We had a great time hosting the first Maker Station Massacre yesterday.
Missed the action? Want to get another look at what happened? Good news, the event video’s located here: https://youtu.be/76QBCtAFj5k
How Do You Like Your Steak?
Prior to attending Robot Battles 72 I decided that it was time to start on a new 3lb build. With the new build in progress and the damage done at the event being pretty spectacular now seems like the time to retire High Steaks.
With that, I’ve also decided to release the full CAD in STEP format.
Feel free to build your own, borrow elements, or just give it a look.
Building a Compact, Portable Test Box
Fabrication files
The above .zip file contains the .dxf’s for the flange, side plate, polycarb holddown polycarb panel (if you want to route it out or similar) and the .step file for the polycarb pull handle. The steel for this build was all laser cut by SendCutSend.
While it’s certainly possible to build a bot, show up to an event, and run it without taking the time to test it’s not the best idea. Similarly, if you’ve got a weapon capable of damaging your opponent, you’ve got a weapon capable of doing real, lasting damage to a person. If you want to test it, you need somewhere safe to do it, and a test box is a great way to protect yourself, protect the other people around you, and test your bot.
With that in mind, I wanted to replace my old bulky test box with something that hit a nice balance of usable space and portability.
The core goals of this design are:
- Small enough to easily go through a door
- Able to be mounted to a wheeled platform
- Big enough for almost any 3lb robot to be tested safely
- Easy to build
- Easy to repair
Goal 1: Small enough to go through a door.
The main structure of the test box is a 26.5″ square frame that can be built to effectively any height. It’s rare to see a door narrower than 30″ so this should fit with room to spare.
Goal 2: Able to be mounted to a wheeled platform.
The hole patterns on the exterior of the flanges will allow the test box to be securely bolted to a frame using a simple hole pattern and #10 hardware.
Goal 3: Big enough for almost any 3lb robot to be tested safely.
With 1/2″ plywood walls the internal usable floorspace is just over 23″ square. Only the largest of the large in the 3lb class can’t fit that footprint.
Goal 4: Easy to build.
The main frame design uses two main parts, a flange and a side plate at qty. 8 each, made from laser cut mild steel. These components key together to aid in fixturing for welding and provide easy attachment points for wall and floor panels. Additionally, the top polycarbonate panel is retained by bolt on flanges and a pin lock to allow a simple rectangle of polycarb to used without any drilling required. The dimensions also allow for 2′ square 15/32″ thick plywood project panels from any local hardware store to be used for the walls and floor with little to no modification required. Similarly, the polycarbonate retainer height can be easily adjusted via 5/16″ OD spacers sized for #10 bolts. For mine I added adhesive backed felt pads to help with sliding the panel in and out. With sufficiently stiff polycarb panels you likely can slide the panel straight back with no issue. If you notice sagging then a small bonded tab that lifts the edge of the panel as it slides in will make closing the test box easy.
Goal 5: Easy to repair
The mild steel frame, easy to swap hardware, and use of commercially available plywood panels means that there’s typically a quick, easy repair option for almost any kind of damage.
For my build I opted to paint much of the plywood, while it’s not necessary it does add a nice finishing touch to the whole thing.
So, what’s left to do? At this point the test box is fully usable. Most of the box is held together using some fairly short #10 wood screws and the pin to lock the polycarb panel in place is McMaster #98320A125 if you want to track down the same part.
RadioMaster MT12 Joystick Mod
For a long time, I’ve wanted a ground style transmitter with a third channel that wasn’t a basic switch or slow scroll through an input range. Not long ago RadioMaster released the MT12 which is a ground style radio running EdgeTX.
Before I get too deep into what I did, here’s the finished mod:
Here are the STL’s you’ll need to print your own:
With that out of the way, here’s how this was made:
After the MT12 was delivered and RadioMaster told me there wasn’t a CAD file available I looked into free 3D scanning apps, eventually settling on Polycam. I took the MT12, set it on a flat metal plate, scanned it, then exported the scan, used a converter to get it into STL format, imported it into Solidworks, then made the first version of the main housing.
Overall, it was ok, but a bit bulky. It also meant that I couldn’t grip the transmitter the way I wanted to. Enter the realm of near impossible to machine parts that are effectively trivial thanks to 3D printing. The second version of the housing dramatically changed the shape and added mounting features. It also made it clear that I’d need at least a short cable extension. V3 quickly followed with fine tuned mounting and a cover for the back of the joystick.
I didn’t happen to have the right connectors on hand, so a quick Amazon order later and I was ready to build an extension cable. For this step the big thing is making sure you don’t swap around the order of the wires from cable to cable since that could cause input issues or damage a board.
With the mod tested and the housing painted it was time for the final step, bonding the housing to the removable base plate with one of my favorite adhesives, Shoe Goo.
The paint’s a bit glossy, so I may give it a matte clearcoat at some point, but beyond that I’m very happy with the final outcome.
High Steaks Deep Dive
Have you ever thought of a terrible pun? Has that terrible pun resulted in dozens of hours of work to transform it into a tangible object?
Big wheeled bots aren’t new. Bots like Huge, Gabriel, Starchild, and plenty of others have been out there fighting for years and are inspiring new designs all the time. While thinking about the pros and cons of this style of bot the thought came up: What would happen if Team Food Fight built a big wheel style bot? While I can’t say what the bot would look like, a name immediately came to mind.
