4. Fork Assembly

Assembled Picasso Box

Assembly Ulna Gearbox & Elbow Tail

[3D] - 6E Picasso Wrist Gearbox Components

[3D] - 5A Fork Components

Alan Keys

Socket Head Driver

Plier [Opt.]

Prepare the following components:

Assembled Picasso Box

[3D] - 6Ea Picasso GB Output Disks

6706 Bearing [30x37x4mm] (x1)

M3x10mm Screws (x4)

M3x20mm Screws (x8)

M3 Hex Nuts (x8)

Clamp 6706 Bearings with two Output Disk components using M3x20mm screws and Hex Nuts

Tighten these nuts as well

Align the 4 Middle Holes of Clamped Output Disk to the side of the Picasso Box

Secure the clamped output disk to the side of the Assembled Picasso Box using M3x10mm Screws

Prepare the following components:

[3D] - 6Ea Picasso GB Housing

[3D] - 6Ea Picasso GB Rotors & 6PE Pulley Gear

[3D] - 6Ea Picasso GB Eccentric Cams

Brass Tube [7/32' x 25.95mm]

6701 Bearings [12x18x4mm] (x3)

M3x4mm Set Screws (x3)

M3x20mm Screws (x4)

Eccentric Cams

"Thin/Top" Eccentric Cam

"Thick/Bottom" Eccentric Cam

Rotors

Make a sharpie mark on the side of the Rotor where it lines up with the B and T label on each Rotors

Brass Tube

Tube end with the two drilled holes = Cam End

Tube end with the one drilled hole = Pulley End

Insert 6701 Bearings to both Top and Bottom Rotors as well as the Top Housing

Slide the Bottom Eccentric Cam to the 2nd hole from the edge in the Cam End of the Brass Tube

First hole is on the other side of the Tube

Align the set screw holes and screw its place using the M3x4mm Set Screw

Slide the Bottom Rotor to the Bottom Eccentric Cam

Label Side of the Rotor is facing the Cam End

Repeat the process with the Top Eccentric Cam and Rotor

Label Side of the Rotor is facing the Cam End

Align the Side Sharpie mark on the Bottom Rotor to the "B" label on the Housing and slide only the Bottom Rotor into the Housing

Align the Side Sharpie mark on the Top Rotor to the "T" labelled on the Housing and slide the rest of the Rotor in.

If everything went smoothly, the gap between 8 holes on each rotor should be equally spaced

Verify that you can manually turn the eccentric shaft in the center and that the rotors smoothly turn inside the housing. Tight printing and misaligned rotors can cause the gearbox to jam.

Insert 6701 Bearing on the Top Housing

Secure the Top Housing to the Rotor Housing using the M3x20mm Screws

DON't screw all the way in. Just to the flushed to the bottom of the Main Housing

Align the Pulley Gear to the Set Screw and slide in the Pulley gear to the Brass Tube

Secure it using M3x4mm Set Screw

Prepare the following components:

[3D] - 5Aa Fork {Bottom & Top}

[3D] - 5I Idler Bearing Cover (x8)

MF83 Flanged Bearings [3x8x4mm] (x8)

M3x20mm Screws (x4)

M3 Hex Nuts (x4)

M3 Nylock Nuts (x4)

Insert MF83 Bearings into the Bearing Sleeves

Insert the M3x20mm Screw in to the Fork Half where there's a chamfered peg on the inner face

Slide one of the Bearing Sleeves to the M3x20mm Screwss with the flanged part on the bottom

Use M3 Hex Nut to secure the Bearing Sleeve in place

Insert another one of the Bearing Sleeves on the M3x20mm Screws but this time with the flanged part facing up

Use M3 Nylock Nuts to secure it in place

Repeat the procedure for 3 other locations.

