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!
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.
MAX Pattern MAXTube
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.
2023 REV ION FRC Starter Bot Utilizing ION Components!
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: [email protected]
Brackets
Brackets are used to join different parts of the robot together. Most brackets can be divided into two categories: Motion and Structure. Motion brackets help create strong attachment points for your motion components and any parts of your robot that move. Structure brackets are designed to hold pieces of extrusion together.
Bracket Basics
In the REV ION Build System, there are two major groupings of brackets: MAXSpline and construction. The major distinguishing feature of MAXSpline brackets is a MAXSpline bore or MAX Pattern to support bearings and MAXHubs. 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.
Follow through the following sections to learn more about brackets:
MAX Pattern Plates
MAX Pattern Plates 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: MAX Pattern Plates
Adjustable Tube Mount
The Adjustable Tube Mount () is a precision machined aluminum bracket designed to give teams fine control over how attaches to robot structure.
Three center counterbored holes allow a MAXTube Endcap to bolt on flush, creating a clean mounting interface for perpendicular tube assemblies. Elongated, counterbored mounting slots on each side provide precise lateral adjustment, making it easy to correct for off pitch spacing, achieve exact alignment, or tension belts and chain with ease. This combination of rigid support and micro adjustability opens up new possibilities for building accurate, refined robot structures.
Specifications
Preparing to Build an EasySwerve Module
Supplies Needed
In addition to the 4in EasySwerve Module Kit (REV-21-3006), you will need tools, motors, an encoder, and a few additional supplies.
Tools
Introduction to Motion
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.
Addendum Shifting in Gears
Addendum shifting, also known as profile shifting or addendum modification, is a technique used in gear design to modify the shape of gear teeth. This modification is achieved by intentionally shifting the basic rack datum line, which is a theoretical line used to generate the gear tooth profile, relative to the reference diameter of the gear.
Why Addendum Shifting is Used
Undercut prevention: When gears have a small number of teeth, the standard involute tooth profile can lead to undercutting, where the tooth tip becomes pointed and weakens the gear. Addendum shifting can be used to modify the tooth profile and prevent undercutting.
Center distance adjustment: By shifting the addendum of one or both gears, the center distance between the gears can be adjusted without changing the gear ratio. This can be useful in situations where the desired center distance is different from the standard center distance for the given gear pair.
Load distribution: Addendum shifting can be used to redistribute the load between the teeth of a gear pair, which can improve the load-carrying capacity and reduce wear.
Types of Addendum Shifting
Positive Addendum Shift (+): Increases the addendum length, moving the teeth slightly outward. This is done to increase the gear's load capacity or avoid undercutting in smaller gears. It can improve tooth strength and reduce bending stress.
Negative Addendum Shift (-): Reduces the addendum length, moving the teeth slightly inward. This can be used to reduce interference between mating gears and allow for a more compact gear design.
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.
Electronics
Other
Coming soon: Updated materials list for assembling an EasySwerve Drivetrain!
NEO Pinions
The NEO family of motors have many pinions to provide compatibility with multiple systems.
15T Spline Pinons
These pinions are compatible the NEO V1.1 Brushless Motor and the NEO Vortex Brushless Motor with a Vortex Shaft - 15T Spline.
20DP NEO Pinions
These pinions allow your motor to directly interface with the .
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
Structure Basics
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.
All REV ION structural components are #10 hardware compatible.
MAXTube with MAX Pattern vs. 1in Extrusion
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.
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.
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.
Polycarbonate Sheet
The REV Polycarbonate Sheet - 3mm - 1/2in Grid Pattern (REV-21-3410) is a lightweight, clear, and durable plastic material designed for fast and flexible robot construction.
Polycarbonate Sheet
Featuring a grid of pre-cut holes on a 1/2in spacing that matches the REV ION pitch, this sheet mounts effortlessly to common build structures with no additional drilling required. The hole pattern helps reduce overall weight while preserving strength, making it ideal for large surface applications.
Cutting to Size
While simple cuts can be made with strong shears or tin snips hole-to-hole, best results are achieved using a bandsaw, scroll saw, table saw, or hacksaw.
Polycarbonate should NOT be laser cut, and Loctite (threadlockers) or chemicals that degrade polycarbonate must be avoided.
Specifications
Material: Polycarbonate
Finish: Clear
Sheet Size: 1194mm x 584mm (47in x 23in)
Thickness: 3mm (0.118in)
The Polycarbonate Sheet arrives with protective masking on both sides to prevent scratches during storage and processing. This should be removed upon installation.
Recommend Uses
Rapid prototyping
Intakes
Hoods
Funnels
Application Examples
Coming Soon!
Cone
REV ION Cone Wheels are designed to give teams controlled, predictable vectoring for game pieces and objects. Their tapered profile naturally guides items toward the smaller diameter, making them especially effective in intake edge zones and in-feed mechanisms where centering or directional control is critical.
Whether used to straighten, funnel, or shift objects laterally, Cone Wheels provide a consistent way to manipulate game pieces without complex mechanical assemblies.
2in to 3in Cone Wheels
3in to 4in Cone Wheels
These wheels are sized within the REV ION System footprint so they can be swapped with other wheels of similar width. Their on pitch outer diameters help preserve necessary clearance in tight mechanisms.
All Cone Wheels use a MAXSpline bore for secure, slip free torque transfer, and they can be easily adapted to other bore types using MAXHubs or similar adapters.
Specifications
Material: Polypropylene & TPR
Durometer: Varies (see table below)
Bore: MAXSpline
Cone Wheel - 2in to 3in
Width: 23.8mm (0.94in)
Weight: 51g (0.112lbs)
Cone Wheel - 3in to 4in
Width: 36.5mm (1.44in)
Weight: 171g (0.377lbs)
Durometer
Application Examples
Coming Soon.
Traction
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.
Size:
Pattern:
Width
2in
MAXSpline
1in
Check out the full line of on the product page
Bumper Brackets
Differential Drivetrain Bumper Bracket Kit
The Differential Drivetrain Bumper Bracket Kit is designed to be a quick and convenient way to install FRC legal bumpers on the REV ION West Coast Drivetrain or an AM14U based drivetrain with included Bumper Adapters (REV-21-3067).
Parameter
Value and Units
Choosing your Motors
Motor Compatibility
EasySwerve supports an exceptionally wide range of motors for both steering and drive. Teams can use NEO 2.0 Brushless Motors, NEO Vortex with SPARK Flex, NEO 1.1, Kraken X60, Falcon with 8mm shaft installed, and even CIM motors.
Motor Orientation
EasySwerve Modules can be assembled with motors mounted on either the top or bottom, providing flexibility for packaging your drivetrain. If a design demands ultimate flexibility, you can even mount one motor on the top and one on the bottom!
Bottom Mounted Motor Clearance
This guideline was defined assuming that the terrain the robot will drive on is flat. Driving over bumps or debris may cause damage to your motors.
Motor Gears - "P17" vs "P27"
Each EasySwerve Module Kit includes QTY 4 - 20DP Motor Gears with different input bores. Only two of these Motor Gears are necessary for assembly; however, most motors are only compatible with one version of the Motor Gear. Below is a table that can help you determine which 20DP Motor Gear is compatible with the drive and steering motors for your EasySwerve.
20DP Motor Gear - 15mm Spline (P27)
20DP Motor Gear - 8mm Keyed (P17)
EasySwerve Tips and Tricks
Tips and Tricks coming soon!
EasySwerve Drivetrain Assembly
Build Guide coming soon!
Supporting Motion
Supporting the mechanisms that move on the robot is very important. Without planning proper supports, shafts may not be able to spin and your mechanisms or actuators could be damaged.
How to Support Motion
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.
EasySwerve Software
Code Template
Steering Encoder Calibration
Verify you have completely assembled your MAXSwerve or EasySwerve Module and have the Steering Motor’s SPARK Flex or SPARK MAX connected to the Module's Through Bore Encoder
Connect the Steering Motor’s SPARK Motor Controller directly to your computer via the included USB-C to USB-A cable
MAXPlanetary Gearbox Assembly
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 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.
Spacer Assembly Guide
The following steps are only required if you are using a CIM, MiniCIM, or Falcon Motor
When to use the CIM/Falcon Spacer
Keyed Input Coupler V1
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.
Keyed Input Coupler V1.1
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.
Falcon Spline Input Coupler
When using a Falcon Spline Input Coupler with your MAXPlanetary Gearbox you do not need to install the spacer.
Getting Started with EasySwerve
What is Swerve Drive?
Swerve drivetrains use standard wheels mounted on their own pivoting mechanisms. Most swerve
drivetrains, including EasySwerve, require two motors per wheel: one to rotate the wheel, and one to control the direction the
wheel points. Your robot can move in any direction because the drive wheels pivot without changing
the orientation of the drivetrain, but this type of drivetrain can become technically complex very quickly.
How is EasySwerve Different from other Swerve Modules?
Designed with accessibility in mind – prioritizing team experience regardless of skill level with simple assembly, easy maintenance, and a fully enclosed geartrain.
Durable Base Plate and Cover made from 30 percent glass-filled nylon for impact resistance and lightweight performance.
Wide motor compatibility including NEO 2.0, NEO Vortex with SPARK Flex, NEO 1.1, and CIM (top-mount only), with both 8mm keyed and 8mm 15T Spline pinions included to adapt additional FRC legal motors like Kraken X60 or Thrifty Pulsar.
Onshape CAD Examples
From simple joints to fully designed mechanisms, our Onshape CAD examples will help your team to get started planning out your robot using the ION Build System in no time!
The library of low complexity Onshape examples includes wheel assemblies, the use of MAX Pattern and MAXSpline, dead axles, and more!
The library of medium complexity Onshape examples includes MAXTube structures, roller assemblies, ratio plates, and more!
The library of high complexity Onshape examples includes drivetrain examples, full mechanisms, and robot designs from previous game years!
MAXSpline Brackets
MAXSpline Brackets
are compatible with the REV ION System and are designed to mount to pieces of 2x1in - with MAX Pattern while maintaining proper pattern spacing.
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.
Pivot Joints
The ION 1in Pivot Joint () can be used in numerous ways within the ION Build System to create a pivot joint at the end of a piece of MAXTube - 1x1 or 2x1 with Grid Structure.
Constraining Motion
For designs where one or more MAXTubing needs to behave fixedly, like an elbow or a hinge. ThePivot Joint can constrain MAXTubing, allowing for rotational movement around a fixed axis for many degrees of rotation.
Gearboxes
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.
2 Motor Drivetrain Gearbox Through Bore
Load Ratings
MAXPlanetary System
Static Load Ratings
The following torque measurements are for a static load condition. The torques listed are for the output of the stage.
Omni
ION Omni Wheels () 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 . Rollers for each wheel size are unique, which ensures perfectly circular wheels.
Compliant
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 .
System Standards
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:
#10 Clearance Holes
All hardware is #10-32 sized
Wheels
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.
Wheel Basics
MAXSwerve Pack Contents
Below are several visual representations of the contents included with the .
Full MAXSwerve Module Kit
The PDF below is included in each MAXSwerve Module kit and shows all parts included as well as a visual comparison of the mechanical parts in the kit.
EasySwerve Overview
4in EasySwerve Module
The 4in EasySwerve Module is designed to bring truly accessible swerve drive performance to every FRC team. Built for simplicity, durability, and broad motor compatibility, EasySwerve removes many of the traditional barriers associated with adopting swerve. Whether you are building your first swerve robot or optimizing a drivetrain for ease of maintenance, this module delivers a dependable and approachable experience at an economical price.
At the heart of EasySwerve is a rugged Base Plate and Cover molded from 30 percent glass-filled nylon. This enclosure shields the entire geartrain from carpet debris while keeping the module lightweight and impact-resistant. A 4in wheel unlocks higher potential speeds, improved obstacle clearance, and compatibility with a wide range of tread options, including new 4in Spiky Wheels for maximum grip.
Ratio Plates
Ratio Plates
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.
Servos
Servo Basics
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 or . 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 () become damaged, they are replaceable using a Replacement Gear Set ().
Choosing Between the Two Motor Gearboxes
When your application demands the use of one of these gearboxes, the right choice may not be entirely clear. Here are two key points to consider when making your selection:
Form Factor - Which one of these will fit and mount comfortably in your use case?
Gear Ratio - How much gearing flexibility do you need out of these gearboxes?
Programming MAXSwerve
MAXSwerve Code Templates
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.
Kraken Input Kit Assembly Guide
This kit requires the (REV-21-2986)
Kit Contents:
MAXSwerve Module Inspection
We recommend checking the following items before each match to ensure that your MAXSwerve Modules are ready to go!
Inspection Checklist
Mounting Features
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
Smart Robot Servo
The REV Robotics Smart Robot Servo (SRS) () 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 the Smart Robot Servo check out our on the SRS.
Any tapped holes are #10-32
Can use 3/16in rivets
1/2 in Hole Pitch
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
1/2 in Rounded Hex Shaft
13.75mm diameter rounded corners for ease of assembly in bearings
Fits standard 1.125in OD Bearings
Fractional Axial Width
Components together along a shaft always have a total width on a fractional interval
Use with motors that have an 8mm 15T Spline output shaft
Use with motors that have an 8mm keyed output shaft. You will need to also use the included motor key and retaining ring to mount your motor.
Examples of compatible motors:
- NEO 2.0
- NEO Vortex with 15mm Spline Shaft installed
- Kraken X60 and more!
Examples of compatible motors:
- NEO V1.1, NEO V1
- NEO Vortex with 8mm Shaft installed
- Falcon with 8mm keyed shaft
- CIM and more!
Documentation Links
Servo Power Module
The REV Robotics SRS Programmer is the key to unlocking all the smart features of the Smart Robot Servo (SRS). 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 Servo Power Module (REV-11-1144) is a 6V 90W power injector that enables the use of standard servos in applications where a robot controller cannot provide adequate power. The following Quick Start Guide describes the Servo Power Module features and the necessary information to get it up and running.
Optimized gearing featuring a 20:1 azimuth reduction and 6.3:1 drive reduction, achieving up to 18.79 ft/s with NEO Vortex or 15.724 ft/s with the NEO 2.0 Brushless Motor.
4in wheel system for high speeds, more ground clearance, and quick wheel changes using the MAXSpline interface.
Tread options include standard 4in wheels and high-traction 4in Spiky Wheels with replaceable TPU tread.
Straightforward calibration using a 1/8in or 3mm hex key that locks into a dedicated azimuth alignment pocket easily accessible from the top meaning you don't need access under the robot.
Easy integration with MAXTube and 0.5in-on-pitch chassis systems using the included mounting holes on the base plate.
Only four tools are necessary for assembly and calibration, keeping your drivetrain maintenance kit light and affordable.
Swaping wheels with a single hex key and minimal hardware
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
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.
MagnitudeSlewRate
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
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.
MAXSwerve Template Changelog:
V2023.1
Added a configurable rate limiting system to prevent excessive loads from causing premature wheel failure.
