Mechanical Issues

Troubleshooting alignment, assembly, and physical component problems

📐 Uneven Folding / Panels Not Aligned

Symptoms:

  • Clothing folded at an angle
  • One side folds more than the other
  • Panels don't meet evenly in the center
  • Inconsistent results between folds

Solutions:

1. Recalibrate servo positions

  • • Remove all servo horns
  • • Run sc.home_all() to set all servos to 90°
  • • Reattach servo horns in horizontal position
  • • Tighten screws firmly (but don't strip)

2. Check mechanical assembly

  • • Verify hinges are parallel to each other
  • • Check that panels aren't warped (lay flat on table)
  • • Ensure servo horns are the same type/length
  • • Verify base frame is level and not twisted

3. Fine-tune in software

# In config.py, adjust servo offsets:
SERVO_OFFSETS = [
    0,  # Servo 0 - no offset
    -5, # Servo 1 - adjust 5° counterclockwise
    3,  # Servo 2 - adjust 3° clockwise
    0   # Servo 3 - no offset
]

🔧 Hinges Binding or Sticking

Symptoms:

  • Panels move slowly or jerkily
  • Servos strain or make grinding noises
  • Movement stops mid-sequence
  • Hinges feel tight when moved manually

Solutions:

1. Lubricate hinges

  • • Use dry lubricant (graphite powder or PTFE spray)
  • • Avoid oil-based lubricants (attract dust)
  • • Apply to hinge pins and moving parts
  • • Work hinge back and forth to distribute

2. Check for tight screws

  • • Hinge screws may be over-tightened
  • • Loosen slightly until panel swings freely
  • • Should have slight play but no wobble

3. Sand rough edges

  • • 3D printed parts may have rough surfaces
  • • Use fine sandpaper (220 grit) on contact points
  • • Remove any stringing or blobs from print

🔩 Loose Servo Horns or Connections

Symptoms:

  • Panel position drifts over time
  • Clicking or slipping sounds during movement
  • Panels don't return to home position accurately

Solutions:

1. Tighten servo horn screws

  • • Use small Phillips screwdriver
  • • Tighten firmly but don't overtighten (can strip plastic)
  • • Consider using threadlocker (blue Loctite 243)

2. Check servo splines

  • • Remove horn and inspect servo output shaft
  • • Ensure horn fits snugly (not stripped)
  • • Replace horn if splines are worn

💔 3D Printed Parts Breaking

Symptoms:

  • Parts crack or snap during use
  • Mounting points for servos breaking
  • Layer separation on stress points

Solutions:

1. Reprint with better settings

  • • Increase infill to 40-50% (from 20%)
  • • Add more perimeters: 4-5 walls instead of 2-3
  • • Print slower: 40-50mm/s for better layer adhesion
  • • Orient parts for strength (layers perpendicular to stress)

2. Use stronger material

  • • PETG: More flexible and durable than PLA
  • • ABS: High strength but harder to print
  • • Nylon: Best for hinges (requires specific printer setup)

3. Reinforce weak points

  • • Add metal inserts for screw holes (heat-set threaded inserts)
  • • Use washers to distribute screw pressure
  • • Consider hybrid design with metal brackets at stress points
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