By Michael

Arctos Robot Arm – X-Axis / Base Modification Summary of Modifications This modification redesigns the X-axis (base) assembly of the Arctos robot arm with a strong focus on improved assembly, durability, and serviceability. The design replaces weak 3D-printed threads with heat-set threaded inserts, simplifies the mounting and alignment of the endstop sensor, improves cable management, and enhances accessibility of critical mounting points. Additionally, several structural and geometric improvements increase overall usability and stability. Detailed Modifications All major connections have been redesigned to use heat-set threaded inserts instead of printed threads or loose nuts. -M3 inserts are installed in the X Upper Core and are used to connect it to the X Lower Core -M5 inserts are used for structural connections, including the interface to the original X motor core and the mounting points on the X Pulley -These inserts eliminate the need for hard-to-reach M5 nuts -Additional M3 inserts are installed in the X Pulley and are used to mount the X Flange This results in significantly improved durability, clean and repeatable assembly, no wear in printed threads, and much easier maintenance and disassembly. A dedicated mounting interface for the WSH231 Hall-effect endstop sensor has been added. -The sensor is mounted directly to the X Upper Core using M2 heat-set threaded inserts -The position is fixed by the geometry of the X Flange This removes the need for manual alignment, ensures reliable and repeatable positioning, simplifies installation, and results in a cleaner integration. Cable routing has been improved by increasing the size of the cable passages compared to the original design. -Easier cable installation -Reduced risk of damage -Improved compatibility with different cable setups The mounting points on the X Lower Core have been moved further outward. -Easier access during installation -Improved stability due to a wider base -Better tool clearance The X Pulley has been redesigned to include integrated M3 threaded inserts. -The X Flange can be mounted directly from the opposite side -Eliminates weak printed threads -Creates a stronger and more reliable connection -Simplifies assembly Two 3x3 mm magnets are integrated into the design and are used in combination with the WSH231 sensor. Assembly Notes: Correct orientation of the X Flange is essential for proper endstop functionality. -In the home (zero) position, the tip of the X Flange must point forward in the direction of the gripper -The flange tip and magnets must be positioned opposite the WSH231 endstop sensor The correct orientation can be verified using the hole pattern of the X Pulley. -The pulley contains four holes for M5 heat-set threaded inserts -Two holes are vertical (straight) -Two holes on the opposite side are angled (diagonal) -The magnets must point toward the side with the vertical (straight) holes Following this orientation ensures correct homing behavior, eliminates the need for manual sensor adjustment, and provides consistent and reliable triggering of the endstop. Bill of Materials: 3D Printed Parts: -X Upper Core, quantity 1, modified -X Lower Core, quantity 1, modified -X Pulley, quantity 1, modified -X Flange, quantity 1, modified Hardware: -M3 screws, quantity 12, length depending on assembly -M2 screws, quantity 2, for WSH231 mounting -M5 heat-set threaded inserts, quantity 8, structural connections -M3 heat-set threaded inserts, as required, used in Upper Core and Pulley -M2 heat-set threaded inserts, quantity 2, for WSH231 sensor Mechanical Components: - 61812 ball bearings, quantity 2, main rotational support Additional Components: - 3x3 mm magnets, quantity 2, endstop trigger - WSH231 Hall-effect sensor, quantity 1

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