// Driving Parameters - Note that these are not the maximum capable speeds of
// the robot, rather the allowed maximum speeds
public static final double kMaxSpeedMetersPerSecond = 4.8;
public static final double kMaxAngularSpeed = 2 * Math.PI; // radians per second
public static final double kDirectionSlewRate = 1.2; // radians per second
public static final double kMagnitudeSlewRate = 1.8; // percent per second (1 = 100%)
public static final double kRotationalSlewRate = 2.0; // percent per second (1 = 100%)
// Driving Parameters - Note that these are not the maximum capable speeds of
// the robot, rather the allowed maximum speeds
constexpr units::meters_per_second_t kMaxSpeed = 4.8_mps;
constexpr units::radians_per_second_t kMaxAngularSpeed{2 * std::numbers::pi};
constexpr double kDirectionSlewRate = 1.2; // radians per second
constexpr double kMagnitudeSlewRate = 1.8; // percent per second (1 = 100%)
constexpr double kRotationalSlewRate = 2.0; // percent per second (1 = 100%)
Select the Steering SPARK from the list of Connected Devices and navigate to the Update Tab to verify your Firmware is up to date.
Ensure the Steering SPARK is still selected, and then navigate to Absolute Encoder under the Utilities Tab.
Insert a 1/8in or 3mm Hex Key into the calibration on the top of the EasySwerve Module. You will feel the Hex Key reach the azimuth gear inside of the top cover.
Rotate the module's wheel manually while applying light pressure to the hex key until it slots into the alignment pocket. The Hex key will travel about 1/4in further into the swerve module when it has aligned.
Click the Set Zero Offset button to calibrate the zero-position of the absolute encoder to this position.
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 (REV-21-2351).
A full listing of brackets is located on the MAXSpline Bracket product page. Compatible 1in extrusion brackets are also available on the ION Brackets product listing page
MAXSpline Bracket Specifications
Material: Aluminum 5052
Weights:
MAXSpline Bracket - Stacked: 35g (0.08lbs)
MAXSpline Bracket - Offset Mount: 91g (0.20lbs)
MAXSpline Bracket - Parallel Top Mount: 49g (0.11lbs)
MAXSpline Bracket - MAX Pattern T: 39g (0.09lbs)
Application Examples
MAX Pattern T Brackets
MAX Pattern T Bracket
MAX Pattern T Brackets are ideal for creating a perpendicular joint of MAX Pattern MAXTube, as seen in the example below:
T Brackets securing two MAX Pattern pieces
Alternatively, the two MAXSpline openings allow for unique gearbox mountings, such as with the MAX 90 Degree Gearbox as shown here:
2 Motor Gearbox using a T Bracket to mount the MAX 90
When using the MAX Pattern T Brackets, the center to center distances of the MAXSpline openings will be offset.
Parallel Top Mount Bracket
Parallel Top Mount Bracket
The Parallel Top Mount Bracket can be used to provide support to the end of a shaft that may be cantilevered otherwise:
Parallel Top Mount Bracket supporting a bearing and shaft
Offset Mount Bracket
Offset Mount Bracket
The Offset Mount Bracket is perfect for allowing a motor to be mounted parallel to the axis of a MAXTube:
Stacked Bracket
The extra row of holes on the Stacked Bracket can be used to tile the MAXSpline pattern on a MAXTube in 2D, keeping the holes and the spline on pitch with the mounting tube. The Stacked Bracket is recommended when the goal is to offset a motor from a tube while wanting to remain on pitch with the original tube spline openings.
First, cut two 1x1 Extrusions to the desired length.
Next, insert four #10-32 x 3/8in Button Head Drive Screws into opposite sides of the Pivot Joint. Repeat for the other Pivot Joint.
Then, place a Tapped 1in 1/2in Hex Shaft into one of the Pivot Joints, and sandwich the two Pivot Joints together. Insert two #10-32 Shaft End Screws into the Hex Shaft to secure the assembly.
Two 1x1 MAXTubing in a typical elbow hinge configuration.
Supporting Motion
If your design calls for moving structures, the 1in Pivot Joint can serve as a shaft bearing to support a wheel. This allows a fixed point to have rotational movement, similar to the example picture.
First, cut the 1in Extrusion to the desired length.
Next, insert four #10-32 x 3/8in Button Head Drive Screws into opposite sides of the Pivot Joint.
Then, place a Tapped 1in 1/2in Hex Shaft into one of the Pivot Joints with a #10-32 Shaft End Screw.
From here, you will need to determine what size spacer would be best for your specific application. But in this example, a 1/4in Hex Spacer and a 1/8in Hex Spacer were used.
Finally, slide your Compliant wheel loaded with 1/2in Hex MAXHubs on the shaft and secured everything with a #10-32 End Screw.
1x1 MAXTube using a 1in Pivot Joint to capture an ION compliant wheel
1in Pivot Joint Example Applications
Motorized angled bracket joint with compliant wheels.
Three Pivot Blocks in the ends of a 2x1 MAXTube.
1x1 to 1x1 MAXTubing in an offset hinge configuration.
The 2 Motor Drivetrain Gearbox Through Bore (REV-21-2190) 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 (REV-11-1271) ensure the gearbox is on the same horizontal plane to help keep alignment frustrations to a minimum.
2 Motor Gearbox - Through Bore
The 2 Motor Gearbox (REV-21-2099) 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.
MAXPlanetary System
The NEO Motor matches the design flexibility of other REV ION products with our optional MAXPlanetary Gearbox (REV-21-2100) 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.
The NEO 550 Motor (REV-21-1651) matches the design flexibility of other REV ION products with our optional UltraPlanetary Gearbox (REV-41-1600). 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 UltraPlanetary Overview section as well as the video above
Cartridge
Torque
3:1 Cartridge
Tested to 290 N⋅m (no failure)
4:1 Cartridge
Fails at 270 N⋅m
5:1 Cartridge
Fails at 240 N⋅m
1/2" Hex Socket Output
Fails at 250 N⋅m
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.
Cartridge Configuration
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.
REV Motors
Load Rating Chart
Other Motors
MAX 90 Degree Gearbox
Static Load Rating
Gearbox ultimate strength - Failure at 180 NM +/- 5%
Please note that this is less than the MAXPlanetary Gearbox can withstand!
REV Robotics offers three types of ION wheels: ION Traction, ION Omni and ION Compliant. There are two types of ION Traction wheels available: the standard ION Traction Wheel and the ION Grip Wheel. The main focus of the traction wheels is to pull a robot (or create traction) in a forward/backwards motion.
ION Grip / ION Traction / ION Compliant 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 provided parts list is updated to include the MAXSwerve V1 to V1.1 Upgrade Kit (REV-21-2986). This pack comes in new module kits as of October 2024.
EasySwerve supports an exceptionally wide range of motors for both steering and drive. Teams can use NEO 2.0 Brushless Motors, NEO Vortex with SPARK Flex, NEO 1.1, and even CIM motors. Modules can be assembled with motors mounted on either the top or bottom, providing flexibility for packaging your drivetrain. For easy integration, the baseplate mounts directly to MAXTube or any 0.5in-on-pitch frame rail.
Serviceability is central to the EasySwerve experience. The top cover removes cleanly while the module stays mounted to the robot, giving full access to the internal geartrain, making repairs and maintenance simple when your next match is queueing soon. Wheel assemblies are faster than ever to replace using a simplified MAXSpline interface with no retaining hardware inside the wheel. A convenient azimuth calibration pocket allows teams to align the module using a simple 1/8in or 3mm hex key which aligns using the top cover, making calibration consistent and repeatable across all modules.
With accessible design, robust construction, and performance that meets the demands of competition, the 4in EasySwerve Module gives every team the opportunity to step confidently into swerve drive.
Specifications
Azimuth Ratio (Steering): 20:1
Drive Speed Gearing: 6.3:1
Top Motor Mounting Height:
With NEO 1.1: 213.8mm (8.42in)
With NEO Vortex and SPARK Flex: 235.2mm (9.26in)
Bottom Motor Mounting Height: 174.6mm (6.87in)
Footprint: 176mm x 176mm (6.93in x 6.93in)
Weight:
Without Electronics: 2064g (4.55lb)
With Throughbore Encoder V2 and 2x NEO 2.0 Brushless Motors: 2815g (6.21lb)
Alignment Markings show the intended direction for the run of chain/belt to have the correct spacing needed for the ratio.
The ½ in Pitch Grid allows the Ratio Plate to match up with the desired MAXTube pattern used for the connected structure
The shifted area marked by the white box allows for the mounting of a motor or bearing and the shaft setup at the denoted ratio spacing
Applications Examples
Standard MAXSpline, present in the MAX Pattern and MAX Tube, has 2in center to center spacing. This is designed for very convenient 1:1 ratios using #25 chain or RT25 belts which have a 0.25in pitch.
If you want to have more specific ratios on pitch (down the tube) you may run into issues due to belt or chain lengths being too loose or too tight due to the correct center to center distance not being a multiple of 2in. To allow for a few specific ratios that teams may want to use, Ratio Plates are designed to give you that very specific spacing while still mounting to the MAX Pattern of MAX Tube!
Ratios
To determine roller chain pitch/link count: Each pin equals a pitch, so count the links and multiply by 2 OR count each individual pin
(REV-21-2567-PK2) Ratio Plate - 2:1
Designed for a 2:1 ratio using a 12T and a 24T sprocket/pulley
The pitch needed for the belt or roller chain is 56 pitches (56 tooth RT25 belt, or roller chain with 28 links)
(REV-21-2574-PK2) Ratio Plate - 3:1
Designed for a 3:1 ratio using a 16T and a 48T sprocket/pulley
The pitch needed for the belt or roller chain is 72 pitches (72 tooth RT25 belt, or roller chain with 36 links)
(REV-21-2575-PK2) Ratio Plate - 4:1
Designed for a 4:1 ratio using a 16T and a 64T sprocket/pulley
The pitch needed for the belt or roller chain is 80 pitches (80 tooth RT25 belt, or roller chain with 40 links)
As seen in the Onshape example, generally three standoffs are used to mount the ratio plate to the MAXTube. One is in the middle towards the alignment markings pointing for direction and the remaining two stand on the opposite side to support the plate and allow clearance for the belts/chain.
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.
Servo Accessories / Adapters
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.
This gearbox utilises two NEO V1.1 Brushless Motors, allowing the user to adjust the gear ratio by changing the pinion and cluster gear to 36:36, 24:48, 18:54, 12:60, or 10:60. (1:1, 2:1, 3:1, 5:1, or 6:1)
In theory, this can also be used for a drivetrain, but its benefit of a narrow profile opens it up for compact applications.
The output shaft is 1/2in Hex through bore, and the output gears have a MAXSpline bore. The motor plate contains two pairs of 2in pitch #10-32 tapped holes for mounting the REV Through Bore Encoder, and the output plate contains an array of holes for mounting to structure, as well as mounting as an input to the MAXPlanetary. The 5:1 Ratio (60:12) can be micro-adjusted slightly larger by swapping the 12T pinion with 11T or 10T.
2 Motor Drivetrain Gearbox - Through Bore
This gearbox utilises two NEO V1.1 Brushless Motors, and can be mounted in a variety of options, including flush with MAXTube or spaced away from the tube to enable both chain-in-tube and chain/belt outside tube designs.
Profiling of this drivetrain is more vertical while still allowing it to be out of the way. Weight distribution is also something to consider if you were to implement this gearbox.
The user can adjust speed by switching pinion gears on the motor between 10T, 11T, 12T, or can adjust wheel size by switching 2nd stage gear pairs. 2 Pairs of 2in pitch #10-32 tapped holes are available on output shaft for mounting the REV Through Bore Encoder, and mount holes for the gearbox are on the same horizontal plane as the output, set 4 inches apart. The output shaft is 1/2in Hex through bore, and the output gears have a MAXSpline bore.
The additional spur gears (21T(22) and 20T(22)), alongside the base spur gear (REV-21-3005-P11) included in the MAXSwerve Module Kit, allow for three distinct wheel speed options.
When using a Kraken X60 with the MAXSwerve, the spur gear will be replaced to adjust speeds instead of the pinion.
In order to utilize the Kraken X60 motor you will need to file approximately 1mm of material off the MAXSwerve Top Plate (to make clearance for the bump out present in the motor) at the corners of the motor mounting pocket.
Locations to file for use with a Kraken
Which corner must be filed will depend on the chosen orientation of the motor.
Top Plate Subassembly with a Kraken
Kraken Spacer
Add the Kraken Spacer to the top of the motor before adding the top plate. This will help to accommodate differences in shaft length between the Kraken and other MAXSwerve compatible motors.
Pinion Spacer
Pinion Spacer (isolated for clarity)
The Pinion Spacer slides over the shaft to provide proper spacing and compatibility with the Encoder Bridge (REV-21-3005-P26).
This step is the same as when using a NEO motor to assemble the Top Plate (Step 4).
Drive Motor Pinion
Kraken with Drive Motor Pinion - 15T Spline Bore - 14T (isolated for clarity)
During Step 6 of the assembly, the default drive motor pinion in the kit will be replaced with the Drive Motor Pinion - 15T Spline Bore - 14T. The pinion boss should be facing away from the motor.
Dead Axle Tube (REV-21-2510) is compatible with the REV ION System and can be used with 3/4in Needle Bearing Carrier (REV-21-2385) and MAXSpline Shaft (REV-21-2520) as the dead axle in a dead axle roller. Can also be used with custom rollers and as structural support.
What is a Dead Axle?
A Live Axle is an axle that transmits torque to a wheel. This can be done through a 1/2in hex hub, gear, pulley, or sprocket. In a live axle assembly, the axle will rotate along with the wheel. Live axles are commonly used in drivetrains or as a flywheel.
In comparison, a Dead Axle is an axle that only supports the wheels and does not move. Generally, bearings are used to support the wheel on the dead axle so it can spin freely. Dead axles remain stationary while the supported wheel is in motion. Some applications include free-spinning intake rollers and non-powered drivetrain wheels.
Application Example
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.
Bushing
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.
Endcaps
This MAXSpline Shaft Endcap () enables you to convert MAXSpline Shaft into a live axle driven by a 1/2in Hex shaft.
Gears
Gear Basics
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.
Anatomy of a Spur Gear
Documentation Coming Soon!
20DP Pocketed Gears
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 15T Spline (). Larger gears include #10 clearance hole patterns, 2in bolt circle, and MAXTube mounting pattern.
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.
Gear Alignment Mark
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.
Using Gears as a Powertrain
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.
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.
Gear Spacing
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.
To learn more about calculating center-to-center distance for Gears visit the .
MAXHubs
MAXHubs
MAXHubs (Product Family Page) 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.
Check out our application example using two #10 Socket Head Cap 1-1/4in Screws and a Traction Wheel - 4in - MAXSpline - Hard ().
