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15MM LINEAR MOTION SYSTEM V2

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 1
TABLE OF CONTENTS
1 INTRODUCTION ...................................................................................................................................................................... 3

1.1 TOOLS AND MATERIALS .............................................................................................................................................. 3

2 ASSEMBLY INSTRUCTIONS .................................................................................................................................................. 4

3 DRIVING LINEAR MOTION ..................................................................................................................................................... 7

3.1 FOUR STAGE CASCADING LIFT ................................................................................................................................... 8

3.2 FOUR STAGE CONTINUOUS LIFT .............................................................................................................................. 14

3.3 CHAIN LIFT (ADVANCED) ........................................................................................................................................... 17

4 KIT COMPONENTS (1:1 Scale) ............................................................................................................................................ 18

Revision History
Revision Date Description
1 08/10/2018 Initial Release

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 2
1 INTRODUCTION
The REV Robotics 15mm Linear Motion kit is designed for use with the REV Robotics 15mm Extrusion. The Linear
Motion Kit v2 (REV-45-1507) contains all the necessary hardware (Figure 1) to build a single stage lift. Items necessary
for powering the linear motion system are sold separately as part requirements are highly dependent on
implementation. This guide is designed to build a three stage lift in two possible configurations (Cascading or
Continuous). Additional materials are needed to finish the build and detailed in Section 1.1.

Figure 1: Linear Motion Kit Contents (REV-45-1507)

1.1 TOOLS AND MATERIALS

To complete the full assembly in this guide a few tools and additional materials are needed. Some quantities are
depended on the type of lift being built. Check individual sections (3.1 or 3.2) for more information.

For this guide you will need:

• A 5.5mm nut driver

• 2mm Allen Key
• REV Robotics 15mm Extrusion
o In this example, 420mm lengths are used (REV-41-1432). Different lengths of REV Robotics 15mm
Extrusion will work depending on application.
• REV Linear Motion Kit v2 – QTY 2
• Hardware not included in the REV Linear Motion Kit v2
o Small Pulley Bearings (REV-41-1368) – Max QTY 5
o M3 x 12mm or longer hex cap bolts (REV-41-1360) – Max QTY 13
o M3 Nyloc Nuts (REV-41-1361) – Max QTY 13
o UHMWPE Cord (REV-41-1162) – QTY 1 (actual length is dependent on length of extrusion)
• Core Hex Motor (REV-41-1300) or HD Hex Motor (REV-41-1301) – QTY 1 (this example uses the Core Hex Motor)
• Surgical Tubing

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 3
2 ASSEMBLY INSTRUCTIONS
These instructions explain how to build one half of a single stage lift. Each linear motion kit contains enough hardware
to create a full single stage lift. Repeat this process four times to create all of the segments needed for the four-stage
lift.

Step 1

Insert 2 M3 x 8mm bolts into the holes on the side of the slider
plate with just the alignment groove, not the slider. Do not fully
tighten these bolts, just start the lock nuts enough so they won’t
fall off, but leave the bolts loose. Make 2 of these assemblies.

Note: use nylock nuts for this application

Step 2

Insert 2 M3 x 8mm low profile button head bolts into the double-
sided slider. Be sure that you insert the bolts from the correct
side because the double-side slider is not completely
symmetrical. The bolt head is placed on the side with the
circular countersunk cutouts, and the nuts fit into the hex
countersunk cutouts. Make 2 of these assemblies.

Note: use regular nuts for this application

Step 3
When assembling the double-sided slider, only tighten the nut so
that it is flush with the bottom of the slider when the bolt head is
all the way down. There should be clearance between the top of
the nut and the slider as shown.

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 4
 Step 4
Insert the double-sided slider into the extrusion channel with the
nuts in the channel. You may have to slightly loosen or tighten
the nut so that it will align with the channel.

One the slider is fully inserted into the channel, tighten the bolt
until snug. Do not overtighten the bolts as it may cause the
slider to deform and bind with the extrusion.

Step 5
Take the slider plate assembly from Step 1 and slide it into the
extrusion channel adjacent to the double-sided slider.

Once the slider assembly from Step 1 is fully inserted into the
channel, tighten just enough so that the slider plate assembly
does not freely slide in the channel, but is still loose enough that
you can move the slider with minimal force.

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 5
The above steps 1-5 will result in the Basic Assembly for a 15mm linear motion elevator using the REV Robotics Linear
Motion Kit and Extrusion (Figure 2). Repeat the steps 1-5 above four times building the four-stage lift in this guide. A
minimum of two assemblies are needed for a single stage lift. Adding additional Basic Assemblies will add more stages
to the lift system.

Figure 2: Basic Assembly (Steps 1-5)

Take two of the basic assemblies created in Steps 1-5

and slide them together.

With the hex cap bolts still slightly loose from step 5,
gently slide the extrusion in and out allowing the slider
plates to shift into optimal alignment. The slide should
only take a minimal effort to move.

