VEX Smart Field Controller Driver Station Towers

VEX Smart Field Control towers designed to reuse common VRC field parts (posts - PVC schedule 80 pipe - post clamps, and miscellaneous #8-32 screws).  When I first started reading up on the smart field control system, I identified the weak point as the connectors on the 25' smart cables that VEX provides in their kit - a broken connector tab mid-competition means having to run a new smart cable from the smart controller to the driver's station.  This design allows the use of 4P4C couplers at the driver station, so that if the tab on the driver end of the cable breaks, all that needs to be replaced is a short smart cable, which can be done in seconds.  At the same time, I was disassembling field elements at the end of a competition season, and an idea was born.

There are two types of tower “bases” - one is a slip fit (a screw can be added to prevent rotation) onto the PVC pipe that VRC uses for posts, and the other mounts onto the old black steel metal towers. They perform the same task, just for different post applications.  There are two post “toppers” - one holds standard RJ9 (ideal, as the smart cables use RJ9 connectors) or RJ11 (will work, needs to be centered in the “plug”) couplers such as these: https://www.amazon.com/Telephone-Connector-Extender-Accessory-Extension/dp/B07W4NJXJ5/ for RJ9 or https://www.amazon.com/SinLoon-Telephone-Straight-Extension-Landline/dp/B08ZCGY32S/ for RJ11, and the other is really just a simple “clamp” that will hold the ends of the smart cables if you prefer to not use the RJ9/RJ11 connectors.  Use adhesive-backed foam tape inside the tower topper to prevent damage to the cables.  The smart cables going to the smart controllers can be routed inside of the pipe for a clean look and less chance of damage.

If using the PVC Pipe, you'll use standard VRC field post clamps to hold the towers; since they are not a part of the game, I did not want the post to be mounted inside the field. To remedy that, I designed a simple spacer that goes inside the metal field wall panel where the clamps are mounted.

Parts are designed to use #8-32 brass heat set inserts for threading https://www.amazon.com/gp/product/B08P1SKYCB/ or you can use a longer screw and nuts.

Parts labeled “for nuts” use a standard #8-32 nylock nut.

PLA is plenty strong enough.  Print .2 or .25mm layer height, 4 perimeters, 5 tops/bottoms, 40% infill.