FIRST Robotics - FRC Mechanical Presentation

FIRST Robotics FRC Mechanical Presentation
Steve Martin Mentor FIRST Team 58 Co-chair Pine Tree Regional South Portland Package Technology Development Fairchild Semiconductor
www.fairchildsemi.com
Outline
Keep it simple Kitbot frame and how it is assembled Definition of gears, sprockets and pulleys Explanation of chains Explanation of belts and what may be in the KOP this year Discussion of chains vs belts (based on the Team 234 paper) Wheel types Discussion of lifts and manipulators and counter balancing of arms
Keep it simple
A lot of information in this Decide what you can do with the resources you have Keep it simple Keep it light! A robot that does 1 thing well is better than a robot that does 2 things poorly Practice time is key so stop build early
Kitbot frame pieces

C channel 3/8-16x7 Hex head bolts for wheel shafts Corner connects -20x1.75 socket cap screws to attach corner connects and c channel
Kitbot frame pieces Six - C-Channel Eight - C-Base Corner Connects Six - 3/8-16 x 7" Hex Head Bolts Six - 3/8-16 Nylock Nuts Thirty Two - individual 1/4-20 x 1.75" Socket Head Cap Screws (Order 50) Thirty Two - individual 1/4-20 Nylock Nuts (Order 100)
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Kitbot frame assembled
Assembled frame with wheels and motors

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Kitbot frame
Robot max dimensions are typically 28 x 38 x 60 Check the rules for 2013 dimensions!!!!!!! Design your frame to be 1 smaller Design to 27x37x59 Frames are not always square Frames dont stay square if they started that way Bolts heads, nuts and other pieces will stick out beyond the edge of the frame and COUNT as your max dimension
Ground clearance
How far above the ground should your frame be? Depends on the competition field
Is the field flat? Do you have to climb over barriers? Do you have to go up ramps? Do you need to keep something from going under the robot?
Are there mechanisms that need certain height for the frame?
Height for ball to be loaded Frame height to get arm at given height
2012 ramp and frame height
5.8 6.0
Ground clearance
Do you adjust wheel diameter or use wheel mounts? Consider cost and weight
Larger wheels are more expensive Only gain 1 height change for 2 diameter change Supports require good mounting
Frame blocks
The first time you run your robot it may not behave as expected!!! Before you run your robot for the first time set it on blocks so the wheels are off the ground Verify wheel motion is correct before setting the robot on the ground!
Power transmission
Power is transmitted from a motor to wheels, arms or other items How to you connect a motor to something you want to move? Power could be transmitted directly by coupling motor shaft to a wheel but typically need to change speed and torque or direction or act away from the motors The change is primarily through the use of gears, sprockets or belts or some combination
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Gears, sprockets, pulleys

definition of gears (regular and miter), sprockets and pulleys how gear ratios work example with drive example with arm (this years robot)
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sprockets
Used with chain Different pitches 25 pitch
Lighter but not as strong
35 pitch (3/8 inch)

Stronger but heavier
25 pitch chain sprockets
Items can be attached to the chain
Images from AndyMark

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35 pitch chain sprockets

gears
Changes direction of power transmission Miter gear Hex shaft or keyed to connect shaft to gear Worm gear
Spiral gear
Flat gear Images from AndyMark or Boston Gear

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Pulleys for synchronous belts

Used with belts Different pitches and widths
http://robotics.gatesprograms.com/resources
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Pulleys for non synchronous belts

Used with belts Continuos belts Polyurethane belting
http://robotics.gatesprograms.com/resources
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Speed/Torque Ratio
driveR
Shaft Size for driveR Center Distance (center shaft to center shaft)
driveN
Shaft Size for driveN
Motor
HP, RPM, Efficiency
Backside Idler
Take-up/Installation Allowance
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Speed/Torque Ratio
R = driveN/wheel R = driveR/motor Slow Down More torque
1:1
Speed UP Less torque
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Speed/Torque Ratio Cont.
Slow Down R N
1:1 R N
Speed up R N
Diameters RPMs Torque (in-lb) HP
5 1000 20 0.3
10 500 40 0.3
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8 1000 20 0.3
8 1000 20 0.3
10 1000 20 0.3
5 2000 10 0.3
Chain vs belts vs gears

Advantages/disadvantages of chain Advantages/disadvantages of belts Comparison of sprockets, gears and pulleys
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Chain
Advantages
Any length possible Easy installation Chains can be put on without removing wheels Little tension required
Disadvantages
Lubrication required Messy Environment Reduced backlash characteristics Heavy
20
Pulleys and belts

Advantages
Lightweight Power dense Minimal backlash No lubrication, clean running
Disadvantages
Set lengths, cant break apart Have to remove axles to put belts on Tension required Bigger pulleys needed
21
Gears
Advantages
Compact Power dense Minimal backlash Best if used next to motor and in combination with belts or chains
Disadvantages
Set distance Requires lubrication Heavy if steel gears
22
Comparison gears, sprockets, pulleys

