# KWR-1 Bill of Materials (engineering draft — procurement blocked)

This is not an orderable release BOM. Read `HARDWARE_CONFIGURATION_CONTROL.md` and the current hardware sourcing audit at the repository root before using it.

Vendor names are catalog-class placeholders ('SHG-25 class, or equal'): they pin envelope, ratings and mounting pattern; the KWR1-PROC-xxx placeholders are resolved at purchasing. CAD column = geometry instances in the model (0 = engineering item without distinct geometry, e.g. inside another envelope).

## Fabricated parts

| ID | Part | Qty | CAD | Material | Process | Tolerance | Finish | Mass/pc kg |
|---|---|---|---|---|---|---|---|---|
| F-CHAS | chassis weldment (frame + side plates) | 1 | 11 | S235 steel 4 mm | laser cut + MIG weld | +/-0.5 general, +/-0.2 bearing bores | powder coat RAL7042 | 38.0 |
| F-DECK | deck plate | 1 | 1 | AlMg3 5 mm | laser cut + tap | +/-0.3 | anodize clear | 8.9 |
| F-BTRAY | battery tray + retention brackets | 1 | 3 | S235 steel 3 mm | laser cut + bend | +/-0.5 | powder coat | 3.2 |
| F-WWELL | wheel well housing | 2 | 2 | S235 steel 3 mm | laser cut + bend + weld | +/-0.5 | powder coat | 1.4 |
| F-EBAY | electronics bay rack + DIN rails | 1 | 1 | AlMg3 3 mm | laser cut + bend | +/-0.4 | anodize | 2.1 |
| F-EPANEL | service panel w/ quarter-turn latches | 2 | 2 | AlMg3 2.5 mm | laser cut + bend | +/-0.4 | powder coat + label | 0.7 |
| F-SBRKT | stabilizer corner bracket | 4 | 8 | S355 steel 5 mm | laser cut + bend | +/-0.3 | powder coat | 0.65 |
| F-SFOOT | stabilizer foot pad holder | 4 | 8 | AlMg3 turned | CNC turn | +/-0.2 | anodize | 0.18 |
| F-PED | pedestal column | 1 | 4 | AlMg3 6 mm | cut + weld + machine | +/-0.3, top face flat 0.05 | powder coat | 9.5 |
| F-MAST | nav camera bracket, pedestal front | 1 | 3 | AlMg3 3 mm | laser cut + bend | +/-0.3 | anodize | 0.06 |
| F-JHOUS1 | joint housing, size 25 (J1/J2) | 2 | 6 | AlMg3 billet | CNC mill/turn | H7 bearing bore, +/-0.05 flange | hard anodize | 1.9 |
| F-JHOUS2 | joint housing, size 20 (J3/J4) | 2 | 4 | AlMg3 billet | CNC mill/turn | H7 bore | hard anodize | 1.5 |
| F-JHOUS3 | joint housing, size 17 (J5/J6) | 2 | 4 | AlMg3 billet | CNC mill/turn | H7 bore | hard anodize | 1.0 |
| F-JHOUS4 | joint housing, size 14 (J7) | 1 | 2 | AlMg3 billet | CNC mill/turn | H7 bore | hard anodize | 0.6 |
| F-LINKU | upper-arm tube + end flanges | 1 | 10 | Al tube D124x4 | cut + machine + bond flanges | flange faces parallel 0.05 | anodize | 2.6 |
| F-LINKF | forearm tube + end flanges | 1 | 6 | Al tube D104x4 | cut + machine | 0.05 parallel | anodize | 1.9 |
| F-WRIST | wrist sleeve | 1 | 6 | AlMg3 turned | CNC turn | +/-0.1 | anodize | 0.5 |
| F-GBODY | gripper body + jaw guides | 2 | 2 | AlMg3 billet | CNC mill | jaw guide slots +/-0.05 | hard anodize | 0.7 |
| F-BRIDGE | aux-arm shoulder bridge (beam + gusset + strut) | 1 | 3 | S355 steel weldment | laser cut + weld + machine | mount faces machined +/-0.05, bolt pattern to pedestal top | powder coat | 6.5 |
| F-FINGER | H1 finger set (3 linkage + 2 synergy: knuckle + proximal + coupler + distal + nail) | 10 | 42 | 17-4PH steel | CNC mill | pivot bores +/-0.02, pad seat +/-0.05 | passivate | 0.085 |
| F-TOOLS | kitchen tool set (scoop/spatula/stirrer/sponge/hook) | 5 | 0 | 304 stainless | laser cut + form + weld | +/-0.5 | electropolish | 0.45 |
| F-STAND | tool stand weldment | 1 | 0 | S235 steel 3 mm | laser cut + weld | +/-1.0 | powder coat | 16.0 |
| F-COVERS | arm cover shell set | 6 | 22 | ABS 3 mm | vacuum form + trim | +/-0.8 | textured | 0.25 |
| F-HUB | wheel hub + shaft | 2 | 4 | C45 steel | CNC turn + mill key | h6 shaft, +/-0.05 | black oxide | 1.1 |

