) is the rate of work over time. The concept of power includes both a physical change and a time period which the change occurs. This is distinct from the concept of work which only measures a physical change. It takes the same amount of work to carry a brick up a mountain whether you walk or run, but running takes more power because the work is done in a shorter amount of time. The SI unit for power is the watt(W) which is the same as one joule per second (J/s).
Often in competition robotics the total power is fixed by the motors and the batteries available. The maximum speed at which an arm can lift a certain load is dictated by the maximum system power.
Selecting sprockets with different sizes relative to the input sprocket varies the output speed and the output torque. However, total power is not effected through these changes.
Sprocket and chain is a very efficient way to transmit torque over long distances. Modest reductions can be accomplished using sprockets and chain, but gears typically provide a more space-efficient solution for higher ratio reductions.
When a larger sprocket drives a smaller one, for every rotation of the larger sprocket, the smaller sprocket must complete more revolutions, so the output will be faster than the input. If the situation is reversed, and a smaller sprocket drives a larger output sprocket, then for one rotation of the input, the output will complete less than one revolution- resulting in a speed decrease from the input. The ratio of the sizes of the two sprockets is proportional to the speed and torque changes between them.
The ratio in size from the input (driving) sprocket to the output (driven) sprocket determines if the output is faster (less torque) or has more torque (slower). To calculate exactly how the sprocket size ratio effects the relationship from input to output, use the ratio of the number of teeth between the two sprockets.
In the image below, the ratio of the number of teeth from the input sprocket to the output sprocket is 20T:15T, which means the input needs to turn 1.3 rotations for the output to complete one rotation ​
Some designs may require more reduction than is practical in a single stage. The ratio from the smallest sprocket available to the largest is 64:16, so if a greater reduction then 4x is required, multiple reduction stages can be used in the same mechanism which is called a compound gear reduction. There are multiple gear or sprocket pairs in a compound reduction with each pair linked by a shared axle. When using sprockets and chain in a multi stage reduction, it’s very common to use gears for the first stage and then use sprockets and chain for the last stage. The figure below is an example of a two-stage reduction using all gears, but one of the pairs could be replaced with sprockets and chain. The driving gear (input) of each pair is highlighted in orange.
Reduction is calculated the same for gears and sprockets based on the ratio of the number of teeth. To calculate the total reduction of a compound reduction, identify the reduction of each stage and then multiply each reduction together.
Where:
CR is the total Compound Reduction
Rn is the total reduction of each stage
Using the image above as an example, the compound reduction is 12:1.
For any gear system, there are a limited number of gear and sprocket sizes available, so in addition to being able to create greater reductions using compound reductions, it is also possible to create a wider range of reduction values or the same reduction of a single stage, but with smaller diameter motion components.
Each additional compound stage will result in a decrease in efficiency of the system.
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
If a ratio other than 1:1 is needed when using the REV ION Build System, use our Ratio Plates to accommodate for the change in center-to-center distance. An ION Ratio Plate provides an offset from the standard MAX Pattern pitch that creates the center-to-center distance.
In order for sprockets to work effectively, it’s important that the center-to-center distance is correctly adjusted. The sprocket and chain example with the red "X" in the image below may work under very light loads, but they will certainly not work and will skip under any significant loading. The sprockets in this example are too close together, so the chain is loose enough that it can skip on the sprocket teeth. The sprockets with the green check mark are correctly spaced, which will provide smooth and reliable operation.
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 blades, like a dremel. Once you have counted the number of links necessary for your application, the chain can be joined using a master link or by replacing the chain pin.
This custom-designed #25 Chain Tool (REV-41-1442) also commonly referred to as a "chain break" or "chain breaker", allows teams to easily break and re-assemble #25 Chain (REV-41-1365). The mandrel is used to push out the chain pin. If using Master Links (REV-41-1366), the pin can be completely removed, but the depth guide screw allows the option of partially pressing out the pin and then re-assembling without master links.
The REV Robotics #25 Chain Tool (REV-41-1442) comes with the following:
1 Chain Tool Block
2 Set Screw Mandrels
1 Depth Guide Screw
1 Cup Point Set Screw
1 4mm Allen Wrench
Before using the #25 Chain Tool for the first time, remove the thread pin screw and use WD-40 or compressed air to remove any shavings left in the tool from the manufacturing process. This will ensure the chain break works smoothly and efficiently breaks your chain. Reinstall the thread pin screw. Once this is complete, the chain break is ready for use.
In almost all applications, chain links are connected to form a loop. While chain can sometimes be purchased in specific length loops, it is more common and economical to buy chain by the foot and make custom loop lengths to fit the application. It’s recommended to use a specialized tool, a chain breaker, to cut chain into desired lengths to prevent accidental damage.
Chain breakers do not actually cut the chain; instead, they are used to press out the pins from an outer link. After the pins have been removed, the chain can be separated, leaving inner links on both ends of the break.
Chain Tools have two methods for resetting chain. Using Master Links and resetting the chain pin. Resetting the pin is results in a stronger chain than using a master link.
Roller chain is typically connected into a continuous loop. This can be done using a special tool to press the pins in and out of the desired outer link as described in the Resetting Chain Pins section, or, if the chain is already the correct length, a common roller chain accessory called a master link, or quick-release link, can be used to connect two ends of the chain.
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 can not be adjusted, so you lose some flexibility in spacing options. 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 REV 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. Since they are both on a 1/4in pitch, they can 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.
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 FIRST Robotics Competition: Brushed DC Motors and Brushless DC motors. Both types are useful in various robot applications, and both have their trade-offs.
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 give it DC power and expect it 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.
The REV NEO Brushless Motor runs an 8mm keyed output shaft which allows for an easy transition from CIM-style brushed motors into brushless. Swap a set of NEO Brushless Motors into your drivetrain or use one in an elevator to save weight and maintain peak performance. When paired with the SPARK MAX, you can use the integrated hall-effect sensors to calculate incremental position or speed from the NEO.
Stall Torque is measured when the motors RPM is zero and the motor is drawing its full Stall Current. This value is the maximum torque the motor is ever capable of outputting. Keep in mind the motor is not capable of outputting this torque for an indefinite period of time. Waste energy will be released into the motor as heat. When the motor is producing more waste heat than the motor body is capable of dissipating the motor will eventually overheat and fail.
Stall Current is the maximum amount of current the motor will draw. The stall current is measured at the point when the motor has torque that the RPM goes down to zero. This is also the point at which the most waste heat will be dissipated into the motor body.
Free Speed is the angular velocity that a motor will spin at when powered at the Operating Voltage with zero load on the motor’s output shaft. This RPM is the fastest angular velocity the motor will ever spin at. Once the motor is under load its angular velocity will decrease.
Operating Voltage is the expected voltage that the motor will experience during operation. If a robot is built using a 12 volt battery the Operating Voltage of the motor will be 12 volts. When controlling the RPM of the motor the DC speed controller will modulate the effective voltage seen by the motor. The lower the voltage seen by the motor the slower it will spin. DC motors have a maximum rated voltage if this voltage is exceeded the motor will fail prematurely.
The key metrics defined above are interrelated. Take some time to familiarize yourself with the definitions and how they connect together.
In order to ensure that an electric motor lasts as long as possible a few rules of thumb should be kept in mind:
Smooth loading - large torque spikes or sudden changes in direction can cause excess wear and premature failure of gearbox components. This is only an issue when the torque spike exceeds the rated stall torque of the motor. When shock loading is necessary, it is best to utilize mechanical braking or a hard stop that absorbs the impact instead of the motor.
Overheating - when a motor is loaded at near its maximum operating torque it will produce more waste heat than when operating at a lower operating torque. If this heat this allowed to build up the motor can wear out prematurely or fail spontaneously.
Poorly supported output shaft, most motor output shafts are not designed to take large thrust forces or forces normal to the shaft. Bearings need to be used to support the axle when loads in these directions are expected.
CAUTION: Improperly wiring the connectors can cause severe motor damage and is not covered by the warranty. DO NOT connect the motor directly to the battery.
When you need a ratio other than 1:1, Ratio Plates make it easy to position sprockets and pulleys at the perfect center-to-center distance for the given ratio and length of #25 chain or RT25 belt. Each ratio plate is designed for the indicated sprocket or pulley combination and a loop of chain or belt that is the indicated length. For example, 56PL equates to a 56 link loop of #25 chain or a 56 tooth RT25 belt.
Connecting the NEO Brushless motors is fairly straightforward. Follow the guide at , and don't forget to connect your encoder sensor wire; the motor will not spin without it!
1) Unscrew the Pin Screw and Compression Screw such that the chain channel is free of obstructions.
2) Insert #25 chain (REV-41-1365) into the chain channel and align the desired link between the two pins above the Cup Point Set Screw.
3) Secure the chain in place with the Compression Screw using the Allen Wrench. Tighten until the chain cannot shift within the channel.
4) Put the Allen Wrench into the Pin Screw and tighten until the pin is entirely removed from the chain. Make sure to have a Master Link (REV-41-1366) on hand.
1) Unscrew the Pin Screw and Compression Screw such that the chain channel is free of obstructions.
2) Insert #25 chain (REV-41-1365) into the chain channel and align the desired link between the two pins above the Cup Point Set Screw.
3) Secure the chain in place with the Compression Screw using the Allen Wrench. Tighten until the chain cannot shift within the channel.
4) Put the Allen Wrench into the Pin Screw and tighten until the pin almost touches the Cup Point Set Screw. You should stop pushing the pin out before it leaves the back plate of the outer links. Considerable pressure will be felt before the pin comes out, but removing the chain from the tool occasionally during the process to check if the pin is unseated from the bushing is recommended. The final result should be the pin still partially connected to the chain, as seen in the second photo.
5) Unscrew the Compression Screw until the channel is empty, and place the unseated pin and outer plates into the open channel. Place the desired empty inside link in between the outer plates and unseated pin.
6) Tighten the Compression Screw using the Allen Wrench until the pin is reseated.
6) Once the pin is fully reseated, release the chain from the tool using the Allen Wrench- your chain should be connected!
1 - 10-32 x 3/8in long Socket Head Screw
Press Fit Pinion
Arbor Press
Do not attempt to run the NEO while a screw is still attached to the back of the motor. Not removing the screw will damage the motor and/or shaft.
NEO V1.0 (REV-21-1650)
A high-quality 1.5mm Allen Key (i.e. WERA Tools, Bondhus)
Loctite 242
Arbor Press
The REV NEO Brushless Motor (REV-21-1650) is the first brushless motor designed to meet the unique demands of the FRC community. Offering an incredible power to weight ratio along with it's compact size it's designed to be a drop-in replacement for CIM-style motors as well as an easy install with mounting options.
Drop-in replacement for CIM-style motors
Shielded out-runner construction
Front and rear ball bearings
High-temperature neodymium magnets
High-flex silicone motor wires
Integrated motor sensor
3-phase hall sensors
Motor temperature sensor
Empirical means based on observations or experience. Theoretical means based on theories and hypotheses. The two terms are often used in scientific practice to refer to data, methods, or probabilities. When we refer to empirical data, we refer to values that were produced via testing. When our documentation refers to theoretical values, those are values that are based on what the product can do, in theory, but have not directly been produced.
Check out the NEO Motor Data Sheet for additional specifications. Also, please pay special attention to the NEO Motor Locked Rotor Testing and please make sure you have read and understand how to set the SPARK MAX Smart Current Limit.
Drop-in replacement for CIM-style motors
Shielded out-runner construction
Front and rear ball bearings
High-temperature neodymium magnets
High-flex silicone motor wires
Integrated motor sensor
3-phase hall sensors
Motor temperature sensor
A tapped #10-32 hole on the end of the shaft, allowing teams to retain pinions on the shaft without using external retaining rings
A tapped #10-32 hole on the back housing of the motor, making it no longer necessary to remove the motor housing to press pinions
Additional holes on the front face of the motor for added mounting flexibility
Empirical means based on observations or experience. Theoretical means based on theories and hypotheses. The two terms are often used in scientific practice to refer to data, methods, or probabilities. When we refer to empirical data, we refer to values that were produced via testing. When our documentation refers to theoretical values, those are values that are based on what the product can do, in theory, but have not directly been produced.
The REV NEO Brushless Motor V1.1 () is the initial update on the first brushless motor designed to meet the unique demands of the FIRST Robotics Competition community. NEO V1.1 offers an incredible power density due to its compact size and reduced weight, and it's designed to be a drop-in replacement for CIM-style motors, as well as an easy install with many mounting options. The built-in hall-effect encoder guarantees low-speed torque performance while enabling smart control without additional hardware. NEO V1.1 has been optimized to work with the SPARK MAX Motor Controller () to deliver incredible performance and feedback.
Check out the for additional information. Also, please pay special attention to the and please make sure you have read and understand how to set the .
Empirical Motor Kv
473 Kv
Empirical Free Speed
5676 RPM
Empirical Free Running Current
1.8 A
Empirical Stall Current
105 A
Empirical Stall Torque
2.6 Nm
Empirical Peak Output Power
406 W
Theoretical Stall Current
150 A
Theoretical Stall Torque
3.75 Nm
Theoretical Peak Output Power
540 W
Nominal Voltage
12 V
Typical Output Power at 40 A
380 W
Hall-Sensor Encoder Resolution
42 counts per rev.