Carefully tighten the hex cap bolts without shifting the

Figure 3: Basic Slide Assembly joining plates and re-check the slide for any binding.
Repeat as necessary.

To finish assembly for the three stage lift, add two

additional basic assemblies to the Basic Slide Assembly
shown in Figure 3. One basic assembly is added to each
side of the Basic Slide Assembly.

Don’t overtighten the bolts as it may cause deformation

of the slider plate and binding.

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 6
 Once all four basic assemblies are slid together,
attach an endcap onto one of the ends of the
extrusion pieces with a M3 x 8mm or larger bolt. Make
sure it is the same end for all four sections of the lift.
The ends of the extrusion need to be tapped* for M3.
These will help keep the lift from overextending as well
as hold the pulleys that are used to drive the lift up
and down. Which type of elevator you are making will
determine which pieces of extrusion on the lift require
an endcap, and which can be left uncovered.

*Tapping will make the attachment easier but is not

necessary. Using a M3 x 16mm bolt and nut driver,
carefully thread into the end of the extrusion. Finish
threading with the nut wrench for addition leverage on
the bolt.

3 DRIVING LINEAR MOTION

Linear motion stages can be driven many different ways, but our recommendation is to use a string wound around a
pulley and segments of surgical tubing to operate as a powered return. The string and pulley arrangement is used in one
of two ways: Cascading or Continuous lifts. In the Cascading lift assembly, all the stages move up simultaneously, each
one by an equal amount. In the Continuous string assembly only one stage moves at a time and the position of each
stage relative to each other is not controlled, only the position of the final stage relative to the start position is
controlled. This distinction is not relevant in most applications; however, it is a feature that can be used to great effect
and is worth keep in mind during design and prototyping. The parts necessary for powering the linear motion system are
sold separately as part requirements are highly dependent on the implementation of the lift. The guide assumes you are
attaching the lift to a robot. For creating this guide REV used a test stand to secure the lift and motor. This stand is
shown in the steps for the Cascading and Continuous lift.

To drive the linear motion system, we recommend using a combination of these products:

• Small Pulley Bearings (REV-41-1368)

• M3 x 12mm or longer hex cap bolts (REV-41-1360)
• M3 Nyloc Nuts (REV-41-1361)
• M3 Plain Nuts (REV-41-1126)
• UHMWPE Cord (REV-41-1162)
• Core Hex Motor (REV-41-1300) or HD Hex Motor (REV-41-1301)
• Surgical Tubing

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 7
3.1 THREE STAGE CASCADING LIFT

Collect parts and tools for Cascading string assembly, see section 1.1 for details. This guide builds a four-stage lift with
a surgical tubing return. These parts are not included in the linear motion kit. You will also need the completed Basic
Slide Assembly.

STEP 1
Drop the locknut into the slot on the top of the endcap.
Slide the bolt through the pully, pulley cover, and the
endcap. Thread the bolt into the locknut and make sure
you thread far enough into the endcap to have the end of
the bolt supported by the endcap. This will act as a
cantilever support and add strength to the pulley axle
when it is under load.

STEP 2
Add a pulley to the top of the first three extrusions. All
pulleys must be on the same side of the assembled linear
motion system.

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 8
 STEP 3
Repeat the previous step for the bottom of the last three
extrusion pieces, but don’t add the pulley or the pulley
cover.

On the bottom of the first piece of extrusion, add a M3 x

16mm bolt and locknut by sliding the bolt into the
extrusion channel. Secure it into place.

STEP 4
Assemble Lift by securely attaching the stationary first
stage extrusion to the frame of your robot using REV
plastic or metal brackets.

Position a motor on the side next to the extrusion

mounted to the frame.

Note: The motor needs a winding spool attached to it.

Attachment of the pulley will vary depending on motor
type. In this example, the REV Core Hex Motor has a
5mm Hex shaft with a spool held in place with a pair of
shaft collars.

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 9
 STEP 5
Attach a length of string to the bolt post on the bottom of
second stage. Run the string over the pulley at the top of
the first stage and down to the winding spool. Secure the
string onto the winding spool.

The line may be hard to get onto the pulley with the
pulley cover attached, but it is not impossible.

An easier but more time-consuming alternative to get the

line onto the pulley is to remove the pulley axle bolt and
slip the pulley out from inside the pulley cover. Attach the
line around the pulley and slide it back into the pulley
cover and reinsert the bolt and tighten.

STEP 6
Attach a length of string to the bolt post on the bottom of
first stage. Run the string over the pulley at the top of the
second stage. Attach the string to the bolt post at the
bottom of the third stage.

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 10
 STEP 7
Attach a length of string to the bolt post on the bottom of
second stage. Run the string over the pulley at the top of
the third stage. Attach the string to the bolt post at the
bottom of the fourth stage.

