Older blog entries for Roko (starting at number 4)

Mini Sumo Motor Mounts

Well, it’s been a while since I’ve updated, and I have gotten a little bit of work done on the robots in between ice diving adventures, and working on the Jeep. Most of the progress made has been playing with software (Investigating webcams and OpenCV for Spyder’s machine vision) and hardware design (PCB layouts for Spyder’s many circuits.)

Motor Mount 4

Motor Mount Prototype

Motor Mount 3

Motor Mount Prototype

Today, however, I sat down and got some machining work done for my mini sumo. I was wrestling (no pun intended) with the idea of how to mount the motors, and eventually decided to make a flanged sleeve for the motor to fit inside, which will then be securly attatched to the frame of the robot. The first attempt turned out pretty good, although not quite perfetct, as I didn’t properly square it off in one of the steps. It’s useable, but I’ll have to decide wether or not I want to make another one.

So, things are slowly comming a long. I’m afraid I won’t have all the circuitry I wanted to put into the mini sumo done in time for the robot games (chiefly goverened by the long lead time for budget PCB’s from batchPCB), but hopefully I can at least get something that will run arount the ring. I suppose as a backup, I do have my H-Bridge prototype board I could use to control it.. Complete with high-efficiency H-Bridge, and a powerful little 9s12 to control it all… Hmm..

Syndicated 2009-03-27 04:13:46 from Roko.ca

Mexico Feb ‘09

I spent the past week and a bit diving in the Yucatan with my lovely girlfriend / dive-buddy-extraordinaire, and the warm water recreational diving oh so easy compared to what we contend with up here (We didn’t have to hike gear into a mountain lake, didn’t have to deal with cold water and plenty of insulation under drysuits requiring plenty of lead to sink, great visibility), and as always in warm water, there was so much amazing life to see. Great diving! It almost makes me want to move somewhere warmer.. But then if I lived somewhere warmer, I know I’d just look forward to vacations back up to Canada for the great west coast diving and rocky mountain lake diving…

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Hangin' out on a safety stop

The funny thing that we both noticed about the cenote diving, however,  is just how much of a striking resemblance the cavern areas resembled the walls at Horseshoe lake in Jasper. Granted that Horeshoe is a sort of a lake-based wall dive, and doesn’t have caverns or caves that we know about, but the rocks, tree limbs, small amount of life, etc, really did seem quite similar.

Now, after a nice warm vacation, we’re getting ready to do some local ice diving.. A bit of a shift, but that’s diving!

Anyways, just some rambling about my trip, and an appology-less explanation why there hasn’t been any progress on my robots in the past couple of weeks.

Syndicated 2009-02-26 03:45:38 from Roko.ca

First Assembly of all Four Legs

Leg Parts straight from waterjet sized

Parts from water jet cutting

I received the remaining water-jet cut parts from Big Blue Saw a couple of weeks ago, and have slowly been working on taking them from rough water-jet cut pieces, to parts that will actually fit into the robot. The water-jet cuts are fairly rough when looking for precision parts, which is why a lot of work goes into the rough parts in order to get things to piece together nicely. To be honest, though.. I wish I had a CNC mill/router that I could have used to precisely cut the parts myself.

Waterjet edges sized

Water Jet Edge Finish

This isn’t to say that water-jet cutting is bad, but it is what it is. You have to account for the fact that water-jet cut parts aren’t 100% perfect to minute tolerances. Some of the issues I have with these parts are that the water-jet seems to have cut at a bit of an angle, which causes tolerance issues requiring some filing work to make sure everything fits together nicely. That said, I’m still happy overall with the water-jet cutting, and would recommend it to anyone trying to make more complicated shapes or numerous parts. I wouldn’t have been able to make all of the more complicated/curvy cuts by hand as precisely and quick as the water-jet service does. Plus, the edge finish has a pretty cool rough effect (Although I will be smoothing it out for this particular robot)

Four Legs in progress

Four Legs!

After a lot of work machining the parts, I finally put togethor the frame of the robot with all four legs for the first time (minus the robot’s feet, which I haven’t gotten to yet). There’s still a lot of tweaking and some machining I have to do on these parts before they’re finished, and then there are a lot of small parts that I still have to make. It’s been around 5 months since I started this project, and things are really starting to come togethor, but I’m thinking it’ll still be another few months at least before the robot even moves, let alone moves in a fashion resembling autonomous walking. At least it’s finally starting to look like an actual quadrupedal walking robot.