Output Shaft Diameter
8mm (keyed)
Output Shaft Length
35mm (1.38in)
Output Pilot
19.05mm (0.75in)
Body Length
58.25mm (2.3in)
Body Diameter
60mm (2.36in)
Weight
0.938 lbs (0.425 kg)
Empirical Motor Kv | 473 Kv |
Empirical Free Speed | 5676 RPM |
Empirical Free Running Current | 1.8 A |
Empirical Stall Current | 105 A |
Empirical Stall Torque | 2.6 Nm |
Empirical Peak Output Power | 406 W |
Theoretical Stall Current | 150 A |
Theoretical Stall Torque | 3.75 Nm |
Theoretical Peak Output Power | 540 W |
Nominal Voltage | 12 V |
Typical Output Power at 40 A | 380 W |
Hall-Sensor Encoder Resolution | 42 counts per rev. |
Output Shaft Diameter | 8mm (keyed) |
Output Shaft Length | 35mm (1.38in) |
Output Pilot | 19.05mm (0.75in) |
Body Length | 58.25mm (2.3in) |
Body Diameter | 60mm (2.36in) |
Weight | 0.938 lbs (0.425 kg) |
1) Take a 10-32 x 3/8in long socket head screw and screw it into the back of the motor finger tight.
DO NOT USE AN ALLEN WRENCH The screw is intended to support the end of the NEO's shaft while pressing on the pinion. Tightening the support screw with an Allen wrench may damage the motor and/or shaft.
2) Using a flat arbor press plate, balance the motor with that screw down on the arbor press
3) Proceed with pressing the pinion as usual. When complete, ensure that you remove the 10-32 socket head screw from the back of the NEO.
1) Locate the first of three screws holding the back can to the front plate of the motor.
2) Using a high-quality 1.5mm Allen Key, remove the bolt and set aside. Repeat this for the other two bolts around the back can. Make sure the Allen Key is fully seated in the bolt head during removal.
3) Remove the back can. Set it and the three bolts aside for reassembly after pressing on the pinion.
4) Place the NEO upright in the arbor press. Make sure to hold the bottom of the motor flat against the press plate, supporting the bottom of the shaft.
5) Press on pinion. After pinion is pressed on reattach the back can. We recommend using Loctite 242 to complete the reassembly.
The REV Robotics Smart Robot Servo (SRS) (REV-41-1097) is a configurable metal-geared servo that takes the guesswork out of aligning and adjusting servo based mechanisms. One SRS can be used as a standard angular servo, a custom angular servo, and a continuous rotation servo by simply changing its settings
For more information on how to use the SRS programmer to change the servo modes see the SRS Programmer section
Servo motors are a specialized kind of motor which can be controlled to move to a specific angle instead of continuously rotating like a DC motor. Instead of a hex output shaft like the DC motor, servos have an output spline. A spline is a specific groove pattern cut into the shaft which allows the rotation of the servo motor to be transmitted to the attached Aluminum Servo Horn (REV-41-1828) or Servo Adapter. Splines are like keys, so only matched types will fit together. The REV Robotics Servos all use a 25T spline pattern. If the gears or spline of the REV Robotics Smart Robot Servo (REV-41-1097) become damaged, they are replaceable using a Replacement Gear Set (REV-41-1168).
Common servo motors take a programmed input signal range and map that to an angular range. For example, for a servo with a 270° range, if the input range was from 0 to 1 then a signal input of 0 would cause the servo to turn to point -135°. For a signal input of 1, the servo would turn to +135°. Inputs between the minimum and maximum have corresponding angles evenly distributed between the minimum and maximum servo angle.
REV Robotics Servo Adapters fit 25T spline servos like the REV Robotics Smart Robot Servo. In addition to the variety pack of generic servo horns which come with the Smart Robot Servo, there are five other custom servo adapters which make using servos with the REV ION Build System easy.
Aluminum Servo Shaft Adapters (REV-41-1558) convert a 25T spline servo output shaft into a female 5mm hex socket. This adapter can be used to drive a hex shaft directly.
Aluminum Servo Horns (REV-41-1828) have a tapped hole pattern that can be directly mounted to any of the REV Robotics gears, wheels, or sprockets with the Motion Pattern.
Aluminum Double Servo Arms (REV-41-1820) have two tapped holes that can be directly mounted to any of the REV Robotics extrusion, channel, or brackets.
Aluminum 1/2in Rounded Hex Servo Shaft (REV-21-2892) converts a servo to a 1/2in Hex shaft for use with all other ION mechanical system components
Plastic 1/2in Hex Linkage Arm (REV-21-2895) used to control a linkage, flap, lever or pushrod
Plastic Face Mount Bracket The ION Servo Face Mount Bracket (REV-21-2896) allows for easy integration of Servo Motors into the ION System.
Most wheels used in FIRST Robotics Competition can be divided into four categories; Standard, Omni, Mecanum, and Compliant. 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.
Switching between continuous rotation, standard servo, and custom angular modes is easy as pressing a button. The SRS Programmer can not only program the SRS, but it is also acts as a standalone servo tester for any standard RC servo.
The REV Robotics SRS Programmer includes the following features:
3 programming modes
Continuous rotation
Angular limits
Reset to factory defaults
Test modes
Automatic sweep
Manual position/direction
Intuitive operation with LED feedback
Self-powered
Power-off reminder
†Not Included
The SRS Programmer has several operating modes for configuring and testing the REV Smart Robot Servo. The following sections describe each operating mode in detail.
Follow the steps below to switch a REV Smart Robot Servo between Continuous Mode and Servo Mode. The figure below shows the process to select Continuous Mode.
Connect the SRS to the programmer.
Turn on the programmer.
Slide the mode switch to the desired mode: C - Continuous, S - Servo.
Press and release the PROGRAM button once.
The PROGRAM LED should blink and then stay solid indicating success.
Follow the steps below to set the angular limits for the Servo Mode. The figure below shows an example of setting a left and right limits at -30° and +60° respectively.
Connect the SRS to the programmer.
Turn on the programmer.
Slide the mode switch to S position.
This step is optional, but recommended to make it easier to see the valid limit ranges. Please refer to the SRS User's Manual for more information about the valid limit ranges.
Press the PROGRAM button to center the servo at 0°.
Press and release the TEST button once to leave the test mode.
Manually rotate the servo to the desired left limit position.
Press and release the LEFT button. The LEFT LED will illuminate if the position is valid.
Manually rotate the servo to the desired right limit position.
Press and release the RIGHT button. The RIGHT LED will illuminate if the position is valid.
After both limits are set, press and release the PROGRAM button. The PROGRAM LED should blink and then stay solid indicating success.
Follow the steps below to reset the Smart Robot Servo to its default mode and limits. The figure below shows the process to reset to defaults.
Connect SRS to the programmer.
Turn on the programmer.
Slide the mode switch to S position.
Press and hold the PROGRAM button for at least 5 seconds.
The LEDs will blink and then the PROGRAM LED will stay solid indicating success.
In either Continuous or Servo Modes, pressing and releasing the TEST button cycles through the two test modes:
1st press - Automatic Sweep Mode
2nd press - Manual Test Mode
3rd press - Return to default state
The section below will cover the two different test modes.
In Automatic Sweep Mode, the SRS Programmer will automatically sweep the SRS through motions appropriate for its configuration. the table below describes the behavior based on the configured mode.
In Manual Test Mode the LEFT, PROGRAM, and RIGHT buttons control the movement of the SRS. The table below describes how the SRS will behave based on the configured mode.
If the SRS Programmer is left on for an extended period of inactivity, it will blink every LED as a reminder to shut off power.
REV Robotics offers three types of ION wheels: , and . There are two types of ION Traction wheels available: the standard and the . The main focus of the traction wheels is to pull a robot (or create traction) in a forward/backwards motion.
/ / wheels can easily be mounted flush when a build needs to gain load capacity or to increase traction as the cross section image above illustrates
The REV Robotics SRS Programmer () is the key to unlocking all the smart features of the Smart Robot Servo (SRS) ().
Start with the SRS already configured in Servo Mode, see section for instructions.
Press and release the TEST button twice to enter Manual Test Mode (see for more information).
Mechanical Specifications |
Dimensions | 70.5mm x 64.5mm x 35.5mm |
Weight |
Electrical Specifications |
Power Source | 4 AA batteries |
Power Output | 6V nominal |
Logic Level (Signal Out) | 3.3V |
Output Pulse Width Range | 550μs – 2450μs |
Center Pulse Width | 1500ÎĽs |
Servo and Programmer Mode | Behavior |
Continuous Mode (C) | Sweeping direction and speed |
Servo Mode (S) | Sweeping between limits |
ION Omni Wheels (Product Family Page) can be used in drive trains allowing robots to move directly sideways or with an intake allowing game pieces to be in-coming at an angle, but still move them forward. Available in a wide range of sizes featuring the MAXSpline or hex hub. Other bores are possible with a separate MAXHub. Rollers for each wheel size are unique, which ensures perfectly circular wheels.
Check out the full line of ION Omni Wheels on the product page
Gearboxes are a very common way to transform motion in 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 kind 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.
Allows user to adjust gear ratio by changing pinion and cluster gear (12:60, 18:54, 24:48, or 36:36)
Output shaft is 1/2in Hex through bore
Output gears have MAXSpline bore
Motor Plate contains 2 pairs of 2in pitch #10-32 tapped holes for mounting the Through Bore Encoder
Output Plate has array of holes for mounting to structure, as well as mounting an input to MAXPlanetary
5:1 ratio can be micro-adjusted by swapping a 12T pinion for an 11T or 10T
Note that the 2 Motor Gearbox Base Kit does not come with Ratio Gear Bundles.
The following items may or may not be included based on your product selection. Selecting a Base Kit and Ratio Gear Bundle are both required to assemble a gearbox.
Each Ratio Gear Bundle comes with one MAXSpline Gear and two 1/2in Hex Bore Gears.
The 2 Motor Drivetrain Gearbox Through Bore () is compatible with the REV ION System and can be mounted in a variety of ways, including flush with tube or spaced to enable both chain in tube and chain/belt outside tube designs. Standard pre-formed mounts for a Through Bore Encoder ensure the gearbox is on the same horizontal plane to help keep alignment frustrations to a minimum.
The 2 Motor Gearbox () Through Bore is compatible with the REV ION System. This two motor into one output gearbox allows the user to adjust the gear ratio by changing pinion and cluster gear (12:60, 18:54, 24:48, or 36:36). The output shaft is 1/2in Hex through bore, and output gears have a MAXSpline for compatibility.
The NEO Motor matches the design flexibility of other REV ION products with our optional MAXPlanetary Gearbox () The MAXPlanetary is primarily intended to be used with the NEO, NEO 550, Falcon 500, and 775 motors. For those utilizing a swerve drive in their build, the NEO Motor is also available with a straight shaft i.e. no gearbox.
To learn more about the MAXPlanetary system check out the as well as the video below
The NEO 550 Motor matches the design flexibility of other REV ION products with our optional UltraPlanetary Gearbox (). This UltraPlanetary System is a cartridge-based modular gearbox designed to handle the rigors of the competition and the classroom. Building on the ability to iterate and adjust designs easily using the REV Building System, the UltraPlanetary System consists of pre-assembled and lubricated cartridges allowing for swapping gear ratios on the fly and with ease.
To learn more about the UltraPlanetary System check out the section as well as the video above
are recommended for use with intakes and shooters but not for drivetrains because of their "softer" material and deformation under a typical robot's weight. Compatible with the REV ION System and come in a wide range of sizes, durometers, and bores. The radial spoke profile allows for more consistent compliance, and more compression than other compliant wheels. Larger wheels contain the MAXSpline, but can be adapted to other bores with a separate .
Check out the full line of on the product page
SKU | DESCRIPTION | QTY. |
---|
RATIO | MAXSPLINE GEAR | 1/2IN HEX BORE GEAR |
---|
Size:
Pattern:
Width
2in
Hex
1in
3/4/5/6in
MAXSpline
1.5in
Size: | Pattern: | Hardness | Width |
2in | Hex | Soft/Med/Hard | .50in |
3/4in | MAXSpline | Soft/Med/Hard | 1.0in |
2 MOTOR GEARBOX HARDWARE PACK | 1 |
REV-21-2099-P01 | 2 MOTOR GEARBOX MOTOR PLATE | 1 |
REV-21-2099-P02 | 2 MOTOR GEARBOX BEARING PLATE | 1 |
2 MOTOR GEARBOX SPACER PACK | 1 |
REV-21-2079 | 1/2IN HEX THROUGH BORE SHAFT | 1 |
REV-21-1879 | 8MM TO 1/2IN HEX ADAPTER | 2 |
BEARING, 30MM ID, 42mm OD, 7MM THICK, SHIELDED, FLANGED | 2 |
1:1 | 20DP GEAR- MAXSPLINE- 36T | 20DP GEAR - 1/2IN HEX - 36T |
2:1 | 20DP GEAR- MAXSPLINE- 48T | 20DP GEAR- 1/2IN HEX- 24T |
3:1 | 20DP GEAR- MAXSPLINE- 54T | 20DP GEAR- 1/2IN HEX- 18T |
5:1 | 20DP GEAR- MAXSPLINE- 60T | 20DP NEO PINION GEAR- 12T |
6:1 | 20DP GEAR- MAXSPLINE- 60T | 20DP NEO PINION GEAR- 10T |
The REV Robotics MAXPlanetary System includes the following features:
Three different, self-contained gear ratio cartridges providing twenty-seven gear ratios ranging from 3:1 to 125:1
High torque density
Easy assembly without modifying the motor
A Socket 1/2in Hex Output with the ability to retain a shaft blind
Assembled front to back for ease of changing the gear ratio while the MAXPlanetary Gearbox is mounted on the robot
Input Spline - Accepts torque from the previous stage while being easy to insert and remove.