## Purchased components

| ID | Part | Qty | CAD | Manufacturer class | PN | Envelope mm | Mass kg | Limits | Mount |
|---|---|---|---|---|---|---|---|---|---|
| P-COMP | fanless industrial PC, 12-24 V | 1 | 1 | x86 embedded class | KWR1-PROC-001 | (150, 105, 50) | 0.9 | power 25 W | 4x M4 side flanges |
| P-DRV | EtherCAT servo drive 48 V 10 A | 7 | 7 | servo drive class | KWR1-PROC-002 | (95, 70, 28) | 0.35 | cont 10 A; peak 25 A | DIN rail |
| P-PDU | power distribution + fusing board | 1 | 1 | custom PCB assembly | KWR1-PROC-003 | (160, 100, 30) | 0.25 | cont 60 A | 4x M3 standoffs |
| P-SAFE | dual-channel e-stop safety relay | 1 | 1 | safety relay class | KWR1-PROC-004 | (99, 22, 114) | 0.21 | category 3 PL d | DIN rail |
| P-CONT | 63 A DC contactor | 1 | 1 | DC contactor class | KWR1-PROC-005 | (78, 55, 70) | 0.35 | cont 63 A | 2x M5 |
| P-DCDC24 | 48->24 V 240 W converter | 1 | 1 | DC-DC class | KWR1-PROC-006 | (110, 62, 32) | 0.3 | out 10 A | 4x M4 |
| P-DCDC12 | 48->12 V 120 W converter | 1 | 1 | DC-DC class | KWR1-PROC-007 | (90, 55, 30) | 0.22 | out 10 A | 4x M4 |
| P-FAN | 60 mm 24 V bay fan + filter | 2 | 2 | axial fan class | KWR1-PROC-008 | (60, 60, 25) | 0.08 | flow 28 m3/h | 4x M4 |
| P-BATT | 48 V 30 Ah LiFePO4 + BMS | 1 | 2 | battery pack class | KWR1-PROC-009 | (550, 400, 140) | 30.0 | cont 60 A; peak 120 A | tray + 2 straps |
| P-CAM-W | wrist depth camera | 1 | 2 | RealSense D435 class | KWR1-PROC-010 | (90, 25, 25) | 0.075 | range 3 m | 2x M3 + 1/4-20 |
| P-CAM-M | mast RGB nav camera | 1 | 1 | industrial RGB class | KWR1-PROC-011 | (35, 90, 30) | 0.1 | fov 90 deg | 2x M4 |
| P-CAM-H | head RGB-D scene camera | 1 | 1 | RealSense D455 class | KWR1-PROC-024 | (35, 110, 60) | 0.18 | range 6 m; fov 85 deg | 2x M4 |
| P-CASTER | 75 mm swivel caster, 100 kg | 4 | 12 | caster class | KWR1-PROC-012 | (75, 60, 102) | 0.45 | load 100 kg | 4x M6 plate |
| P-ESTOP | 40 mm twist-release e-stop head | 1 | 1 | e-stop class | KWR1-PROC-013 | (40, 40, 55) | 0.06 | contacts 2 NC | 22 mm panel hole |
| P-TC | manual-profile pneumatic-free tool changer | 1 | 2 | tool changer class | KWR1-PROC-014 | (63, 63, 34) | 0.45 | payload 10 kg; moment 25 Nm | ISO 9409-1-50 flange |
| P-TC-A | tool-side adapter plate | 5 | 0 | tool changer class | KWR1-PROC-015 | (63, 63, 16) | 0.25 | payload 10 kg | 4x M5 on 40 mm BC |
| P-WHEEL | 160 mm PU-tread drive wheel | 2 | 2 | PU wheel class | KWR1-PROC-016 | (160, 50, 160) | 0.9 | load 120 kg | keyed 12 mm bore |
| P-WMOT | wheel gearmotor (motor+24:1+brake+encoder) | 2 | 8 | BLDC hub-gearmotor class | KWR1-PROC-017 | (104, 150, 104) | 3.4 | rated 15 Nm; peak 40 Nm; rated 5.5 A | 6x M5 face flange |
| P-DISC | battery service disconnect, rotary | 1 | 1 | battery switch class | KWR1-PROC-018 | (50, 50, 45) | 0.12 | cont 100 A | 2x M5 + panel |
| P-BRKR | 63 A DC thermal-magnetic breaker | 1 | 1 | DC breaker class | KWR1-PROC-019 | (60, 35, 70) | 0.18 | trip 63 A | panel mount |
| P-STAB | 750 N self-locking linear actuator | 4 | 8 | linear actuator class | KWR1-PROC-020 | (48, 48, 260) | 1.1 | force 750 N; stroke 100 mm | clevis + M12 rod end |
| P-JMOT | frameless torque motor ring (per size) | 14 | 14 | frameless motor class | KWR1-PROC-021 | (150, 150, 35) | 0.9 | see 0 JOINT_DRIVES | bonded stator + keyed rotor |
| P-JGEAR | strain-wave reducer (per size) | 14 | 14 | Harmonic Drive SHG class | KWR1-PROC-022 | (140, 140, 24) | 0.7 | see 0 JOINT_DRIVES | bolt circle both faces |
| P-JCRB | crossed-roller output bearing (per size) | 14 | 14 | CRBH class | KWR1-PROC-023 | (140, 140, 12) | 0.4 | see 0 JOINT_DRIVES | pressed + clamped |
| P-JENC | 19-bit absolute output encoder ring | 14 | 14 | BiSS-C ring encoder class | KWR1-PROC-024 | (120, 120, 8) | 0.08 | bits 19  | 3x M2 + read head |
| P-JBRK | 24 V spring-applied holding brake | 14 | 14 | safety brake class | KWR1-PROC-025 | (120, 120, 10) | 0.35 | holding 2.5 Nm-motor | 6x M3 |
| P-JSEAL | joint output lip seal (per size) | 14 | 14 | NBR seal class | KWR1-PROC-026 | (140, 140, 4) | 0.02 | ip 54  | pressed |
| P-GRIP-CL | G2 close drive (BLDC + ballscrew + SEA + whiffle tree) | 2 | 2 | servo gripper drive class | KWR1-PROC-027 | (60, 50, 28) | 0.42 | clamp 80 N; floor 3 N; stroke 112 mm | 4x M4 into palm |
| P-GRIP-SY | H1 synergy tendon spooler (single-tendon ring+little flexion, SoftHand-style) | 2 | 2 | smart servo class | KWR1-PROC-030 | (40, 34, 28) | 0.09 | flexion 100 %; tendon 250 N | 2x M3 into palm |
| P-TACT | fingertip tactile pad (silicone, 0.2 N resolution) | 6 | 0 | tactile pad class | KWR1-PROC-031 | (24, 40, 6) | 0.012 | resolution 0.2 N; range 50 N | bonded + 4-pin FPC |

