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IED Unit 3 • Lesson 3.4

Rover Assembly: As-Built Joints

Focus question: How can we make an already-positioned rover function using rigid and revolute As-Built Joints?

Your lesson guide

Objective

Explain the difference between a Joint and an As-Built Joint. Identify and build every fixed and rotating relationship in the rover chassis, suspension, wheels, arm and gripper. Ground the fixed frame and create As-Built Joints without repositioning parts.

Materials

For the online work: a browser and your engineering notebook. Follow the activity’s materials list for any physical build, and get teacher approval before using equipment.

Plan your time

Suggested work block: 45–60 minutes. Physical builds and projects may span several classes; follow your teacher’s schedule.

Unit 3 Learning Studio • Lesson 3.4

Understand, visualize, and apply the concept

Concept

As-Built Joint

Applies a mechanical relationship to components that are already in their correct locations. It defines motion without moving the parts into alignment.

Decision

Rigid or revolute?

Use Rigid when two parts must move as one. Use Revolute when one part must rotate around a specified axle or pivot axis.

Proof

A functional rover

  • Stationary chassis or frame grounded.
  • Fixed brackets and supports attached correctly.
  • All intended wheels rotate around the correct axis; nothing else drifts or detaches.
  • Joint limits stop suspension and arm mechanisms before they move through parts or beyond their mechanical range.
01 / Real rover reference

Identify the components in your actual Fusion rover

These names were recovered from Rover Assembly Practice.f3d, the instructor's supplied model. Fusion may append occurrence numbers (for example, Wheel:1) to repeated components. Do not rename parts until you understand the assembly structure.

Actual 3D Fusion rover assembly: six knobby wheels with red gear motors, blue suspension frame and linkages, gray payload box, and an articulated arm with gripper
Preview extracted from the exact teacher-supplied .f3d model, not a generic example.
Component names from fileLikely role in joint plan
Base BodyPrimary frame reference; ground the stationary base component.
Wheel (six visible)Revolute at each wheel hub; six independent wheel-rotation checks.
MotorMotor housing is rigid to its mounting leg or bracket; wheel rotates relative to the support.
Rear Legs, Rear Legs 2, Leg ShaftSuspension support and shaft parts. Determine which connections are rigid and which form real pivots before adding a joint.
Payload BoxRigid to its intended frame mount.
Arm Base, Arm, Gripper WristArticulated arm subsystem; identify pivot axes for the optional extension.
GripperMechanism, Servo MG966R_Predeterminado, holder and small hardwareAdditional gripper and servo parts; keep fixed housings rigid and identify only genuinely articulated mechanisms as pivots.

Important distinction: Component names and six wheels are confirmed from the provided archive and preview. The design names identify the parts, while pivot origins and clearance-limited angles must be established in Fusion using the procedures in this lesson.

02 / Fusion command reference

As-Built Joint — when parts are already in position

Official Autodesk walkthrough

Use Design → Solid → Assemble → As-Built Joint. Select two existing components. For wheels, choose Revolute, identify the hub center and orient the rotation axis down the axle. For fixed mounts, choose Rigid.

Autodesk: Create an As-Built Joint ↗

Use Preview Motion before accepting and Animate Joint from the Joints folder for verification. For joints with physical stops, also use Edit Motion Limits to define allowable minimum and maximum positions.

Joint types and motion

Rigid: zero movement between parts. Revolute: rotation about one chosen axis. A rigid motor housing can support a revolute wheel without becoming a moving body itself.

Autodesk: Joint Relationships Tutorial ↗

Do not substitute Move, Align, standard Joint or a rigid group for the required As-Built Joint demonstrations.

03 / Exact assembly work order

Build the rover one subsystem at a time

Starting condition: every component is already positioned. Each student opens Rover Assembly Practice.f3d, saves their own copy and creates As-Built Joints—not standard Joints, Move commands or new geometry. Expand the relevant component in the Browser and use Select in Canvas to distinguish repeated occurrences.

Stage A — Frame and payload

  1. Ground Base Body. This is the stationary reference. Right-click its top-level occurrence and choose Ground. Never ground a wheel, leg or arm.
  2. Payload Box → Base Body: Create a Rigid As-Built Joint at the frame where the gray electronics box is mounted. Test: selecting and dragging the box must not move it separately from the chassis.
  3. ELECTRIC BOX DHAKNA → Payload Box: Create a Rigid As-Built Joint for the gray box cover. Test: the lid cannot move relative to the box.

