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Overview

The Brushless Actuator Module Core v1.1 is an updated version of the core v1 module that uses the “Plug & Play” ODRI Encoder Kit from PWB Encoders GmbH. This eliminates the need for custom machining of pulleys and motor shafts, significantly simplifying the build process.
Key Advantage: The ODRI Encoder Kit includes all machined parts pre-assembled, eliminating interaction with machine shops and reducing preparation time.

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Key Specifications

Weight

150g total assembly

Torque Output

2.5 Nm @ 12A

Segment Length

160mm

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What’s New in v1.1

The v1.1 module maintains the same core functionality and performance as v1.0 but simplifies the sourcing and assembly process:
1

ODRI Encoder Kit

Pre-assembled motor shaft unit with high-resolution code wheel, center pulley, and modified encoder head available as an off-the-shelf product.Kit Contents:
  • Fully prepared motor shaft assembly
  • Center pulley (Aluminum 7075)
  • Broadcom AEDT-9810-Z00 encoder head
  • Total kit weight: 11g
2

Simplified Assembly

All motor shaft preparation steps are pre-completed, eliminating:
  • Custom machining coordination with machine shops
  • Motor shaft preparation procedures
  • Codewheel mounting and alignment
  • Pulley installation on motor shaft
3

Identical Performance

Functionally equivalent to self-made assemblies - components are compatible and interchangeable between v1.0 and v1.1.
If you want to machine parts yourself or already have machining capabilities, refer to the Actuator Module Core v1 documentation.

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ODRI Encoder Kit

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Kit Description

ODRI Encoder Kit Components The ODRI Encoder Kit (Order #109381) from PWB Encoders GmbH includes:

Motor Shaft Assembly

Complete motor shaft with bearings, motor pulley, and codewheel mounted and alignedWeight: 4.6g

Center Pulley

Precision-machined aluminum 7075 center pulley with AT3 tooth profile10 teeth, custom profile

Encoder Head

Broadcom AEDT-9810-Z00 optical encoder with 5000 cpr resolutionPre-tested and verified

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Ordering Information

Send an email to [email protected] requesting a quote for the ODRI Encoder Kit v1.0 (Order #109381). PWB ships worldwide.

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Core Components

The v1.1 module uses identical core components to v1.0, with only the encoder and machined parts sourcing changed.
Core components weight: 95g (excluding shell structure)

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Component Overview

All specifications match the v1.0 module:
  • Transmission: Dual-stage timing belt system with 9:1 total reduction (3:1 per stage)
  • Motor: T-Motor Antigravity 4004 300kV (53g)
  • Encoder: Broadcom AEDT-9810-Z00 with 5000 cpr (included in ODRI Kit)
  • Timing Belts: Conti Synchroflex AT3 GEN III (4.5g total)
  • Bearings: EZO stainless steel miniature bearings (16g total)
  • Fasteners: Various M3 screws and helical inserts (2.9g)
See Actuator Module Core v1 for detailed component specifications.

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3D Printed Parts

Total weight: 11g
Use stereolithography (SLA), Polyjet, or Multijet printers for precise tooth profiles on pulleys.
Print Direction: Positive Z direction of STL files for all components
PartWeightSTL FileNotes
Transmission Pulley AT3 T30 Center4.2gtransmission_pulley_at3_t30_center.STLSLA/Multijet/Polyjet
Transmission Pulley AT3 T30 Output6.7gtransmission_pulley_at3_t30_output.STLSLA/Multijet/Polyjet
Timing Belt Tensioner Roller (10mm)0.2g eachtransmission_belt_tensioner_roller_10.0mm.STLSLA/Multijet/Polyjet
Multiple tensioner roller diameters available (10.0mm, 10.5mm, 11.0mm, 11.5mm) for belt tension adjustment.
Encoder Mount Not Needed: The ODRI Encoder Kit eliminates the need for the encoder codewheel mount (encoder_codewheel_pwb_mount.STL or encoder_codewheel_kit_mount.STL).

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Off-the-Shelf Components

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Brushless DC Motor

T-Motor Antigravity 4004 300kV
  • 24 magnets / 12 pole pairs / 18 slots
  • 3-phase WYE configuration (Star configuration)
  • Rotor diameter: 45mm
  • Weight: 53g
  • Sold in sets of 2 pieces

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Timing Belts

Conti Synchroflex AT3 GEN III - Heavy duty polyurethane with steel cord reinforcements
StageLengthTeethWidthWeight
First150mm504mm1.5g
Second201mm676mm3.0g
Total weight: 4.5g Ordering:

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Bearings

EZO Stainless Steel Miniature Roller Bearings (Total weight: 16g)

