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Sea Perch Project

Sea Perch
Construction Manual

Sea Perch Construction Manual
January 2007
0 - 1

Table of Contents







Construction Manual Cover.................................................................................Page 0 - 1
Table of Contents...........................................................................................................0 - 2

Unit 1 Assembly of Subsystem One: The Vehicle Frame .............................................1 - 1

Step 1: Cut the frame parts.................................................................................1 - 2

Step 2: Create drain holes in vehicle frame .......................................................1 - 3

Step 3: Assemble the vehicle frame...................................................................1 - 4

Step 4: Assemble the float supports and tighten the frame................................1 - 5

Step 5: Attach the motor mounts to the frame ...................................................1 - 6

Step 6: Attach the payload netting .....................................................................1 - 7

Unit 2 Assembly of Subsystem Two: The Thruster Assembly......................................2 - 1

Step 1: Assemble the potting holder ..................................................................2 - 2

Step 2: To test the motors and mark polarity of the terminals...........................2 - 3

Step 3: Seal the motors from the wax ................................................................2 - 4

Step 4: Drill holes in the thruster containers......................................................2 - 5

Step 5: Attach the tether wires to the motors.....................................................2 - 6

Step 6: Pot (waterproof) the motors with wax first half .................................2 - 8

Step 7: Mount the propellers on the motors.......................................................2 - 10

Step 8: Complete the thruster potting ................................................................2 - 12

Step 9: Mount the thrusters on the vehicle frame ..............................................2 - 13

Step 10: Waterproof the tether cable .................................................................2 - 14

Unit 3 Assembly of Subsystem Three: The Control Box ..............................................3 - 1

Sea Perch Circuit Diagram.................................................................................3 - 2

Step 1: Gather the parts for the control box assembly .......................................3 - 3

Step 2: Prepare the control box..........................................................................3 - 4

Step 3: Assemble the power cable .....................................................................3 - 5

Step 4: Wire the push-button switches (vertical thruster controls)....................3 - 8

Step 5: Wire the toggle switches (horizontal thruster controls).........................3 - 11

Step 6: Finish the control box ............................................................................3 - 15

Step 7: Testing your Sea Perch ROV.................................................................3 - 17

Parts and Tools List ....................................................................................................PL - 1

Parts and supplies............................................................................................PL - 2

Tools and batteries ..........................................................................................PL - 3

Websites and accessories ................................................................................PL - 4


Sea Perch Construction Manual
January 2007
0 - 2 UNIT 1
ASSEMBLY OF SUBSYSTEM ONE
THE VEHICLE FRAME






FOR THIS UNIT YOU WILL NEED:
Tools Materials
Ruler
Marker
PVC pipe cutter or saw
Phillips Screwdriver
Drill
1/4 drill bit
3/32 drill bit
5 ft. (1.5 meters) of 1/2 PVC pipe
10 1/2 PVC elbows
4 1/2 PVC Ts
15 Plastruct H-beam
2 Football Floats
3 Motor Mounts
6 #6 x 1/2Screws
6 #6 washers
Netting
Tie Wraps (zip ties)
Time: Unit one requires approximately 2 hours to complete:
1 class period to cut the PVC pipe and drill the holes
1 class period to assemble the frame, and attach the payload netting and motor mounts.
Sea Perch Construction Manual

January 2007
1 - 1 STEP 1

PURPOSE: Cut the frame parts

MATERIALS:

5 (1.5m) of 1/2 PVC
pipe


TOOLS:

Ruler
Marker
PVC Pipe cutter
(or saw)

Figure 1:
PVC pipe cutter, Cut sections of PVC pipe, Elbows and Ts

PROCEDURE:
1.

From a straight end of the pipe measure and cut:
Two pieces 2 1/2 or 6.4 cm long
Two pieces 4 or 10.2 cm long
Two pieces 4 1/2 or 11.4 cm long
Four pieces 1 1/2 or 3.8 cm long
Four pieces 5 or 12.7 cm long

Try to cut straight, so that the ends of each piece are square with the sides, but
dont worry if its not prefect.

2.

You may want to write the length on each piece to keep track.


Pipe Cutting Tips

PVC pipe can be cut in many ways, each of which has its own concerns:
Ratchet Style Pipe Cutters are the easiest and safest option. To open the cutter, pull the
handles FAR apart. Then click them closed through the pipe by pumping the handles
together and apart.
Non-ratchet Pipe Cutters are a cheaper alternative, but more difficult to use. Place the
pipe in the cutter, push down LIGHTLY, and turn the cutter around the pipe slowly,
applying light pressure, until it cuts through all the way.
Hack Saws and other saws can cut through PVC, but are the most labor intensive option.
Band Saws are large pieces of shop equipment, and can be very dangerous. Make sure to
get your teachers permission and supervision before using one.
Sea Perch Construction Manual

January 2007
1 - 2 STEP 2

PURPOSE: Create drain holes in vehicle frame

MATERIALS:

10 1/2 PVC elbows


TOOLS:

Hand drill or
drill press

1/4 drill bit

Vise


Figure 2: Drain holes drilled with 1/4 drill bit

PROCEDURE:

1.

Secure a PVC elbow in the vise (or drill press vise).
2.

Place the 1/4" drill bit in the drill (or drill press), and drill a hole in the outer
corner of the elbow.
3.

Repeat for each of the ten PVC elbows.

These holes are meant to let water fill the frame when you put your SeaPerch in
the water and for the water to drain out when you take the SeaPerch out.

Drill Safety:

Drills can be dangerous pieces of equipment, but are very useful if operated properly.
Always get your teachers permission and supervision before using a drill or other power
tool. Always wear safety glasses when using a drill or other power tool.

It is good practice to secure the object you are drilling in a vise before drilling. This
keeps it steady, prevents it from spinning and hurting your hand if the drill should bind,
and keeps your fingers away from the drill bit while drilling.

If you do not have a vise available, push the elbow onto one end of a long (5 or more)
piece of PVC pipe, and hold the pipe while drilling the hole. DO NOT drill the elbow
while holding it in your hand!
Sea Perch Construction Manual

January 2007
1 - 3 STEP 3

PURPOSE: Assemble the vehicle frame

MATERIALS:

Cut pieces of pipe
from step 1

10 1/2 PVC elbows
with holes drilled from
step 2

4 1/2PVC Ts

Figure 3: PVC Frame Parts

PROCEDURE:
Assemble the frame using all the PVC parts as shown in Figure 4 below.


Figure 4: Frame Assembly
Sea Perch Construction Manual

January 2007
1 - 4 STEP 4

PURPOSE: Assemble the float supports and tighten the frame

MATERIALS:
Assembled frame
15 Plastruct H-beam
2 Football Floats
PVC pipe scraps


TOOLS:
PVC Pipe Cutter



Figure 5: H-beam Assembly for floats

PROCEDURE:
1.

Cut the 15 Plastruct H-beam into two 7 1/2 pieces.
2.

Cut Four 3/4 (2cm) pieces of PVC pipe from your scraps.
3.

Insert one of the 3/4 (2cm) PVC pipe pieces into the open end of each of the
four PVC angles on the top of your vehicle.
4.

Insert an H-beam through each of your floats and between each pair of PVC
angles.
5.

Push all parts of your vehicle frame together HARD, so that H-beams cannot
fall out of the PVC angles.



Figures 6: Assembly of H-beam float supports.

TIP: If you place the vehicle on your work bench and push down hard from all
sides, you can squeeze all the frame sections together tightly. Unless you are
building a larger frame, or have PVC that remains loose, it is not necessary to
glue or screw the jo