Very nice job! It’s great to see a design approach where the bumper interfaces are so thoughtfully considered.
I wanted to quickly comment about a design tradeoff inherent in how this corner is constructed:
First of all:
- Plenty of teams do it the way you have currently designed it, and it’s perfectly valid to proceed like this!
- What’s great about your current design is that it’s very easy to support the bumper, because you are free to extend the ladder bar all the way to the frame perimeter.
If you look at the drive rail as a free body, there is a force couple on it [a torque equal to (half the weight of the robot) * (the wheel cantilever distance) ] that is totally reacted by both in- and out-of-plane loads on the gusset plates.
Alternatively, if you were to use construction method {B}, then this couple could be reacted by bearing between the faces of the tubes as well as by the gusset plates. Team 610 has some great historical examples of doing perpendicular tube joinery using this principle.