Specifications
MAXHub
Outside Diameter
Width
Bore
Weight
Material
Locking MAXHubs
The Locking MAXHub - 1/2in Hex is a compact, dual plate hub system designed to secure 1/2in hex shafting inside any MAXSpline bore component. Each kit includes two identical wedge locking plates and the necessary #10-32 hardware. When the plates are drawn together, their internal geometry twists and expands to simultaneously clamp onto the 1/2in hex shaft and the outer MAXSpline bore.
Each plate features three #10 clearance holes and three matching #10-32 threaded holes. This layout allows the included button head screws to tighten from either direction, making the MAXHub easy to install even in tight assemblies. While only three screws are required for locking, all six can be installed for added security. Once preloaded, the hub requires only a small quarter turn to fully lock or unlock, enabling quick adjustments and service. The result is a space efficient and highly reliable solution for securing wheels, sprockets, and other MAXSpline bore components to 1/2in hex shafts.
Specifications
Parameter
Value and Units
2 Motor Drivetrain Gearbox - Through Bore
Features
Adjustable speed based on pinion gears
Adjustable wheel size based on second stage gear pairs
Mountable in a variety of options to allow for chain-in-tube and chain/belt outside tube designs
Kit Contents
SKU
DESCRIPTION
QTY.
Grip
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.
Size:
Pattern:
Width
1in
Hex
.50in
Check out the full line of on the product page
Elevator Bearing Block Assembly
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.
MAXSwerve Wheel V1 Tread Reinforcement
Materials Needed
The materials listed below will reinforce ONE Plastic MAXSwerve Wheel
Item & SKU
QTY
MAXSwerve Wheel V1 - Plastic
(REV-21-3004)
1
Reinforcement Steps
Preparing the 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.
Constraining Motion
Constraining Motion Basics
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.
How to Constrain Motion
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.
Actuator Brackets
ION UltraPlanetary Bracket
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.
Specifications:
Sprockets and Chain
Sprockets and Chain are ideal for transmitting motion over long distances. A chain consists of a continuous set of links that ride on the sprockets to transmit motion. The two most commonly used sizes of chain in 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.
Sprocket Basics
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.
Assembly Tips and Tricks
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.
Recommended Order of Assembly
Conveyor Brush System
The ION Conveyor Brush System is a customizable solution for creating wide to narrow intake brushes that adapt to a variety of game pieces.
The 24in brush can be cut to any length using a bandsaw or hacksaw, allowing teams to fine tune coverage and stiffness for their intake or conveyor design. The nylon bristles are firm enough to control and center objects, yet flexible enough to accommodate irregular shapes or soft materials. Shortening the brush increases bristle stiffness, giving teams a simple and reliable way to tailor brush behavior to the task at hand.
Resizing
Motor Orientation
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.
In our example we chose two Left-Hand and two Right-Hand orientations to allow for clean wire management and a balanced drivetrain.
NEO Orientation Options
MAXSwerve Tips and Tricks
Applying Loctite to your MAXSwerve Module
Ensuring your screws are secure is crucial when assembling your MAXSwerve Modules. Neglecting proper Loctite applications may result in potential damage to your drivetrain. Here is a video with some best practices to keep in mind while applying Loctite or a similar thread locker to your screws.
EasySwerve Maintenance
4in Spiky Wheel Tread Evaluation
The 4in Spiky Wheel Tread is designed to be very durable and last for several matches of play. Determining when to replace the tread is highly dependent on the use case of the wheel. If you notice flat spots or uneven wear, we recommend replacing your tread right away. For general use, replace once the wheel's diameter has decreased by 1/8in.
Wheel Options
Regardless of which wheels you choose for your EasySwerve Module, they should be replaced as the tread wears down due to regular use. For more information, check out our !
Traction Wheel - MAXSpline - 4in - Hard V2
MAXSwerve SPARK MAX Mounting Bracket Assembly
Materials Needed
The materials listed below will attach the SPARK MAX Mounting Bracket for ONE MAXSwerve Module
Shaft Retention Assembly
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.
2 MOTOR DRIVETRAIN GEARBOX 1/2IN HEX CLUSTER SHAFT
1
2 Motor Drivetrain Gearbox - Through Bore
REV-25-2489
Material: Glass-Filled Nylon
Weight: 6g (0.01lb)
MAXSpline Bracket - Motor Mount - Flat
The MAXSpline Bracket - Motor Mount - Flat (REV-21-2360) facilitates quick mounting of motors or gearboxes with a 2in bolt pattern to MAXTubing or structures. It includes a MAXSpline Bore for accommodating bearings, shaft integration, or other MAXSpline Bore-compatible components.
Specifications:
Material: 5052 Aluminum
Thickness: 3mm (0.12in)
Motor Mounting Holes: #10-32 on 2in bolt circle
Mounting Holes: 5mm (0.196in) holes on 0.5in grid
Weight: 33g (0.073lb)
MAXSpline Flat Bracket
MAXSpline Bracket - Motor Mount - Bent
The MAXSpline Bracket - Motor Mount - Bent (REV-21-2361) offers similar functionality to the flat version but features a 90-degree bend on the mounting tabs for versatile positioning. It also includes a MAXSpline Bore for bearing and shaft integration or other compatible components
Specifications:
Material: 5052 Aluminum
Thickness: 3mm (0.12in)
Motor Mounting Holes: #10-32 on 2in bolt circle
Mounting Holes: 5mm (0.196in) holes on 0.5in grid
Weight: 27g (0.060lb)
MAXSpline Bent Bracket
Universal Motor Bracket
The Universal Motor Bracket (REV-21-2804) is compatible with most motors or gearboxes, allowing rapid attachment to structures. It features 5mm (0.196in) holes on 0.25in pitch horizontal spacing for precise positioning without the risk of plate slippage. This bracket is ideal for quick problem-solving and efficient prototyping systems.
Specifications:
Material: 6061 Aluminum
Thickness: 4.76mm (0.188in)
Length: 108mm (4.252in)
Width: 63.5mm (2.5in)
Mounting Holes: 5mm (0.196in) holes on 0.5in vertical and 0.25in horizontal grid
Compatible with the following motors and accessories:
The MAXPlanetary Kraken X44 & Minion Adapter Plate (REV-21-4444) is designed with counterbored motor mounting holes and #10-32 tapped holes on a 2-inch bolt circle for seamless REV ION compatibility. Its compact footprint ensures a streamlined setup no matter if you are using it as an input for MAXPlanetary or mounting directly to MAX Pattern.
Material: 6061 Aluminum
Finish: Black Anodized
Thickness: 9.5mm (0.374in)
Motor Mounting Holes: #10 clearance
Motor Hole Counterbore: 10mm (0.394in) diameter, 5mm (0.196in) depth
Mounting Holes: #10-32 on 2in bolt circle
Through Bore Diameter: 19mm (0.752in)
Mounting Footprint Narrow Side Width: 50.8mm (2in)
Mounting Footprint Rounded Side Diameter: 60mm (2.362in)
Weight: 50g (0.11lb)
MAXPlanetary Kraken X44 & Minion Adapter Plate
ION Servo Face Mount Bracket
The ION Servo Face Mount Bracket (REV-21-2896) allows for easy integration of Servo Motors into the ION System. Mount a servo motor, such as our Smart Robot Servo (REV-41-1097), on a 1/2in pitch and line up perfectly with the MAXPattern on MAXTube.
1in Flat Universal Motor Bracket V2 [Discontinued]
The 1in Flat Universal Motor Bracket V2 (REV-21-1841) changes the holes on the 25mm bolt circle from an M4 to an M3 tight fit hole to accommodate 550 style motors, including the NEO 550 Brushless Motor. To use a BAG Motor, the holes on the 25mm bolt circle need to be drilled out to a M4 tight fit.
Specifications:
Material: 5052 Aluminum
Thickness: 3mm (0.12in)
0.196in holes on 0.5in grid
Compatible with the following motors:
NEO 1.1, NEO 550, Falcon 500, CIM/Mini CIM, 775Pro/Redline, BAG
Weight: 46g (0.102lb)
1in Flat Universal Motor Bracket
1in Bent Universal Motor BracketV2 [Discontinued]
The 1in Bent Universal Motor Bracket V2 (REV-21-1842) 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 NEO 550 Brushless Motor. To use a BAG Motor, the holes on the 25mm bolt circle need to be drilled out to a M4 tight fit.
Sprocket and chain is a very efficient way to transmit torque over long distances.
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 (REV-41-1365) using compatible #25 Sprockets.
ION Sprockets
Our #25 ION Sprockets are compatible with the REV ION system and designed for use with #25 Roller Chain. 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.
Anatomy of a Sprocket
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.
Anatomy of Chain
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.
Using Sprockets and Chain as a Powertrain
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).
To learn more about ratio calculations for sprockets, check out the Sprocket Ratio section on our Advanced Page!
Chain Tension
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.
To learn more about calculating center-to-center distance for sprockets visit the Spacing and Center-to-Center Distance 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 (REV-41-1442) or Master Link (REV-41-1366) to break and reform the chain.
To learn more about using the Chain Tool and Master Link, check out the Manipulating Chain section.
Attempting to stack the Input Coupler onto the gear cartridges, rather than pressing the Input Coupler into the stack is often more difficult.
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.
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.
MAX 90 Degree Gearbox Assembly Wedge
To help teams properly align their Bevel Gear while assembling the MAX 90 Degree Gearbox we developed an Assembly Wedge tool. This tool can be 3D printed and reused to assemble multiple MAX 90 Degree Gearboxes.
1) With all screws in the MAX 90 Degree Gearbox installed slightly loose, insert an Assembly Wedge on either side of the gearbox ensuring the flat side of the wedge is in contact with the bottom plate.
2) While applying pressure to both Assembly Wedges, tighten the screws in the MAX 90 Degree Gearbox on alternating sides. Use the image below as a guide for tightening the screws.
3) Once all of the screws are secure, remove the Assembly Wedges and spin the gearbox to ensure it moves smoothly.
Each brush contains a steel spine that supports the bristle segments. When trimming the brush to length, pinching the cut end of the outer steel channel ensures the internal rod and bristles remain securely captured
Mounting
The brush segments mount to either of the two dedicated hubs: a 1/2in hex version that holds up to three brush segments, or a MAXSpline version that accommodates up to six.
Both hubs include zip tie holes that wrap around the brush to secure it firmly and allow the assembly to rotate smoothly on its shaft.
Specifications
Conveyor Brush Hub - 1/2in Hex
Conveyor Brush Hub - 1/2in Hex
Material: 6061 Aluminum
Finish: Anodized Black
Bore: 1/2in Hex
Outer Diameter: 44mm (1.73in)
Width: 12.7mm (0.5in)
Ziptie Hole Size: 6x 5mm (0.197in)
Weight: 31g (0.068lb)
Conveyor Brush Hub - MAXSpline
Conveyor Brush Hub - MAXSpline
Material: 6061 Aluminum
Finish: Anodized Black
Bore: MAXSpline
Outer Diameter: 65mm (2.56in)
Width: 12.7mm (0.5in)
Locking Screw Threads: 3x #10-32
Ziptie Hole Size: 12x 5mm (0.197in)
Weight: 56g (0.123lb)
Conveyor Brush
Conveyor Brush
Material: Steel spine with nylon bristles
Bristle Color: Black
Height: 101.6mm (4in)
Length: 609.6mm (24in)
Weight: 326g (0.719lb)
Assembly
Check out this video of Brad showing the ins and outs of the Conveyor Brush and Conveyor Brush Hub system!
Forgot to Apply Loctite to the UltraPlanetary Gearbox
If you forgot to apply Loctite during the assembly of the UltraPlanetary Subassembly, you can use a Wicking Grade Loctite to apply thread locker to the pre-assembled gearbox.
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.
Applying Grease to your MAXSwerve Module
We recommend applying grease to your MAXSwerve Modules during assembly and reapplying as needed to maintain your drivetrain. This lubrication helps the hardware that experiences high friction last longer and maintain performance.
When you apply grease, put on a pair of nitrile gloves. You can either squeeze the grease onto your gloved finger or directly onto the gear teeth. Work the grease in, making sure it's evenly distributed throughout the system. Wipe away any excess to avoid making a mess.
It is not necessary to grease the UltraPlanetary Gearbox Cartridges as they are pre-lubricated.
MAXSwerve Gears to Consider
Since the motor pinion is difficult to access after assembly, we recommend applying a full pinky finger's worth of grease to your choice of speed pinion.
You can use a Q-Tip to cover the crests and roots of the gear.
Your Steering Gear directly interacts with the Steering Pinion, so it's a good idea to keep this component moderately greased.
Simply put on some gloves and work the grease into the gear teeth; a little goes a long way.
Similar situation as before, the Wheel Bevel Gear directly interacts with the Bevel Pinion, so there's high friction going on.
Squeeze a healthy bead trail along the teeth and work it in good.
The Drive Spur Gear interacts directly with the Speed Pinion; these are two parts you want a healthy coat of lubricant on.
When orienting the MAXSwerve Module in this position, you have access to the Wheel Bevel Gear, Steering Gear, and Drive Spur Gears.
Perfect for a quick application with the WD-40 Specialist White Lithium Grease Spray.
Traction Wheel Evaluation
Axial vs. Radial Wear
In this section, we will describe different features wear patterns as Axial or Radial. Here are some descriptions of what these terms mean on a REV ION Traction 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
Visual Representation of Radial
Visual representation of Axial
Wheel Rating Guide
Green Wheels - 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.
Yellow Wheels - 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 - 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.
Brand New Wheels
Brand new REV ION Traction Wheels can also be classified as Green and will not have any peeling or separation of the tread from the hard plastic core of the wheel.
Green Wheels
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
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.
Red Wheels
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 REV ION Traction 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.
Each EasySwerve Module Kit includes one Traction Wheel - MAXSpline - 4in - Hard V2 (REV-21-4418)
To ensure your Traction Wheel - MAXSpline - 4in - Hard is the updated version, look for a star (circled on the image above) on the tread. We do not recommend using older Traction Wheels with EasySwerve because they are significantly more susceptible to delamination and rapid wheel wear.
Wheel Specifications
Parameter
Value and Units
Material
Glass-Filed Nylon & TPR
Durometer
75A
Diameter
4.00in
Width
1.50in
Weight
208g (0.46lbs)
4in Spiky Wheel - Aluminum Hub & Tread
Overview
The 4in Spiky Wheel and it's associated tread are designed to be used with the 4in EasySwerve Module. The Spiky tread provides superior grip and performance, especially on carpet. The one-piece split tread design allows for quick and seamless replacements without the need to fully remove the wheel. As a consumable component, these treads are built for performance but will naturally wear down over time.
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
Assembly Instructions
The MAXSwerve SPARK MAX Mounting Bracket is reversible and can be used on any corner of your MAXSwerve Drivetrain
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
Optional Fourth Mounting Hole
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. We recommend using threadlocker on this screw.
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) 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.
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.
