A few years ago, [patchartrand] decided to build a robot arm. The specs were simple: he needed a drive system that would be at least as strong as a human arm. After looking at motors, [patch] couldn’t find a solution for under $3,000. This led to the creation of the Ultra Servo, an embiggened version of the standard hobby servo that provides more than ten thousand oz-in of torque.
Your typical hobby servo has three main components. The electronics board reads some sort of signal to control a motor. This motor is strapped into a gear train of some sort, and a potentiometer reads the absolute position of a shaft. This is basically what the Ultra Servo is doing, although everything is much, much bigger.
The motor used in the Ultra Servo is a very large brushed DC motor. This is attached to a 160:1 planetary gearbox and the electronics are built around four reasonably large MOSFETs. The electronics are built around the ATmega168 microcontroller, and the specs for the completed servo include 12 V or 24 V operation, TTL, SPI, and standard RC communication, 60 RPM no load speed, and 60 ft-lbs of torque.
This is not your standard servo. This is a massive chunk of metal to move stuff. If you’ve ever wanted a remote-controlled Cessna, here you go. That said, servos of this size and power will always be pricey, and [patch] is looking at a cost of $750 per unit. Still, that’s much less than the thousands of a comparable unit, and a great entry to the Hackaday Prize.