3D Printed CAT 963K Track Loader w/Raspberry Pi Control

[RexRacer19]

This is my first construction equipment build. It is inspired by JDH429's awesome D10 3D printed build, SteinHDan's Raspberry Pi controlled projects, and my interest in track loaders in general.

I decided to go with the newest CAT 963K loader for this project. I have not seen any RC versions up to this point. The scale will be 1:14.

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/C10501126_zpsudppjxhi.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/C10501126_zpsudppjxhi.jpg.html)

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/C10319816_zpstjvrdaei.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/C10319816_zpstjvrdaei.jpg.html)

I am using Solidworks to do all of the 3D modeling for this project. A 2-view image was used to create a scale reference in the software. The image is scaled to the overall height of the 963K and then most dimensions, outlines, angles etc., can be pulled from that to create parts. It has worked really well so far.

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/963K%20Drawing_zpse1ied4ym.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/963K%20Drawing_zpse1ied4ym.jpg.html)

So far most of my time has been spent creating the solid models. I have the undercarriage mostly done, along with the tracks. The main frame/tub of the loader is still in basic form with a lot of the detail still needing to be added. The bucket and loader arm assembly is nearly done, with only a few details left to add. Here are some screenshots of the CAD work so far:

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/963K%204_zpsljpa7pxn.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/963K%204_zpsljpa7pxn.jpg.html)

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/963K%206_zpsazywrkbf.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/963K%206_zpsazywrkbf.jpg.html)

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/963K%205_zpspkf4grxr.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/963K%205_zpspkf4grxr.jpg.html)

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/963K%207_zpscco4gyis.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/963K%207_zpscco4gyis.jpg.html)

Progress has been a little slow in the last couple of weeks because of work, but hopefully I can get back on it and make some headway again soon.

[liftmys10]

Keep up the great work! That's my favorite machine!

[RexRacer19]

Was able to spend a little more time doing CAD this week. I was able to rough in the engine cover, rear grille, and the basic cab structure. The overall look is starting to shape up.

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/963K%209_zpsixqouyu1.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/963K%209_zpsixqouyu1.jpg.html)

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/963K%2010_zpszru7w5pw.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/963K%2010_zpszru7w5pw.jpg.html)

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/963K%2011_zpsedt2dxkz.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/963K%2011_zpsedt2dxkz.jpg.html)

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/963K%2013_zpsqrzbnrca.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/963K%2013_zpsqrzbnrca.jpg.html)

[egronvold]

Seems like a lot of hours spent in front of the computer. It will be exciting to follow this thread.

[SteinHDan]

Very nice CAD work!

Best regards,
Stein :-)

[RexRacer19]

Keep up the great work! That's my favorite machine!

Thank you.

Seems like a lot of hours spent in front of the computer. It will be exciting to follow this thread.

Yes it has been, and will continue to be. I think that putting in the time up front to develop a good CAD model will pay off when the build actually starts.

Very nice CAD work!



Thank you. Lots more to come.

[RexRacer19]

Made a little more progress...

I started adding some detail to the chassis tub up front and along the sides.

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/963K%2014_zpsqrkgagvo.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/963K%2014_zpsqrkgagvo.jpg.html)

I have also been finishing up the details on the undercarriage and designing the oscillating mechanism.

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/963K%2015_zpsjkxzkwmu.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/963K%2015_zpsjkxzkwmu.jpg.html)

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/963K%2016_zpsstwrf6xk.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/963K%2016_zpsstwrf6xk.jpg.html)

I think the undercarriage is almost to the point to where I can start printing parts for them. It will be nice to finally have some of this thing exist in the real world instead of just being virtual.

[Finster]

Looks great so far. Just curious are you going to print this yourself or send it to a 3d printing Co. like Shapeways?

[RexRacer19]

Thanks. I plan on printing it myself.

[D8R]

That will be a sweet model. Guess there are some hours put in behind the computer. What type of program are you using? Update, ignore that question, just read tread again and you said SW. Same program I used for the D8, now I have to change computer and will need a new program, SW to expensive :(
Will follow this closely, interesting with the 3D printed models. Do you have your own printer, if so what make?
1st real Caterpillar I owned was an HT4, it was very physical to drive with pedals, gearshifting and so. Those new machines looks much more driver friendly :)
/Dan

[RexRacer19]

Lots of hours. I should keep track, but I'm not sure I actually want to know. :) Good CAD software seems to always be expensive unless you have an older copy or something. I use Solidworks for my job, so I always have access. One program you might want to look into is Onshape. It is cloud based, so no need for software. There is a free version with limited models, and a subscription service with unlimited models.