Output Spline - Provides torque transfer between one stage and the next while being easy to insert and remove.
Assembly Holes - The screws holding the gearbox together pass through these holes.
Shields - Keeps the internal components of the gear stage in their place when the stage isn’t assembled into a gearbox. Also retains grease to keep the gear stage lubricated throughout its service life.
Alignment Tabs - Alignment features that engage with the alignment notches on the previous stage. The directional nature of the alignment features prevent the user from assembling any gearbox components backwards.
Alignment Notches - Provides a socket for the alignment tabs to engage with. These features keep the rotating components concentric as well as providing angular alignment to keep the flat faces of the gearbox in plane.
Side Mounting Holes - These 10-32 holes allow the gearbox to be mounted on top of structural components without obstructing the front of the gearbox.
Assembly Holes - The screws holding the gearbox together pass through these holes.
Alignment Notches - Provides a socket for the alignment tabs on the first gear stage to engage with. These features keep the rotating components concentric as well as providing angular alignment to keep the flat faces of the gearbox in plane.
NEO Mounting Holes - These holes are for mounting NEO-class motors to the input block.
550 Mounting Holes - These holes are for mounting the NEO 550 to the gearbox.
775 Mounting Holes - These holes are for mounting 775-series motors to the gearbox
775 Vent Holes - These holes line up with the vent holes on the face of 775-series motors and allow cooling air to pass through the motor.
Socket 1/2in Hex Output - Engages with a 1/2in hex shaft to drive a robot mechanism. The output includes a #10 clearance hole through the middle which allows a shaft to be retained in the output.
Face Mounting Holes - These 10-32 holes allow the gearbox to be mounted to the face of a bracket or tube in several useful orientations.
Side Mounting Holes - These 10-32 holes allow the gearbox to be mounted on top of structural components without obstructing the front of the gearbox.
Threaded Assembly Holes - The screws holding the gearbox together thread into these holes to clamp the gearbox stack together.
Input Spline - Accepts torque from the last gear stage while being easy to insert and remove.
Alignment Tabs - Alignment features that engage with the alignment notches on the last stage. The directional nature of the alignment features prevent the user from assembling any gearbox components backwards.
The MAXPlanetary System (REV-21-2100) is a cartridge-based modular planetary gearbox designed from the ground up for NEO-class motors. The design of the MAXPlanetary has been carefully optimized to provide torque density unavailable in FRC up until now.
The MAXPlanetary is intended for use with the NEO, NEO 550, Falcon 500, and 775 motors. Building on the ability to iterate and adjust designs easily, the MAXPlanetary System consists of lubricated cartridges allowing for swapping gear ratios on the fly and with ease. Users can configure a single-stage planetary using one of three different reduction cartridges or build multi-stage gearboxes by stacking individual cartridges together. The user can use the included 1/2in hex shaft or use a custom length of hex shaft best suited for the application. The gearbox also provides two mounting options, face mount and side mount, for ultimate flexibility in your robot design.
Designed with an efficient right-angle configuration, the MAX 90 Degree Gearbox offers a robust and high-performance solution to building a more compact robot. Connect the MAX 90 Degree Gearbox to the MAXPlanetary System in a 90-degree orientation for maximum flexibility and ease of use in tight spaces. The through bore design of the gearbox allows for easy mounting and integration into a wide range of applications. Its 90-degree output orientation provides a compact and efficient way to transmit power and torque at right-angle configurations.
The REV Robotics MAXPlanetary Gearbox includes the following features:
Three different, self-contained gear ratio cartridges providing twenty-seven gear ratios ranging from 3:1 to 125:1
High torque density
Easy assembly without modifying the motor
A Socket 1/2in Hex Output with the ability to retain a shaft blind
Assembled front to back for ease of changing the gear ratio while the MAXPlanetary Gearbox is mounted on the robot
When assembling the MAX 90 Degree Gearbox we recommend adding grease during assembly and re-applying as needed for the maintenance of your mechanism. For most applications, using White Lithium Grease or Red Tacky Grease will provide sufficient lubrication.
Input Spline - Accepts torque from the previous stage while being easy to insert and remove.
Output Spline - Provides torque transfer between one stage and the next while being easy to insert and remove.
Assembly Holes - The screws holding the gearbox together pass through these holes.
Shields - Keeps the internal components of the gear stage in their place when the stage isn’t assembled into a gearbox. Also retains grease to keep the gear stage lubricated throughout its service life.
Alignment Tabs - Alignment features that engage with the alignment notches on the previous stage. The directional nature of the alignment features prevent the user from assembling any gearbox components backwards.
Alignment Notches - Provides a socket for the alignment tabs to engage with. These features keep the rotating components concentric as well as providing angular alignment to keep the flat faces of the gearbox in plane.
Side Mounting Holes - These 10-32 holes allow the gearbox to be mounted on top of structural components without obstructing the front of the gearbox.
Assembly Holes - The screws holding the gearbox together pass through these holes.
Alignment Notches - Provides a socket for the alignment tabs on the first gear stage to engage with. These features keep the rotating components concentric as well as providing angular alignment to keep the flat faces of the gearbox in plane.
NEO Mounting Holes - These holes are for mounting NEO-class motors to the input block.
550 Mounting Holes - These holes are for mounting the NEO 550 to the gearbox.
775 Mounting Holes - These holes are for mounting 775-series motors to the gearbox
775 Vent Holes - These holes line up with the vent holes on the face of 775-series motors and allow cooling air to pass through the motor.
Socket 1/2in Hex Output - Engages with a 1/2in hex shaft to drive a robot mechanism. The output includes a #10 clearance hole through the middle which allows a shaft to be retained in the output.
Face Mounting Holes - These 10-32 holes allow the gearbox to be mounted to the face of a bracket or tube in several useful orientations.
Side Mounting Holes - These 10-32 holes allow the gearbox to be mounted on top of structural components without obstructing the front of the gearbox.
Threaded Assembly Holes - The screws holding the gearbox together thread into these holes to clamp the gearbox stack together.
Input Spline - Accepts torque from the last gear stage while being easy to insert and remove.
Alignment Tabs - Alignment features that engage with the alignment notches on the last stage. The directional nature of the alignment features prevent the user from assembling any gearbox components backwards.
The following torque measurements are for a static load condition. The torques listed are for the output of the stage.
Shock loads can cause the gearbox to fail in situations where the steady-state torque is still within allowable limits.
Cantilevered load on the output shaft puts additional stress on the gearbox and will reduce the torque the gearbox can withstand.
The following chart shows which gear cartridge configurations are allowable with different motors. Cells shown in GREEN are allowed and cells shown in RED are not allowed.
These ratings are based on the default current limit on the Spark MAX (or Talon FX). Increasing the current limit increases the maximum torque the motor can produce and may put components of the gearbox outside of their load rating.
Gearbox ultimate strength - Failure at 180 NM +/- 5%
Please note that this is less than the MAXPlanetary Gearbox can withstand!
SKU | DESCRIPTION | QTY. |
---|---|---|
Cartridge | Torque |
---|
REV-21-2190-P01
2 MOTOR DRIVETRAIN GEARBOX MOTOR PLATE
1
REV-21-2190-P02
2 MOTOR DRIVETRAIN GEARBOX OUTPUT PLATE
1
REV-21-2190-P03
2 MOTOR DRIVETRAIN GEARBOX 1/2IN HEX CLUSTER SHAFT
1
REV-25-2489
2 MOTOR DRIVETRAIN GEARBOX SPACER PACK
1
REV-25-2488
2 MOTOR DRIVETRAIN GEARBOX HARDWARE PACK
1
REV-21-2079
1/2IN HEX THROUGH BORE SHAFT
1
REV-21-2819
1
REV-21-1916-PK2
FLANGED BEARING FOR 1/2IN ROUNDED HEX - 2 PACK
1
REV-21-1937
1
BEARING, 30MM ID, 42MM OD, 7MM THICK, SHIELDED, FLANGED - 2 PACK
1
3:1 Cartridge | Tested to 290 Nâ‹…m (no failure) |
4:1 Cartridge | Fails at 270 Nâ‹…m |
5:1 Cartridge | Fails at 240 Nâ‹…m |
1/2" Hex Socket Output | Fails at 250 Nâ‹…m |
The MAXPlanetary is a modular planetary gearbox designed for use with NEO-class motors and is optimized for torque density. By following these tips and tricks, you can ensure that your gearbox is assembled properly and functions efficiently. With the help of this guide, you will be able to assemble your MAXPlanetary gearbox with confidence and ease.
Attempting to stack the Input Coupler onto the gear cartridges, rather than pressing the Input Coupler into the stack is often more difficult.
Keep in mind that it may require a decent amount of force to couple the gearbox stack with the motor- it is not expected to be a slip-fit.
The 3in MAXSwerve Module (REV-21-3005) is compatible with the REV ION System, features a 3in Swerve Wheel, and is commonly used in a set of four to build a swerve drivetrain. This module gives a robot the ability to drive forward and backward, side-to-side, and rotate simultaneously without sacrificing traction. The 3in MAXSwerve Module uses the small size and low mass of the NEO 550 Brushless Motor and UltraPlanetary Gearbox to save a significant amount of space and weight.
When assembling the MAXSwerve Module we recommend adding grease during assembly and re-applying as needed for the maintenance of your mechanism. For most applications, using White Lithium Grease or Red Tacky Grease will provide sufficient lubrication.
Metal construction
3in wheel diameter
Module mounting maximizes wheelbase footprint
Compatible with NEO Brushless Motor or Falcon 500 (with replacement shaft)
Azimuth driven by NEO 550 Brushless Motor & UltraPlanetary Gearbox
All steel gears in drive powertrain
Gear-driven azimuth drive
The materials listed below will complete the wiring for ONE MAXSwerve Module
The SPARK MAX Mounting Bracket has an optional fourth hole that teams can use to secure the Mounting Bracket directly to their MAXSwerve module!
Teams can use #10-32 3/8in Button-Head Socket Cap Screws to attach this Mounting Bracket to the module, as pictured below.
The following images will describe a rating system we have developed for determining if a MAXSwerve Wheel should still be used on your robot.
This rating system was developed from our internal testing and feedback from teams who had contacted us about their MAXSwerve Wheel failures. Please make sure that you take your team's robot design and driving style into consideration.
Okay to keep using this wheel because it is still in good shape. There is minor wear or damage to the tread but no signs of too much axial force or scrub.
The affected wheel should be monitored closely because it is showing signs of wear that could lead to delamination of the tread. Please be sure to check the wheel again after your next match!
Red Wheels need to be replaced right away and before the next match if possible. Delamination is very likely to occur with continued use beyond this state.
In this section, we will describe different features of the MAXSwerve Wheel and wear patterns as Axial or Radial. Here are some descriptions of what these terms mean on a MAXSwerve Wheel.
Radial - Describes features that occur radiating from the center of the wheel towards the tread
Axial - Describes features that occur side to side along the wheel’s axle
Green wheels show early signs of wear that will eventually lead to the tread delaminating from the core of the wheel. When evaluating green wheels it is important to note that tread depth is something to be aware of, but it will not affect the rating of the wheel.
Green wheels have little to no radial separation (or peeling) of the tread. Also, the tread is still resilient enough to spring back quickly if it is stretched along the separation.
Small cuts or gouges in the wheels do not disqualify it from being rated as green. You will also see no axial separation on green wheels.
Sometimes looking at your wheel from the top down along the tread can help you identify radial separation easily. Green wheels will have straight borders since they have not had any axial separation yet.
Yellow wheels show moderate signs of wear that will eventually lead to the tread delaminating from the core of the wheel. When evaluating yellow wheels it is important to note that tread depth is something to be aware of, but it will not affect the rating of the wheel. Even if a MAXSwerve Wheel has near-perfect tread grooves, if there is any axial separation from the core it should be classified as yellow.
Yellow wheels have some radial separation of the tread from the core as well as clear axial separation. The tread may be able to spring back still when moved, but it will remain separated from the core.
Axial Separation on a yellow wheel is noticeable but does not interfere with the forks of your module or create excess friction in your drivetrain.
When looking at the wheel from a top-down view, you can sometimes see axial separation on a yellow wheel along the edges. Also within the axial separation, you will not be able to see the core's support posts.
Red wheels show serious signs of wear that will soon lead to the tread delaminating from the core of the wheel. When evaluating red wheels it is important to note that tread depth is something to be aware of, but it will not affect the rating of the wheel. Even if a MAXSwerve Wheel has near-perfect tread grooves, if there is a large amount axial separation from the core it should be classified as red.