15T Spline Bearing
Featuring a 8mm internal diameter and a 1.125in outer diameter, this bearing is designed to fit into a MAXSpline bore while supporting a 15T Spline shaft. The flange adds a way to retain it in place while this bearing supports high-speed loads from many forms of mechanisms that are driven by a 15T Spline shaft including supporting the end of motor shafts.
1/2in Hex Bearing
This flanged bearing provides a reliable way to locate and support a 1/2in hex shaft or 1/2in rounded hex shaft while it rotates. The flange ensures secure installation in MAXSpline or similar diameter hole without additional retention. Perfect for high-load and high-speed applications such as drivetrains, this pack of four offers that specific hex bearing ID.
Needle Bearing
The Needle Bearing with 3/4in ID and 1in OD, fits into MAXSpline Shaft and is used for dead axle applications. Hold it in place securely using a 3/4in Needle Bearing Carrier .
Needle Bearings should be lightly greased and not run dry on shafts. We recommend or other Lithium based grease.
Specifications
15T Spline Bearing - Flanged - 1.125in OD (REV-21-3294)
Material: Steel
ID: 8mm (0.315in)
OD: 28.58mm (1.125in)
1/2in Hex Bearing - Flanged (REV-21-1915)
Material: Steel
Bore: 0.5in Hex
OD: 28.58mm (1.125in)
Weight: 23g (0.05lbs)
1/2in Rounded Hex Bearing - Flanged (REV-21-1916)
Material: Steel
ID: 13.75mm (0.541in)
OD: 28.58mm (1.125in)
Weight: 23g (0.05lbs)
Needle Bearing - 3/4in ID (REV-21-2386)
Material: Steel
ID: 19.05mm (0.75in)
OD: 25.4mm (1in)
Width: 12.7mm (0.5in)
Bearing Blocks
Bearing Retaining Plate
The Bearing Retaining Plate () is compatible with the REV ION System and is designed to securely hold bearings in place, ensuring that they remain stable and aligned during use.
Specifications
Material: Glass-filled nylon
Weight: 3g (0.01lb)
Compatible with MAX Pattern
The bearing retaining plate can be aligned to sit parallel or at an angle along the MAXTube.
MAXSpline Pillow Block
The MAXSpline Pillow Block is compatible with the REV ION System and allows for MAXSpline Shaft () to be rigidly mounted to any surface featuring a 2in mounting hole pattern. This enables easy attachment to rotating high torque applications.
Specifications
Material: Aluminum 6061
Finish: Black Anodized
Overall Length: 60.3mm (2.38in)
Overall Height: 44.5mm (1.75in)
Ideal for use with the or . The small notch, located between the mounting points, is designed to clear the MAX 180 output shaft, which connects to the linear actuator. This feature provides an in-line rotation point for the linear actuator.
The MAXSpline Pillow Block may also be used to support bearings, create a dead axle mount, or as part of support of an angled structural design just to name a few examples.
MAXSpline Shaft Bearing Blocks
The MAXSpline Shaft Bearing Block Kit and MAXSpline Bearings are perfect for using MAXSpline Shaft in a live axle application or any other similar sized rotational needs.
It's recommended to support most applications with a minimum of two MAXSpline Shaft Bearing Blocks properly spaced for best results.
Specifications:
MAXSpline Bearing - Radial
Material: Steel
OD: 47mm (1.850in)
ID: 35mm (1.378in)
MAXSpline Bearing Blocks
MAXSpline Bearing Blocks quickly add bearing support to any location on REV ION extrusion without the need for precision machining.
The MAXSpline Bearing Blocks can be used in west coast style drivetrains to add center wheel drop, while also allowing teams the ability to quickly move their wheels to their desired position.
Specifications
Material: Aluminum 6061
2 Motor Gearbox - Through Bore
Features
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
Base Kit Contents
SKU
DESCRIPTION
QTY.
Ratio Gear Bundle Contents
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.
RATIO
MAXSPLINE GEAR
1/2IN HEX BORE GEAR
MAXSwerve
MAXSwerve Module Overview
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.
Greasing Guide
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 or will provide sufficient lubrication.
Features
Metal construction
3in wheel diameter
Module mounting maximizes wheelbase footprint
Specifications
MAXSwerve Resources
High Complexity
Don't see what you're looking for? Check out our other Onshape examples too!
This drivetrain incorporates two . Each gearbox drives two sprocket and chain systems to omni-directional wheels. This model utilizes the and .
The full BOM is available on the.
3in MAXSwerve Drivetrain -
This drivetrain takes advantage of four , allowing the robot the ability to drive forward and backward, side-to-side, and rotate simultaneously without sacrificing traction. In this example the MAXTube has been cut to a shorter length than what comes in the drivetrain kit.
The full BOM is available on the
Mechanisms
2019 Combined Mechanism -
Designed for the 2019 Deep Space FRC game, this mechanism uses a pulley system driven by NEOs to secure panels and cargo (balls).
2018 Intake -
Designed for the 2018 Power Up FRC game, this mechanism uses a pully system driven by NEOs to retrieve cubes.
Linear Actuator Arm -
Showcases the as part of a liftable arm. In this example, the Linear Actuator is mounted using a to a on a to allow adjustable movement as the arm lifts.
Full Robots
Bumper Brackets on West Coast Drive Drivetrain -
Designed to showcase the on a West Coast Drive Drivetrain and featured in the .
Bumper Brackets on the FRC Kit of Parts Chassis (AM14U5) -
Designed to showcase the on the FRC Kit of Parts Chassis (AM14U5) and featured in the .
2023 REV ION FRC Starter Bot -
Designed for the 2023 FRC game CHARGED UP as part of the . This robot was able to clamp down on the different game pieces to secure them for placement. The full bill of materials is .
2024 REV ION FRC Starter Bot -
Designed for the 2024 FRC game CRESCENDO as part of the . This robot was able to retrieve and shoot note game pieces into the different goals. The full bill of materials is .
2025 REV ION FRC Starter Bot -
Designed for the 2025 FRC game REEFSCAPE as part of the . This robot was able to place coral on the reefs with its single-stage elevator and integrated wrist, as well as pick up algae. The full bill of materials is .
NEO Vortex
NEO Vortex Multi-Stage Assembly Instructions
For assembly you will need a 5/32" Allen Wrench.
Assembly Instructions
When building your gearbox make sure the highest gear reduction is closest to the motor.
Troubleshooting
Space Between Input Plate and Gear Cartridge
Some Vortex MAXPlanetary Input Kits () purchased after November 2024 have a MAXPlanetary Input Coupler that is slightly too shallow. This may cause a space between the MAXPlanetary Vortex Input Stage and the first MAXPlanetary Cartridge leading to instability in the full gearbox stack.
This minor variation in depth still allows for the proper amount of engagement between the Vortex MAXPlanetary Input Coupler and the MAXPlanetary Gearbox stages.
Spacer Installation
Greasing Guide
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 or .
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.
MAXTube comes in .
Advanced Gears
Gear Physics
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
MAXSwerve Wheel V1 Evaluation
MAXSwerve Wheel V2 should be replaced when the tread disappears. We advise replacing wheels at 1/2 inch depth loss for proactive repairs.
The following images will describe a rating system we have developed for determining if a MAXSwerve Wheel should still be used on your robot.
Flap
ION Flap Wheels are designed for intakes and conveyance that need reliable performance when interacting with irregular or variable gamepieces. Similar to compliant wheels, they provide a flexible interface, but their flap-based design introduces intentional slip between the wheel and the gamepiece.
This helps smooth out transitions, reduce jams, and improve handling consistency across a wide range of shapes and materials. Each wheel is built from a durable polypropylene core with flexible TPR flaps that can be trimmed to width using the printed cut marks, allowing teams to tailor the wheel to their specific mechanism or gamepiece requirements.
1/2in Hex Flap Wheels
MAXSwerve Spiky Wheel
Overview
The 3in MAXSwerve Spiky Wheel Tread is designed to be used with the 3in MAXSwerve Module. The Spikey tread provides superior grip and performance especially on carpet. The one-piece split tread design allows for quick and seamless replacements without the need to fully remove the wheel. As a consumable component, these treads are built for performance but will naturally wear down over time.
System Features
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
MAXSwerve Assembly Tips
If you encounter any problems while assembling your MAXSwerve Module(s) please contact [email protected]
Applying Loctite to your MAXSwerve Module
Advanced Sprockets and Chain
Sprocket and Chain Physics
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.
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.
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)
Compatible with NEO Brushless Motor or Falcon 500 (with replacement shaft)
Azimuth driven by NEO 550 Brushless Motor & UltraPlanetary Gearbox
On the 1in sides of these MAXTube extrusions, there is 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
MAXTube Hole Patterns
MAX Pattern
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.
Grid Pattern
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.
MAXTube Available Sizes
Size
Pattern
Position/Length
Nut Groove
1/2x1/2in
Grid
47in
No
1x1in
Grid
47in
Yes
1x1in - 1/16in Wall
Grid
1in Extrusion
The 1in Extrusion (REV-21-1000) 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.
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.
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 N⋅m or in⋅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.
Gear Train
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.
Gear Ratio
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.
Idlers
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.
Compound Gearing
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.
Center-to-Center Distance
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 × N
PD = (OD × N) / (N + 2)
PD = OD - (2 × M)
Then, use the pitch diameters to calculate the center-to-center distance (CCD).
CCD = ((PD1) / 2) + ((PD2) / 2)
Any two 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
Addendum Shifting
Documentation Coming Soon!
CR=R1×R2×…×Rn
CR=R1×R2=3060×1590=2×6=12
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.
MAXSwerve Wheel V1 - Plastic Evaluation
Green Wheels
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.
Yellow Wheels
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
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.
Quick Reference
Axial vs. Radial
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
Visual Representation of Radial
Visual representation of Axial
Please see the table below for examples of wheels that demonstrate the criteria for each rating.
MAXSwerve Wheel V1 Evaluation Details
Brand New Wheels
Brand new MAXSwerve wheels can also be classified as Green and will not have any peeling or separation of the tread from the hard plastic core of the wheel.
Green Wheels
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
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.
Red Wheels
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.
s
The 1/2in Hex Flap Wheels feature cut marks every 3.2mm on the flaps for consistent cutting, allowing for versatility and adaptability. These flap wheels have a solid 1/2in Hex Hub molded into the wheel.
These wheels come in three different durometers, outlined below. As the tread durometer increases the compliant flap gets harder which will change traction, wear, and compliance of the flap.
On the 2024 REV ION FRC Starter Bot, the flap wheels on the intake aid in grabbing the CRESCENDO game pieces to be secured for the launcher.
2024 REV ION Starter Bot using the flap wheels on the lowered intake
The flap wheels spin while the intake is lowered to sweep game pieces into the compliant wheel rollers providing a further reach.
MAXSpline Flap Wheels
The MAXSpline Flap Wheels feature a MAXSpline bore and 6 flaps for higher load applications. The increased contact area and six independent flaps allow for more aggressive engagement.
Specifications
Parameter:
Value and Units:
Flap Length:
6.25in (158.75 mm) (end to end)
Flap Width:
0.94in (23.8mm)
Bore:
MAXSpline
Durometer Specs
Hardness:
Color:
Durometer:
Soft
Light Gray
35A
Medium
Dark Gray
50A
Hard
Black
75A
Specifications
Hub
Parameters
Value and Units
Material
Aluminum 6061
Diameter
67.2mm (2.65in)
Width
31.0mm (1.22in)
Weight
97.5g (0.220lbs)
Tread
Parameters
Value and Units
Material
Injection-Molded TPU 95A
Length
203.4mm (8in)
Width
31.2mm (1.23in)
Thickness
7.4mm (0.29in)
Weight
40g (0.088lbs)
MAXSwerve Spiky Wheel Tread Evaluation
The MAXSwerve Spiky Wheel Tread is designed to be very durable and last for several matches of play. Determining when to replace the tread is highly dependent on the use case of the wheel. If you are seeing flat spots or uneven wear we recommend replacing your tread. For general use, if you are seeing a decrease of 1/8in in the diameter of wheel we recommend replacing the tread.
3in MAXSwerve Spiky Wheel Assembly
Threadlocker is highly recommended on all screws used in this assembly. We recommend LOCTITE® Threadlocker Blue 242 or an equivalent threadlocker.
1) Install a #10-32 3/8in button head screw in the center hole of the Spiky Tread and Spiky Wheel Aluminum Hub. Do not fully tighten this screw to allow the tread to flex.
2) Insert a second #10-32 3/8in button head screw in one end of the of the tread and wrap it around and install into the Hub. We recommend using a T-Handle Allen Wrench for the extra leverage. Bring the end of the screw into the corresponding hole on the aluminum hub. With a reasonable amount of force, stretch the tread as you bring it up and angle the screw into alignment with the hole, all while slightly spinning the screw counterclockwise or in the direction of loosening it. This is key to help seat the screw before trying to insert it all the way. With everything aligned, the screws should go in smoothly without any extra force.
Note: We recommend watching our linked at the top of these instructions for additional tips and examples.
3) Insert a third #10-32 3/8in button head screw in the opposite end of the tread and the opposite corner as the previous screw.
4) Install the last two remaining #10-32 3/8in button head screws into the Spiky Tread and Spiky Wheel Aluminum Hub.
5) Tighten the #10-32 3/8in button head screw in the center hole to finish assembly.
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
Cartridge Features
A breakdown of the MAXPlanetary Cartridges
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 prevents 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.
Input Features
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.
MAXPlanetary Universal Input Stage V2 Additional Features
The MAXPlanetary Universal Input Stage V2 (REV-21-2146) is a redesigned mounting solution for integrating a wide range of FRC motors into the MAXPlanetary System. Built as the next evolution of the original universal input stage, V2 enhances strength, expands motor compatibility, and enables even more compact gearbox configurations.
Updated universal input stage for MAXPlanetary System integrations
New 1.375 inch bolt circle supports additional motor mounting (e.g. Kraken X44)
CIM class motor pattern clocked 45 degrees for improved fitment and packaging
Allows NEO 2.0 Brushless Motor flats to align flush for extremely compact assemblies
Reinforced mounting tabs increased from 0.125 inch to 0.25 inch thickness
Direct motor compatibility with no additional input kits required for:
NEO 2.0, NEO 1.1, NEO 1.0
Kraken X60, Kraken X44
Compatible with additional motors when used with corresponding input kits:
NEO 550 (REV-21-2117)
Minion (REV-21-2139)
Output Features
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 prevents the user from assembling any gearbox components backwards.
MAXPlanetary MAXSpline Output Coupler
The MAXPlanetary MAXSpline Output Coupler (REV-21-3630) provides a compact and reliable way to interface a MAXPlanetary Gearbox’s 1/2 inch hex output with MAXSpline Shaft systems.