I do have my own printer. I am using a Makerfarm Pegasus 10" printer. It is a rep-rap style printer with a 250mmx250mmx250mm print volume. I will post some pictures at some point in this thread.

[SteinHDan]

Another alternative is AutoDesk Fusion 360. Completely free for hobbyists and enthusiasts, but has all the bells and whistles, no limitations. That's what I'm using currently.

- http://www.autodesk.com/products/fusion-360/overview


Best regards,
Stein :-)

[doodlebug]

http://www.3ds.com/products-services/draftsight-cad-software/
Another free option, cheers!

[D8R]

Another alternative is AutoDesk Fusion 360. Completely free for hobbyists and enthusiasts, but has all the bells and whistles, no limitations. That's what I'm using currently.

- http://www.autodesk.com/products/fusion-360/overview


Best regards,
Stein :-)

Hi Stein, thanks for the link. maybee time to scrap the 2003? version of SW that I currently use. I know, when started using the SW, that it takes som time to be up and running again, will definitly look into this one.
Just to check hardware requirements.
/Dan

[Stefan]

Hi Jeff, I can only agree with the previous postings: Very fine CAD modelling. Do you intend to 3D print all parts or maybe have some of the load carrying parts/plates laser cut from metal for increased stability?
Stefan

[avel]

Will you be 3D printing the tracks?

[RexRacer19]

Hi Jeff, I can only agree with the previous postings: Very fine CAD modelling. Do you intend to 3D print all parts or maybe have some of the load carrying parts/plates laser cut from metal for increased stability?
Stefan

Thank you. I am planning on printing as much as possible. I am trying to design extra strength into the load bearing areas of the chassis and moving components. Hopefully it works out well, but there is always the option of making some things from metal if needed.

Will you be 3D printing the tracks?

Yes. I have done some test prints of tracks already to test the clevis pin links that I intend to use, and they seem to work ok.

[Kausekaos]

Sweet, can't wait to see the finished product.

[RexRacer19]

Spent a little more time modeling in some details. Also, I started working on some motor mounts. I plan to use Pololu 25D motors for motivation so I have been designing the mounting system based around those.

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/963K%2020_zpsw56i7zv1.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/963K%2020_zpsw56i7zv1.jpg.html)

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/963K%2018_zps77tncsih.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/963K%2018_zps77tncsih.jpg.html)

The mounts are integrated into the main chassis tub to tie everything together for strength. There are caps that get bonded to the bottom to cover the exposed part of the motor, and the end mounts get screwed and pinned to the main chassis. I think it should all be pretty solid.

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/963K%2019_zpstvssklcm.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/963K%2019_zpstvssklcm.jpg.html)

I designed a fan shroud that works with a 60mm computer fan to help keep things cool inside and provide for additional scale looks.

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/963K%2017_zpsn7wtvkkd.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/963K%2017_zpsn7wtvkkd.jpg.html)

The hydraulic cylinder specs were finalized, and I sent some drawings off to Magom to see if they will be able to make the cylinders to my specs. I sent them an email on Sunday, but haven't heard back yet. Hopefully soon...

[RexRacer19]

I made some progress over the holiday weekend and actually started printing a few parts. Since 76 are going to be required, I started off with some track link/pads.

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/IMG_3242_zpsuzexaivi.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/IMG_3242_zpsuzexaivi.jpg.html)

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/IMG_3241_zpsxbjp8ls7.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/IMG_3241_zpsxbjp8ls7.jpg.html)

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/IMG_3240_zpshxycjzy1.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/IMG_3240_zpshxycjzy1.jpg.html)


I am happy with how they are turning out. they will need a little bit of finishing work before painting, but they link together well and work with the 3/16" clevis pins I chose to use.

I also printed the outer part of the motor mounts. These came out nice, and fit the motors well. They seem to be plenty strong, too.

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/IMG_3244_zpsqrjvknfr.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/IMG_3244_zpsqrjvknfr.jpg.html)

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/IMG_3243_zpsoocilhxh.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/IMG_3243_zpsoocilhxh.jpg.html)

[Trucker_Jo]

I'm excited to see some parts printed up, everything looks killer! Yet another build thread that threatens me to sell some toys to buy another one~ A printer of course.

[RexRacer19]

Managed to get a few more parts printed and some hardware ordered. I now have over half the tracks printed (38 per side) and the hardware to link them together.

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/IMG_3263_zps6dzvvjpq.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/IMG_3263_zps6dzvvjpq.jpg.html)


The front idlers are printed also. I chose to print them in halves to make it easier to get the concave dish to print well. 2mm dowel pins are used for alignment and then they are bonded together with acetone.