Red wheels have major radial separation of the tread from the core as well as clear major axial separation. The tread may not be able to spring back when moved but regardless of how the tread behaves your team should replace this wheel.
Large gaps of both radial and axial separation on a red wheel may interfere with the forks of your module or create excess friction in your drivetrain as the tread expands.
When looking at the wheel from a top-down view, you will likely be able to see axial separation of the tread from the core of a red wheel. Within the axial separation, you will also be able to see at least one core support post (shown below)
Below are two GitHub Repositories for template projects that will control an FRC swerve drivetrain built with REV MAXSwerve Modules.
Note that this is meant to be used with a drivetrain composed of four MAXSwerve Modules, each configured with two SPARK MAXs, a NEO as the driving motor, a NEO 550 as the steering motor, and a REV Through Bore Encoder as the absolute turning encoder.
Within the Constants file for both the Java and C++ MAXSwerve Templates, there are three variables that your team can tune for your robot's Slew Rate needs. To determine the default values we loaded a test MAXSwerve Drivetrain to approximately 140lbs (Including bumpers and battery) and tuned the parameters until we found values that made the MAXSwerve Wheels last the longest amount of time.
DirectionSlewRate is the most important parameter for reducing MAXSwerve Wheel failures. Lower values limit the rate of change of the direction of the robot. This avoids high-speed J turns that put destructive side loads on the wheels. Note that direction changes faster than the slew rate are allowed at lower speeds. The value here is the slew rate at 100% linear speed.
The MagnitudeSlewRate, or acceleration, in the linear direction. Generally, adjustments to the direction slew rate should be applied here as well (i.e. both should be increased or both should be reduced).
RotationalSlewRate is not a major contributor to wheel wear but may help smooth other motions out. If the robot has to do a lot of spinning due to defense or a particular style of mechanism, reducing this could help reduce tread wear.
Added a configurable rate limiting system to prevent excessive loads from causing premature wheel failure.
We recommend checking the following items before each match to ensure that your MAXSwerve Modules are ready to go!
Download MAXSwerve Inspection Checklist to print and laminate for your next event!
It is best to perform this inspection while your robot is powered off
Item & SKU | QTY |
---|---|
More details found at
More details found at
Height with NEO: 171.5mm (6.75in)
Height with Falcon: 194.4mm (7.66in)
Footprint with mounting tabs: 133.1mm x 133.1mm (5.24in x 5.24in)
Footprint without mounting tabs: 100.5mm x 100.5mm (3.96in x 3.96in)
Weight with NEO: 1720g (3.80lb)
Weight with Falcon: 1800g (3.97lb)
MAXSwerve Module (REV-21-3005), Completed with one NEO and one NEO 550 installed to the module
1
2
1
2
1
10
Zip-Ties - 10in
2 Required, 5 Suggested
1) Place the motor with the motor shaft and Universal Input Stage facing upwards.
2) Slide the Input Coupler on the motor shaft. Ensure that the key is engaged and the Input Coupler has been slid all the way against the motor.
3) Take your stacked output stages and gear cartridges and align them with the Universal Input Stage.
4) Slide the stack of gear cartridges onto the motor shaft and input stage. Ensure that the input spline on the rear gear cartridge and the input coupler is properly engaged.
Note: This may require twisting the gear cartridges by hand slightly to line up the splines, and then rotating back once the spline is engaged. Make sure the entire stack is pressed together and all alignment features are properly engaged.
5) Make sure the stack is fully seated and no gap is present between the stack and the input plate before inserting and tightening the gearbox assembly screws.
1) Locate the 6-pin JST port for the Through Bore Encoder inside of the MAXSwerve Module
2) Plug in the 15cm 6-Pin JST Extention Cable to your Through Bore encoder and then separate the wires into groups so that the NEO 550's wires and the Through Bore Encoder's Cable are on either side of the module
3) Ensure the SPARK MAX Mounting Bracket is attached to your MAXSwerve Module Drivetrain. Then thread a zip-tie through the top two mounting holes.
Secure the zip-tie in a very loose loop, only letting the zip-tie click a couple of times to latch.
4) Slide the V+/V- side of both SPARK MAX Motor Controllers into the zip-tie loop so that the power and ground wires are facing away from the MAXSwerve Module and the data port on the top is facing away from the SPARK MAX Mounting Bracket.
Then tighten the zip-tie to secure.
5) Attach the Through Bore Encoder Cable to the Absolute Encoder Adapter
6) Thread a zip-tie through the other two mounting holes as shown.
7) Plug in the Absolute Encoder Adapter to the Data port on the top of the SPARK MAX that will be driving your NEO 550. In this image, we chose to use the Upper SPARK MAX.
Then tighten the zip tie to secure both SPARK MAXs and the Encoder Adapter.
8) Wire the Phase Wires of the NEO motor to the SPARK MAX on the underside of your swerve module.
Be sure to plug in the NEO's Sensor Wire!
9) Wire the Phase wires of the NEO 550 motor to the controller on the underside of your swerve module.
10) Ensure that you have plugged in both the Through Bore Encoder into the Absolute Encoder Board and the NEO 550's sensor wire directly into the SPARK MAX's Encoder Port.
11) Bundle your wires for each SPARK MAX, checking to make sure that there is enough slack, and then secure them to the top mounting hole with another zip-tie.
12) Plug in your CAN/PWM cables to the SPARK MAX's 4-pin JST signal port.
It is next to the USB C port on the SPARK MAX itself.
13) Finish wiring for both SPARK MAXs and the CAN by connecting the V+ and V- wires to your Power Distribution and the CAN cables to the rest of your CAN Bus.
The materials listed below will reinforce ONE Plastic MAXSwerve Wheel
Identify the pockets in the core that align with the lower ridges in the tread, this is where we will be placing the rivets
Drill 6 holes in the tread that line up with the pockets of the core using a #9 drill bit. These holes should be slightly off-center towards the direction of the side of the wheel that the pockets are on. Use the image below as a guide for the placement of these holes.
Once all 6 of your holes have been drilled, place 6 rivets in the wheel. Be sure to compress the tread while you are putting the rivets in so that they will not get caught on the field carpet.
Repeat with the remaining wheels that need to be reinforced.
The 3in MAXSwerve Aluminum Wheel (REV-21-3002) was designed for the 3in MAXSwerve Module (REV-21-3005). You can attach your favorite tread material to this wheel, allowing it to be reused throughout the season.
During the 2023 FRC season, we designed a template to prepare replacement strips of treads for the 3in MAXSwerve Aluminum Wheel used on the 3in MAXSwerve Module.
Our template has been crafted to ensure a tight fit of the treads onto the 3in diameter x 7/8in wide billet wheel. Once you have found your perfect tread, the template can be scaled to various sizes to produce treads with the correct hole spacing for various recommended treads. With this jig, the tread installation process is seamless, resulting in a tight and secure fit every time.
Drill bushings can be pressed into the fixture to ensure that the jig will remain usable for an extended period of time. However, users should note that they will need to grind a flat into the bushings, as the screw placement is narrowly spaced.
Keep in mind that this template may need to be scaled/adjusted based on your team's choice of tread. We have found that a 103% scaling of the PDF works for the type of tread suggested earlier. Be sure to double check your dimensions are correct for your scale and choice of tread!
Once you know the correct size of tread that is necessary for your team's specific use application, it can be helpful to pre-cut large quantities of tread at once.
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Showcases the 1in Bracket - 45deg by fastening MAXTube - 2x1 Tubes together via rivets
Showcases the 1in Bracket - 90deg by fastening MAXTube - 1x1 Tubes together via full length screws
Showcases the 1in Bracket - 90deg by fastening MAXTube - 2x1 Tubes together via screws and captured Nylon Lock Nut
Showcases the 1in Bracket - 135deg by fastening MAXTube - 2x1 with MAX Pattern Tubes together via screws and captured Nylon Lock Nut
Showcases the 1in Bracket - T-Shape by fastening MAXTube - 2x1 Light with Grid Pattern Tubes together via screws and captured Nylon Lock Nut
Dead Axle interfacing with MAX Pattern
Dead Axle Interfacing with the 1x1in MAXTube Grid Pattern
Shows how to mount an angled 1X1 Tube with a horizontal MAX Pattern Tube
Shows how to mount a vertical Max Pattern Tube backed against a horizontal MAX Pattern Tube
Shows how to mount a sprocket to a MAX Pattern Tube
Shows how to mount a MAXSpline Gear to a MAX Pattern Tube
Shows how to mount a 1/2in Hex Gear to a MAX Pattern Tube
Shows how to mount a pulley to a MAX Pattern Tube
MAXSpline interfacing with multiple motion components
MAXSpline interfacing with a grip wheel
MAXSpline interfacing with a traction wheel
MAXSpline interfacing with a compliant wheel
MAXSpline interfacing with a omni wheel
MAXSpline interfacing with a gear
MAXSpline interfacing with a pulley
MAXSpline interfacing with a sprocket
Showcases how to interface a MAXSpline to a dead axle in high speed applications
Showcases how to interface a MAXSpline to a dead axle in high load applications
Showcases how to interface a MAXSpline to a 1/2in hex axle
Mounting a NEO Directly to a MAX Pattern Tube
Mounting a NEO driven MAXPlanetary to a MAX Pattern Tube
Mounting a NEO 550 driven UltraPlanetary to a MAX Pattern Tube
Mounting a Smart Robot Servo to a MAX Pattern Tube
Directly mounting a sprocket to a wheel in a dead axle application
Directly mounting a gear to a wheel in a dead axle application
Directly mounting a pulley to a wheel in a dead axle application
Back-to-back mounting of two traction wheels
Interfacing a Traction Wheel with an Aluminum MAXHub
Interfacing a Traction Wheel with flanged bearings
Interfacing a Omni Wheel with an Aluminum MAXHub
Interfacing a Grip Wheel with a Plastic MAXHub
Interfacing a Compliant Wheel with a Plastic MAXHub
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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 or 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 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 too 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.
The diagram below gives an overview of how bearing quantity and arrangement can impact the stability of load configuration.
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Demonstrates how to make a 3-4-5 triangle with MAXTube - 1x1 Tubes
Demonstrates how to make a 3-4-5 triangle with MAXTube - 2x1 with MAX Pattern Tubes
Demonstrates how to make an offset 3-4-5 triangle with MAXTube - 2x1 with MAX Pattern Tubes
Demonstrates how to make an open-offset 3-4-5 triangle with MAXTube - 2x1 with MAX Pattern Tubes
Creating a roller series in the ION line
Showcases the use of the MAX Pattern Plates by creating a contained “gearbox” with both gears and pulleys
Shows how to side-mount a NEO
Shows how to side-mount a driven roller
Shows how to side-mount a motion part
Usage of a 2:1 ratio plate with a MAX Pattern Tube
Usage of a 4:1 ratio plate with a MAX Pattern Tube
Driven roller through chain-in-tube
Driven roller through belt-in-tube
Driven roller through chain-out-of-tube
Driven roller through belt-out-of-tube
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Item & SKU | QTY |
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Example Linear Actuator Arm featuring
1
6
Power Drill
1
#9 Drill bit
1
Rivet tool
1
1) Mark the tread to the length of the scaled tread template, and cut the tread to the correct length. We recommend using a Bandsaw for this process but you can use other cutting tools, like tinsnips too.
2) Mark the tread with holes for mounting and with lines to create the proper width of the tread. Use a bandsaw or tinsnips to cut the tread to the proper width of the wheel.
3) Drill or punch through the mounting holes using a 5mm/#9 drill bit. After creating the holes, "countersink" the tread by using flush cutters on both sides of the tread, especially if the holes are drilled. Punched holes may not need to be countersunk, as there may not be residual tread left by the punch process.
1) Pre-load screws into the tread. Be sure that the screw has a few threads showing through the tread, but don’t thread it all the way through yet. Screws should be #10-32 Button Head Screws, but the length will depend on which tread is being used, as tread height varies by brand.
For the recommended treads we are using the following: 1/2in #10-32 Button Head Hex Drive Screws (REV-29-2943-PK50)
2) Attach the screws to the wheel. Ensure that you are properly threading the screw into the hole, as the tread can cause the screw to be pulled out of alignment. If this step is proving difficult, it may help to rotate the screw backward to align the threads prior to tightening it fully.
3) Wrap the tread tightly around the wheel, and attach the two remaining screws to the wheel and tread, taking care not to cross-thread them. You may need to wiggle, stretch, or rotate the screw within the tread for the screw to align the threads.
Marking the path of the threaded hole, as seen to the right, can also make attaching the screws easier.
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. Make use of brackets and additional extrusion or c-channel to strengthen and constrain these structures.
Gears and sprockets must stay aligned or else they won’t 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.
When assembling their 3in MAXSwerve Module, teams have a choice of either left-hand or right-hand assembly, meaning teams can choose which direction their motors' wires face.
Depending on the choice the team makes, your layout of the MAXSwerve may look like either of these, at various stages of the assembly process.