One side of the coupler accepts up to 0.47 inch of 1/2 inch hex shaft and uses a #10-32 screw that threads into the shaft end to lock it in place. The opposite side is machined for MAXSpline Shaft and provides 0.5 inch of engagement, secured using a removable two piece clamping collar tightened by two M3 socket head screws. The collar can be opened or removed without fully disassembling the system, making assembly and maintenance easier while ensuring strong, consistent shaft retention
Parameter
Value and Units
Outside Diameter
25mm (0.98in)
Length/Width
19.1mm (0.75in)
Input Bore
1/2in Hex
Output Bore
MAXSpline Bore
Shaft Collar Locking Screw Size
M3 x 16mm Socket Cap (2.5mm Hex Key)
Material
6061 Aluminum
Additional Input Coupler Options
8mm Keyed Input Coupler Kit (REV-21-2108) - Compatible with NEO Vortex, NEO V1.1, NEO 550 and CIM motors.
1/2in Hex Input Coupler (REV-21-2110) - Compatible with 2 Motor Gearbox - Through Bore and the MAX 180 Degree Gearbox, all designed to drive the MAXPlanetary
14T Spline Input Coupler (REV-21-2124) - Compatible with Falcon 500 and other 14T spline motors.
15T Spline Input Coupler (REV-21-2138) - Compatible with the SplineXS (Kraken and Minion) shaft spline, and other motors that have a 15T output.
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.
Forgot to Apply Loctite to UltraPlanetary Gearbox
If you forgot to apply Loctite during the assembly of the UltraPlanetary Subassembly you can use a Wicking Grade Loctite to apply thread locker to the pre-assembled gearbox
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.
Securing the MAXSwerve Motor Key
We recommend using superglue to ensure that the key stays securely in place
When putting together the Top Plate Subassembly 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.
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
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 close to the end of the motor shaft 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. Use superglue to secure the motor key once you have placed it in the correct location.
Key Not Fitting in Keyway
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.
UltraPlanetary Cartridge Mounting Holes
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.
Wheel Axle - Tight Fit (REV-31-3005-P18)
3in MAXSwerve Module Wheel Axles that shipped with the first batch of MAXSwerve Modules (January 2023) may have a tighter fit than expected.
To help with the fit of your Wheel Axle assembly, use a fine grit emery cloth, sandpaper, or scotchbrite 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.
We recommend using a product that is 400 grit or higher for this process
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 N⋅m or in⋅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.
Chain Drive
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.
Sprocket Ratio
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 20T/15T=1.3
Compound Reduction
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.
Spacing and Center to Center Distances
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.
Spacing
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.
CR=R1×R2×…×Rn
CR=R1×R2=3060×1590=2×6=12
1) Place the Vortex Shaft - MAXPlanetary Input Coupler, securing it with the #10-32 Shaft End Screw.
2) Place the Vortex Input Stage on the SPARK Flex, securing it with the four #10-32 Socket Head Screws x5/16in.
Note: If using a NEO Vortex Solo Adapter, the placement is the same.
3) Place the appropriate gear cartridge on the Vortex Shaft - MAXPlanetary Input Coupler.
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.
4) Continue stacking gear cartridges away from the motor in the appropriate order.
Note: Ensure that the alignment features of each cartridge are properly engaged with the cartridges next to it.
5) Place the 1/2" Hex Socket Output onto the previous gear cartridge.
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.
6) Insert the appropriate length of 10-32 Socket Head Cap Screws into the gearbox assembly holes. Tighten the gearbox assembly screws down.
0 Cartridges: 1/2in Long Screws
1 Cartridge: 1in Long Screws
2 Cartridges: 1-1/2in Long Screws
3 Cartridges: 2in Long Screws
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) Get a MAXPlanetary Spacer (REV-21-3249) using one of the following methods:
Use the spacer included in Vortex Shaft - MAXPlanetary Input Kits purchased after March 10th, 2025
3D Print a spacer using a rigid print material and the .STL file linked
Gap caused by shallow input coupler highlighted in orange.
Spacer Installed to resolve gap.
MAXComposite
What is MAXComposite?
MAXComposite is made from self-reinforced polypropylene (SRPP), a pure thermoplastic material combining two molecular weights of polypropylene with different melting points.
During production, polymer chains are stretched and aligned into individual sheets, which are stacked and heat pressed under precisely controlled temperature, time, and pressure. This causes only the lower melting point polypropylene to bond, forming a matrix that secures the unmelted fibers (thus “self-reinforced”). The result is an exceptionally strong and rigid sheet with significantly higher strength than standard polypropylene.
MAXComposite sheet in 0.1in (top) and 0.2in (bottom)
MAXComposite is available in 0.1-inch and 0.2-inch thicknesses with sheet sizes of 47 by 23 inches. MAXComposite is 25% lighter than polycarbonate and impervious to Loctite, making it a durable and lightweight choice for various mechanisms and builds.
How to Use
Prototyping & Test Cuts
To reduce material waste and optimize designs, it is highly recommended to prototype using similar thickness materials such as 5mm (0.2-inch) underlayment or plywood before committing to MAXComposite.
Before cutting large parts, perform:
Small test cuts with simple shapes to dial in laser or CNC settings.
Critical tolerance tests, such as press-fit bearing holes or shaft clearances, to ensure accuracy.
Cutting & Fabrication
Laser Cutting
CO₂ laser cutting is the most effective method for precise fabrication. Proper laser settings are essential to achieve clean cuts without excessive melting or rebonding. The laser also seals the edges, preventing delamination. A higher flow air assist is recommended for best results. Ensure adequate ventilation as moderate smoke is produced during cutting.
Recommended Laser Cutting Settings (Based on a 100W CO₂ Laser):
Diode lasers are generally not recommended for cutting MAXComposite.
If you notice plastic spraying up onto the surface or excessive smoke coming up from the cut line, it is likely that it is not fully cut through.
Manual Cutting Methods
For resizing sheets to fit laser cutter beds, conventional tools such as table saws, bandsaws, or jigsaws can be used. However, be cautious of overheating and rapid air cooling, which may cause jamming in high-speed tools.
Processing Techniques:
Table saw / Circular saw – effective for straight cuts and resizing for laser beds
Jigsaw – useful for intricate or curved cuts or quick edits
Bandsaw - slightly more controlled cuts than a jigsaw, but may not remelt edges
Fitment & Finishing
Testing & Fitment
Before cutting larger parts, test fitment for bearing presses and hardware clearance. On our laser, a 1.1-inch diameter hole results in a snug arbor press fit for a rounded hex bearing.
Finishing Techniques
Some melted plastic may accumulate on the back of cut parts. Consider which surfaces need to remain smooth and use the following techniques for cleanup:
Sanding
Deburring tools
Knife trimming
Note: Keep edges slightly melted together to prevent delamination.
Drilling & Adhesion
Drilling: Sharp drill bits work for additional holes, and hole saws or jigsaws are effective for non-precision cuts.
Adhesion: Due to polypropylene’s low surface energy, most adhesives do not bond well. Stickers and graphics require large surface areas, and for aesthetic purposes, you can mask and paint MAXComposite using plastic primers and paints.
CNC Machining
CNC Routing Considerations
While CNC machining is possible, CO₂ laser cutting provides the best results. If CNC routing is necessary, compression bits and proper workholding are critical.
Best CNC Machining Practices:
Use a compression bit for optimal edge quality.
Secure material with a vacuum table or screw it into a spoil board.
Maintain a slight melt on edges to prevent delamination.
Tested CNC Settings:
1/8-inch compression bit
18,000 RPM spindle speed
108 in/min feed rate (0.003 inches per tooth)
Avoid excessive heat buildup, as this can cause melting and material deposits on the bit.
Bending MAXComposite
Heat Bending Guidelines
MAXComposite can be heat-formed best using fixturing at 230-240°F. Avoid exceeding 250-260°F + to prevent degradation. Polypropylene melts at 320°F, so staying within the recommended range ensures proper bending without compromising strength.
For best results, use a heat source such as a strip heater or heat gun, applying even heat across the bending area. Secure the part in a bending jig immediately after heating to achieve the desired shape and prevent warping.
Chemical Resistance
MAXComposite is made entirely of polypropylene blends, making it highly resistant to chemicals. It remains unaffected by:
Threadlockers (e.g., Loctite)
Solvents (e.g., acetone)
This chemical resistance ensures that builds using Loctite remain secure and durable, even in the most intense competitions.
Best Practices & Recommendations
General Guidelines:
Prototype with plywood to reduce material waste.
Test laser settings on small cuts before full-scale production.
Ensure proper ventilation when laser cutting.
By following these best practices, MAXComposite offers exceptional strength, weight savings, and fabrication ease, making it an ideal choice for a variety of applications.
The MAXPlanetary System () 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.
MAXPlanetary Gearbox Features
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
MAX 90 Degree Gearbox
Looking for the Ultra 90 Degree Gearbox ()? Check out the in our Crossover Documentation.
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.
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 or will provide sufficient lubrication.
MAXPlanetary 1:1 Brake Cartridge
The MAXPlanetary 1:1 Brake Cartridge enables your MAXPlanetary System to mechanically hold it's position. A steel internal ring housed in a lightweight aluminum case provides excellent strength and durability while maintaining a compact standard cartridge size. The cartridge integrates seamlessly with all other MAXPlanetary stages and occupies only a single slot. Designed around the principles of a sprag clutch, sometimes referred to as a torque diode, clutch, or overrunning clutch, this cartridge prevents backdriving in either direction by locking the output whenever the motor or input is stationary. The brake engages automatically when the output velocity exceeds the motor velocity, and it can be reliably released because the unlocking torque is approximately eighty percent of the locking load.
The Brake Cartridge can be added anywhere within the gear stack assembly, however it is recommended to use the Brake Cartridge as the first cartridge, closest to the motor, before any gear reduction to maximize it's life.
Assembly Instructions
For teams using three reduction cartridges, the brake remains fully compatible. This setup requires 2.5 inch socket head screws, which are not included in the MAXPlanetary Base Kit.
Follow the guide and install the MAXPlanetary 1:1 Brake Cartridge in your gearbox just like you would a gear cartridge. There are two places you can place your Brake Cartridge:
Before Gear Reduction (Closest to Motor): This is the recommended assembly. This will decrease the shock loading done to your Brake Cartridge and increase it's longevity.
After Gear Reduction (Furthest from the Motor): This will decrease the shock loading done to your gear cartridge(s) and is only recommended for high gear ratio applications.
Specifications
Parameter
Value and Units
Cartridge Features
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.
Input Features
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.
Output Features
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.
Chain Tool
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.
#25 Chain Tool Basics
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.
Kit Contents
The REV Robotics #25 Chain Tool () comes with the following:
1 Chain Tool Block
2 Set Screw Mandrels
1 Depth Guide Screw
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.
Manipulating Chain
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.
Using the Chain Tool
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 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.
During the 2023 FRC season, we designed a template to prepare replacement strips of treads for the used on the .
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.
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.
Template PDF
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!
Preparing 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.
Putting Tread on Wheel
MAX 90 Degree Gearbox Assembly
MAX 90 Degree Gearbox Assembly Instructions
Greasing Guide
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 or 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.
For assembly you will need a 5/32" and 3mm Allen Wrench.
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.
If your robot requires shaft retention in the gearbox, follow the instructions now before proceeding.
When building your gearbox make sure the highest gear reduction is closest to the motor.
MAXSwerve Drivetrain Assembly
Getting Started
MAXSwerve Module Assembly
Before assembling your drivetrain you will first need to assembly your MAXSwerve Modules, follow the to assemble all four modules.
Cutting Guide
The MAXSwerve Drivetrain kit comes with full-length MAXTubes with endcaps and essential hardware, allowing you to customize the drivetrain's dimensions by cutting the tubes to fit your design. The image below will be used when going through this assembly guide. The guide will reference the extrusion labeled in this image.
Use the below instructions when cutting your extrusion to stay on pitch and ensure your drivetrain is assembled square.
Drivetrain Assembly
2 Motor Drivetrain Gearbox Assembly
2 Motor Drivetrain Gearbox - Through Bore Assembly Instructions
Greasing Guide
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 or 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.
Linear Actuators
Linear actuators are a device that creates motion in a straight line, as opposed to the rotational motion of a motor. It consists of a motor, a lead screw, and a moving rod or shaft. The rotation of the motor turns the lead screw, this screw is threaded in a way that converts the rotational motion of the motor into linear motion, causing the rod or shaft to extend or retract. Linear actuators are commonly used in applications that require precise and controlled straight-line movement, such as climbing tasks, driving arms, actuating intakes, and deploying other diverse mechanisms. Their design allows for efficient, reliable, and smooth operation in various mechanical systems.
Linear Actuator - 12in Stroke
Wiring MAXSwerve
Optional Fourth Mounting Hole
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 to attach this Mounting Bracket to the module, as pictured below.
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
1:1 Brake Cartridge Working Torque (No Failure) at Output
16.95Nm (150 in-lb)
Height
50.8mm (2in)
Width
13.72mm (0.54in)
Length
61.91mm (2.44in)
Weight
154g (0.340lb)
Face Mounting Pattern
#10-32 on a 2in Bolt Circle
1:1 Brake Cartridge Static Torque (No Failure) at Output
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.
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)
Edge remelt techniques – reapplying heat to edges can help prevent delamination
Use proper tools to maintain material integrity.
Remelt edges slightly after cutting to prevent delamination.
For CNC machining, prioritize compression bits and stable workholding.
Wood prototyping on a CO₂ Laser
Cutting MAXComposite on CO₂ Laser (2X speed)
Using a table saw to process MAXComposite
Using a common hole saw on MAXComposite
CNC Routing 0.2in MAXComposite (2X speed)
The effects of Loctite, polycarbonate (left) and MAXComposite (right)
Prototyping samples of MAXComposite
1 Cup Point Set Screw
1 4mm Allen Wrench
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.
7) Once the pin is fully reseated, release the chain from the tool using the Allen Wrench- your chain should be connected!
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) 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.
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
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.
Get:
12 - MAXTube Internal Support 2x1
2 - MAXTube 2x1 with Grid Pattern - Side B
Insert 3 MAXTube Internal Supports into each end of the MAXTube pieces. Take care to ensure they do not fall out before securing them in the next step.
Get:
4 - MAXSwerve Module, fully assembled
12 - #10-32 Button Head Screws x 3in
12 - #10-32 Low Profile Nylon Lock Nut
2 - Assemblies from Step #1
Attach one MAXSwerve Module to each end of an 18in MAXTube piece. We recommend mounting one right-hand and one left-hand module so that the wires point toward each other.
Secure the MAXSwerve Modules to the MAXTube using screws so that each screw passes through a MAXTube Internal Support and the Nylon Lock Nt is on top.
Make two of these.
Get:
12 - MAXTube Internal Support 2x1
2 - MAXTube 2x1 with Grid Pattern - Side A
Insert 3 MAXTube Internal Supports into each end of the MAXTube pieces. Take care to ensure they do not fall out before securing them in the next step.
Get:
8 - #10-32 Button Head Screws x 3in
8 - #10-32 Low Profile Nylon Lock Nut
2 - Assemblies from Step #3
Connect the two MAXSwerve Module rails with two screws on each side so that each screw passes through a MAXTube Internal Support and the Nylon Lock Nut is on top.
