Embedded Files
Boxer Bot Dummy.
Transparent body of the Boxer Bot Dummy's early body design.
Background
Background
In my ME 408 Mechanical Systems Design II class, every student had to group up to design and present their senior project. I grouped up with my friends Patrick McCormack, Joshua Torres, and Brian Byrnes. Together, for our senior project we designed an automated boxing stand called the Boxer Bot Dummy. We envisioned it to be a boxing stand with arms that can punch back to improve a boxer's reflexes.
Problem
Problem
The modeling of our project needs to adhere to the engineering design standards provided by the Machinery's Handbook. The product has to undergo a design analysis based on our professor's observation. In this case, the Boxer Bot Dummy has to undergo kinematic analyses on the arms and gears, dynamic force analysis on the arm when it punches, static analyses on various parts of the robot such as the arms and body, and fatigue analysis on the parts. Several prototypes of the parts have to be 3-D printed as well.
The analyses done on the designs of the robot needed to be included in the report. This includes simulations and inputted and outputted values calculated from theoretical equations. The report requires an analysis on the product's manufacturability, economics, health and safety standards, a project schedule, and engineering drawings.
Solution
Solution
We designed the robot using SolidWorks, since all of us were most familiar with it. Our work was divided between Brian and Joshua working on the arms and its motion when the robot strikes, I worked on the body and the hip motion similar to when a boxer punches, and Patrick works on the report by gather and organizing the data, as well as research the manufacturability, economics, and health and safety standards to could be applied to this robot.
The body of the robot is divided into three sections: ground (lower) base, rotational (mid) base, and punching (upper) base. The ground base houses a large motor and pillars to support the weight and rotate the other two bases on-top. The rotational base has two sets of gears to replicate a boxer's movement. A internal gear set connecting the lower and middle base replicates the rotation of a boxer's whole body when facing their opponent. A planet gear set connecting the middle and upper base replicates the boxer's hip rotation when striking against their opponent. Another motor is placed inside the rotational base to rotate the upper body. The punching base is where the boxer will strike at the Boxer Bot Dummy like a regular boxing stand. The arms are attached to the upper level of the punching base.
Both gear sets that were used retain similar designs and dimensions to each other to save time and money for manufacturability. They both adhere to the same engineering standards, such as dimensions and material used. The ring gears used are attached to a slew bearing to help it rotate, with the bearings themselves attached to the bases. The materials chosen for the bases was polycarbonate (ABS) due to its lightweight, cheap, and semi-durable properties. Support pillars made of AISI 4140 steel were used help uphold the weight of the bases if it became to heavy to hold.
Results
Results
While we managed to finish the design of the Boxer Bot Dummy, we noted that there were problems with our design. First, the weight of the robot was over 200 lbs. Second, when trying to animate the robot, it did not move properly because of the parts interfering with each other or it being assembled incorrectly. Third, our design couldn't be refined in time. This was largely due to time crunch we experienced between working on this project and balancing other work, projects and tests from our other classes. Admittingly, when working on this project I did not have much experience designing and handling robotics.
Despite the troubles, our group did gain a lot of knowledge and experience doing this project. We learned a lot about using engineering standards, expanded our skills and imagination in CAD modeling, conduct design analysis and computer simulations, research manufacturability, economics, health and safety standards, and learned how to write a engineering report. While the final result was something that didn't match what we envisioned, we were nonetheless proud of our accomplishments. We liken this experience to trial by fire, that everything we learned about engineering came down to this very moment and we had to apply it. Despite the hardship of this project, it is the best learning experience I have ever received. In future, when I gain more experience in designing and assembling robotics, I plan on going back to this project and redoing the Boxer Bot Dummy.
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