Assembly Instructions
Teams should choose their preferred orientation of their motors prior to assembly. Images that detail the various options can be found here: Motor Orientation
Reference the MAXSwerve Pack Contents Guide for help identifying the Bearings, Spacers, and Hardware from your kit!
When assembling the 3in MAXSwerve Module we recommend adding grease during assembly and re-applying as needed for the maintenance of your mechanism. For most applications, using White Lithium Grease or Red Tacky Grease will provide sufficient lubrication.
When applying the grease of your choice, add a small amount to the gearbox’s gears, ensuring that it gets evenly distributed throughout the system.
Several of the below steps call for the use of threadlocker with certain screws. We recommend LOCTITE® Threadlocker Blue 242 or an equivalent threadlocker.
The Steering UltraPlanetary Subassembly is dependent on which orientation (left hand or right hand) was chosen during Top Plate Subassembly.
Some of the UltraPlanetary Cartridges have a mounting hole that is partially closed. Please see our guide on how to fix this: UltraPlanetary Mounting Holes Fix
If you forgot to apply threadlocker during the assembly of the UltraPlanetary Subassembly you can use a Wicking Grade Threadlocker to apply threadlocker to the pre-assembled gearbox.
For instructions see our MAXSwerve Assembly Tips section
Some 3in MAXSwerve Module Wheel Axles may not be a slip fit. Please see our MAXSwerve Assembly Tips section for a solution: Wheel Axle - Tight Fit
Once you assemble your MAXSwerve Modules onto your Drivetrain, check out the following sections for help to start moving!
The materials listed below will attach the SPARK MAX Mounting Bracket for ONE MAXSwerve Module
The MAXSwerve SPARK MAX Mounting Bracket is reversible and can be used on any corner of your MAXSwerve Drivetrain
The SPARK MAX Mounting Bracket has an optional fourth hole that teams can use to secure the Mounting Bracket directly to their MAXSwerve module!
If you encounter any problems while assembling your MAXSwerve Module(s) please contact support@revrobotics.com
Making sure your screws are secure is important when building your MAXSwerve Modules. Here is a video with some best practices to keep in mind while applying Loctite or a similar thread locker to your screws.
To use, apply the Wicking Loctite to the top of the UltraPlanetary Gearbox Assembly where the screw tips are showing. The Loctite will wick between the engaged threads using capillary action to secure your screws.
When placing the MAXSwerve Motor Key (REV-21-3005-P10) you need to pay close attention to two areas of the key, these are marked as A and B in the image below. For area A at the end of the motor's output shaft, make sure that the key is placed high enough in the keyway for the notch in the key to rest slightly above the lip of the encoder bridge. Area B of the key will need to sit as flush as possible with the NEO's Keyway so that it does not catch inside the encoder bridge and get pulled out.
We recommend using superglue to ensure that the key stays securely in place
Some of the UltraPlanetary Cartridges that shipped with the first batch of MAXSwerve Modules (January 2023) have a mounting hole that is partially closed. There is a small amount of plastic leftover from the manufacturing process that will need to be removed before use.
To clear the mounting hole, use a 1/8in drill bit to drill out the excess plastic. Be sure to drill from the side of the UltraPlanetary Cartridge with the output spline facing up so that the through hole does not get off center.
3in MAXSwerve Module Wheel Axles that shipped with the first batch of MAXSwerve Modules (January 2023) may have a tighter fit than expected.
We recommend using a product that is 400 grit or higher for this process
If you are experiencing difficulty getting the key for your motor to rest on the lip of the encoder bridge, it is possible that the key is too large for the keyway. We have received this report specifically from teams using NEO V1s and Falcon 500s with the MAXPlanetary Falcon Input Kit, as the keyways changed sizes between the NEO V1 and the NEO V1.1. To resolve this issue, we recommend sanding down the key using a jeweler's file. Start by taking off a small amount and checking the fit, then continue to remove more as needed.
Left-Hand Orientation | Right-Hand Orientation |
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Left-Hand Orientation | Right-Hand Orientation |
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Item & SKU | QTY |
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Teams can use to attach this Mounting Bracket to the module, as pictured below.
Below are several visual representations of the contents included with the .
If you forgot to apply Loctite during the assembly of the UltraPlanetary Subassembly you can use a to apply thread locker to the pre-assembled gearbox
When putting together the of your MAXSwerve Module, ensure that the MAXSwerve Motor Key's notch rests slightly above the lip of the encoder bridge. If the notch is not located above the encoder bridge's lip and falls into the slot, the module will not function properly and the key will become damaged.
To help with the fit of your Wheel Axle assembly, use a fine grit emery cloth, sandpaper, or to remove a small amount of material from the axle. It is easiest to put the Wheel Axle in a drill and then sand the Axle until the bearings are a slip fit.
The REV Robotics MAXPlanetary comes with the gearbox deconstructed allowing for the user to modify the total reduction needed for the application. Each cartridge is pre-assembled and lubricated allowing for easier customization. Below are links to steps for assembling a two-stage gearbox for specific motors.
MAXPlanetary Gearboxes purchased before 11/14/2022 will need to install the included spacer to use a CIM, miniCIM, or Falcon 500. Follow the Spacer Installation Guide now before proceeding to the other steps. If you are unsure if a spacer is needed for your MAXPlanetary Gearbox, you can find more information about the changes in the When to use a Spacer section.
1) With the NEO motor sitting shaft upwards on a flat surface, position the Top Plate upside down on the motor boss- the small raised circle on the center of the motor. Align the motor holes for your preferred configuration, either left hand or right hand. CAD examples of those options can be found here: NEO Orientation
2) Install the Through Bore Encoder on the motor shaft, lined up with the correct holes in the motor body for your preferred configuration. Ensure that the motor shaft is perfectly centered in the hex bore of the encoder. Fasten the encoder and motor together using two 1/2in 10-32 button head screws, applying threadlocker to the screws.
3) Install Motor Key into motor shaft keyway. The thinnest part of the key should be facing towards the motor. See our MAXSwerve assembly tips for additional images to help with proper key placement!
4) Align the Encoder Bridge’s clearance notch with the key in the motor shaft and insert the Encoder Bridge into the encoder. Ensure that the notch in the key rests slightly above the lip of the encoder bridge, as shown in the cross-section to the right. If the notch is not above the lip and falls into the slot, the module will NOT function properly and may get damaged.
5) Install the appropriate motor pinion for the preferred speed option (low, mid, or high) onto the motor shaft, with the pinion boss facing away from the motor. Set Top Plate subassembly aside.
1) Install the Steering Pinion bearing into the top of the Bottom Plate.
2) Insert the main steering bearing into the Bottom Plate.
3) Install six screws into the Bottom Plate to hold the main bearing in place, applying threadlocker to the screws. Set aside the Bottom Plate.
4) Take Steering Gear and insert the main Bevel Pinion bearing into the bottom side of the Steering Gear.
5) Insert Steering Gear into Bottom Plate.
6) Insert motor shaft bearing into the top of the Steering Gear.
7) Flip the Bottom Plate over and insert the Bevel Pinion into the Bevel Pinion bearing.
8) Flip Bottom Plate back over and put Drive Spur Gear onto Bevel Pinion shaft. Fasten the Drive Spur Gear in place with one 3/8in 10-32 button head screw, applying threadlocker to the screw. If you are having difficultly tightening the screw, we recommend firmly gripping the Steering Gear from the short edge of the Bottom Plate.
1) Install the two Bevel Pinion end bearings into the Active Fork. Set the Active Fork aside.
1) Install one of the two Steering Pinion bearings into the UltraPlanetary Block.
2) Install the Steering Pinion into the UltraPlanetary Block. Set the UltraPlanetary Block aside.
1) Install the UltraPlanetary 550 Motor Pinion onto the NEO 550. See our documentation on the NEO 550 Product Page for more information about pressing pinions onto NEO 550s and using NEO 550s with UltraPlanetary Gearboxes.
2) Install the UltraPlanetary Motor Plate on the NEO 550 with two 8mm M3 button head screws, applying threadlocker to the screws. Ensure that you orient the motor based on the configuration chosen. CAD examples of those NEO 550 orientations can be found here: NEO 550 Orientation Options
3) Stack the 4:1 UltraPlanetary Cartridge onto the UltraPlanetary Motor Plate, followed by the 3:1 Cartridge, and the UltraPlanetary Block (with steering pinion). Ensure that these components are oriented to allow alignment features to interlock, and that they provide the correct wire orientation for your configuration. CAD examples of those wire configurations can be found here: NEO 550 Orientation Options Ensure that the pinion is fully engaged with the UltraPlanetary Cartridge output spline and fully inserted into the bearing in the UltraPlanetary Block.
4) Install and tighten two 25mm M3 socket head screws, applying threadlocker to the screws, into the notched side of the UltraPlanetary Block, through the UltraPlanetary stack, and into the UltraPlanetary Motor Plate. Take care not to over-tighten the gearbox housing screws. Hand tight is enough to keep the gearbox assembled.
1) Insert the Active Fork Subassembly into the pocket on the bottom side of the Steering Gear. Ensure that the Bevel Pinion is inserted properly into the end bearings in the Active Fork.
2) Fasten the Active Fork in place with two 1in 10-32 socket head screws, applying threadlocker to the screws. Leave these screws slightly loose. Remember to come back after MAXSwerve Wheel Installation and tighten these screws in a reasonable amount of time to ensure the threadlocker is effective.
3) Insert the Passive Fork into the Steering Gear opposite from the Active Fork. Fasten the Passive Fork in place with two 1in 10-32 socket head screws, applying threadlocker to the screws. Leave these screws slightly loose. Remember to come back after MAXSwerve Wheel Installation and tighten these screws in the same day to ensure the threadlocker is effective.
1) Insert the Wheel Hub into the MAXSwerve Wheel. Take care to align the holes in the wheel and the hub.
2) Insert the Wheel Bevel Gear into the opposite side of the wheel. Take care to align the holes in the wheel and the gear.
3) Fasten the Wheel Hub and Wheel Bevel Gear to the MAXSwerve Wheel with six 1in long 10-32 button head screws, applying threadlocker to the screws. These screws are inserted through the Wheel Hub side and are threaded into the Wheel Bevel Gear.
4) Insert the two wheel bearings into either side of the MAXSwerve Wheel Assembly. One bearing should go into the Wheel Bevel Gear, and one bearing should go into the Wheel Hub.
5) Insert the Wheel Axle through the wheel bearings. If you struggle to put the Wheel Axle through the bearings, it may be easier to put a bearing on one side of the Axle, and then "sandwich" other the bearing onto the Axle and into the Wheel.
6) Place the two wheel spacers onto the Wheel Axle, one on either side of the MAXSwerve Wheel.
1) Insert the MAXSwerve Wheel Subassembly between the two forks with the Wheel Bevel Gear engaged with the Bevel Pinion.
2) Apply threadlocker to a 2in 10-32 socket head screw and insert it through the Passive Fork, through the Wheel Axle, and thread it into the Active Fork. Leave this screw slightly loose.
3) Tighten the four screws holding the forks in (see the orange arrow), and tighten the Wheel Axle screw. Do not overtighten these screws.
1) Install the UltraPlanetary stack on the top of the Bottom Plate. The end of the Steering Pinion should be inserted into the Steering Pinion bearing.
2) Apply a small amount of threadlocker to the ends of the four 60mm M3 socket head screws.
3) Install and tighten the four 60mm M3 socket head screws through the Bottom Plate, through the UltraPlanetary stack, and into the UltraPlanetary Motor Plate. Take care not to overtighten the screws.
4) Spin the fork and wheel assembly by hand to check that it moves freely. It should move easily, with some inertia, in both directions. The torque required to spin it should be uniform through an entire rotation. If significant resistance is felt, check that the leads from the NEO 550 aren't touching each other, as this can produce an artificial braking effect.
1) Set the Top Plate Subassembly upside down on a flat surface.
2) Place the three structural standoffs into their respective pockets in the inverted Top Plate.
3) Retrieve the Bottom Plate Subassembly. Place it upside down, and drop three 2in long 10-32 socket head screws into the appropriate holes in the bottom plate.
4) Carefully lower the Bottom Plate Subassembly down on top of the inverted Top Plate Subassembly. Ensure that the screws line up with (and slide inside) the structural standoffs. It may be necessary to rotate the MAXSwerve Wheel Subassembly to properly line up the four holes in the Steering Gear with the four pegs on the Encoder Bridge.
5) Insert three Nylock Nuts into the pockets on the Top Plate, and thread the 2in socket head screws into them. Tighten down the screws.
6) Test spin the module by hand, both rolling the wheel and rotating the steering. It should move easily, with some inertia, in both directions. The torque required to spin it should be uniform through an entire rotation.