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/IMG_3252_zpsh37b9ppf.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/IMG_3252_zpsh37b9ppf.jpg.html)

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/IMG_3253_zpslec28nuy.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/IMG_3253_zpslec28nuy.jpg.html)

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/IMG_3254_zpsmdfidlco.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/IMG_3254_zpsmdfidlco.jpg.html)


The drive sprockets were also printed. They bolted up to the motor hubs perfectly, and line up well with the tracks. There is a dummy planetary unit that will hide the screws and provide a more scale appearance.

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/IMG_3264_zpszga4fgdg.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/IMG_3264_zpszga4fgdg.jpg.html)

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/IMG_3266_zpsbkzta1ic.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/IMG_3266_zpsbkzta1ic.jpg.html)


I was also able to finalize my cylinder designs and get an order placed with Magom for the hydraulic system. I am looking forward to getting that stuff in so I can finalize my main chassis design.

[RCP57]

Great job!

[Manfred]

It looks great. :jaw:

Manfred

[Trackerman]

Rexracer 19,
Can you post a link to where you bought the 3/16 grooved Clevis pins please. Followed the link over on the D10b3d print build but they do not seem to have them any more. Appreciate any help locating the hardware and with you sharing the build.

Cheers

Trackerman. :bounce:

[RexRacer19]

No problem. I picked mine up from McMaster-Carr. "Grooved Clevis Pin w/Retaining Ring"

http://www.mcmaster.com/#clevis-pins/=14p669l

[Trackerman]

RexRacer19,
Thank you for the link for the Clevis pins. Printing the track segments, what side did you have facing down on the print bed? Really interesting build, keep it up and thanks for sharing.

Cheers

Trackerman. :popcorn:

[RexRacer19]

No problem, Trackerman. It took me a fair amount of trial and error to find a way of printing the tracks that made me happy. I ended up designing some "ears" on the outside that provided a footing that stuck to the print bed and was able to be broken away cleanly after printing. There is also some support that goes under the pads and center section. The pic shows the print orientation on the left and what the support and ears look like on the right.

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/45FFCF63-5751-46F1-A7F8-76EA1036E6D6_zpsdr8o4fgf.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/45FFCF63-5751-46F1-A7F8-76EA1036E6D6_zpsdr8o4fgf.jpg.html)

[Trackerman]

Rexracer 19,
Nice solution for supporting the printed part. Thank you.

Cheers

Trackerman

[Machfab]

No problem, Trackerman. It took me a fair amount of trial and error to find a way of printing the tracks that made me happy. I ended up designing some "ears" on the outside that provided a footing that stuck to the print bed and was able to be broken away cleanly after printing. There is also some support that goes under the pads and center section. The pic shows the print orientation on the left and what the support and ears look like on the right.

http://i746.photobucket.com/albums/xx109/RexRacer19/CAT%20963K/45FFCF63-5751-46F1-A7F8-76EA1036E6D6_zpsdr8o4fgf.jpg (http://s746.photobucket.com/user/RexRacer19/media/CAT%20963K/45FFCF63-5751-46F1-A7F8-76EA1036E6D6_zpsdr8o4fgf.jpg.html)

Do you have the supports "necked down" where they meet the bottom of the track pad for easy removal? Are you cutting supports for removal or do they break away? How long is the cycle time for printing? Nice Work!!

[RexRacer19]

The supports, other than the triangular pieces at the end of the track pads, are generated by my 3D Printing software. The way support structures typically work, is that the printer will skip a layer or two (user controlled) between the top of the support and the first layer of the structure that sits on top of them. That way the top of the support has a little time to cool, and the next layer is not "pressed" into the support layer below it because of the gap of the missing layer. This forms a weak bond which makes the support easier to break away. It all works pretty well, but the part does require at least a little bit of sanding/filing to clean up some scars at the interface.

I have been printing my tracks two at a time, and it takes one hour for the pair. I could print more at a time, but I was concerned that the extra time between layers would allow too much cooling and reduce the bond strength between layers. These parts will likely see the most stress over anything else on the loader, so I want them as strong as the printer can make them.

[Machfab]

What is your material of choice for printing these parts? ABS?

[RexRacer19]

I'm using ABS for most everything. It is easy to work with and can be strengthened and bonded with acetone. I am tempted to try some carbon fiber impregnated filament for the lift arms and front bucket pivot arm to see if they might be a little stronger.

[Hofabooz]

Hi

What can I say great work this is the direction I wish to go with my 3D printer and CAD.

thanks for sharing

[JDH429]

Looking good, any updates?

[RexRacer19]

Thank you. This project had to be put on hold for a while. Hopefully I will be able to pick back up on it in a few months.