Assembly
This section contains all the information about the kart, organized as a tree of sub-assemblies. Each sub-assembly includes detailed specifications, components, and relevant documentation.
Assembly Instructions
Step-by-step assembly instructions are still a work in progress.
Hardware Overview
| Subsystem | Component | Key Specs | Details |
|---|---|---|---|
| Chassis | Tony Kart Extreme | CIK ICA 330/99, 30/32mm CrMo tubing, 40mm rear axle | Chassis |
| Computer | NVIDIA Jetson AGX Orin | 12-core ARM, 62 GB RAM, Ampere GPU (CUDA 12.6), NVMe boot | Computer, Orin Setup |
| Camera | ZED 2 stereo | USB 3.0, RGB + depth + IMU, used for cone detection | Camera |
| Microcontroller | ESP32-S3 "Kart Medulla" | USB serial (CDC-ACM) to Orin, controls actuators | Kart Medulla |
| Steering | DC motor + H-bridge | MT6701 magnetic angle sensor read as PWM, closed-loop PID on the ESP32 | Steering, H-bridge, Angle Sensor |
| Throttle | MCP4922 SPI DAC → motor controller | 0–5 V analog signal | Throttle Pedal |
| Motor | Electric kart motor | Controlled via motor controller + throttle signal | Motor |
| Power | Battery pack | Supplies 12V to Orin (via barrel jack 9–20V) + motor controller | Battery |
| Pneumatic braking | ASB (proportional) + EBS (emergency) | VPPM + solenoid valve merged by an OR valve; EBS in shutdown circuit | Pneumatic Braking |
| Hydraulic braking | Kart's original hydraulic circuit | M10×1.0 inverted-flare hoses, Sensata PTE7100 pressure sensor (0–200 bar) | Hydraulics |
| Wiring | Custom harness | Color-coded: black=GND, red=12V, orange=5V, yellow=3.3V | Wiring, Net Naming |
The two braking systems are not alternatives: the pneumatic side is what the autonomous stack and the emergency circuit actuate, and it pushes on the kart's existing hydraulic brakes.
Loose assembly notes
Things learned on the kart that have no better home yet. Move each one onto its subsystem page as that page grows.
- The red plastic piece of the steering column goes on top of the bolt that holds it.
- The wheel bearings are separated by a spacer tube, so the bolts can be torqued down without putting a constant shear load on the bearings. Its dimensions are not recorded — measure the ID, OD and length off the kart and fill them in here.