MAXSwerve SPARK MAX Mounting Bracket (REV-21-2998) | 1 |
1 |
1 piece for attaching the MAXSwerve Bracket, More will be needed for assembling a whole MAXSwerve Drivetrain |
2 |
2 |
1) Insert your 2x1 MAXTube into the mounting slot on the MAXSwerve Module |
2) Slide the MAXSwerve SPARK MAX Mounting Bracket over the tabs of the MAXSwerve module that you just inserted the MAXTube into |
3) Secure the MAXSwerve SPARK MAX Mounting Bracket and 2x1 MAXTube to the MAXSwerve Module with 2 - 3in #10-32 Button Head Screws and Nylock Nuts |
A MAXSwerve Motor Key properly seated in the NEO's keyway with the notch resting slightly above the lip of the encoder bridge | Blue Edge: MAXSwerve Motor Key Orange Edge: Encoder Bridge |
Elevator Bearing Block (REV-25-2285) These instructions apply to individual bearing blocks. Depending on the option purchased, these will either ship in a 2-pack or an 8-pack. Each block uses the following parts:
1x Bearing Block Body
2x R188ZZ Bearings
1x 1/4in x 1/4in Shoulder Screw
1x 6-32 x 3/8in Button Head Socket Cap Screw
Tools needed: 1x 1/8in hex key or T-handle. 1x 5/64in hex key or T-handle.
For assembly you will need a 5/32" Allen Wrench.
If your robot requires shaft retention in the gearbox, follow the Shaft Retention Assembly instructions now before proceeding.
When building your gearbox make sure the highest gear reduction is closest to the motor.
MAXPlanetary Gearbox Cartridges are pre-lubricated and sealed. If during maintenance you find that a cartridge needs more grease, we recommend using a Molybdenum Grease to apply more lubrication such as Synthetic NLGI #2 Molybdenum Grease or MOLYKOTE® G-2008 Synthetic Tool Gear Grease.
For assembly you will need a 5/32" and 2.5mm Allen Wrench
If your robot requires shaft retention in the gearbox, follow the Shaft Retention Assembly instructions now before proceeding.
When building your gearbox make sure the highest gear reduction is closest to the motor.
The MAXPlanetary Base Kit comes with a 3in long rounded 1/2in hex shaft with a 10-32 tapped hole at either end. This shaft can be retained in the MAXPlanetary 1/2in Socket Hex Output with a screw installed from the back side before assembling the rest of the gearbox.
In addition to the included hex shaft, additional lengths of pre-tapped shaft are available from REV. Also, any length of team-provided 1/2in hex shaft (with or without rounded corners) can be retained in the output provided that it has a 10-32 tapped hole.
For assembly you will need a 1/8" Allen Wrench.
A full step by step guide on switching the shaft on the Falcon can be found in the and once completed, follow the instructions and then follow the (Note: the Falcon 500 User Guide link above is hosted outside the REV Robotics documents site)
If your robot requires shaft retention in the gearbox, follow the instructions now before proceeding.
1) Press the adapter shaft onto the NEO 550 shaft. Make sure the adapter shaft and motor shaft are perfectly aligned in order to prevent damage to the motor.
2) Place the spacer plate on the front of the motor.
3) Place the motor and spacer plate onto the MAXPlanetary input block.
4) Attach the motor to the input block with the 2 M3 screws.
5) Place the shaft key in the keyway in the adapter shaft.
6) Slide the input coupler all the way onto the adapter shaft.
1) Slide 1 bearing on the shoulder screw. The bearing needs to be aligned very straight with the screw in order to slide it on easily.
2) Thread the shoulder screw with bearing into the hole on the side of the bearing block body. Tighten the screw down with the 1/8in hex key/T-handle.
3) Place the second bearing on the stud at the end of the bearing block body. The bearing needs to be aligned very straight with the screw in order to slide it on easily. If the bearing fit is too tight, it may be pressed on with gentle pressure, taking care to keep the assembly lined up straight.
4) Insert the 6-32 screw in the end of the bearing block body to retain the bearing. Tighten the screw with the 5/64in hex key/T-handle.
1) Place the Universal Input Stage on the motor.
2) Align two of the mounting holes on the motor with the holes in the input stage.
3) Insert the 1/2in long 10-32 Socket Head Cap Screws in the motor mounting holes and tighten them down.
Note: It is a best practice to spin both screws all the way into the holes without tightening them and then alternate between tightening the two screws to snug them up.
4) Insert the 2mm key in the motor shaft keyway.
Note: The key should be located as close to the motor as the keyway will allow.
5) Align the key with the keyway in the Input Coupler.
6) Slide the Input Coupler on the motor shaft. Ensure that the key is engaged and the Input Coupler has been slid all the way against the motor.
7) Place the appropriate gear cartridge on the 1/2" Hex Socket Output.
Note: The cartridge may need to be rotated to get the splines to line up. Once the splines are inserted continue to rotate the cartridge to ensure that the alignment features are completely engaged.
8) Continue stacking gear cartridges backwards towards the motor in the appropriate order.
Note: Ensure that the alignment features of each cartridge are properly engaged with the cartridges next to it.
9) Align the stacked output stage and gear cartridges with the input stage.
10a) Slide the stack of gear cartridges onto the motor shaft and input stage. Ensure that the input spline on the rear gear cartridge and the input coupler are properly engaged.
Note: This may require twisting by hand the gear cartridges slightly to line up the splines and then rotating back once the spline is engaged. Make sure the entire stack is pressed together and all alignment features are properly engaged.
10b) Gap - Having a gap in this location is bad. If a gap is present, it means that all alignment features are not properly engaged. This may require twisting by hand the gear cartridges slightly to line up the splines and then rotating back once the spline is engaged. Make sure the stack is fully seated and no gap is present before inserting and tightening the gearbox assembly screws
11) Insert the appropriate length of 10-32 Socket Head Cap Screws into the gearbox assembly holes
0 Cartridges: 1/2in Long Screws
1 Cartridge: 1in Long Screws
2 Cartridges: 1-1/2in Long Screws
3 Cartridges: 2in Long Screws
12) Tighten the gearbox assembly screws down.
Note: It is a best practice to spin both screws all the way into the holes without tightening them and then alternate between tightening the two screws to snug them up.
7) Place the appropriate gear cartridge on the 1/2" Hex Socket Output.
Note: The cartridge may need to be rotated to get the splines to line up. Once the splines are inserted continue to rotate the cartridge to ensure that the alignment features are completely engaged.
8) Continue stacking gear cartridges backwards towards the motor in the appropriate order.
Note: Ensure that the alignment features of each cartridge are properly engaged with the cartridges next to it.
9) Align the stacked output stage and gear cartridges with the input stage.
10a) Slide the stack of gear cartridges onto the motor shaft and input stage. Ensure that the input spline on the rear gear cartridge and the input coupler are properly engaged.
Note: This may require twisting the gear cartridges slightly to line up the splines and then rotating back once the spline is engaged. Make sure the entire stack is pressed together and all alignment features are properly engaged.
10b) Gap - Having a gap in this location is bad. If a gap is present, it means that all alignment features are not properly engaged. This may require twisting by hand the gear cartridges slightly to line up the splines and then rotating back once the spline is engaged. Make sure the stack is fully seated and no gap is present before inserting and tightening the gearbox assembly screws
11) Insert the appropriate length of 10-32 Socket Head Cap Screws into the gearbox assembly holes
0 Cartridges: 1/2in Long Screws
1 Cartridge: 1in Long Screws
2 Cartridges: 1-1/2in Long Screws
3 Cartridges: 2in Long Screws
12) Tighten the gearbox assembly screws down.
Note: It is a best practice to spin both screws all the way into the holes without tightening them and then alternate between tightening the two screws to snug them up.
1) Line up the hex of the shaft and the output block. |
2) Insert the hex shaft in the output. Ensure that the shaft bottoms out in the socket. Note: If the shaft has been cut, ensure that any burrs have been removed from the cut end, so that the shaft will fit in the output properly. |
3) Apply thread-locking compound to the 1/2in long Button Head Cap Screw (included in the MAXPlanetary Base Kit or Hardware Kit). Note: We recommend Loctite 243 (commonly known as “Blue Loctite”). | *not to scale |
4) Insert the button head screw into the back side of the output. Note: This is typically easiest with a hex key or t-handle WITHOUT a ball end. |
5) Tighten down the screw into the threads in the end of the output shaft. |
1) Press the adapter shaft onto the 775 motor shaft. Note: Make sure the adapter shaft and motor shaft are perfectly aligned in order to prevent damage to the motor. |
2) Place the spacer plate on the front of the motor. |
3) Place the motor and spacer plate onto the MAXPlanetary input block. |
4) Attach the motor to the input block with the 2 M4 screws. |
5) Place the shaft key in the keyway in the adapter shaft. |
6) Slide the input coupler all the way onto the adapter shaft. |
7) Place the appropriate gear cartridge on the 1/2" Hex Socket Output. Note: The cartridge may need to be rotated to get the splines to line up. Once the splines are inserted continue to rotate the cartridge to ensure that the alignment features are completely engaged. |
8) Continue stacking gear cartridges backwards towards the motor in the appropriate order. Note: Ensure that the alignment features of each cartridge are properly engaged with the cartridges next to it. |
9) Align the stacked output stage and gear cartridges with the input stage. |
10a) Slide the stack of gear cartridges onto the motor shaft and input stage. Ensure that the input spline on the rear gear cartridge and the input coupler are properly engaged. Note: This may require twisting the gear cartridges slightly to line up the splines and then rotating back once the spline is engaged. Make sure the entire stack is pressed together and all alignment features are properly engaged. |
10b) Gap - Having a gap in this location is bad. If a gap is present, it means that all alignment features are not properly engaged. This may require twisting by hand the gear cartridges slightly to line up the splines and then rotating back once the spline is engaged. Make sure the stack is fully seated and no gap is present before inserting and tightening the gearbox assembly screws |
11) Insert the appropriate length of 10-32 Socket Head Cap Screws into the gearbox assembly holes 0 Cartridges: 1/2in Long Screws 1 Cartridge: 1in Long Screws 2 Cartridges: 1-1/2in Long Screws 3 Cartridges: 2in Long Screws |
12) Tighten the gearbox assembly screws down. Note: It is a best practice to spin both screws all the way into the holes without tightening them and then alternate between tightening the two screws to snug them up. |
When assembling the MAX 90 Degree Gearbox we recommend adding grease during assembly and re-applying as needed for the maintenance of your mechanism. For most applications, using White Lithium Grease or Red Tacky Grease will provide sufficient lubrication.
When applying the grease of your choice, add a small amount to the gearbox’s gears, ensuring that it gets evenly distributed throughout the system.
MAXPlanetary Base Kits purchased before 11/14/2022 included a MAXPlanetary CIM/Falcon Spacer (REV-21-2119) to ensure that the input stage for CIM, MiniCIM, and Falcon 500 motors sits correctly in the MAXPlanetary Gearbox. Please be sure to install the spacer before assembling your MAXPlanetary Gearbox and attaching the Input Stage to your motor.
The following steps are only required if you are using a CIM, MiniCIM, or Falcon Motor
MAXPlanetary Gearboxes purchased before 11/14/2022 use Version 1 of the MAXPlanetary Keyed Input Coupler and will need to install the included spacer to use a CIM, miniCIM, or Falcon 500. If your Keyed Input Coupler is a V1, the dimension highlighted in the drawing below will be 14.9mm or 0.59in.
MAXPlanetary Gearboxes purchased after 11/14/2022 use Version 1.1 the MAXPlanetary Keyed Input Coupler and do not need the spacer. If your Keyed Input Coupler is a V1.1, the dimension highlighted in the drawing below will be 14.4mm or 0.57in.
When using a Falcon Spline Input Coupler with your MAXPlanetary Gearbox you do not need to install the spacer.
When assembling the 2 Motor Drivetrain Gearbox we recommend adding grease during assembly and re-applying as needed for the maintenance of your mechanism. For most applications, using White Lithium Grease or Red Tacky Grease will provide sufficient lubrication.
When applying the grease of your choice, add a small amount to the gearbox’s gears, ensuring that it gets evenly distributed throughout the system.
When assembling the Linear Actuator we recommend adding grease during assembly and re-applying as needed for the maintenance of your mechanism. For most applications, using White Lithium Grease will provide sufficient lubrication.
When applying the grease of your choice, add a small amount to the lead screw, ensuring that it gets evenly distributed throughout the system by moving the lead screw nut up and down.
The Linear Actuator is ideally operated by a NEO Brushless Motor and a single stage MAXPlanetary Gearbox.
In order to use a MAXPlantary in a 1:1 configuration it will require cutting the shaft of the NEO 1.1 or CIM motor. Using a Dremel tool or other abrasive grinder is the recommended method.
The REV Hardware Client is software designed to make managing REV devices easier for the user. This Client automatically detects connected device(s), downloads the latest software for those device(s), and allows for seamless updating of the device(s). The REV Hardware Client also allows for you to monitor Telemetry on REV ION Control System Devices, as well as control the SPARK MAX and Pneumatic Hub without the need for a roboRIO.
When applying the grease of your choice, add a small amount to the gearbox’s gears, ensuring that it gets evenly distributed throughout the system.
For additional information including a download link, check out the full documentation page -
When assembling the 2 Motor Gearbox we recommend adding grease during assembly and re-applying as needed for the maintenance of your mechanism. For most applications, using or will provide sufficient lubrication.
If you are utilizing Gear Ratio 5:1 or 6:1, See the following:
1) Install one of the Flanged Bearings in the Bottom Block.
2) Install the Input Gear into the bearing.
3) Set the Middle Plate so that the bearing counterbore is facing up. Insert the small bearing into the Middle Plate.
4) Place the bearing and Middle Plate upside down on top of the Input Gear.