Stage B — Suspension and leg shafts

  1. Leg Shaft → Base Body: Use a Revolute As-Built Joint at the blue upright suspension pivot. Put the origin at the center of the cylindrical shaft; align the revolute axis along the shaft, not across the leg.
  2. Rear Legs → their matching Leg Shaft: Create a Rigid As-Built Joint at the shaft-to-leg attachment. The leg and shaft form one rotating support; the shaft pivots relative to the chassis.
  3. Rear Legs 2 → their matching Leg Shaft: Repeat the Rigid As-Built Joint for the second rear-leg structure. Use the occurrence that occupies the same side and pivot as the leg being constrained.
  4. Motion limit on each leg-to-chassis Revolute: Set a minimum and maximum that keep the blue leg links from passing through the chassis or adjacent rods. Follow the limit-measurement procedure below; record the two resulting angles.

Selection rule: for repeated leg and shaft occurrences, first hide and show the specific part in the Browser. Join the components at the same physical pivot, never arbitrary identically named occurrences.

Stage C — All six drive wheels and motors

Label the wheels by their positions: left-front (LF), left-middle (LM), left-rear (LR), right-front (RF), right-middle (RM), right-rear (RR). Treat the gripper end as the rover's front.

Wheel positionRequired As-Built Joints
LFMotor housing to matching blue leg mount: Rigid. Wheel to its matching motor output/axle support: Revolute centered on the wheel hub.
LMMotor housing to matching blue leg mount: Rigid. Wheel to its matching motor output/axle support: Revolute centered on the wheel hub.
LRMotor housing to matching blue leg mount: Rigid. Wheel to its matching motor output/axle support: Revolute centered on the wheel hub.
RFMotor housing to matching blue leg mount: Rigid. Wheel to its matching motor output/axle support: Revolute centered on the wheel hub.
RMMotor housing to matching blue leg mount: Rigid. Wheel to its matching motor output/axle support: Revolute centered on the wheel hub.
RRMotor housing to matching blue leg mount: Rigid. Wheel to its matching motor output/axle support: Revolute centered on the wheel hub.

Test each wheel separately: Drive/Animate its revolute joint one complete revolution. The wheel must spin without wobbling, separating from its shaft or moving the red motor housing. Do not add angular limits to these six continuously rotating wheel joints.

Stage D — Rover arm and wrist

  1. Arm Base → front chassis support (Base Body): Create a Revolute As-Built Joint centered on the arm's mounting pivot. This controls the first arm rotation.
  2. Arm → Arm Base: Create a Revolute As-Built Joint at the shoulder hinge joining the two arm sections. Rotate about the pin/cylinder axis, not the arm's long dimension.
  3. Gripper Wrist → Arm: Create a Revolute As-Built Joint at the cylindrical wrist connection. The end effector should turn without separating from the arm.
  4. Limits: Set and test min/max motion limits for the base pivot, shoulder and wrist. Do not permit the arm to rotate into the chassis or the gripper assembly to pass through a neighboring part.

Some of these named parts are nested within imported subassemblies. Make the joints between the matching physical components, not between the overall assembly folder and a small part.

Stage E — Gripper and servo: required

  1. Gripper Motor Cup → Gripper Wrist: Make a Rigid As-Built Joint between the mounting cup and the wrist.
  2. Servo MG966R_Predeterminado → Gripper Motor Cup: Make a Rigid As-Built Joint between the servo housing and its cup. The servo case must not rotate or fall out during wrist motion.
  3. holder → gripper Base: Make a Rigid As-Built Joint that holds the servo's fixed bracket to the stationary gripper base.
  4. Gripper Base → Gripper Wrist: Make a Rigid As-Built Joint so the gripper's fixed structure follows the wrist.
  5. GripperMechanism → gripper Base: Make a Revolute As-Built Joint at the mechanism hinge or servo output pivot. This is the movable grasping mechanism, not the stationary servo housing.
  6. gripper → GripperMechanism: Make a Rigid As-Built Joint so the gripper geometry follows the moving mechanism. Treat the supplied gripper as one tool component; this activity does not require remodeling it into independently actuated fingers.
  7. Set gripper motion limits: Adjust the mechanism's minimum and maximum until the moving gripper stops at the closed and open positions without passing through its fixed base.

Required final tests

  1. Frame: the grounded Base Body, electronics box and cover remain fixed.
  2. Suspension: each leg pivot moves within its defined range and stops before interference.
  3. Wheels: LF, LM, LR, RF, RM and RR each make one full revolution about their own hub.
  4. Arm: base, shoulder and wrist rotate about their intended axes and stop at both limits.
  5. Gripper: servo and mounting parts remain rigid while GripperMechanism moves within its opening/closing limits.
  6. Whole model: use Animate Joint Relationships to confirm that moving one joint does not pull apart or move unrelated components.

Do not submit an assembly that only looks correctly positioned. A screenshot alone does not prove that components are connected or that the motion is constrained.

