2016 Bosch motor 6004 RA3 194-06

[kprzewodek]

Originally Posted by Bennett548

Have you tried drilling out the star pattern at 3/8" and broaching a key or a 3/8" hex?

This motor seems like a good choice when you would like to use a hobby servo motor, but need much more power (and have a home position sensor). The biggest issue I see with this motor is that it can't support any load on the output. In FRC we love to abuse our motors and gearboxes by hanging way too much weight on them.

Do you know if these will be available from AndyMark after First Choice is over?

I do have a 3/8" rotary broach and may give that a try. I think it might take too much of the wall out though.

You definitely need to mount this to a completely supported shaft since that acts as the output and second support. If you use the motor to support the shaft then you will most likely have problems.

We decided to offer in limited amounts to get a feel if teams will use them. If there is enough demand then we may be able to consider another order. This is a high volume production motor so it's fairly easy to order more if needed.

[HumblePie]

We received our first 2 motors yesterday. It looks like the internal star pattern will also accept a 6mm square key (I measured 6.05mm). Oversized key stock (+0/+0.08 tolerance) will probably fit nicely (in stock at McMaster-Carr). I'm also thinking about modifying a 1/4" bore AndyMark hub to accept the 6mm square. Thoughts?

[MrForbes]

The reason I suggested putting a wrench on the output of this motor, is because of the speed at which it rotates. There really isn't much use for a shaft, is there?

[kprzewodek]

As long as what you are driving is fully supported there really isn't much need for a shaft I guess.

[kprzewodek]

Seems like broaching a 3/8" hex still leaves some meat on the gear. Think I'll try and see how it holds up.

[HumblePie]

I laid out one concept for packaging this motor that would fully support the load by sandwiching 2 mounting plates around (1 or 2) piece(s) of 1" square tube. The motor has only one (slotted) mounting hole, so I added a bore to locate on one of the motor bosses and provide some "clocking" of the motor. The drive shaft is a piece of 1/2" hex milled down to a 6mm square on one end. Another option would be to use a 3/8" hex all the way, so I'm curious to see Kevin's results on broaching the motor out to a 3/8" hex.

If there's interest, I'd happily share the CAD file. I got one quote online for waterjet cutting the plates, and it looks like about $100 to make 10 pieces.

[topgun]

I am interested in the CAD file. SolidWorks format hopefully.

[kprzewodek]

That's a nice robust design. I'll experiment over the weekend with broaching a hex and see how it goes.

For a less robust way of doing it I've had success 3D printing a hub inside two plates that you can mount an arm. Simplifies a bit in that you can eliminate bearings.

[HumblePie]

Originally Posted by topgun

I am interested in the CAD file. SolidWorks format hopefully.

Well, let's give it a shot.....

I modified the original plate to better serve as a corner gusset if you should choose to use it that way.

I then saved the Solidworks file as a Parasolid and zipped it. The link (to get around the 5MB limit) is here:

https://app.box.com/s/lcv76duqngz2pukh9qdnlgqz7i5hlqq1

Let me know what you think, and Merry Xmas to all......

[kprzewodek]

I was able to broach a 3/8" hex and it appears to work quite well. I haven't put the motor through FRC type durability testing yet but so far that seems to be a good option.

Actually the rotary broach that I have goes about 3/4 of the way through the gear however I was able to carefully tap a hex shaft the remaining distance by making sure the gear was supported.

For those on the fence about investing in a linear or rotary broach I would highly recommend as we have used several times over the years. The nice thing about a rotary broach is that the main investment is the tool holder (~$300) and then you can add a wide range of cutting inserts for around $40 a piece.

[D.gimon]

Hi Kevin,

Seeing as you work for Bosch, is there a source for connectors for last year's Bosch donated spindle motor (PN 6 004 RA3 353-01) which also has Hall signal pins? Looking at the provided PDFs, the motor connectors look very similar.
Can you confirm that the harness will work on both motors?

Thanks,
Dan

[kprzewodek]

It's the same connector. I can send you some if you PM me your address.