1) Install the Flanged Bearings in the two Side Plates. The bearing flange should be on the opposite side of the plate from the counterbores.
2) Install the two Standoffs into one of the Side Plates with two 3/8in long 10-32 button head screws.
3) Insert the through bore shaft into the bearing in the Side Plate with the Standoffs. The end of the shaft with hex should be facing away from the Side Plate.
4) Turn the bottom stack on its side and set it on the Side Plate so that the Middle Plate slots into the notches in the Side Plate. The edges of the Bottom Plate should be flush with the Side Plate.
5) Slide the Bevel Gear onto the through bore shaft.
6) Drop the second Side Plate and bearing onto the end of the through bore shaft.
7) Install four 3/8in long 10-32 button head screws through the Side Plate into the Standoffs and the Bottom Plate. Leave these screws slightly loose.
8) Flip the gearbox over and install the remaining two 3/8in long 10-32 button head screws through the Side Plate into the Bottom Plate. Leave these screws slightly loose.
9) Spin the gearbox a few times and then tighten all screws. Spin the gearbox afterwards to ensure it spins smoothly.
1) Place the MAXPlanetary CIM/Falcon Spacer onto your motor.
2) Align two of the mounting holes on the motor with the holes in the spacer.
1) Start with the 2 Motor Drivetrain Gearbox Motor Plate- the larger of the two plates included in the base kit.
2) Affix your motors to the Motor Plate using four 1/2in long 10-32 button head screws.
3) Install a Flanged Bearing for 1/2in Rounded Hex into the smaller hole of the Motor Plate, and install the larger Flanged Bearing in the larger hole of the Motor Plate. The flanges should face away from the motors.
4) Insert the 1/2in Hex Cluster Shaft into the smaller Flanged Bearing, and insert the 1/2in Hex Through Bore Shaft into the larger Flanged Bearing on the Motor Plate.
5) Install the 1/2in MAXSpline spacer on the output shaft of the gearbox.
6) Install the gears onto the shafts. First, the 52-tooth gear goes on the cluster shaft closest to the motors. The smaller hex bore gear then also goes on the cluster shaft, and the larger MAXSpline gear goes on the output shaft. See the product page to determine the appropriate Wheel Gear Ratio here: 2 Motor Drivetrain Gearbox - Through Bore
7) Insert the 2mm keys into the motor shaft keyways.
8) Slide the appropriate pinions, based on the speed option of your gearbox, onto the motor shafts.
9) Install the external retaining rings on the ends of the motor shafts.
10) Retrieve the Output Plate from the kit, and install a Flanged Bearing for 1/2in Rounded Hex into the smaller hole of the Output Plate, and install the larger Flanged Bearing in the larger hole of the Output Plate.
11) Slide the Output Plate with bearings onto the ends of the shafts of the Motor Plate. The flanges of the bearings should face inwards, towards the gears.
12a) Slide a 1-1/8in spacer between the two plates and line it up with one of the holes near the middle of the plates.
12b) Install a 1-5/8in long 10-32 button head screw through the Output Plate, through the spacer, and into the Motor Plate. Leave this screw loose, for now.
12c) Repeat steps 12a-12b for the other screw and spacer on the top left side of the plate.
13a) Slide a 1-1/8in spacer between the two plates and line it up with one of the holes near the bottom of the plates, on the far outside edges.
13b) Install a 2in long 10-32 button head screw through the Output Plate, through the spacer, through the Motor Plate, and retain it with a locknut at the end. Leave this screw loose, for now.
13c) Repeat steps 13a-13b for the other screw and spacer on the bottom left side of the plate.
14) Ensure that the gearbox is well-aligned, and then begin tightening the four screws holding the Motor and Output plates together.
Note: Do not tighten one screw all the way tight before tightening the other screws. Alternate between tightening all of the screws a little bit at a time. For best results, spin the gearbox by hand between tightening each screw until you have completed assembly!
1) Screw the Lead Screw Nut onto the Lead Screw. Please reference the Greasing Guide.
2) Slide the Spacer onto the Lead Screw.
3) Add the Brass Stopper onto the Lead Screw. Tighten with a 2mm Allen Key. Please note, to adjust the extension length move the Brass Stopper up or down the Lead Screw.
4) Slide 1x1 MAXTube (REV-21-2160) onto the Lead Screw. Fasten the MAXTube with four #10-32 x 1/4in Button Head Hex Drive Screw and a 1/8in Allen Key.
5) Press the two 6904-2Z bearings into the End Cap. Press them in until you hit the stop in the End Cap.
6) Slide the End Cap and Bearings onto the Lead Screw. Fasten the Lead Screw with a Snap Ring and Snap Ring Pliers. Please make note of the orientation so that the grooves on the End Cap will line up with the grooves on the Housing in the next step.
7) Slide the Linear Actuator Housing onto the MAXTube and Lead Screw.
8) Slide the Top Cap onto the MAXTube and Lead Screw. Please make note of the orientation so that the grooves on the Top Cap line up with the grooves on the Housing.
9) Fasten the End Caps and Housing with eight #10-32 x1in Socket Head Screw and a 5/32in Allen Key.
Cut the MAXPlanetary 1/2 Rounded Hex Shaft to 7/8in.
Follow the MAXPlanetary Build Guide to assemble a single stage MAXPlanetary gearbox then attach it to using two #10-32 x 1/2in Socket Head Screws and a 5/32in Allen Key.
1) Add two 8mm Shaft Spacers to the NEO Brushless Motor output shaft. |
2) Insert the NEO Shaft Key. |
3) Slide the 1/2 Hex Shaft Adapter to the NEO output shaft. |
4) Fasten the base plate to the NEO using the left holes in the base plate and two #10-32 x 1/2in screws with a 1/8in Allen Key. |
5)Press a Flanged Bearing into the base with the flanged side opposite of the NEO. |
6) Press a 1/2in Hex Through Bore Shaft into the Flanged Bearing. |
7) Slide a 1/8 MAXSpline Spacer onto the 1/2in Hex Through Bore Shaft. |
8) Screw together two MAXSpline Pulley halves with six M3x12mm screws. |
9) Screw together two MAXSpline to 1/2 Hex Adapter halves with two #12-32x1/2in Socket Head screws with a 5/32in Allen Key. |
10) Screw together two MAXSpline Pulley halves with six M3x12mm screws. |
11) Place the 48-tooth RT25 Belt around both the NEO Pulley and MAXSpline Pulley, then slide them onto the Output Shaft of the NEO and 1/2in Hex Through Bore Shaft at the same time. |
12) Secure the NEO Pulley with a Retaining Ring. |
13) Slide a 1/8 and a 1/16 MAXSpline Spacer onto the 1/2in Hex Through Bore Shaft. |
14) Press a Bearing onto the 1/2in Hex Through Bore Shaft. |
15) Press the Pulley Cover Plate onto the 1/2in Hex Through Bore Shaft Bearing. |
16) Secure the Pulley Cover Plate with three #10-32 x1-1/2in screws and #10 Spacers using a 1/8in Allen Key. |
1) Fasten the base plate to the NEO using the right holes in the base plate and two #10-32 x 1/2in screws with a 1/8in Allen Key. |
2)Press a Flanged Bearing into the base with the flanged side opposite of the NEO. |
3) Press a 1/2in Hex Through Bore Shaft into the Flanged Bearing. |
4) Slide a 1/8 MAXSpline Spacer onto the 1/2in Hex Through Bore Shaft. |
5) Press a Retaining Ring onto the the Output Shaft of the NEO. Please Note: You will adjust this placement later in step 7. |
6) Screw together two MAXSpline Pulley halves with six M3x12mm screws. |
7) Place the 40-tooth RT25 Belt around both a 12tooth-RT25 Pulley and MAXSpline Pulley, then slide them onto the Output Shaft of the NEO and 1/2in Hex Through Bore Shaft at the same time. Please Note: Adjust the Retaining Ring on the shaft of the NEO to make the 12tooth-RT25 pulley level with the MAXSpline Pulley. |
8) Secure the 12tooth-RT25 Pulley with a second Retaining Ring. |
9) Slide a 1/8 and a 1/16 MAXSpline Spacer onto the 1/2in Hex Through Bore Shaft. |
10) Press a Bearing onto the 1/2in Hex Through Bore Shaft. |
11) Press the Pulley Cover Plate onto the 1/2in Hex Through Bore Shaft Bearing. |
12) Secure the Pulley Cover Plate with three #10-32 x1-1/2in screws and #10 Spacers using a 1/8in Allen Key. |
1) Install one of the Flanged Bearings into the Motor Plate. |
2) Insert the two motors into the back side of the Motor Plate, and fasten them into place using two 1/2in long 10-32 button head screws per motor. |
3) Insert the end of the Through Bore Shaft into the bearing. The shoulder of the shaft should be fully seated against the face of the bearing. |
4) Slide one of the 1/8in long MAXSpline spacers onto the through bore shaft. |
6) Slide one 1/8in long and one 1/4in long MAXSpline spacer onto the through bore shaft. Ensure that the stack of spacers and the gear are pressed firmly together and that the end of the last spacer is flush with the shoulder at the end of the through bore shaft. |
7) Install the motor shaft key into each of the motors. |
1) Install the 1/2in Hex Adapter onto each of the motor shafts. |
2) Slide one 1/16in long and one 1/4in long 1/2in Hex Shaft Spacers onto each of the Hex Adapters. |
3) Slide the appropriate 1/2in Hex Bore Gear for the selected ratio onto each of the Hex Adapters. Ensure that the gears are properly meshed with the center gear. |
4) Slide an 8mm Shaft Spacer onto the end of each of the motor shafts. |
5) Install an external retaining ring on the end of each motor shaft to hold the shaft stack-up into place. |
1) Slide an 8mm Shaft Spacer onto each of the motor shafts. |
2) Install the appropriate motor pinion for the selected ratio on each motor shaft. Ensure that the pinions are properly meshed with the center gear. |
3) Install an external retaining ring on each motor shaft to hold the pinion in place. |
1) Install the remaining Flanged Bearing in the Outer Plate. The flange of the bearing should be on the opposite side of the plate from the screw head cutouts on the corners of the plate. |
2) Place the Outer Plate and bearing onto the through bore shaft with the bearing flange facing inwards. |
3) Slide the four 1-1/8in long #10 spacers in between the Outer Plate and Motor Plate, and line them up with the four corner holes in the Outer Plate. |
4) Insert the four 1-1/2in long 10-32 button head screws through the Outer Plate, through the #10 spacers, and into the threaded holes in the Motor Plate. Leave the screws slightly loose. |
5) Rotate the gearbox shaft a few times and then tighten the screws. Test spin the gearbox to ensure that it rotates freely. |
The REV Power Distribution Hub (REV-11-1850) is the latest evolution in power distribution for the FIRST Robotics Competition (FRC). With 20 high-current (40A max) channels, 3 low-current (15A max), and 1 switchable low-current channel, the PDH gives teams more flexibility for overall power delivery. The Power Distribution Hub features tool less latching WAGO terminals, an LED voltage display, and the ability to connect over CAN or USB-C to the REV Hardware Client for real-time telemetry, making it easier than ever to wire and debug your robot.
For additional information including connections, specs and troubleshooting, check out the complete Power Distribution Hub Overview section
The REV Radio Power Module (REV-11-1856) is designed to keep one of the most critical system components, the OpenMesh OM5P-AC WiFi radio, powered in the toughest moments of the competition. Traditional barrel jacks easily work themselves loose and often require hacks, like hot glue, to prevent intermittent power losses. The Radio Power Module eliminates the need for powering the radio through a traditional barrel power jack. Utilizing 18V Passive Power over Ethernet (POE) with two socketed RJ45 connectors, the Radio Power Module passes signal between the radio and roboRIO while providing power directly to the radio. After connecting the radio and roboRIO, easily add power to the Radio Power Module by wiring it to the low-current channels on the Power Distribution Hub utilizing the color coded push button WAGO terminals.
For additional information including connections, specs and applications, check out the complete Radio Power Module Overview section
The REV Mini Power Module (REV-11-1956), or MPM, is a compact power distribution module that allows you to securely and quickly power peripheral devices to your robot. Need more low-current channels on your PDH? Wire the MPM to one of the high-current channels on the PDH to power more peripheral devices and custom circuits.
For more information including specifications check out our complete documentation here - Mini Power Module
The WAGO 221 Inline Splicing Connector (REV-15-2491) is a robust and easy to use splicing connector that makes fiddling with hard-to-master crimp-style connectors a thing of the past. Simply lift the lever up, insert the stripped wire, and push the lever back down to make the connection.
Compatible with up to 12 AWG solid, stranded, and fine-stranded conductors, the lever actuated WAGO CAGE CLAMP® excels both in electrical conductivity and mechanical holding force when compared to other common connectors used on FRC robots. Its printed-on strip length guide and transparent housing takes all of the guesswork out of installation and inspection, virtually guaranteeing a proper connection every time.
The REV Robotics SPARK MAX Motor Controller (REV-11-2158) is an all-in-one USB, CAN, and PWM enabled motor controller that can drive both 12 V brushed and 12 V brushless DC motors. SPARK MAX is designed for use in the FIRST® Robotics Competition (FRC), incorporating advanced motor control in a small, easy-to-use, and affordable package. Configure and run the SPARK MAX through its built-in USB interface without needing a full control system.