Teacher design note: These joint pairs define the required classroom motion model based on the named components and preview in the supplied Fusion archive. The archive does not provide tested pivot axes, collision-free end angles or independent gripper-finger components. Students establish each exact origin from its cylindrical hardware and determine the safe range using the measured limit protocol below.

04 / Physical motion limits

Measure safe motion — do not guess joint angles

Why: A revolute joint controls the axis of rotation. A minimum and maximum Motion Limit prevent the joint from moving outside its allowed range. Wheels are continuously rotating and need no angular stop; suspension pivots, arm hinges and the gripper have bounded travel. Autodesk Fusion does not automatically detect all collisions when limits are set.

One required procedure for every bounded revolute joint

  1. Finish the joint. Right-click it in the Joints folder and select Drive Joints. Return the model to its supplied starting orientation (home position).
  2. Beginning at the home angle, move in 5° steps in the positive direction. At each step visually inspect the moving part and use Inspect → Interference on the relevant neighboring parts when clearance is uncertain.
  3. At the first position that passes through another solid or violates a physical stop, return to the previous clear 5° increment. Record that as your Maximum.
  4. Return home. Repeat in −5° steps to find the Minimum. The home orientation is 0° unless you deliberately changed its joint reference.
  5. Right-click the joint → Edit Motion Limits; enable Minimum and Maximum, and enter the two measured angles. If no collision is reached in the tested range, stop the investigation at ±45° for the arm joints and ±30° for suspension joints and use those values as classroom planning caps, not as measured mechanical stops.
  6. Use Drive Joints and Animate Joint Relationships to test the minimum, home and maximum settings; record all three. If any component collides at a limit, reduce that limit by another 5° and repeat.

Joint limit records (required)

Moving connectionLimit requirement
Leg Shaft / Base Body pivotsMeasured ± range; investigate to 30° in each direction
Arm Base / chassisMeasured ± range; investigate to 45° in each direction
Arm / Arm BaseMeasured ± range; investigate to 45° in each direction
Gripper Wrist / ArmMeasured ± range; investigate to 45° in each direction
GripperMechanism / gripper BaseDetermine closed and open endpoints from physical interference; cap search at 45° each way
Six Wheel revolutesUnlimited 360° rotation — no Min or Max
Rigid joints (motors, box, cover, hardware)No limits — relative motion is already locked

For each limited joint, record: name, Minimum, Maximum, and one sentence explaining which physical obstruction would prevent further travel.

Critical distinction: ±30° and ±45° are maximum search envelopes for this lesson, not verified joint capabilities of the uploaded rover. Real collisions or stops always take priority; students must stop earlier if needed.

Autodesk: Joint Motion Limits ↗
05 / Check for understanding

Decide which relationship is correct

Joint type explorer

Imagine two parts are already in the right place. Select the relationship needed between them.

Before you leave

Why use As-Built instead of a regular Joint here?

The rover components are already in the correct locations. An As-Built Joint adds the motion relationship without repositioning them.

What needs to be grounded?

The stationary chassis or frame that serves as the assembly reference—not the freely rotating wheels.

How do you know the assembly works?

Every intended rotating part turns about its correct axis; fixed hardware remains connected; the grounded frame does not drift; bounded joints stop at realistic endpoints.

Should wheel joints have minimum and maximum rotation limits?

Not when the wheels must rotate continuously. Limits belong on mechanisms with physical end stops, such as some suspension and arm pivots.

Do joint limits automatically prevent every collision?

No. A limit controls the range of one joint. Check real part clearance throughout the permitted motion.

Lesson Overview

What You Are Learning

Learning Targets

  • Explain the difference between a Joint and an As-Built Joint.
  • Identify and build every fixed and rotating relationship in the rover chassis, suspension, wheels, arm and gripper.
  • Ground the fixed frame and create As-Built Joints without repositioning parts.
  • Measure and set motion limits on suspension, arm and gripper joints; leave continuously rotating wheels unlimited.
  • Verify all six wheels, each suspension pivot, arm motion and gripper opening/closing.

Unit 3 Progression

Apply earlier work with joint types and limits to a realistic rover assembly, then inspect the mechanism before moving to the rocket design project.

RigidRevoluteAs-BuiltGroundLimitsAnimateVerify
Individual Fusion Assignment · 40 Points

3.4 — Complete the Entire Rover Assembly

Starting file: Rover Assembly Practice.f3d. Use your instructor's already-positioned rover. Your work is to complete its joint relationships and prove physically realistic motion. Do not remodel, translate or rearrange the original components.