Feature Sprockets/chain Belt/Pulleys Gears
Weight Distance Rotation direction
Some what heavy Length dependent Driver can be far from driven Driver and driven rotate same direction
Lighter than chain Driver can be far from driven Driver and driven typically rotate same direction but belt can be twisted to cause rotation in opposite direction Fixed lengths Cant be adjusted Changing pulley size may require different belt
Typically steel so heavy Driver must be near to driven Each stage rotates in opposite direction
Flexibility
Can be any length and can be adjusted
Fixed spacing base on gear sizes
23
Kit of Parts Belts

Expect kits will be similar except for pulley instead of sprockets and belts instead of chain
24
Team 234 Belt Drive conclusions

Based on the results from this testing, the following high level conclusions can be drawn: 1. A belt drive system could save approximately 2 pounds on a six wheel drive. 2. The Belt drive system is approximately 3 4% more efficient. 3. The belt drive system was approximately 6% faster to a set distance. 4. The belt drive system traveled about 8% further for a given time of power application. 5. There was no measurable difference in belt or chain stretch when pulled under load. 6. There was no noticeable difference in noise level of belt or chain. 7. Chain is overall simpler to work with from a design / repair perspective.
25
Wheels
Wheel types Wheel chair
Reasonable traction
Traction
Good traction Harder to turn
Omni
Good traction in rotation direction but can slide ways Good for steering with center drive wheels Can be easily pushed sideways
Wheel diameter Typically 4, 6, 8 or 10inch Height will depend on competition and ground clearance
Mecanum
Rollers at 45 deg to direction of rotation Allows robot to move sideways or at angle Need set of 4 Very maneuverable but can be easily pushed Good where alignment to target is needed Not good if pushing or resistance to pushing needed Add torque boost system
26
Manipulators
Articulating Arms Telescoping Lifts Grippers Latches Turrets Ball Handling Systems Shooters Winches
Information from Andy Baker Mech. Engineering Mentor: 45 (1998-present) President and Co-owner: AndyMark, Inc. 2003 Championship Woodie Flowers Award
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Four Bar Linkage

Pin loadings can be very high Watch for buckling in lower member Counterbalance if you can Keep Center of Gravity aft Limited rotation Keeps gripper in known location
28
Telescoping Lifts
Extension Lift
Motion achieved by stacked members sliding on each other
Scissor Lift
Motion achieved by unfolding crossed members
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Extension - Rigging
Continuous
Cascade
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Scissor Lifts
Advantages
Minimum retracted height - can go under field barriers
Disadvantages
Tends to be heavy to be stable enough Doesnt deal well with side loads Must be built very precisely Stability decreases as height increases Loads very high to raise at beginning of travel I recommend you stay away from this!
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Arm vs. Lift

Feature
Reach over object Fall over, get up Go under barriers Center of gravity (Cg)
Small space operation
Arm
Yes Yes, if strong enough Yes, fold down Not centralized No, needs swing room
More articulations, more height (difficult)
Lift
No No Maybe, limits lift height Centralized mass Yes
More lift sections, more height (easier)
How high? Complexity Powerful lift Combination
Moderate Moderate Insert 1-stage lift at bottom of arm
High High
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Grippers
Gripper (FIRST definition): Device that grabs a game object How to grip How to hang on Speed Control
254 in 2008
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How to grip
Pneumatic linkage grip 1 axis 2 axis Motorized grip Roller grip Hoop grip Pneumatic grip
768 in 2008
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Pneumatic linear grip

Pneumatic Cylinder extends & retracts linkage to open and close gripper Easy to manufacture Easy to control Quick grab Limited grip force Requires pneumatic system
Recommended
35
968 in 2004
Pneumatic linear grip
Pneumatic Cylinder, pulling 3 fingers for a 2-axis grip Recommended
60 in 2004
36
Motorized Linear Grip

Slow More complex (gearing) Heavier Tunable force No pneumatics
49 in 2001
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Roller Grip
Allows for misalignment when grabbing Wont let go Extends object as releasing Simple mechanism Have a full in sensor Slow
Recommended
45 in 2008
148 in 2007
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Hoop grip
Slow Needs aligned Cant hold on well
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Pneumatic Grip
Needs vacuum generator Uses various cups to grab Slow Not secure Not easy to control Simple Problematic Not recommended
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Speed
Quickness covers mistakes Quick to grab Drop & re-grab Fast Pneumatic gripper Not fast Roller, motor gripper, vacuum
41
Ball Systems
Accumulator: rotational device that collects objects
Horizontal tubes: gathers balls from floor or platforms Vertical tubes: pushes balls between vertical goal pipes Wheels: best for big objects
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Conveying & Gathering