For more information including specifications check out our complete documentation here - SPARK MAX
The REV Through Bore Encoder (REV-11-1271) is specifically designed with the end user in mind, allowing teams to place sensors in the locations closest to the rotation that they wish to measure. This rotary sensor measures both relative and absolute position through its ABI quadrature output and its absolute position pulse output. Mounting an encoder has never been easier with a 1/2" Hex Through Bore paired with the molded mounting holes which allow users to quickly place this encoder on the object they want to measure. Using one of the included inserts allows for the 1/2” hex to convert to 3/8” hex, 5mm hex, or 1/4” round for additional flexibility.
Need more information? Check out the Through Bore Encoder Data Sheet and Getting Started Video
The SPARK MAX Data Port Breakout Board (REV-11-1278) makes it easy to connect external sensors to the SPARK MAX Data Port.
For additional information, check out our Spark Max Data Port Guide
This JST-PH 6-pin Breakout Board (REV-11-1276) is designed to adapt external sensors to the SPARK MAX 6-pin Encoder Port standard. It features a JST PH 6-pin connector, labeled solder pads, and through-hole pads that are compatible with popular 63R style quadrature encoders. This breakout makes it easy to connect external encoders to the SPARK MAX when running in Brushed Mode.
These JST PH 6-pin Joiner Boards (REV-11-1277) are intended to be used with the JST PH 6-pin Extension Cables to extend the reach of your NEO Brushless Motor sensor cables.
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.
Digital and analog pressure sensor ports are built into the device, increasing the flexibility and feedback functionality of the pneumatic system. The USB-C connection on the Hub works with the REV Hardware Client, allowing users to test pneumatic systems without a need for an additional robot controller.
The REV Robotics Magnetic Limit Switch is a three-sided active-low digital hall effect switch with three internal hall effect elements located on the top and sides of the sensor. The three elements are connected in parallel so that any one of them will trigger the sensor.
Hall effect sensors detect the presence of magnetic fields. The REV Magnetic Limit Switch is an omnipolar momentary switch meaning it will trigger when there is sufficient field strength of either magnetic pole (north or south) detected.
5) Slide the appropriate MAXSpline Gear for your selected ratio onto the through bore shaft. The appropriate gears to be used for your ratio can be found here:
The REV Pneumatic Hub () is a standalone module that is capable of switching both 12V and 24V pneumatic solenoid valves. The Pneumatic Hub features 16 solenoid channels which allow for up to 16 single-acting solenoids, 8 double-acting solenoids, or a combination of the two types. The user selectable output voltage is fully regulated, allowing even 12V solenoids to stay active when the robot battery drops as low as 4.75V.
For additional information including connections, specs and troubleshooting, check out the complete section
The REV Robotics Analog Pressure Sensor () is a 5V sensor that can measure pressures up to 200 PSI. It outputs an analog voltage that is proportional to the measured pressure and can plug directly into the , roboRIO, or the .
Check out our to our
The Blinkin LED Driver () is designed to make it straight forward to add controllable LEDs to a robot, cart, or any other project which would benefit from some extra lumens without needing any specialized programming. The Blinkin is a compact, all-in-one solution which can control LEDs in a stand-alone mode with just a 12V power source or in a dynamic mode, changing patterns by supplying a standard servo-style PWM signal.
Check out all the specs and documentation including wiring and programming on the
This 5V WS2812B Addressable RGB LED Strip () is compatible with the REV (REV-11-1105). Each LED contains an integrated driver IC and three LEDs; a red, green, and blue LED. Each individual LED can be controlled to create colorful patterns.
Check out our on using this 5V addressable LED strip with our Blinkin LED Driver
This 12V RGB LED Strip () is compatible with the REV Blinkin LED Driver (). Each LED on the strip is wired in parallel and actually contains three embedded LEDs; a red, green, and blue LED. Each color can be controlled separately to create any color that you desire. Because these LEDs are wired in parallel, the entire strip will be the same color.
Check out our on using this 12V RGB LED strip with our Blinkin LED Driver
The REV Robotics Color Sensor () V3 is a combined color and proximity sensor. From a single sensor you can measure colors and rough distances to various targets. Version 3 introduces a new sensor chip from Broadcom due to the end-of-life of the V1/V2 color sensor chip.
Check out the full documentation including specs and example use cases for the here
The REV Robotics 2m Distance Sensor () uses the ST Microelectronics VL53L0X Time-of-Flight (ToF) laser-ranging module to measure distances up to 2m with millimeter resolution. Unlike other ranging sensors that rely on the intensity of reflected light, this sensor can measure how long it takes for the light to bounce back, the “time of flight.” This results in much more accurate measurements that are independent of the target’s reflectance.
Check out the full documentation including specifications and example use cases for the here
Check out the full documentation including specs and example use cases for the here
This 4-pin JST PH to 4-pin roboRIO I2C Cable () is designed to connect REV I2C sensors, like the , to the I2C port on the NI roboRIO for use in the FIRST Robotics Competition. Each cable is approximately 36 inches long.
1) Place the NEO 550 upright in the arbor press. Make sure to hold the bottom of the motor flat against the press plate, supporting the bottom of the shaft.
2) Place the pinion on the shaft and press. Take care to not over-press on the NEO 550 shaft!
Below is a suggested base set of tools you will need to work effectively with the ION build system. If brand names are shown, they are not intended to be endorsements or requirements.
The 1/8" Bondhus ProHold Ball End Hex Driver is the right hex screwdriver for the demanding pace of FIRST build seasons. 1/8in hex is commonly used in #10 button and countersunk hex head hardware.
With #10 Hardware standardized across the REV ION Build System, a #10 Nut Driver is a must have item for your toolbox.
22 in 1 small magnetic screwdriver set, an all-in one multi-function pocket repair tool. This set has the right attachment for whatever small screws you need to tighten or remove.
A Cordless Power Drill/Driver kit is a great tool for working in tight spaces, like on your robot. Quickly fasten nuts or drill holes with ease.
Drills holes perfectly sized for your #10 hardware with a 3/16in drill bit.
For everything else the 3/16in drill bit can't handle, there is the multi-size step bit!
Small and portable, a hack saw is perfect for making cuts through aluminum extrusion.
From set screws to the bolts that hold together your robot, always be prepared with the right sized Hex Key when you have the whole set.
For cutting bumper fabric, trimming surgical tubing, and all of your cutting needs, be sure to invest in a good pair of scissors.
Wire cutters, or diagonal cutting pliers, can go a long way when cutting wires to length for your control system.
Cleanly strip and cut wire to prepare it for use in your control system with a pair of wire strippers.
Used to smooth out rough cuts, sharp corners, uneven grooves and to open up holes that need a little more coaxing.
Drill and thread your own 10-32 holes with a tap set like this one.
150 grit medium-cut sandpaper sheets are ideal for sanding wood, metal and plastics.
A staple gun is great for tacking down thin materials like plywood, fabric, and corrugated plastic quickly.
The REV NEO 550 (REV-21-1651) Brushless Motor is the newest member in the NEO family of brushless motors. Its output power and small size are specifically designed to make NEO 550 the perfect motor for intakes and other non-drivetrain robot mechanisms. Mounting holes and pilot match a standard 550 series motor, making it natively mount to many existing off-the-shelf gearboxes.
The REV NEO 550 Brushless Motor runs a 0.12in output shaft which, when combined with its 550-style mounting features, allows for easy installation in many off-the-shelf gearboxes.
Its small size and weight make it easy to put power where you need it, whether that is on intakes, end-effectors, or other weight-sensitive mechanisms. However, keep in mind that this motor does have a lower thermal mass than a NEO, CIM or Mini CIM, and thus it may not be ideal for some drivetrain applications.
Connecting the NEO 550 Brushless motors is fairly straightforward. Follow the guide at Wiring the Spark Max with the NEO Brushless Motor, and don't forget to connect your encoder sensor wire; the motor will not spin without it!
CAUTION: Improperly wiring the connectors can cause severe motor damage and is not covered by the warranty. DO NOT connect the motor directly to the battery.
Mounting features match other 550 series DC motors
Front and rear ball bearings
High-temperature neodymium magnets
High-flex silicone motor wires
Integrated motor sensor (3-phase hall sensors)
Motor temperature sensor
Check out the NEO 550 Motor Data Sheet for additional specifications and charted motor curves. Also, please pay special attention to the NEO 550 Motor Locked Rotor Testing and please make sure you have read and understand how to set the SPARK MAX Smart Current Limit.
The NEO 550 has been optimized to work with some of the above products, like the SPARK MAX Motor Controller (REV-11-2158) and the 550 Motor Pinions (REV-41-1608) to deliver best-in-class performance and feedback.
Nominal Voltage
12 V
Motor Kv
917 Kv
Free Speed
11000 RPM
Free Running Current
1.4 A
Stall Current
100 A
Stall Torque
0.97 Nm
Peak Output Power
279 W
Motor Wire Gauge
16 AWG
Hall-Sensor Encoder Resolution
42 counts per rev.
Output Shaft Diameter
0.125in (3.175mm)
Output Shaft Length
0.267in (7mm)
Output Pilot
0.512in (13mm)
Body Length
1.752in (44.5mm)
Body Diameter
1.378in (35mm)
Weight
0.142 kgs (0.313 lbs)
UltraPlanetary Gearbox Kit (REV-41-1600) for the NEO 550 (REV-21-1651) is available. The kit comes with UltraPlanetary Cartridges to support six different final gear reductions, ranging from nominally 3:1 to 60:1 (125:1 w/ optional cartridges), allowing for the right amount of torque for the application at hand.
Watch the video linked below to learn how to use a NEO 550 with our UltraPlanetary Gearbox.
You can learn more about the UltraPlanetary system on the
Recommended for use on drive trains, intakes or shooters, ION Grip Wheels (Product Family Page) are compatible with the REV ION System and come in a wide range of sizes, durometers, and bores. Larger wheels contain the MAXSpline hub but can be adapted to other bores with a separate MAXHub. Wheels with spokes have a bolt circle of #10 clearance holes patterned outward at 1/2in pitch and also have a 3/8in wide nut groove, which removes the need for a wrench when utilizing the holes on the spokes. Multiple wheels can be mounted flush next to each other when more surface area is needed.
Check out the full line of ION Grip Wheels on the product page
Size:
Pattern:
Width
1in
Hex
.50in
2in
Hex
.50in
2in
MAXSpline
.50in
3/4/5/6in
MAXSpline
1.5in
Recommended for use on drivetrains, ION Traction Wheels (Product Family Page) come in a wide range of sizes, durometers, bores and material. Larger wheels contain the MAXSpline, but can be adapted to other bores with a separate MAXHub. Wheels with spokes have a bolt circle of #10 clearance holes patterned outward at 1/2in pitch and also have a 3/8in wide nut groove, which removes the need for a wrench when utilizing the holes on the spokes. Multiple wheels can be mounted flush next to each other when more surface area is needed.
Check out the full line of ION Traction Wheels on the product page
The REV Servo Power Module (REV-11-1144) is a 6V 90W power injector that enables the use of high-power RC servos in applications where a robot controller cannot provide adequate power.
The Servo Power Module has two screw terminals for 12V power input. It is recommended to use ring or fork terminals designed for #6 or M3 screw terminals.
Using an appropriate wire gauge, 18 AWG or larger, tightly crimp either a ring or fork terminal on the wire. Insert the crimped terminal into the screw terminal and tighten the screw.
The input and output channels accept standard 3-wire 0.1” pitch servo/PWM cables. Please refer to the figure above or the case markings for proper orientation.
Each channel has a corresponding status LED that will indicate the sensed state of the connected PWM signal. The table below describes each state’s corresponding LED pattern.
If the Servo Power Module detects a total output current larger than 15A it will enter a shutdown mode where the 6V output is disabled until the over-current condition has remedied. While in shutdown the blue power LED will turn off, dim, or flicker indicating the over-current condition is still present.
In the case of frequent over-current shutdowns, ensure that the total stall current of all connected servos does not exceed 15A.
Size:
Pattern:
Width
2in
MAXSpline
1in
2/3/4/5/6in
MAXSpline
1.5in
Key Terms
Key Metrics
Nominal Input Voltage
12V
Operating Voltage Range
7.0V - 20V
Minimum Startup Voltage
9.0V
Output Voltage
6V
Number of Channels
6
Max. Total Output Current
(across all Channels)
15A
Max. Total Output Power
90W
Size
3.6” x 1.52” x 0.81”
Weight
2.0oz/57g
State
Pattern
No Signal
Blinking Amber
Left/Reverse Signal
Solid Red
Center/Neutral Signal
Solid Amber
Right/Forward Signal
Solid Green
All 10-32 Screws used for Assembly and Mounting
10-32 Face Mounting Holes on a 2in Bolt Circle with 2 Orientations
2in Gearbox Height
Gearbox does not protrude above or below common FRC structural tubes
Output shaft stays on 1.0in pitch when the gearbox is mounted using the side holes
Side Mounting Holes are on a 0.5in pitch regardless of number of stages