With that pun, the CAD effort began and Hotkoin was contacted for the logo you see above.
So, what are the goals of High Steaks?
- Re-use the hubmotor and electronics from M-80
- Test viability of PLA+ for semi-protected structural elements in a 3lb bot
- Test segmented cleats as a means of increasing grip and adding structural stability to UHMW wheels
- Lean hard into the theme
With those goals the parts list and profile started taking shape. High Steaks would recycle the drive and weapon esc’s from M-80 along with the hubmotor. Some left over FingerTech Mega Sparks would be the drive solution with an extra 2:1 reduction to the wheels.
If you’re gonna go all in on a steak theme, you can’t be generic on your weapon disk. This lead to the question of just how steak-like a disk can be made to look. After some digging around I settled on two base colors and the Montana Cans white marble effect paint.
With the electronics pulled mostly from an existing bot the wiring process was fast with the main challenge being routing wires between the two halves of the chassis. The rear channel was snug, but it wasn’t too difficult to pull the wires through with the assistance of some forceps and a bit of patience.
Thanks go out to SendCutSend for making the weapon disks, steel chassis components, and spring steel cleats.
With all the pre-event goals met that leaves the final question: How did it do?
Overall I’m very happy with the performance. The one serious design issue that popped up didn’t really impact the results, but with the width of the tips on the side forks it would require the axle to be removed to replace a wheel, which isn’t ideal if there’s a time crunch. Because of that some new side forks have been designed that keep the aesthetic while allowing the hex bore on the wheels to slip over them for easy replacement. Beyond that, some extra UHMW wheels and cleats have been made to ensure enough spares are on hand and that there’s a heavier duty wheel option for bots where wheel damage is particularly likely.
Outlier Deep Dive
Outlier is the teams newest 1lb bot and is the end result of trying out a bunch of new stuff and new ideas.
Going into the design the core goals were:
1. Build a 1lb electric lifter that’s competitive
2. All brushless (this goal came in after initial concepts used some brushed parts)
3. Run 4s lipo effectively
4. Test viability of TPU lifter arms
5. Try new wheel construction methods
CAD from the early concept stages through the design that was made
Over the course of a few design revisions and a few product releases the bot went from a semi-direct brushless drive, brushed lifter with all of the components integrated into a single chassis to an all brushless lifter with replaceable weapon modules and indirect brushless drive.
Key components in Outlier:
Drive/Lifter: Repeat Robotics Repeat Mini Mk3’s (prototype HR gearbox for the lifter)
ESCs: Repeat Brushless Drive ESC for drive, Repeat AM32 Drive ESC for the lifter
Battery: 2x 2s 250mAh lipos from Palm Beach Bots
Power Switch: FingerTech Mini Power Switch
Weapon Module Structure: Custom Printed by Team Malice
BEC: iFLIGHT 3S to 6S Micro 5V 3A BEC
In addition to the above, the chassis, forks, and plow on outlier were made from 0.050″ laser cut 4130 steel from SendCutSend, the baseplate was 1mm carbon fiber, and there were a lot of PLA+ and TPU parts printed in house.
Assorted photos from the build including test fits and some adhesive testing
Test install of the drive wheels & weapon module
With that done and the event rapidly approaching a lot of things happened off camera with the end result being a working 1lb robot.
Outlier is a pretty dense little bot and was probably one of the more challenging wiring jobs I’ve done.
So, how’d the event go?
The good:
The drive power was insane, even with the fairly grippy silicone it was easy to spin the tires.
The chassis and drive mounting held up great, even with some major hits repairs were easy.
The TPU lifter arms took crazy hits without any trouble.
The PLA+ – TPU – Silicone wheel combo held together well even when taking some nasty hits
The bad:
The D shaft I was using had a very small flat, so between the Delrin gear and printed TPU adapter it was struggling to transfer torque, so the lifter often struggled to lift.
Changing configurations took longer than I’d like which meant I ran a config that wasn’t well suited to my opponent and took some massive damage to the weapon module & plow during the fight
After a few fights in close succession the printed PLA+ motor guards deformed, jamming the drive motors in the final, luckily late enough that it didn’t cost Outlier the match.
So, what’s next?
1. New homemade titanium D shaft for the lifter module
2. Modified, lighter, 1095 steel plow design that will allow weight for wheel guards so changeover time is reduced between configs
3. Explore additional wheel configurations
4. Connectorized weapon motor to allow easy swapping of entire weapon module
I’ve Made a Huge Mis-Steak
When it comes to robots trying new things can be scary, but it can also be rewarding. So, was High Steaks a success? Was it a Huge mis-steak?
Find out for yourself:
Introducing High Steaks
Robot Battles 71
Video from Robot Battles 71
Introducing Outlier
What’s the current meta in the Antweight class? Compact verts? Probably. Big horizontals? Fair chance. Wedges? Certainly a contender. Whatever it is, it certainly isn’t… Outlier.
Some brief specs:
Drive motors, weapon motors, and esc’s from Repeat Robotics.
2x 250mah 2s LiPo from Palm Beach Bots wired in series.
Welded 4130 chassis with a printed weapon module and carbon fiber baseplate.