47a8b40fdb
TREE(74): training modules, entity profiles, 2890 references, keyword indices SPROUT(42): knowledge pages, project docs, curated source material SEED(164): daily notes, raw session logs, unprocessed material Updated AUDIT_MANIFEST.json with growth classifications.
98 lines
3.8 KiB
Markdown
98 lines
3.8 KiB
Markdown
---
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title: "REV ION Build System — Team 2890 Structure"
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tags:
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- hardware
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- structure
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- extrusion
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- REV
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- 2890
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- ion
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type: hardware-spec
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owner: 2890
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status: active
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sources:
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- "https://docs.revrobotics.com/ion-build"
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- "https://docs.revrobotics.com/ion-build/structure/extrusion"
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growth: tree
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---
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# REV ION Build System — Structure & Extrusion
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## Overview
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Team 2890 uses the **REV ION Build System** as their primary mechanical structure system. ION is designed to enable rapid iteration and reconfiguration without large budgets or extensive manufacturing resources. The system is built around the **MAXSpline** — a unique spline shape that combines bearing support with torque transfer.
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## Core Concepts
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### MAXSpline
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The MAXSpline is the foundation of the ION system. It appears in:
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- MAX Hubs (for bearing and sprocket mounting)
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- Live axle applications
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- Motion components (linear slides, rotations)
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The shape allows bearing support and torque transfer to be combined in a single feature — making mechanisms more compact.
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### MAX Pattern
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The MAX Pattern combines:
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- **#10 clearance holes** in a 1/2" pitch grid
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- **MAXSpline bore** every 2" down the length
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This pattern enables:
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- Easy bearing mounting with correct center-to-center distances
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- 1:1 power transmission with #25 chain or RT25 belting
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- Rapid prototyping with standard #10 hardware
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### Grid Pattern
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Some MAXTube features **three rows of #10 holes** on a 1/2" pitch grid. This is ideal for rapidly building structures with 1in brackets.
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## MAXTube Extrusions
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MAXTube is aluminum 6061 extrusion. Available sizes:
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| Size | Pattern | Length | Nut Groove |
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|------|---------|--------|------------|
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| 1/2 × 1/2 in | Grid | 47in | No |
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| 1 × 1 in | Grid | 47in | Yes |
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| 1 × 1 in (1/16" wall) | Grid | 47in | No |
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| 1 × 1 in (1/8" wall) | Grid | 47in | No |
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| 2 × 1 in Light | No Pattern / Grid | 47in | Yes |
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| 2 × 1 in | No Pattern / Grid / MAX | 3–47in | Yes |
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| 2 × 2 in | Grid / MAX / MAX+Grid | 47in | No |
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**Nut groove note:** On 1in sides, the nut groove holds #10 nuts in place where a wrench can't reach. Use **2×1 Standard** for secure bearing fit; **2×1 Light** where weight is critical.
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## 1in Extrusion (REV-21-1000)
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4-sided slot extrusion accepting standard #10 hardware including low-profile nylock nuts. No T-nut needed — slide #10 hex head through slot, adjust as needed. Can be tapped 10-32 for permanent mounting.
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Good for builds that don't fit the standard pitch patterns.
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## MAXSpline Bore Spacing
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For proper chain alignment: center-to-center distances are set for simple 1:1 #25 chain transmission. The MAX Pattern bore spacing every 2in makes this straightforward.
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## Connection to Training
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**For students:** The ION system replaces custom machining. Understanding:
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- **Why standardized patterns matter** — interchangeable parts, no custom drilling
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- **MAXSpline as a system** — one spline shape across multiple components (hubs, bearings, motion)
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- **Nut grooves eliminate blind assembly problems** — you can hold the nut while fastening
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- **Pitch grid = predictable spacing** — 1/2in pitch means you always know where holes line up
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**Related training modules:**
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- [[swerving-modules]] — MK4i mounts to this structure
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- [[motor-basics]] — how motors mount to structural extrusions
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- [[frc-mechanical-basics]] — understanding structural systems
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## Source Links
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- ION Build overview: https://docs.revrobotics.com/ion-build
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- Extrusion guide: https://docs.revrobotics.com/ion-build/structure/extrusion
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- Product catalog: https://www.revrobotics.com/ion-system/
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## Notes
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Chris and team use this as their standard build system. The compatibility between ION mechanical and ION electrical (SPARK Flex, NEO Vortex) means the whole robot — structure, drivetrain, and motor control — uses one integrated system. |