Stepping the shaft from 4mm to 3mm sized

Stepping the Axles

I also turned the axles on the lathe recently. Eight of the axles are simply straight 3mm shafts, however the four hip/base axles are 4mm in the center, and 3mm on either end with a center groove to hold an e-ring which is used to keep the flat-flex cable in place, and out of the gears. I still need to put the axles on the mill in order to flatten them out to keep set screws in place, and to drive the potentiometers I am using for axle position sensing. I’ll post more on those in the future when I get to that stage of the build

One of the other things I still need to complete are the motor controllers, and the actual robot’s brain (likely a Gumstix Overo, but I would have to make my own carrier baord). I have tweaked and fixed small bugs in the design of h-bridge prototype I built in the fall, however I want to move the same circuit into a shape that will fit into the actual upper-leg side piece. Luckily that gives me more space to work with than the current itteration of the board (which will be used for controlling the inner four motors), so it should be a relatively easy task once I find the time.

Syndicated 2009-02-08 22:07:44 from Roko.ca

Mini Sumo Beginnings

As with many projects, a mini sumo has been several years in the making, and has undergone several design revisions without actually having time to begin construction. But, finally, I took a bit of a break from the quadruped to start work on a mini sumo robot in the past couple days.

Aluminum Wheel Stock sized

Start of a wheel

I had some round aluminum stock sitting around, and felt like playing around with the lathe. I got my trusty hack-saw out, cut off a chunk of aluminum, chucked it up on the lathe, and started spinning. Over the course of one evening, I came up with a basic wheel and hub assembly to go with the Maxon 17:1 gear motors I’ve had lying around for almost a year now, waiting for a sumo robot to be built around them. This is the same Maxon motor many people use, and I had to contend with the same issue, that the motor length itself is half the maximum width of a mini sumo robot (About 50mm). This called for making a hollow wheel that would slide over the motor.

I made a two piece assembly, with a hub that is attached to the motor with a set screw, and a wheel that is attached to the hub with several 2-56 screws.

Wheel Bore Action Shot sized

Boring in Action

Overall, the boring went well on the lathe, but was definately a learning experience. The process itself was tedious, starting with drilling out a center hole using drill bits of incremental sizes until I had a center hole large enough to fit the boring tool, then slowly boring out a 21mm depth, 0.1-0.2mm at a time, slowing down as I approached the desired tolerance.

The tool itself chatters easily if you’re not careful, but I managed to produce a mostly clean bore. I’ll have to experiment/research a bit more on the best chip rates for turning aluminum stock…

Making the inner hub itself was easy to do, simply turning down the outside of a piece of aluminum, then using a couple drill bits to center drill a hole to about 2.85mm, then using a reamer to finish the center hole at a nice, clean 3mm to fit the shaft. A 4-40 set screw fit nicely, though I did have to file down a fraction of a millimeter that was sticking out from the hub itself, as that part of the hub fit with close tolerance into the wheel itself.

Wheel Assembly Parts sized

Prototype Wheel Parts

Wheel Assembly Assembled sized

Prototype Wheel Assembly

Using a milling machine to precisely drill the holes that I would then use to tap and mount the actual wheel to the hub helped keep everything nice and accurate. Once finished, the wheel and hub aligned very well, and I had a completed wheel assembly.. Now to finish the other wheel, make a tire mold, mold the tires, mount the motors to a chassis, and make a brain for it all.. Hopefully I can have a basic robot ready in time for this year’s Robot Games.

Syndicated 2009-02-04 06:02:27 from Roko.ca

Upcoming 2009 IEEE Robot Games

The 2009 IEEE/WCRG Robot games have been announced for May 9th, 2009. I used to be an avid participant, but first school and then work travel got in the way and as such I’ve only managed to make it out once in the past few year.

This year, I’m hoping to have a mini-sumo ready in time, one that I’ve been designing in the back of my head for several months (years?) now. I’ve had some tiny Maxon motors sitting around that I bought a year ago with the hopes of finding time to start this robot, and today took a break from the quadruped to finally start machining the wheels. I’ll try and post details later.

Anyways, if you can make it out to Calgary for May 9th, it’s definatley worth checking out the Robot Games. If you have spare time, make a robot to compete! It doesn’t have to be perfect, it’s more fun building a robot than winning…

Syndicated 2009-02-03 06:32:18 from Roko.ca

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