Note - Leave the middle hole and MAXTube Internal Support empty, it will be used in a later step
Get:
4 - SPARK MAX Motor Controller
4 - Absolute Encoder Adapter
4 - JST PH 6-pin Extension Cable - 30cm
12 - WAGO 221 Inline Splicing Connector
Zip Ties
For each MAXSwerve Module, wire the NEO 550 and Through Bore Encoder to a SPARK MAX with an Absolute Encoder Adapter installed in the data port. Then, secure the SPARK MAX to the module’s SPARK MAX Mounting Bracket using zip ties.
Note - Placing a zip tie over the Absolute Encoder Adapter and aligned with its notches is highly recommended to ensure a secure connection
Get:
2 - MAXTube 2x1 with Grid Pattern - Side C
4 - MAXTube Endcap - 2x1
8 - #10-32 Button Head Screws x 5/16in
Insert MAXTube Endcaps into both ends of the MAXTube with MAXPattern. Secure both MAXTube Endcaps with 2 screws, onon the top and bottom of the 1in face of the MAXTube.
Get:
6 - #10-32 Button Head Screws x 1 1/2in
Add this MAXTube to your MAXSwerve Drivetrain as the first middle brace. The factory edge, used as a reference in the above steps, should be mounted towards the front of the robot indicated by the green arrow.
Add the MAXTube to your MAXSwerve Drivetrain as the second middle brace. The factory edge, used as a reference in the above steps, should be mounted towards the front of the robot indicated by the green arrow as shown.
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.
If you are having difficulty installing the retaining rings, you can use a socket to press the retaining ring onto the shaft. We recommend a 10mm (3/8in) deep socket.
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) 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
The safety pin on the leadscrew is rated to shear at 500lbs of tensile load GIVEN that the linear actuator is mounted rigidly as demonstrated in this application example - .
Motor Tables
The below tables provide the mathematical performance possibilities, and assume 1:1 gearing and 100% vertical load. Cantilever load and gear reductions will change these numbers. We recommend using a lead screw calculator such as the AMB Robotics Calculator for Lead Screws to find the numbers for your application.
Link to pre-filled AMB Linear Actuator Calculator
Special thanks to Ari Meles-Braverman for creating and maintaining the AMB Robotics Calculator!
NEO Vortex Brushless Motor
MAX RPM Percentage
Input RPM
Applied Torque (N*m)
Maximum Output Load (N) @ Stall
Maximum Linear Speed (m/s) @ Zero Load
20
1357
2.88
1508
0.27
40
2714
2.16
1131
0.54
60
NEO Brushless Motor V1.1
MAX RPM Percentage
Input RPM
Applied Torque (N*m)
Maximum Output Load (N) @ Stall
Maximum Linear Speed (m/s) @ Zero Load
20
1164
2.40
1257
0.23
40
2328
1.80
942
0.47
60
Wiring Steps
Materials Needed
The materials listed below will complete the wiring for ONE MAXSwerve Module
Item & SKU
QTY
Completed with one and one installed to the module
1
2
1
2
1
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 power input 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.
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.
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.
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.
1in Corner Brackets
1in Inside Corner Bracket
1in Basic Corner Bracket
1in Angled Corner Bracket
1in Inside Corner Bracket (REV-21-1203) 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 Basic Corner Bracket (REV-21-3293) is a compact, low-profile solution for strengthening MAXTube joints or adding simple mounting points where space is limited. Each 2in leg includes three #10 clearance holes on a 1/2in pitch, and the clearance holes in the radiused bend offer screw head clearance. The 1in width aligns cleanly with 1x1 MAXTube and integrates seamlessly into the REV ION System.
1in Angled Corner Bracket (REV-21-3291) is a compact, heavy duty solution for reinforcing MAXTube joints and building rigid structures in tight spaces. Its 5mm thick aluminum body provides consistent strength, while the integrated angle dramatically boosts joint stiffness by resisting torsion and bending loads. Each end of the bracket includes two #10 clearance holes on a 1/2in pitch, giving teams flexible mounting options for corner reinforcement or general structure assembly. At only 1in wide, it nests cleanly alongside 1x1 MAXTube and fits easily into dense robot designs.
Corner Bracket Specifications
1in Brackets
3-4-5 Brackets
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.
The 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
Full Structural Brackets List and Weights
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.
Bracket Name
Weight
Image
NEO & Other 500 Motors
Follow these instructions if you are using a Neo Brushless V1.1, Flacon 500, Kraken, or CIM Motors. Use the below information to determine the correct MAXPlanetary Input Coupler for your motor.
NEO Brushless V1.1, CIM, or other motors with an 8mm output shaft - MAXPlanetary 8mm Keyed Input Coupler Kit (REV-21-2108)
Falcon 500 or other motors with a 14T output shaft - MAXPlanetary 14T Spline Input Coupler (REV-21-2124)
Kraken or other motors with a 15T output shaft - MAXPlanetary 15T Spline Input Coupler (REV-21-2138)
NEO Multi-Stage Assembly Instructions
For assembly you will need a 5/32" Allen Wrench.
If your robot requires shaft retention in the gearbox, follow the instructions now before proceeding.
When building your gearbox make sure the highest gear reduction is closest to the motor.
Greasing Guide
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 or .
Belts and Pulleys
Belts and Pulleys
Belts and pulleys are a great, lightweight option for building a smooth-running mechanism. They are very similar to chain and sprockets, with the belt replacing chain and pulleys replacing sprockets. The biggest difference is that belts are a set size and 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 6mm Round Belt System as well as 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.
The ION 6mm Round Belt System provides a simple and adaptable way to transfer power in compact robot mechanisms. Designed around a 2in outer diameter when the belt is installed, the system stays on pitch with the REV ION wheel lineup, making it easy to integrate into intakes, conveyors, feeders, and other custom assemblies. At its core is a solid polyurethane round belt that can be cut to length and heat welded to form custom closed loops. Trimming the belt about 8 percent shorter than the final path helps account for stretch after welding and ensures proper tension once installed.
Heat Welding Instructions
Coming Soon!
Specifications
Item
Bore
Tooth
Weight
Material
NEO 550 & 550 Sized Motors
NEO 550 Multi-Stage Assembly Instructions
For assembly you will need a 5/32" and 2.5mm Allen Wrench
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 correct Coupler for the motor shaft you are assembling.
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
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.
15T Spline
12T
16g (0.035lb)
Aluminum 6061
REV-21-2205
1/2in Hex
16T
26g (0.06lb)
Aluminum 6061
REV-21-2206
1/2in Hex
16T
44g (0.10lb)
Aluminum 6061
REV-25-2224
MAXSpline Bore
24T
Single: 23g (0.05lb)
Double: 36g (0.08lb)
Glass-Filled Nylon
REV-25-2236
MAXSpline Bore
32T
Single: 44g (0.010lb)
Double: 71g (0.16lb)
Glass-Filled Nylon
REV-25-2248
MAXSpline Bore
40T
Single: 74g (0.16lb)
Double: 119g (0.26lb)
Glass-Filled Nylon
REV-25-2260
MAXSpline Bore
48T
Single: 98g (0.22lb)
Double: 158g (0.35lb)
Glass-Filled Nylon
REV-25-2272
MAXSpline Bore
56T
Single: 120g (0.27lb)
Double: 192g (0.42lb)
Glass-Filled Nylon
REV-25-2284
MAXSpline Bore
64T
Single: 148g (0.33lb)
Double: 240g (0.53lb)
Glass-Filled Nylon
REV-21-4018
1/2in Hex
-
15g (0.033lb)
Glass-Filled Nylon
REV-21-4019
MAXSpline Bore
-
8g (0.018lb)
Glass-Filled Nylon
The Round Belt Pulley with a 1/2in hex bore is a compact solution for direct driven shafts and includes a 1in bolt circle for alternate mounting methods. A single sided bearing race boss makes it possible to stack multiple pulleys, and teams needing bearing contact on both sides can add the 1/2in Hex Shaft Spacer 1/8in (REV-21-2004-PK10).
The MAXSpline version offers the same belt driven outer diameter in a lighter, narrower profile that integrates cleanly with the MAXSpline ecosystem. Using either pulley allows the system to work with the matching shaft option, while the design also supports easy integration of multiple belts.
The Polyurethane Round Belt itself is flexible, durable, and well suited for light power transmission tasks such as intakes and conveyors. Its ability to be welded into custom lengths gives teams the freedom to build mechanisms around the geometry they need, while the compliant belt and glass filled nylon pulleys provide smooth and low maintenance operation
REV-21-2200
8mm Keyed
12T
15g (0.03lb)
Aluminum 6061
REV-21-2201
1/2in Hex
12T
11g (0.024lb)
Aluminum 6061
REV-21-4485
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.
If your robot requires shaft retention in the gearbox, follow the Shaft Retention Assemblyinstructions now before proceeding.
When building your gearbox make sure the highest gear reduction is closest to 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 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
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.
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.
Check out the space for detailed information on the NEO Family of Brushless Motors and SPARK family of motor controllers!
NEO Vortex
The is a high-power, high-performance, and high-resolution sensored brushless motor from REV Robotics. It features a dockable controller interface that can be mounted directly to the
or a
allowing control from any brushless motor controller, like the SPARK MAX. Its through-bore rotor is the heart of its unique interchangeable shaft system, facilitating easy integration with various robot mechanisms.
Features
High-resolution encoder
Integrated motor parameter and calibration memory
Through-hex bore with taper for numerous quick-change shafts
No motor wires - reliable and robust docking connections for motor phases and sensor
Dual sensor, direct contact winding temperature sensing
560KV (RPM per volt)
640 Watts (375 @ 40A)
#10-32 threaded holes on a 2in bolt circle
The motor and motor controller's silhouette fits behind a standard 2in rectangular tube
1/2in hex through-bore rotor compatible with any length hex shaft or application-specific Vortex Shafts:
8mm keyed
Falcon compatible spline
Motor Specifications †
Parameter
Value and Units
Nominal Operating Voltage
12 V
Motor Kv
550 Kv
Free Speed
6784 RPM
Free Running Current
3.6 A
Stall Current
211 A
Stall Torque
3.6 Nm
†
Pre-production motor testing. Updates with production motor data will be made if necessary.
‡
A firmware update will be required to access higher resolution encoder data.
The NEO 2.0 Brushless Motor (REV-21-1653) builds on the proven performance of the original NEO, delivering the same high-efficiency brushless power in a refined package designed for easier integration and mounting. With updates to its shaft, encoder connection, and overall profile, NEO 2.0 offers teams more flexibility and streamlined assembly while remaining fully compatible with existing REV ION ecosystem components.
Features
High-performance brushless DC motor designed for competitive robotics
Compatible with all SPARK brushless motor controllers.
Fully integrated hall-effect encoder for closed-loop control
Adopts the SPARK FLEX mounting pattern for direct compatibility with MAXPlanetary and the broader REV ecosystem, aligning flats for a low-profile fit
Drop-in replacement for CIM-style motors
Front and rear ball bearings
High temperature neodymium magnets
Motor temperature sensor
Connectorized motor sensor output for use with the NEO 2.0 Sensor Cable
Diametrically magnetized magnet on the rotor-end of the shaft to support magnetic encoder.
New to NEO 2.0
15T spline shaft for secure power transfer without the need for keys or keyways
Detachable encoder cable for easy replacement and serviceability.
Slimmed 2-inch width profile with exposed outrunner design, allowing mounting within the silhouette of common 2in structural tubing like MAXTube.
Repositioned sensor board for better thermal reliability.
Motor Specifications
Parameter
Value and Units
Nominal Operating Voltage
12 V
Motor Kv
473 Kv
Free Speed`
5676 RPM
Free Running Current
1.8 A
Stall Current
150 A
Stall Torque
3.75 Nm
NEO V1.1
The REV NEO Brushless Motor V1.1 (REV-21-1650) 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 (REV-21-2158) to deliver incredible performance and feedback.
Features
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
New to NEO V1.1
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
The REV NEO 550 Brushless Motor (REV-21-1651) is the newest member of 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, allowing it to 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 has a lower thermal mass than a NEO, CIM, or Mini CIM, and thus it may not be ideal for some drivetrain applications.
Features
Mounting features match other 550 series DC motors
Out-runner construction (i.e. Rotor housing is compatible with REV Motion Pattern; you can mount metal Gears, Sprockets, and Pulleys)
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.
Hardware
#10 Hardware Basics
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.
Hardware Specifications
Button Head Socket Cap Screws
Length is measured from tip to underside of screw head
#10 Low Profile Nylon Lock Nut ()
#10-32 Socket Hex Cap Screws
Length is measured from tip to underside of screw head
Shaft End Screws
Standoffs
Aluminum threaded standoffs 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.
Shafts / Spacers / Collars
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.
MAXSpline Shaft is compatible with the REV ION System. The inner profile is compatible with bearings and bushings like the 1/2in Rounded Hex Bearing (REV-21-3197-PK4), allowing smooth rotation when used with a 1/2in rounded hex deadaxle.
This shaft is available as an extruded aluminum option (REV-21-2520) that provides a high strength alternative to 1/2in hex shaft, or a polycarbonate option (REV-21-6520) that gives teams a lightweight, cost effective way to expand their MAXSpline based designs.
MAXSpline Shaft can be cut to length using a bandsaw, hacksaw, or similar tools.
Specifications
Product
Material
Weight
Length
Inner Diameter
MAXSpline Shaft
Aluminum 6061
571g (1.26lb)
1193.8mm (47in)
25.4mm (1in)
MAXSpline Shaft - Polycarbonate (REV-21-6520)
Polycarbonate
247g (0.545lb)
1193.8mm (47in)
25.4mm (1in)
MAXSpline Shaft - Polycarbonate is not intended for high torque or heavy structural applications.
15T Spline Shaft
The 15T Spline Shaft (REV-41-6457) is a solid stainless steel shaft sized at 480mm for long span applications or to be used as stock to cut custom length shafts. Its 15 tooth involute spline profile features an 8mm outer diameter and interfaces with the REV ION ecosystem. Compatible spline adapters make it easy to integrate this shaft into drivetrains, mechanisms, and custom assemblies for reliable motion transfer.
1/2in Rounded Hex Shaft
The 1/2in Rounded Hex Shafts (Product Family Page) 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 (Product Family Page) 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.
Diameter
Length
Tapped
1/2in Rounded Hex
1.0-8.0in
#10-32 tapped
1/2in Rounded Hex
36in
Not Tapped
1/2in Hex Shaft Adapters
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.
UltraPlanetary 1/2in Hex Adapter
Easily attach the UltraPlanetary 1/2in Hex Adapter (REV-41-1620) to the output of your UltraPlanetary Gearbox to provide a convenient 1/2in hex output shaft
8mm to 1/2in Hex Adapter
With the 8mm to 1/2in Hex Adapter (REV-21-1879) 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 V1.1 (REV-21-1650).
