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Week 1
After watching the kickoff video, the team began analyzing the finer points of this year's game, Rack 'n' Roll. With the help of a Power Point made by an alumnus, Patrick Wang, even the rookie members were able to understand the many tradeoffs of different strategies.
>>  Patrick's Game Analysis |
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StrategizingNext we broke the team into small groups, in which they discussed what would be the best strategy to use this year. The members debated whether we should build a stacking robot with a ramp or a robot that could score ringers. In the end, the team took a vote and decided our priority would be to score ringers during both the teleoperated period and autonomous period, as well as remove spoilers. |
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Breaking into GroupsWith the strategy decided, the electrical division began testing and programming various sensors, while the mechanical division was divided into five (5) groups: Chassis, Drivetrain, Manipulator 1 (M1), Manipulator 2 (M2) and Manipulator 3 (M3). While the Chassis and Drivetrain groups immediately began inventorizing parts, the manipulator groups did research and calculations on various manipulator designs. M1 looked into the geometry of an arm design and calculated the number of stages needed to reach the top spider leg. M2 began designing an arm that only scored during autonomous. M3 investigated an elevator design by looking at El Toro VIII. |
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PrototypingThe manipulator groups were responsible for not only finding a means to life ringers, but also a way to grab ringers. So, each group began to design and prototype various grabbing mechanisms. M1 came up with a design to grip the ringer from the inside (lower left picture). M2 looked into 2 different designs. They first tried using the suction cups that came in the kit, but fount that it would not hold well if the ringer was dirty (upper right picture). Next they came up with a claw design that would hold the ringer from the outside (upper left picture). M3 designed a grabber that would hold one side of the ringer (lower right picture). |
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Design Review #1At the end of the week, we invited our mentors, advisors, engineers and parents to a design review where members presented their designs and received feedback.
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Week 2 |
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ModificationsWith the feedback from the engineers, members began modifying their designs and prototypes. Two days later, the improved grabber designs were all tested. After carefully weighing the pros and cons of each design, the decision was made to use M3's grabber design because it was the most versatile. However, there were many concerns regarding this design. It needed a herding device to make picking up ringers much easier. The grabber also needed to be able to keep the ringer from rotating downward, as we had decided that holding it horizontally would be optimal position. |
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RegroupWith the design of the grabber chosen, the two other manipulator groups had their jobs reassigned. M1 was once again assigned to design the arm, since we had decided the elevator would be too heavy and complex. M2 was sent in search of a mechanical breaking system, which would keep the arm from back driving. |
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Trudging OnMeanwhile, the electrical division continued testing a variety of sensors, including the gyro, the CMU camera and a shaft encoder. Unfortunately our testing proved the gyro unreliable. The Chassis group constructed the bottom layer of the chassis and began work on the bumpers. The Drivetrain group put together the BanBots CIM gearbox with a two motor adapter. |
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Design Review #2With more detailed and fleshed out designs, we called our second design review. The engineers gave us ideas and suggestions to help us improve our current design.
>> Design Review Notes |
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Week 3 |
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The Finer PointsWith general designs decided, each group began working on the finer details of their design. The Arm group (M1) worked out torque calculations, gear ratios and the pneumatic stroke length, while the Grabber group (M3) figured out how to mount their grabber. Meanwhile, the drivetrain is finally put together and wired, allowing electrical to debug their drivetrain code.
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Week 4 |
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Finalizing DesignsAs we work our way into the second half of the build season, our designs are finalized. The Arm group (M1) completed placed the finishing touches on the pneumatic mount design, and finalized gear ratio calculations. The Grabber group (M3) calculated the pneumatics needed and designed its mount and clevis as well. By the end of the week, Inventor models of the upper chassis, arm, grabber and brakes were all completed. Around 10 pm Saturday night, the second stage of the arm came to life! |
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Week 5 |
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FabricatingDuring the fifth week, the robot finally begins to materialize. The Chassis group began fabricating of the upper layer of the chassis out of aluminum L-brackets. The Arm group (M1) got the holes drill in the aluminum tubing for the arm and the sprockets. The Grabber group (M3) also got all of its parts machined, including mounting blocks, L-plates and aluminum extrusion. |
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Ideas become realityAs the fifth week draws to an end, the team scrambles to finish building our robot so that we can utilize Castilleja's rack (Team 1700) to practice on the following day. As all the parts begin to come together, the wiring is completed and at last the robot came to LIFE! |
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Week 6 |
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CastillejaThe week started with a trip to Castilleja, home of Gatorbotics Team 1700, after they graciously allowed us to use their rack. At Castilleja, we tested our robot on their rack by scoring ringers and tested the motion of the rack. |
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Finishing TouchesAs the last week rolls by, the final pieces of El Toro X come together. A shaft encoder is connected to the arm by a timing belt, allowing the robot to get feedback on the arm's current position. Meanwhile, the chassis group struggles to put together their riveted L-bracket structure for the upper layer of the chassis. After redoing many rivets, the structure finally fits on to the base of the chassis. A battery mount is created out of polycarbonate and mounted on the chassis. The arm is also modified so that it fits into the starting box properly. Finally, a chain guard is created for the arm. |
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TestingWith all mechanical parts up and running, it was finally time for Electrical to take the stage and perform their magic. With the digital shaft encoder mounted, Electrical begins fine-tuning their arm program to allow the arm to move to each of its three scoring positions, with the flip of a switch. Robot drivers also got valuable practice time, allowing them to also fine-tune their skills. |
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Crunch Time (literally)As the last hours of build tick by, disasters strike! Yes, disasters with an "s" at the end. After stress testing our new drivetrain, half of it mysteriously stops running. Upon further inspection, we find that the carrier plate inside the gearbox failed. While we were prepared to swap in last year's gearbox to allow us to continue testing the robot, we managed to temporarily fix the carrier plate and continue running
Within hours of the first incident, a second tragedy befell our team. While testing our autonomous code, the arm was driven backwards into itself, causing it to tear itself to pieces, shearing 2 hardened bolts and ripping the aluminum tubing apart! Again, we luckily found a quick fix to the problem, and after milling a 1x1 block of aluminum to replace the blown-up tubing, the robot was once again in running condition
ShippingWith a few laughs and tears, we finally waved good-bye to El Toro X, knowing we will meet him again at the competitions. |
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