Prepare the following components:

Assembled Ulna Gearbox, Picasso Box and Wrist Gearbox

Fork Bottom {w/ Idler installed}

Timing Belt GT2-336mm & GT2-400mm

M3x10mm Screw (x1)

M3x22mm Screws (x6)

M3x4.5x12mm Hex Standoffs (x7)

M3 Square Nuts (x2)

Place the GT2x400mm Timing Belt on the outer pulley on Assembled Ulna Gearbox

Place the GT2x336mm Timing Belt on the inner pulley

Align the Ulna Sensor Plate and Ulna Output Gearbox to the Fork Bottom with the Hex Standoff insert pointing upward

Insert M3x4.5x12mm Hex standoffs and secure its place using M3x22mm Screws

Use M3x10mm Screw in this location

Insert the Picasso Output pins to the Picasso Gearbox

Rotate the Input Pulley of the Picasso Gearbox to align the gearbox housing

Insert the assembled Picasso Box into the Bearing Slots of the Fork Bottom

Make sure to wrap the Timing Belts on both Pulley Gears AND the Bottom Idlers

The SMOOTH SIDE of the Belt on the IDLERS

Insert M3 Square Nuts in the Square Nut insert on the Fork Bottom

Secure the Picasso Gearbox by tightening the bottom screws on the Gearbox Housing

Prepare the following components:

Fork Bottom Prepared

Fork Top {w/ Idlers Installed}

M3x10mm Screw (x1)

M3x25mm Screws (x6)

M3 Nylock Nuts (x4)

M3 Square Nuts (x2)

[Opt.] - Tape

Insert the M3 Square Nuts in the Fork Top

Insert the M3 Nylock Nuts in both Fork Top and Bottom on the side wall

Optionally, put tape over the nuts as the friction fit alone may not be enough to keep them on.

This step may be the hardest to execute so follow through carefully. Use Alan Key as a "hook" if you need to

Align the 400mm GT2-Timing Belt {outer belt} to the Top Idler

Take the Belt off of the Gearbox Pulley if you need to.

Make sure the SMOOTH side of the belt is on the Idler

Rotate the Top Fork and let it FLOAT over the Bottom Fork

Put the 400mm Belt back on the Pulley

Notice that the Top Fork is shifted forward relative to the Bottom Fork

While the Fork is shifted forward, put the 336mm GT2-Timing Belt on the Inner Pulley on the other side

Make sure the both Inner and Outer Belts are on ALL the Pulley Gears

Shift the Top Fork back and align the "Pulley Separating Wall"

Double check that the Picasso Gearbox Side is all good too

Once all Hex Standoffs are aligned too, Clamp the Top Fork down

Secure the Picasso Gearbox to the Top Fork by tightening the top screws on the Housing

Use M3x25mm Screws and M3x10mm screw to secure the Top Fork to the Bottom Fork

Prepare the following components:

[3D] - AS6147 Sensor Adapter 2

[3D] - 5Ac Fork Cable Clamp

AS5147 Sensor {right angle header on the label side}

6-pin Ribbon Cable M/O - Brown to Blue {sensor 5 Hand} - [1470mm]

6-pin Ribbon Cable F/O - Brown to Blue {sensor 4 Wrist} - [1520mm]

M2x6mm Screws (x8)

M3x10mm Screws (x4)

Connect the Hand Sensor Cable Extension to the Wires that comes out of the Picasso Box {Hand Sensor}

Mount AS5147 Sensor to the Sensor Adapter 2 using M2x6mm Screws

Insert the Wrist Sensor Cable {Female} through the Cable Clamp

Connect the Wrist Sensor Cable to AS5147 Sensor

If you don't remember the Connection Orientation from previous steps, just copy the picture.

Use M2x6mm Screws to secure the Sensor Adapter to the Fork

Organize the Cables on the Cable Clamp area

The Hand Sensor Connector is below the Wrist Sensor Cable

Use M3x10mm Screws to clamp the sensor cables with Fork Cable Clamp Plate

There's only one orientation that the Clamp Plate can go on,

Make sure the Version Label is facing the Cable

Chamfered Part is where the Cable comes Out

Prepare the following components:

[LSR] - Fork Acrylic Plates {Large & Small}

M2x6mm Screws (x8)

Small Acrylic Plate goes on the Sensor Side

Large one goes on the Wrist Gearbox Side

Secure them with M2x6mm Screws

Rotate the Motor Shafts on the Elbow Tail Side to rotate the joints

Align the Picasso Box to the Fork

Align the Fork to the Ulna Gearbox

Align the Hand to the Picasso Box.

Movement for all three joints should be smooth and without play in both directions.

Congratulation! You are nearly there!!!