Output Bearing

EZO 61705 2RS VA
  • 32mm × 25mm × 4mm
  • Weight: 6.9g
  • Quantity: 2

Transmission Bearing

EZO MR84 VA
  • 8mm × 4mm × 2mm
  • Weight: 0.4g
  • Quantity: 3

Tensioner Bearing

EZO 683 2Z VA
  • 7mm × 3mm × 3mm
  • Weight: 0.4g
  • Quantity: 2
Ordering Sources:
  • Italy: Emiliana Cuscinetti or Doppiaemme
  • USA: EZO USA
  • Worldwide: SBN ([email protected]) - Part numbers: C02748 (output), N09724 (transmission), N05560 (tensioner)
  • Alternative: Chrome steel bearings from Online Bearing Store

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Fasteners

Total weight: 2.9g
Fastener TypeSizeQuantityMaterialOrdering
MotorM3 × 5 flat head4Stainless steelOnline Schrauben
Timing belt tensionerM3 × 10 flat head2Stainless steelOnline Schrauben
Tensioner washersM2.5 washer2Stainless steelOnline Schrauben
EncoderM3 × 16 Phillips flat head2Polyamide plasticConrad #839967
Output shaft insertHelicoil M3 × 62SteelRS #470-834, McMaster #91732A773
M3 Helicoil tools required for helical insert installation.

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Wiring and Connectors

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Motor Phase Connectors

  • Type: 2mm gold connectors (Reely RE-1373188)
  • Quantity: 3 pairs
  • Ordering: Conrad #1373188 (2 pairs/set) or HobbyKing (10 pairs/set)
  • Wire: LiY 0.50 mm² black cable
    • Kabeltronik #1601050 (most flexible)
    • Conrad #609337
    • McMaster #8054T14

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Encoder Connector

  • Housing: Hirose DF13 Socket 5-pin
    • RS #143-015
    • DigiKey #H2182-ND
  • Crimp terminals: Hirose DF13-2630SCF (5 pieces)
    • RS #503-8325
    • DigiKey #H9992CT-ND
  • Wire: LifY 0.14 mm² (Kabeltronik #1601014)
    • Colors: red, yellow, black, white, green
  • Crimp tool: Hirose DF13-TB2630HC (RS #503-8331)
Encoder Wiring Convention: Follow standard color coding with proper shielding to microcontroller. See source documentation for detailed wiring diagrams.

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Alternative Components

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Timing Belt Tensioner - Option B

7mm × 3mm × 3mm bearings (EZO 683 2Z VA) with 3D printed rollers and M2.5 washers

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Comparison: v1.0 vs v1.1

v1.0 (Self-Made)

Advantages:
  • Lower cost if machining available
  • Full control over part specifications
  • Learn complete fabrication process
Requirements:
  • Machine shop access or coordination
  • Motor shaft preparation skills
  • Codewheel alignment expertise
  • Additional assembly time

v1.1 (ODRI Kit)

Advantages:
  • No machine shop needed
  • Faster assembly process
  • Pre-tested and aligned components
  • Reduced preparation steps
Requirements:
  • Higher component cost
  • Wait time for kit delivery
  • Less customization flexibility
Both versions are functionally identical and produce the same performance. Components are fully compatible and interchangeable.

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Bill of Materials Summary

The v1.1 BOM differs from v1.0 in the following items: Replaced (v1.0 → v1.1):
  • ❌ Broadcom AEDT-9810-Z00 encoder (separate)
  • ❌ PWB Codewheel #104768
  • ❌ Motor pulley (machined aluminum)
  • ❌ Center pulley (machined aluminum)
  • ❌ Motor shaft (machined stainless steel)
  • ❌ Encoder codewheel PWB mount (3D printed)
Added (v1.1):
  • ✅ ODRI Encoder Kit #109381 (includes all above components pre-assembled)
Unchanged:
  • Motor, timing belts, bearings, fasteners, other 3D printed parts, wiring components

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Assembly Documentation

Simplified Assembly

v1.1 eliminates these preparation steps:
  • Motor shaft preparation
  • Codewheel mounting
  • Motor pulley installation
  • Center pulley preparation (partially)
Remaining steps:
  • Motor preparation
  • Encoder preparation (simplified)
  • Output pulley preparation
  • Shell preparation
  • Final module assembly

Testing Procedures

Testing procedures identical to v1.0:
  • Encoder calibration
  • Motor phase identification
  • Torque control verification
  • Performance validation

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Technical Resources

ODRI Kit Product Flyer

View the official “Plug & Play” ODRI Encoder KIT Product Flyer from PWB Encoders.

Technical Drawings

Complete PDF drawings available in source repository for reference and shell design.

STL Files

All required 3D printable component files in source repository stl_files directory.

Assembly Guide

Step-by-step instructions with photos for complete v1.1 module assembly.

Actuator Module v1.0

View the original version with custom machined parts

Specifications

Complete technical specifications table
Authors: Felix Grimminger License: BSD 3-Clause License Copyright: © 2019-2021 Max Planck Gesellschaft and New York University

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