Conveyor - device for moving multiple objects, typically within your robot Continuous Belts Best to use 2 running at same speed to avoid jamming Individual Rollers Best for sticky balls that will usually jam on belts and each other
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Conveyors
Why do balls jam on belts? Sticky and rub against each other as they try to rotate along the conveyor Solution #1 Use individual rollers Adds weight and complexity Solution #2 Use pairs of belts Increases size and complexity Solution #3 Use a slippery material for the non-moving surface (Teflon sheet works great)
44
Ball System Tips
More control is better

Avoid gravity feeds these WILL jam Try to reduce random movements
Not all Balls are created equal

Balls tend to change shape Building adaptive/ flexible systems
Speed vs. Volume

Optimize for the game and strategy The more capacity, the better (?)
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Roller example: 188
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Intake roller example: 173 & 254
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Ball Shooter Systems

Secure shooting structure = more accuracy Feed balls individually, controlling flow Rotating tube or wheel One wheel or two 2006: 2000-4000 rpm Protect for safety Turret allows for aiming Sensors detect ball presence & shot direction
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Winches
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Wonderful Uses for Spectra Cable

First you must learn to tie a proper knot in this stuff
I use a triple pretzel knot (I doubt you - I made it up) :
will find this name in any scouting book
Simple lift cables - pretty obvious use, but how do you adjust the slack (steel cables use turnbuckles)?
Use a tourniquet like device - use a dowel pin to twist the cable on the outside of the spool or actuated device, and tie-wrap in place This works great for adjusting the location of travel also
If slack can occur, add a latex slack tensioner Remote actuations - this cable is so easy to route within your robot frame efficiently
Linear motions (come see team 111 bumper actuation) Rotary motions
50
Power
Power = Torque/ Time OR Power = Torque x Rotational Velocity Power (FIRST definition) how fast you can move something
51
Arm: Power Example

Same torque w/ Twice the Power results in Twice the Speed Power = Torque/ Time
10 lbs
10 lbs
125 Watts, 100 RPM
250 Watts, 200 RPM
52
Power
Summary All motors can lift the same amount (assuming 100% power transfer efficiencies) - they just do it at different rates No power transfer mechanisms are 100% efficient Inefficiencies (friction losses, binding, etc.) Design in a Safety Factor (2x, 4x)
53
Braking: Prevent Back-driving

Ratchet Device - completely lock in one direction in discrete increments - such as used in many winches Clutch Bearing - completely lock in one direction Brake pads - simple device that squeezes on a rotating device to stop motion - can lock in both directions
Disc brakes - like those on your car Gear brakes - applied to lowest torque gear in gearbox
Dynamic Breaking in electrical components let go when power is lost Any gearbox that cannot be back-driven alone is probably very inefficient
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Design is an Iterative Process
Evaluate
Research
Final Design
Test Design
Prototype
55
Keep it simple
A lot of information in this Decide what you can do with the resources you have Keep it simple A robot that does 1 thing well is better than a robot that does 2 things poorly Practice time is key so stop build early
56
References
http://files.andymark.com/ManiupulatorDesign.pdf http://files.andymark.com/FIRST-Robotics-Drive-Systems.ppt http://files.andymark.com/am-0952AssemblyInstructions.pdf http://robotics.gatesprograms.com/first http://first.gatesprograms.com/assets/first/zips/FIRST.zip http://robotics.gatesprograms.com/video
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FIRST Robotics - FRC Mechanical Presentation

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FIRST Robotics FRC Mechanical Presentation

Kitbot frame pieces

Kitbot frame assembled

Assembled frame with wheels and motors

Gears, sprockets, pulleys

35 pitch (3/8 inch)

25 pitch chain sprockets

Items can be attached to the chain

Images from AndyMark

35 pitch chain sprockets

Flat gear Images from AndyMark or Boston Gear

Pulleys for synchronous belts

Pulleys for non synchronous belts

Shaft Size for driveN

Speed UP Less torque

Speed/Torque Ratio Cont.

Diameters RPMs Torque (in-lb) HP

Chain vs belts vs gears

Pulleys and belts

Comparison gears, sprockets, pulleys

Weight Distance Rotation direction

Can be any length and can be adjusted

Fixed spacing base on gear sizes

Kit of Parts Belts

Team 234 Belt Drive conclusions

Four Bar Linkage

Arm vs. Lift

How high? Complexity Powerful lift Combination

Moderate Moderate Insert 1-stage lift at bottom of arm

Pneumatic linear grip

Pneumatic linear grip

Pneumatic Cylinder, pulling 3 fingers for a 2-axis grip Recommended

Motorized Linear Grip

Conveying & Gathering

Ball System Tips

More control is better

Not all Balls are created equal

Speed vs. Volume

Roller example: 188

Intake roller example: 173 & 254

Ball Shooter Systems

Wonderful Uses for Spectra Cable

Arm: Power Example

125 Watts, 100 RPM

250 Watts, 200 RPM

Braking: Prevent Back-driving

Design is an Iterative Process

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