The front an back shell of the torso are mounted to the structure of the torso by means of a clip-mechanism. The individual shells are fixed together with simple elastic straps (Pinky) or by means of a clip-mechanism (Brain) depending on the robot.

Disconnecting the shells

To unmount the shells you will first need to disconnect the front and back shell at their interfaces (blue and red marked.

Open

Pinky

The front and back shell are connected with elastic straps. The following pictures show the locations of these straps.

Open

The straps can be removed as well as mounted by using an Allen key or something similar.

Note that not all the hooks at the top interfaces are used, as it has shown to not be necessary.

Brain

To disconnect the shells you will first need to remove the clips, which are located at the interfaces of the shells at the bottom left and right, as shown in the following pictures.

Next you need to pull apart the shells at the top left and right as shown in the following picture. The shells are only stuck together, so only little force is needed.

Unmounting the shells (both robots)

After disconnecting the front and back shells at their interfaces, each shell can be unmounted by pushing the shell upwards. Each shell is fixed at two points to the structure of the torso by means of a clip mechanism. The locations for the front shell are marked in the following picture, on the back shell you will find them at the same height.

The clip-mechanism is shown in detail in the following picture. By pushing up the shell, the pin, which is fixed to the shell itself, will slide along the geometry and eventually escapet the slot.

It is recommended to use both hands, placing them centrally at the bottom and at the top edges. Then push slightly towards the robot and jerk the shell upwards using both hands.

Mounting the shell works similar. Use both hands and push the shell down, so the pin slides into the slot and snaps into the geometry. After that connect the shells at their interfaces, the same way you disconnected them.

The Arm-, Leg- and Head-Shells are mounted elastically with a rotary-hinge and button-lock. The shells of the arms and legs always have two hinges, made of a dowel pin (which is not the hinges' axis) pressed into a 3D-printed geometry. This slides onto the grey FDM-printed hinge which is connected to the skeleton by rubber-dampers. In the figures below, you can see how the shells are sliding onto the hinges.

On the Other side of the shells, they get locked into the grey Button-Lock. This component is a spring-loaded button, which releases two shells when pressed. It is also connected to the skeleton by a rubber-damper (see figures below).

The lower Arms contain a small version of the Hinges and Button-Lock which function equally. All shells are marked with “L” or “R” for left or right. Do not force the shells in position to lock them. They should align with the Button-Lock. If they don’t, you might have the wrong shell. The Shells on the upper arms, however, require some force to snap onto the Hinges.

The face shell is mounted at three positions: one button-lock (see description above) on each side above the ear, a hinge at the chin. To unmount the face shell you need to complete the following steps.

First disconnect all cables which lead to the jetson inside the face shell. Next, loosen the two button locks, while holding the face shell with the other hand. Now slightly tilt the face shell to the front.

Next, move the shell downwards so that the hinge at the chin is free.

Following picture shows the hinge as seen from inside the face shell.

Now you can remove the face shell.

To mount the face shell follow the steps in reverse order.

Pinky

Brain

Roboy can and should be mounted using the three mounts inside the pelvis. As indicated in the following picture one mount is in the front (1) and two are in the back, left (2) and right (3). Use something solid with a firm stand on the ground to mount Roboy on.

The three mounts constitute an equilateral triangle with a side length of 121,244 mm.

Use M6 screws and nuts to mount the robot. The thread length of the screws should be at least 14 mm but not more than 16 mm plus the thickness of your mounting base (i.e. wooden plate with 30 mm thickness → screws with 44-46 mm thread length). For mount 1 the screw needs to be placed from the top and the nut from below. For mount 2 and 3 put the nuts in the corresponding socket first before fixing the robot with the screws to your basis plate from below.