## Standard hardware

| ID | Kind | Spec | Qty | CAD | Torque Nm | Used at |
|---|---|---|---|---|---|---|
| S-M6X20 | screw | M6x20 SHCS ISO 4762 A2 | 40 | 12 | 9.5 | deck plate, battery tray, e-bay |
| S-M8X25 | screw | M8x25 SHCS ISO 4762 8.8 | 28 | 24 | 23.0 | pedestal base flange, stabilizer brackets |
| S-M6X16 | screw | M6x16 SHCS ISO 4762 A2 | 48 | 48 | 9.5 | J1/J2 joint flanges, arm mount |
| S-M5X16 | screw | M5x16 SHCS ISO 4762 A2 | 60 | 72 | 5.5 | J3-J6 flanges, e-bay rack, tool stand |
| S-M4X12 | screw | M4x12 SHCS ISO 4762 A2 | 44 | 16 | 2.8 | J7 flange, wrist, covers, cameras |
| S-M3X8 | screw | M3x8 BHCS ISO 7380 A2 | 30 | 0 | 1.2 | electronics, camera brackets, labels |
| S-WASH6 | washer | M6 plain ISO 7089 A2 | 88 | 0 |  | under all M6 |
| S-WASH8 | washer | M8 plain ISO 7089 A2 | 28 | 0 |  | under all M8 |
| S-NYLOC6 | nut | M6 nyloc ISO 10511 A2 | 16 | 0 | 9.5 | caster plates |
| S-INSERT | insert | M5 threaded insert, Al tube | 32 | 0 |  | link tube flanges |
| S-GLAND12 | gland | M12 cable gland IP67 | 10 | 14 | 2.0 | joint housings, base entries |
| S-GLAND16 | gland | M16 cable gland IP67 | 4 | 1 | 3.0 | base power entries |
| S-CON-M12 | connector | M12 8-pin X-code (EtherCAT) | 9 | 6 | 0.6 | per-joint encoder/brake tees |
| S-CON-M12S | connector | M12 4-pin S-code (power) | 8 | 0 | 0.8 | per-joint motor power |
| S-CON-SB50 | connector | Anderson SB50 | 2 | 1 |  | battery + charge port |
| S-CON-JGH | connector | JST-GH 6-pin | 4 | 0 |  | cameras, limit switches |
| S-DIN | rail | DIN 35 mm rail, 300 mm | 2 | 1 |  | servo drives, safety relay |
| S-BUMP | bumper | PU bumper strip 30x15, per m | 4 | 4 |  | chassis perimeter |
| S-PAD | foot pad | NBR 80 Sh pad D100x10 | 4 | 14 |  | stabilizer feet |
| S-LSW | switch | subminiature limit switch, lever | 8 | 8 | 0.5 | stabilizer end stops (2 per leg) |
| S-LABEL | label | safety/service label set | 1 | 17 |  | e-stop ring, HV warning, datum marks, zero marks |
| S-BRG-6205 | bearing | 6205-2RS deep groove, 25x52x15 | 4 | 4 |  | wheel shafts (2 per wheel) |

Rolled-up component mass: **232.8 kg** (spec target 158.3 kg incl. structure)