STEP 8
To set up the surgical tubing return system, add bolts on
the back side of the endcaps from where you just
attached the drive lines. The bolts will mount just like the
anchor bolts for the drive lines you mounted earlier in
Step 3. Mount one at the base of the first piece of
extrusion, and two more in each of the first two end caps.

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 11
 STEP 9
Add bolts to the second and third endcaps like the
last step, and a third at the top of the last stage,
similarly to the last step as well.

STEP 10
Push a screw into an end of the surgical tubing.

STEP 11
With string tightly wrap the surgical tubing onto the
screw and tie it off. Then tie a loop of string such that the
loop can be hooked over a screw post.

*alternatively, you can simply tie an end loop knot in the

end of the surgical tubing.

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 12
 STEP 12
On the back side of the lift, opposite the drive lines,
attach 3 surgical tube lengths to the anchor bolts in the
end caps in an arrangement seen left.

Adjust the length of each piece to adjust the force that

pulls the lift down. For a starting point, the surgical
tubing should be just slightly in tension when the lift is in
the closed position.

Done!

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 13
3.2 THREE STAGE CONTINUOUS LIFT

Collect parts for Continuous String assembly. This guide assumes you are building a four-stage lift with a surgical
tubing return. These parts are not included in the linear motion kit.

STEP 1
Drop the locknut into the slot on the top of the
endcap. Slide the bolt through the pully, pulley cover,
and the endcap. Thread the bolt into the locknut and
make sure you thread far enough into the endcap to
have the end of the bolt supported by the endcap.
This will act as a cantilever support and add strength
in bending to the pulley axle when it is under load.

STEP 2
Add a pulley to the top of the first three extrusions and
the bottom of the two center stages. All pulleys must be
on the same side of the assembled linear motion system.

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 14
 STEP 3
Add a screw post to the bottom of the last stage. The
screw post must be on the same side of the assembled
linear motion system as the pulley. Attach lift securely to
robot frame using our metal or plastic brackets

STEP 4
Secure the string onto the winding pulley. Run the string
over the pulley at the top of the first stage and down to
the pully on second stage. Then back up to the pulley on
the top of second stage. The string then goes down to
the pully on third stage. Then back up to the pulley on the
top of third stage. The string then goes down to the
screw post on the last stage.

The line may be hard to get onto the pulley with the
pulley cover attached, but it is not impossible. An easier
but more time-consuming alternative to get the line onto
the pulley is to remove the pulley axle bolt and slip the
pulley out from inside the pulley cover. Attach the line
around the pulley and slide it back into the pulley cover
and reinsert the bolt and tighten.

Note: The motor needs a winding pulley attached to it.

Attachment of the pulley will vary depending on motor
type. In this example, the REV Core Hex Motor has a
5mm Hex shaft with a pulley held in place with a pair of
shaft collars.

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 15
 STEP 5
Push a screw into an end of the surgical tubing.

STEP 6
With string tightly wrap the surgical tubing onto the
screw and tie it off. Then tie a loop of string such that the
loop can be hooked over a screw post.

*alternatively, you can simply tie an end loop knot in the

end of the surgical tubing.

STEP 7
To set up the surgical tubing return system, add bolts on
the back side of the endcaps from where you just
attached the drive lines. The bolts will mount just like the
anchor bolts for the drive lines you mounted earlier.
Mount one at the base of the first piece of extrusion, and
two more in each of the first two end caps.

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 16
 STEP 8
Add bolts to the second and third endcaps like the last
step, and a third at the top of the last stage, similarly to
the last step as well.

STEP 9
On the back side of the lift, opposite the drive line, attach
3 surgical tube lengths to the anchor bolts in the end
caps in an arrangement seen left.

Adjust the tension in each piece to adjust the force that

pulls the lift down.

3.3 CHAIN LIFT (ADVANCED)

Chain based lifts are conceptually the same as the continuous string lift. The chain loops back and forth along the
stages of the lift and is fixed to the final stage of the lift. The remainder of the chain then loops back to the drive
sprocket completing the loop. Interferences and misalignments that a string-based lift is able to tolerate cannot
generally be tolerated by chain-based lift. It should be noted that in order to properly tension a chain drive lift a spring-
loaded chain tensioner should be used. If a spring-loaded chain tensioner cannot be used the chain must remain vertical
or horizontal during operation minimize sine/cosine error stack ups. Given these complexities of implementation a
Chain lift should only be used if a team has the expertise to execute and time to properly debug the lift.

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 17
4 KIT COMPONENTS (1:1 Scale)

M3 x 8mm Low Profile Socket Cap Bolt – x8

M3 x 8mm Hex Cap Bolt – x8

M3 Nut – x8

M3 Locknut – x8

REV-41-1511: Endcap – x4

REV-41-1512: Pulley Cover – x4

REV-41-1519: Slider Plate – x4

REV-41-1520: Double Sided Slider – x4

15mm Linear Motion System – Rev 1 Copyright © 2018 REV Robotics, LLC 18