Required checklist — complete every subsystem

  1. Chassis and payload: Ground Base Body. Rigid-connect Payload Box and ELECTRIC BOX DHAKNA to their corresponding mounts.
  2. Suspension: Create revolute joints where Leg Shaft turns relative to the chassis; connect Rear Legs and Rear Legs 2 rigidly to their matching rotating shafts. Measure and enter physical travel limits.
  3. All six motors and wheels: Secure each motor housing rigidly to the corresponding leg. Add six correctly aligned wheel revolute joints—LF, LM, LR, RF, RM, RR—and drive every wheel a full 360° without angular limits.
  4. Arm: Revolute-connect Arm Base, Arm and Gripper Wrist at their physical axes; set and test min/max travel limits.
  5. Gripper: Rigid-connect Gripper Motor Cup, Servo MG966R_Predeterminado, holder and gripper Base to their specified supports. Create the GripperMechanism revolute joint and attach the named gripper component rigidly to that mechanism. Test open and closed limits.
  6. Complete verification: Check every joint in the Browser; drive the six wheels, suspension, arm and gripper; confirm all specified limits and no accidental translation or loose components.

Grading rubric · 40 points

  • 5 points — intact original model, grounded chassis, payload and cover rigid joints.
  • 7 points — suspension, leg and shaft joint relationships, including appropriate limits.
  • 12 points — all six motors rigidly mounted and six correctly centered wheel revolute joints (2 points per wheel station).
  • 6 points — arm base, shoulder and wrist motion with realistic limits.
  • 5 points — gripper motor cup, servo, holder, base, mechanism and gripper joint relationships with opening/closing limits.
  • 5 points — full-motion verification, documented limit values and complete evidence.

Recommended pacing: 3–4 class meetings. Stage A–C first, followed by arm/gripper work and final verification. All listed systems are required—there is no optional or unfinished gripper section.

Submission

What to Submit

Upload each item to the IED Lesson 3.4 Google Classroom assignment:

  1. Completed Fusion model (.f3d): LastName_FirstName_3_4_Rover.f3d with the complete chassis, suspension, motor/wheel, arm and gripper As-Built Joints.
  2. Joint and limit report (.pdf): LastName_FirstName_3_4_JointReport.pdf containing six labeled screenshots: (1) full rover with Joints folder, (2) chassis/payload rigid joint, (3) wheel revolute axis and motor mount, (4) suspension pivot and its min/max limits, (5) shoulder/wrist revolute joint and its min/max limits, and (6) gripper mechanism joint and its open/closed limits. Include a table listing each limited joint's Minimum, Maximum and what prevented further travel.
  3. Motion recording (.mp4, 30–60 seconds): LastName_FirstName_3_4_RoverMotion.mp4 demonstrating at least three different wheel stations (one each from front/middle/rear), suspension travel, arm base/shoulder/wrist movement, and the gripper opening/closing. Test all six wheels separately even though only three need to appear in the recording.
  4. Three-sentence engineering explanation: Explain (1) why As-Built Joints are appropriate for this positioned model, (2) why wheels have Revolute joints but motor housings have Rigid joints, and (3) how your measured limits stop the suspension, arm or gripper from moving through other components.

Grade standard: The complete rover must be correctly constrained and mechanically plausible. Leaving arm or gripper parts unjoined does not satisfy the requirements.

Resources

Lesson Resources

Unit Hub

IED Unit 3

Return to the Unit 3 lesson map and project sequence.

Course Hub

Introduction to Engineering Design

Return to the IED course hub.

Build your lesson report

Checkpoint: is your evidence ready?
  • Check calculations, units, labels, and measurements against the activity requirements.
  • Record what actually happened, including unexpected results.
  • Explain what you changed and why; attach required drawings, photos, CAD, or code in your classroom assignment.

Upload each item to the IED Lesson 3.4 Google Classroom assignment: Completed Fusion model (.f3d): LastName_FirstName_3_4_Rover.f3d with the complete chassis, suspension, motor/wheel, arm and gripper As-Built Joints. Joint and limit report (.pdf): LastName_FirstName_3_4_JointReport.pdf containing six labeled screenshots: (1) full rover with Joints folder, (2) chassis/payload rigid joint, (3) wheel revolute axis and motor mount, (4) suspension pivot and its min/max limits, (5) shoulder/wrist revolute joint and its min/max limits, and (6) gripper

A PDF download is not a submission. Review it, then upload it and any required attachments through your classroom assignment system.

IED Unit 3 · Lesson 3.4 — Rover Assembly: As-Built Joints

Name: __________________________ Period: ______ Date: __________

Real file: Rover Assembly Practice.f3d • Six wheel revolute joints required.

Mark one fixed and one moving component

Why use As-Built Joints on the already-positioned rover?

Which components need joint limits to prevent impossible motion, and why?

Before submitting:

Fusion (.f3d), six labeled screenshots and limit table (.pdf), 30–60-second motion recording (.mp4), and three-sentence explanation.