When adding the retaining rings, use a 9mm socket head wrench to press against the ring and over the shaft. If needed, a light mallet can be used. To remove a retaining ring, use pliers.
With the 15T to 1/2in Hex Adapter (REV-21-4484) you can convert 15T shafts to drive 1/2in hex bore wheels, sprockets, gears, and more! Use these with any motors that have a 15T output shaft, like the NEO 2.0 Brushless Motor (REV-21-1652).
Spacers
MAXSpline Spacers
MAXSpline Spacers (Product Family Page) 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.
MAXSpline Spacer with MAX Pattern
Primarily used with ION wheels and sprockets, the MAXSpline Spacer with MAX Pattern (REV-21-2547-PK4) 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
1/2in Hex Shaft Spacers (Product Family Page) are primarily used with a hex shaft as a spacer between components with 1/16in, 1/8in, 1/4in, 1/2in widths available.
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
8mm Shaft Spacer
The 8mm Shaft Spacer (Product Family Page) 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.
#10 Spacers
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 (Product Family Page) 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.
Outside Diameter
Length
3/8in
1/8in
3/8in
1/4in
3/8in
3/8in
3/8in
1/2in
3/8in
3/4in
Collars / Shaft End Screw
#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.
The narrow profile collar is intended for applications with strict space or weight constraints. It uses M3 hardware to minimize overall size, resulting in a 0.25in wide collar with a 1.88in outer diameter. Its compact geometry allows it to retain parts on the shaft without interfering with nearby mechanisms, and the two piece design enables installation without removing other components from the shaft.
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)
1 Piece Shaft Collar - Narrow - 1/2in Hex Bore The 1 Piece Shaft Collar - Narrow - 1/2in Hex Bore uses a 2.5mm hex key to tighten and secure onto shafting. The narrow profile collar is intended for applications with strict space or weight constraints. Its compact geometry allows it to retain parts on the shaft without interfering with nearby mechanisms, and the two piece design enables installation without removing other components from the shaft.
Locking Shaft Collar - MAXSpline (REV-21-6532) The Locking Shaft Collar - MAXSpline is a compact, purpose built clamping solution for securing components to a MAXSpline shaft. It can be paired with a second collar or mounted directly to any MAXSpline wheel or sprocket that features standard nut pocket slots. The collar uses an internal wedge mechanism that engages as the assembly is tightened. As the collar is drawn toward its mating plate or wheel, the wedges cause a counter twisting action between it and its interface thus creating a strong, reliable grip on the MAXSpline profile.
Uses #10-32 hardware and nyloc nuts.
Slide a 1-1/8in rounded hex bearing onto the 1/2in rounded hex shaft with the flange on the azimuth gear side as shown.
Get:
1 - 20DP Speed Gear - MAXSpline - 36T
Slide the 36T MAXSpline gear onto the 1-1/8in rounded hex bearing as shown.
Get:
1 - 20DP Gear - MAXSpline - 62T
Slide the 62T MAXSpline gear into 36T MAXSpline gear as shown.
Get:
1 - 1/2in Rounded Hex Bearing - Flanged - 1in OD
Slide a 1in rounded hex bearing onto the 1/2in rounded hex shaft and into the 62T MAXSpline gear as shown.
Get:
1 - Drive Gear
Insert the drive gearing into the 10mm bearing as shown.
Get:
1 - Grease (Not Included in 4in Easy Swerve Module)
Apply about a teaspoon of grease across the Azimuth gear, steering gear, drive gear, and the 36T MAXSpline gear. You may need to lift the center stackup to access the 36T MAXSpline gear.
Get:
4 - 10mm Bearing - 22mm OD
Slide two 10mm bearings onto the drive and steering gears and then insert two 10mm bearings into the base plate as shown.
Get:
1 - Cover
2 - #10-32 Low Profile Nylon Lock Nut
Press two lock nuts into the locations shown on the cover.
Slide two 12T motor gears onto the motor shafts cover as shown.
If your motors have 8mm Keyed shafts you will need the shaft key from the 8mm Keyed Shaft Retaining Hardware Pack.
Get:
7 - Socket Head Screws #10-32 x 1/2in
Secure the cover and motors onto the base plate using seven 1/2in socket head screws in the locations shown.
Get:
1 - Live Fork
Press the bevel pinion shaft and 10mm bearing into the live fork as shown.
Get:
2 - #10-32 Low Profile Nylon Lock Nut
2 - Socket Head Screws #10-32 x 1in
Insert two lock nuts into the live fork shaft as shown, then secure the fork to the azimuth gear with two 1in socket head screws.
Get:
1 - Static Fork
2 - #10-32 Low Profile Nylon Lock Nut
Get:
1 - 10mm Bearing - 22mm OD
Press a 10mm bearing onto the bevel pinion shaft as shown.
Get:
1 - 20DP Speed Gear - 15t Spline - 18T
Slide the 18T speed gear onto the bevel pinion shaft as shown.
Get:
1 - #10-32 Shaft End Screw V2 - 1/2in
Secure the 18T speed gear with a shaft end screw, applying threadlocker to the screw.
Get:
2 - Motors (Not Included in 4in Easy Swerve Module)
4 - Socket Head Screws #10-32 x 3/8in
Secure two motors onto the base plate with two 3/8in socket head screws each as shown.
Get:
1 - Traction Wheel - MAXSpline - 4in - Hard V2
1 - Bevel Drive Gear
Insert the bevel drive gear into the 4in traction wheel as shown.
=
Get:
1 - 1/2in Rounded Hex Bearing - Flanged - 1in OD
Press a 1in rounded hex bearing into the bevel drive gear as shown.
Slide a 1-1/8in rounded hex bearing onto the 1/2in rounded hex shaft with the flange on the azimuth gear side as shown.
Get:
1 - 20DP Speed Gear - MAXSpline - 36T
Slide the 36T MAXSpline gear onto the 1-1/8in rounded hex bearing as shown.
Get:
1 - 20DP Gear - MAXSpline - 62T
Slide the 62T MAXSpline gear into 36T MAXSpline gear as shown.
Get:
1 - 1/2in Rounded Hex Bearing - Flanged - 1in OD
Slide a 1in rounded hex bearing onto the 1/2in rounded hex shaft and into the 62T MAXSpline gear as shown.
Get:
1 - Drive Gear
Insert the drive gearing into the 10mm bearing as shown.
Get:
1 - Grease (Not Included in 4in Easy Swerve Module)
Apply about a teaspoon of grease across the Azimuth gear, steering gear, drive gear, and the 36T MAXSpline gear. You may need to lift the center stackup to access the 36T MAXSpline gear.
Get:
2 - 20DP Motor Gear - 8mm Keyed - 12T OR 2 - 20DP Motor Gear - 15t Spline - 12T
Slide two 12T motor gears onto the motor shafts cover as shown.
If your motors have 8mm Keyed shafts you will need the shaft key from the 8mm Keyed Shaft Retaining Hardware Pack.
Get:
4 - 10mm Bearing - 22mm OD
Slide two 10mm bearings onto the drive and steering gears and two 10mm bearings onto the 12T motor gears as shown.
Get:
1 - Cover
2 - #10-32 Low Profile Nylon Lock Nut
Press two lock nuts into the locations shown on the cover.
Insert seven lock nuts into the locations shown on the underside of the base plate.
Get:
1 - 80mm Bearing - 100mm OD
Insert the 80mm bearing into the location shown.
Get:
4 - M3 x 8mm Flange Head Screw
4 - M3 x 8mm Washer
Slide one washer onto each of the four M3 screws, apply threadlocker, then screw them into the locations shown to secure the 80mm Bearing.
Get:
2 - 10mm Bearing - 22mm OD
Insert two 10mm bearings into the locations show.
Get:
1 - Azimuth Gear
1 - 1/2in Rounded Hex Shaft - 2.5in - Tapped
1 - #10-32 Shaft End Screw V2 - 1/2in
Insert the 1/2in rounded hex shaft into the azimuth gear as shown. Secure the 1/2in rounded hex shaft with a shaft end screw, applying threadlocker to the screw.
Insert the azimuth gear with 1/2in rounded hex shaft into the base plate as shown.
Get:
1 - Shaft Spacer 1/2in Round Hex, 1/8in Long
1 - Bevel Pinion Shaft
Slide a shaft spacer onto the bevel pinion shaft as shown.
Get:
1 - Base Plate
7 - #10-32 Low Profile Nylon Lock Nut
Insert seven lock nuts into the locations shown on the underside of the base plate.
Get:
1 - 80mm Bearing - 100mm OD
Insert the 80mm bearing into the location shown.
Get:
4 - M3 x 8mm Flange Head Screw
4 - M3 x 8mm Washer
Slide a washer onto the four M3 screws, apply threadlocker, then screw them into the locations shown to secure the 80mm Bearing.
Get:
2 - 10mm Bearing - 22mm OD
Insert two 10mm bearings into the locations show.
Get:
1 - Azimuth Gear
1 - 1/2in Rounded Hex Shaft - 2.5in - Tapped
1 - #10-32 Shaft End Screw V2 - 1/2in
Insert the 1/2in rounded hex shaft into the azimuth gear as shown. Secure the 1/2in rounded hex shaft with a shaft end screw.
Insert the azimuth gear with 1/2in rounded hex shaft into the base plate as shown.
Get:
1 - Shaft Spacer 1/2in Round Hex, 1/8in Long
1 - Bevel Pinion Shaft
Slide a shaft spacer onto the bevel pinion shaft as shown.
Get:
1 - 10mm Bearing - 22mm OD
Slide a 10mm bearing onto the bevel pinion shaft as shown.
Get:
1 - 10mm Bearing - 22mm OD
Slide a 10mm bearing onto the bevel pinion shaft as shown.
MAXSwerve Module Assembly
Assembly Instructions
This assembly guide was updated in October 2024.
3in MAXSwerve Module Assembly Instructions
Teams should choose their preferred orientation of their motors prior to assembly. Images that detail the various options can be found here:
In the event your team feels the need to apply lubricant to the MAXSwerve Hardware during assembly, we recommend . We also recommend for post assembly applications.
Reference the for help identifying the Bearings, Spacers, and Hardware from your kit!
Several of the below steps call for the use of threadlocker with certain screws. We recommend or an equivalent threadlocker.
Greasing Guide
We recommend adding grease to your MAXSwerve Module(s) during assembly and reapplying as needed to maintain your drivetrain.
When applying the grease of your choice*, add a small amount to all of the gears in the MAXSwerve module, ensuring that it gets evenly distributed throughout the system. It is not necessary to grease the UltraPlanetary Gearbox Cartridges as they are pre-lubricated.
*We recommend using or
Top Plate Subassembly
If your MAXSwerve Module Kits do not contain the 3in MAXSwerve Module V1 to V1.1 Upgrade Kit, please start at the
Steering Gear Subassembly Part 1
MAXSwerve Wheel and Axle Subassembly
Some 3in MAXSwerve Module Wheel Axles may not be a slip fit. Please see our MAXSwerve Assembly Tips section for a solution:
Active Fork Subassembly
Fork Insertion Subassembly
MAXSwerve Wheel Installation
Steering Gear Subassembly Part 2
UltraPlanetary Block Subassembly
The Steering UltraPlanetary Subassembly is dependent on which orientation (left hand or right hand) was chosen during Top Plate Subassembly.
Steering UltraPlanetary Subassembly
Some of the UltraPlanetary Cartridges have a mounting hole that is partially closed. Please see our guide on how to fix this:
If you forgot to apply threadlocker during the assembly of the UltraPlanetary Subassembly you can use a to apply threadlocker to the pre-assembled gearbox.
For instructions see our section
Steering Drive Installation
Top & Bottom Plate Mating
Once you assemble your MAXSwerve Modules onto your Drivetrain, check out the following sections for help to start moving!
2 - Socket Head Screws #10-32 x 1in
Insert two lock nuts into the static fork shaft as shown, then secure the fork to the azimuth gear opposite the live fork with two 1in socket head screws.
Secure the 1/2in rounded hex shaft with two shaft end screws and split lock washers until snug but still allowing the wheel to freely rotate.
2 - Socket Head Screws #10-32 x 1in
Insert two lock nuts into the static fork shaft as shown, then secure the fork to the azimuth gear opposite the live fork with two 1in socket head screws.
4) Slide the Pinion Spacer over the motor shaft press it into the Encoder Bridge.
5) Install Motor Key into motor shaft keyway. The key should fit into keyway and should rest on top of the Pinion spacer
6) Install the appropriate drive motor pinion for the preferred speed option (low, mid, or high) onto the motor shaft, with the pinion boss facing away from the motor as shown the the second image.
Set Top Plate subassembly aside.
The below instructions are for Top Plate Subassembly of a MAXSwerve Module with a NEO Vortex using the Vortex Shaft - MAXSwerve Integrated Key. The continuation of this assembly guide will show images of MAXSwerve Module assembled with a NEO Brushless Motor v1.1 as the next steps are identical across all motors.
1) With the NEO Vortex motor sitting shaft upwards on a flat surface, position the Top Plate upside down on the on the mounting surface of the SPARK Flex Motor Controller. † Align the motor holes for your preferred configuration, either left hand or right hand.
CAD examples of those options can be found here:
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.
CAD examples of those options can be found here:
3) Install the Encoder Bridge into the Through Bore Encoder so that the hex side of the bridge rotates the Through Bore Encoder.
MAXSwerve Module V1.0 - Top Plate Subassembly
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:
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.
CAD examples of those options can be found here:
3) Install Motor Key into motor shaft keyway. The thinnest part of the key should be facing towards the motor.
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.
CAD examples of those options can be found here: NEO Orientation
3) Install the Encoder Bridge into the Through Bore Encoder so that the hex side of the bridge rotates the Through Bore Encoder.
1) Insert the main steering bearing into the Bottom Plate.
2) Install six 3/8in button head screws into the Bottom Plate to hold the main bearing in place, applying threadlocker to the screws. Set aside the Bottom Plate.
3) Take Steering Gear and insert the main Bevel Pinion bearing into the bottom side of the Steering Gear.
4) Insert Steering Gear into Bottom Plate.
5) Flip the Bottom Plate over and insert the Bevel Pinion into the Bevel Pinion bearing.
Set Steering subassembly aside.
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.
Checkout our video on threadlocker application for tips and tricks.
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) Install the two Bevel Pinion end bearings into the Active Fork.
Set the Active Fork aside.
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 the same day 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 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. If you have a torque wrench tight these screws to ~15 Inch-lbs Min ~19 Inch-lbs Max.
Do not overtighten these screws.
1) Install the Steering Pinion bearing into the top of the Bottom Plate.
2) Insert motor shaft bearing into the top of the Steering Gear.
If you are experiencing the motor shaft bearing falling out of the gear you can use two small strips of tape on two sides of the bearing to keep it in place.
3) Fasten the Drive Spur Gear onto Bevel Pinion shaft 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 MAXSwerve wheel and the Forks at the same time.
