Mechanical Hardware
Mechanical Hardware
Our design strategy was to create a DEV that could win in any jousting match. We accomplished this goal by creating a heavy bot with a "turbine" to provide extra thrust when pushing a barrier to the other side of the arena.
The turbine is capable of providing 950 grams (~2 pounds) of additional thrust.
The extra weight is provided by our use of four NiMH batteries and two 5v rechargeable batteries. We kept as many of our components as possible on the base layer of the DEV to keep the center of gravity low.
The DEV was constructed using laser cut Duron. The use of Duron allowed us to easily make last minute changes if we deemed necessary. The pieces were then secured with the use of M3 nuts and bolts to allow for easily disassembly.
The chassis was constrained to a 32 x 32 x 32 cm cube. Due to the size of our "turbine" and our strategy of being as heavy as possible, we capitalized on the constraint and made our DEV 32 x 32 x 32 cm. The extra height of our base layer also allowed us to attach the batteries vertically, along the vertical walls. This made for easy removal and insertion for charging.
The chassis is constructed using a three tier design. All of the tiers have precut moutning holes for switches, PCB boards, and other misc. hardware that needed mounting. By mounting all of our hardware rigidly we avoid anything breaking or falling out during motion/collisions.
The bottom tier houses our drive train assembly, "turbine", NiMH batteries, ultrasonic sensors, and motor/turbine PIC32's. It is optimized to carry all of the heaviest components to keep the center of gravity low
The middle tier houses the logic PIC32, the LED circuit, 5V power supply, the power distribution boards, and the servo.
The top tier houses the IR sensor box, signal conditioning board, kill switchcs for both power distribution boards, and an acrylic LED light display.
Image D1: Drive train breakdown
Image D2: Assembly of bearings
The drive train is comprised of eight key components:
DC motors: two DC motors are rigidly mounted for a two drive wheel vehicle
encoders, made using hall effect sensors: allows us to implement specific turns based on encoder ticks rather than timers
bearings: two bearings are used on each side to stabilize the shaft
80mm scooter wheels: large wheels with no treads gave us the advantage of quick speed with minimal friction to overcome with the ground during acceleration. Attached with a scooter wheel adapter kit
6mm shafts: appropriate size for scooter wheel adapter kit
flexible couplers: help to eliminate any side moments onto the motor due to misalignment
motor drivers: PCB boards designed to support SN54410 H-bridge
caster wheel: by doing a three wheel drive we eliminate any headache from misalignment of four wheels
The IR detection box was designed to:
narrow the vision of the phototransistor using an inverted conical shape
block out ambient light with high walls and blocking of the back of the phototransistor
house the signal conditioning board and hold the phototransistor in an isolated area to eliminate any unneccesary noise from running long cables
Image I1: IR detection box, wrapped in black to block out any stray lights
Image I2: The CAD Model of the IR detection box
Individual mounts for the DC motors, reflection sensor, ultrasonic distance sensors and EPU allowed for vital sensors to be stabilized while the DEV is in action.
S1: Ultrasonic Sensor mount
S2: DC Motor Mount
S3: Hall effect sensor mount for DIY Encoder
Note: While we affectionately refer to the propeller on the back of the DEV as a turbine, we must note that it does not produce actual power, therefore it is not TECHNICALLY a turbine
The idea of using a turbine arose when we thought about how to win in a one-against-one situation, meaning that two robots try to push a barrier at the same time. Since the project requirements limited us to only two wheels touching the floor, we came up with an alternative solution generating extra thrust in those situations.
The turbine consists of three parts:
The Brushless DC Motor (BLDC) and the Propeller are operated at a voltage of ~15 Volts and consume up to 20 Amperes. That means that at maximum speed (~34,000 RPM), the propeller will be powered with ~300 Watts. At this speed, it generates a thrust of around 950 grams (~2 pounds).
The motor is controlled by an ESC (Electric Speed Controller) which takes a DC voltage at input and then generates the three phases needed to power the BLDC motor. Before using the ESC, the programmable settings had to be adjusted, e.g. to allow for a NiMH battery to be connected instead of a LiPo. The ESC itself is controlled by a PWM signal which comes from the Turbine-PIC. A duty cycle of 5% corresponds to the minimum value, meaning that the motor won't spin at all. A cycle of 10% lets the motor rotate at maximum speed. The behavior of the motor being accelerated slowly from 5% to 10% was tested before the integration (see video on the right).
For safe operation, the motor-propeller system was encapsulated in a casing (see image T2 and T3). The casing was 3D printed in three separate parts and then assembled (see image T4). The robot was designed such that the whole turbine would fit into it. The distance between the robot's bottom and middle tier was increased to allow for an unhindered airflow.
Image T1: Components for the Turbine
Image T2: CAD Model of the Turbine Casing from a tilted right position
Image T3: CAD Model of the Turbine Casing from the front
Image T4: Partially assembled turbine.
There are two LED boxes at the top of the DEV, one for team color indication and one for repo indication. This light display is created by using an array of LEDs mounted below plates of acrylic. The acrylic has the words REPO or TEAM rastered onto it, which allows the light to refract through and shine brightly.
L1: Red team indicator
L2: Blue team indicator
L3: In REPO Indicator
Interested in more details? Click below to see engineering drawings and a Bill of Materials!