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) 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) We recommend applying more threadlocker than you normally would in this step. Install and tighten four 60mm M3 socket head screws, applying threadlocker to the screws, through the Bottom Plate, through the UltraPlanetary stack, and into the UltraPlanetary Motor Plate.
Take care not to overtighten the screws. We recommend applying threadlocker then tighten all screws until the screw heads are touching the output plate or the outermost metal.
Tighten screws in a star pattern (see photo) a 1/4 turn each at a time until the gearbox becomes noticeably harder to spin by hand then back out the screws 1/2 turn.
Let the threadlocker cure for a full 24 hours before use.
3) Spin the fork and wheel assembly by hand to check that it moves freely. It should move easily and quickly coast to stop, continuing to rotate 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.
If you are having issues with these screws issues with these screws falling out, we recommend placing a small amount of tape over the screw holes in the bottom plate.
If you are experiencing the motor shaft bearing falling out of the gear you can use two small strips of tape on two sides of the bearing to keep it in place.
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 and quickly coast to stop, continuing to rotate with some inertia, in both directions. The torque required to spin it should be uniform through an entire rotation.
4) 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 as shown the the second image.
Set Top Plate subassembly aside.
†
The instructions are the same for the NEO Vortex Solo Adapter.
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. See our if you are finding this step difficult.
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 as shown the the second image.
Set Top Plate subassembly aside.
Showcases the by fastening tubes together using rivets
90 Degree Bracket -
Showcases the by fastening tubes together
90 Degree Bracket: Sharp Interior -
Showcases the by fastening together
135 Degree Bracket -
Showcases the by fastening a pair of tubes together
T-Shape Bracket -
Showcases the by fastening tubes together
Sharp 90deg Bracket
Showcases securing MAXTube at a 90 degree angle with sharp interior brackets offering a place to mount additional MAXTube
See parts list
Sharp T Bracket
Showcases securing MAXTube at a perpendicular angle using T brackets and allowing room for additional MAXTube to be mounted
See parts list
Dead Axle
MAX Pattern with Dead Axle -
Dead Axle interfacing with MAXTube via MAXHubs and captured using a Tube Nut
See parts list
1x1in MAXTube with Dead Axle -
Dead Axle Interfacing with the 1x1 MAXTube using a Tube Nut
See parts list
MAX Pattern Structure
3-4-5 Shallow Bracket -
Shows how to mount an angled 1x1 MAXTube to a horizontal 2x1 MAXTube using external 1in brackets
See all parts
MAX Pattern T Bracket -
Demonstrates how to mount two at a perpendicular angle using a pair of secured with rivets
MAX Pattern Motion Interface
Sprocket -
Demonstrates how to mount a #25 Plate Sprocket to a MAX Pattern MAXTube with spacers
See parts list
Gear: MAXSpline -
Shows how to mount a 20DP Gear to a MAXTube with spacers
See parts list
Gear: 1/2in Hex -
Showcases how to mount a 20DP Gear to a MAX Pattern MAXTube using spacers
See parts list
Pulley -
Demonstrates how to mount a RT25 Pulley to a MAXTube using spacers
See parts list
MAXSpline Motion Interface
MAXSpline Total Motion Stack -
MAXSpline Shaft interfacing with multiple compatible motion components together
See parts list
MAXSpline Grip Wheel Interface -
interfacing with a
MAXSpline Traction Wheel Interface -
interfacing with a
MAXSpline Compliant Wheel Interface -
interfacing with a
MAXSpline Omni Wheel Interface -
interfacing with an
MAXSpline Gear Interface -
interfacing with a
MAXSpline Pulley Interface -
interfacing with an
MAXSpline Sprocket Interface -
interfacing with a
MAXSpline Shaft
Needle Roller Bearing -
Demonstrates how to use a and to turn a into a dead axle roller
Bushing -
Adding a to the end of a
Endcap -
Adding a to the end of a
Pivot Joints
Pivot Joint Hinge -
Demonstrates using the with a to create a hinged pair of
Offset Hinge -
Demonstrates using a with the to create an offset hinge of
Multiple Hinges -
Demonstrates using a series of 1in Pivot Joints to have multiple moveable hinges at the end of a 2x1 MAXTube
See parts list
Power Train Mounting
NEO -
Mounting a NEO Brushless Motor Directly to MAXTube using button head screws
See parts list
NEO with MAXPlanetary -
Mounting a NEO V1.1 with a MAXPlanetary Gearbox to a MAXTube using button head screws and rounded hex bearing
See parts list
(single 3:1 cartridge configuration)
NEO 550 with UltraPlanetary -
Mounting a NEO 550 with an UltraPlanetary Gearbox to MAXTube using the ION UltraPlanetary Face Mount Bracket
See parts list
Servo -
Mounting a Smart Robot Servo using the Servo Face Mount Bracket to MAXTube
See parts list
ION UltraPlanetary Face Mount Bracket
UltraPlanetary Gearbox with Bearing Blocks -
Demonstrates using the face mount bracket to secure a NEO 550 with an UlraPlanetary Gearbox to bearing blocks as part of a pulley powered wheel set up
See parts list
UltraPlanetary Gearbox with MAXSpline Brackets -
Demonstrates using the face mount bracket to secure a NEO 550 with an UltraPlanetary Gearbox to stacked MAXSpline brackets allowing for the creation of a enclosed gear train
See parts list
Wheel Assemblies
Traction Wheel and Sprocket -
Directly mounting a #25 Plate Sprocket with a to a MAXSpline Traction Wheel as part of a dead axle application
See parts list
Traction Wheel and Gear -
Directly mounting a 20DP Gear to a MAXSpline Traction Wheel as part of a dead axle application
See parts list
Traction Wheel and Pulley -
Directly mounting a pulley to a MAXSpline Traction Wheel as part of a dead axle application
See parts list
Traction Wheel and Traction Wheel -
Using a Double Sided MAXHub to back-to-back mount two MAXSpline Traction Wheels
See parts list
Wheels
Traction Wheel with Aluminum MAXHub -
Interfacing a with an on each side
Traction Wheel with Bearing -
Interfacing a with
Omni Wheel with Aluminum MAXHub -
Interfacing an with an on each side
Grip Wheel with Plastic MAXHub -
Interfacing a with a on both sides
Compliant Wheel with Plastic MAXHub -
Interfacing a with a
Don't see what you're looking for? Check out our other Onshape examples too!
Demonstrates how to make a 3-4-5 triangle with 1x1 MAXTube, Internal 3-4-5 Brackets, and 90deg Brackets
See parts list
MAX Pattern 3-4-5 Triangle -
Demonstrates how to make a 3-4-5 triangle with MAXTube, MAXSpline Brackets, and External 3-4-5 Brackets
See parts list
MAXPattern Offset 3-4-5 Triangle -
Demonstrates how to make an offset 3-4-5 triangle with MAXTube, MAXSpline Brackets, and 1in Brackets
See parts list
MAXPattern Open-Offset 3-4-5 Triangle -
Demonstrates how to make an open-offset 3-4-5 triangle with a mixture of 2x1 and 1x1 MAXTube and 1in Brackets
See parts list
Belt and Chain Roller Connections
Pulley and Sprocket Rollers -
Creating a roller series using MAXTube and MAXSpline with Dead Axle Tubes - This example demonstrates turning the rollers with both a pulley and sprocket system
See parts list
MAXPattern Plates
Direction Reversal -
Showcases the use of the MAX Pattern Plates by creating a contained “gearbox” with gears driven by a NEO V1.1. The gears drive two sets of pulleys and belts in opposite directions
See all parts
MAXSpline Brackets: Parallel Side/Top Mount
NEO Attachment: Basic -
Using an Offset Mount bracket to mount a NEO V1.1 with the MAXPlanetary Gearbox along the side of a MAXTube with no pattern
See parts list
NEO Attachment: MAXSpline -
Shows how to side-mount a driven MAXSpline roller to a patternless MAXTube using the Offset Brackets
See parts list
Parallel Top Mount -
Demonstrates using the Parallel Top Mount bracket to support a pulley seated off the side of MAXTube
See parts list
Ratio Plates
Ratio Plate: 2:1 -
Utilizes the Ratio Plate to lift and offset a NEO V1.1 from the MAXTube structure for use with a pulley system controlling a rolling MAXSpline shaft
See parts list
16:64 Sprocket Live Axle -
Using 4:1 Ratio Plates to raise and offset a NEO V1.1 with MAXPlanetary gearbox to drive a sprocket and chain system
See parts list
Roller Assemblies
Chain-in-tube -
Containing a sprocket and chain system within the MAXTube while creating a NEO V1.1-driven compliant wheel roller
See parts list
Belt-in-tube -
Containing a pulley and belt system within the MAXTube while creating a NEO V1.1-driven compliant wheel roller
See parts list
Chain Outside -
Creating a complaint wheel roller driven by a NEO V1.1 turning a sprocket and chain system alongside MAXTube
See parts list
Belt Outside -
Creating a complaint wheel roller driven by a NEO V1.1 turning a pulley and belt system alongside MAXTube
See parts list
Smart Robot Servo
Servo Driving a Single Internal Chain -
Demonstrates using a servo to drive a single sprocket and chain within MAXTube
See parts list
Servo Driving Two Internal Chains -
Demonstrates using a servo to drive two chains contained by MAXTube
See parts list
Servo Driving an Internal Pulley -
Demonstrates using a servo to drive a pulley belt within a MAXTube
See parts list
Servo Driving an External Chain -
Demonstrates using a servo to drive a single external chain alongside MAXTube
See parts list
Servo Driving Two External Chains -
Demonstrates using a servo to drive two external chains alongside MAXTube
See parts list
Servo Driving an External Pulley -
Demonstrates using a servo to drive an external pulley alongside MAXTube
See parts list
Servo Driving Two External Pulleys -
Demonstrates using a servo to drive two external pulleys alongside MAXTube
See parts list
Servo Driving Gears -
Demonstrates using a servo to drive a geartrain alongside MAXTube
See parts list
NEO v1.1 with no Gearbox
NEO with MAXTube Belt -
Showcases the NEO driving a pulley and belt within MAXTube
See parts list
NEO with MAXTube Chain -
Showcases the NEO driving a chain and sprocket within MAXTube
Show parts list
NEO Driven Geartrain -
Showcases the NEO driving a geartrain enclosed with MAX Pattern Plates
Show parts list
NEO Driven Pulley -
Showcases the NEO driving a pulley and belt enclosed with MAX Pattern Plates
See parts list
NEO Driven Chain -
Showcases the NEO driving a sprocket and chain enclosed with MAX Pattern Plates
Show parts list
NEO v1.1 with MAXPlanetary
Single Chain in Tube -
Showcases NEO and MAXPlanetary System driving a single #25 Roller Chain inside of MAXTubing
Shows parts list
Single Chain Out of Tube -
Showcases NEO and MAXPlanetary System driving a single #25 Roller Chain outside of MAXTubing
Shows parts list
Double Chain in Tube -
Showcases NEO and MAXPlanetary System driving two #25 Roller Chains inside of MAXTubing
Shows parts list
Double Chain Out of Tube -
Showcases NEO and MAXPlanetary System driving two #25 Roller Chains outside of MAXTubing
Shows parts list
Single Belt in Tube -
Showcases NEO and MAXPlanetary System driving a single RT25 Belt inside of MAXTubing
Shows parts list
Single Belt Out of Tube -
Showcases NEO and MAXPlanetary System driving a single RT25 Belt outside of MAXTubing
Shows parts list
Double Belt Out of Tube -
Showcases NEO and MAXPlanetary System driving two RT25 Belts outside of MAXTubing
Shows parts list
Gear Outside Tube -
Showcases NEO and MAXPlanetary System driving two 20DP Gears outside of MAXTubing
Shows parts list
Shaft & Compliant Wheels -
Showcases NEO and MAXPlanetary System driving a 1/2in Hex Shaft with five Compliant Wheels
Shows parts list
NEO 550 with UltraPlanetary
Single Chain in Tube -
Showcases NEO 550 and UltraPlanetary System driving a single #25 Roller Chain inside of MAXTubing
Shows parts list
Double Chain in Tube -
Showcases NEO 550 and UltraPlanetary System driving two #25 Roller Chain inside of MAXTubing
Shows parts list
Single Belt in Tube -
Showcases NEO 550 and UltraPlanetary System driving a single RT25 Belt inside of MAXTubing
Shows parts list
Gearing Outside Tube -
Showcases NEO 550 and UltraPlanetary System driving two 20DP Gears outside of MAXTubing
Shows parts lis
Gearing Between Structure -
Showcases NEO 550 and UltraPlanetary driving two 20DP Gears between MAXPlate and MAXTubing
Shows parts list
Single Chain Between Structure -
Showcases NEO 550 and UltraPlanetary driving a #25 Roller Chain between MAXPlate and MAXTubing
Shows parts list
Double Chain Between Structure -
Showcases NEO 550 and UltraPlanetary driving two #25 Chains between MAXPlate and MAXTubing
Shows parts list
Single Belt Between Structure -
Showcases NEO 550 and UltraPlanetary driving a single RT25 Belt between MAXPlate and MAXTubing
Shows parts list
Double Belt Between Structure -
Showcases NEO 550 and UltraPlanetary driving two RT25 Belts between MAXPlate and MAXTubing
Shows parts list
2 Motor Gearbox
Parallel Gearbox Tube Mounting -
Demonstrates mounting the 2 Motor Gearbox parallel to MAX Pattern MAXTube to drive an internal sprocket and chain
Shows parts list
Perpendicular Gearbox Tube Mounting -
Demonstrates mounting the 2 Motor Gearbox perpendicular to MAX Pattern MAXTube to drive an external sprocket and chain
See parts list
Gearbox MAX Pattern Plate Mounting -
Demonstrates mounting the 2 Motor Gearbox to MAX Pattern Plates as part of a custom internal pulley system contained between the plates with standoffs
See parts list
Offset Gearbox Mounting -
Demonstrates using spacers to mount the 2 Motor Gearbox raised and offset from the MAXTube, allowing an external pulley system to run below it along the tube
See parts list
MAX 90 Degree Gearbox
Parallel Mounted MAX 90 -
Showcases the MAX 90 Degree Gearbox mounted parallel to MAXTube to drive a pulley system
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Perpendicular Mounted MAX 90 -
Showcases the MAX 90 Degree Gearbox mounted perpendicular to MAXTube to drive a pulley system
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Shaft to Shaft Series of MAX 90s -
Demonstrates using two MAX 90 Degree Gearboxes powered by one motor to drive multiple shafts on a compliant wheel intake
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MAXPlanetary Base Kit with the MAX 90 -
Shows additional variations for mounting the MAX 90 Degree Gearbox to MAXTube using the MAXPlanetary Base Kit
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2 Motor Gearbox with MAX 90 -
Utilizing the MAX 90 to mount the 2 Motor Gearbox parallel to MAXTube
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Don't see what you're looking for? Check out our other Onshape examples too!
