How Industrial Robot Safety Was Written In Blood

February 5, 2026 by 31 Comments

It was January 25th of 1979, at an unassuming Michigan Ford Motor Company factory. Productivity over the past years had been skyrocketing due to increased automation, courtesy of Litton Industry’s industrial robots that among other things helped to pick parts from shelves. Unfortunately, on that day there was an issue with the automated inventory system, so Robert Williams was asked to retrieve parts manually.

As he climbed into the third level of the storage rack, he was crushed from behind by the arm of one of the still active one-ton transfer vehicles, killing him instantly. It would take half an hour before his body was discovered, and many years before the manufacturer would be forced to pay damages to his estate in a settlement. He only lived to be twenty-five years old.

Since Robert’s gruesome death, industrial robots have become much safer, with keep-out zones, sensors, and other safety measures. However this didn’t happen overnight; it’s worth going over some of the robot tragedies to see how we got here.

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Light Following Robot Does It The Analog Way

January 28, 2026 by 12 Comments

If you wanted to build a robot that chased light, you might start thinking about Raspberry Pis, cameras, and off-the-shelf computer vision systems. However, it needn’t be so complex. [Ed] of [Death and the Penguin] demonstrates this ably with a simple robot that finds the light the old-fashioned way.

The build is not dissimilar from many line-following and line chasing robots that graced the pages of electronics magazines 50 years ago or more. The basic circuit relies on a pair of light-dependent resistors (LDR), which are wrapped in cardboard tubes to effectively make their response highly directional. An op-amp is used to compare the resistance of each LDR. It then crudely steers the robot towards the brighter light between turning one motor  hard on or the other, operating in a skid-steer style arrangement.

[Ed] then proceeded to improve the design further with the addition of a 555 timer IC. It’s set up to enable PWM-like control, allowing one motor to run at a lower speed than the other depending on the ratio between the light sensors. This provides much smoother steering than the hard-on, hard-off control of the simpler circuit. [Ed] notes that this is about the point where he would typically reach for a microcontroller if he hoped to add any additional sophistication.

In an era where microcontrollers seem to be the solution to everything, it’s nice to remember that sometimes you can complete a project without using a processor or any code at all. Video after the break.

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Building A Little Quadruped Robot

January 24, 2026 by 7 Comments

Robots don’t have to be large and imposing to be impressive. As this tiny quadruped from [Dorian Todd] demonstrates, some simple electronics and a few servos can create something altogether charming on their own.

This little fellow is named Sesame. A quadruped robot, it’s built out of 3D-printed components. Each leg features a pair of MG90S hobby servos, one of which rotates the leg around the vertical axis, while the other moves the foot. The ESP32 microcontroller controls all eight servos, enabling remote control of Sesame via its built-in wireless connectivity. Sesame also gets a 128×64 OLED display, which it uses to display a range of emotions.

Mechanically, the Sesame design isn’t particularly sophisticated. Where it shines is that even with such a limited range of motion, between its four legs and its little screen, this robot can display a great deal of emotion. [Dorian] shows this off in the project video, in which Sesame scampers around a desktop with all the joy and verve of a new puppy. It’s also very cheap; [Dorian] estimates you can build your own Sesame for about $60. Files are on GitHub for the curious.

If you prefer your quadrupeds built for performance over charm, you might consider an alternative build. Video after the break.

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Robot Sees Light With No CPU

January 19, 2026 by 10 Comments

If you ever built a line following robot, you’ll be nostalgic about [Jeremy’s] light-seeking robot. It is a very simple build since there is no CPU and, therefore, also no software.

The trick, of course, is a pair of photo-sensitive resistors. A pair of motors turns the robot until one of the sensors detects light, then moves it forward.

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The Best Robot Mop System: Flat, Spinning, Or Roller?

January 17, 2026 by 5 Comments

When it comes to designing a mopping robot, there are a number of approaches you can pick from, including just having the movement of the robot push the soggy mop over the floor, having spinning pads, or even a big spinning roller. But what difference does it make? Recently the [Vacuum Wars] channel ran a comparison to find out the answer.

The two spinning pad design is interesting, because it allows for the bot to move closer to objects or walls, and the base station doesn’t need the active scrubber that the simple static pad requires. The weakness of both types of flat mop design is that they are quickly saturated with dirt and moisture, after which they’ll happily smear it over the floor.

The spinning roller is the most complex, with the robot having its own onboard water tank, and a way to extract the dirty water from the mop and store it for disposal in the base station. Theoretically this would be the clear winner, with basically all of them having features like avoiding carpet.

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Detail of Horus's face, from a statue of Horus and Set placing the crown of Upper Egypt on the head of Ramesses III. Twentieth Dynasty, early 12th century BC.

HORUS Framework: A Rust Robotics Library

January 9, 2026 by 7 Comments

[neos-builder] wrote in to let us know about their innovation: the HORUS Framework — Hybrid Optimized Robotics Unified System — a production-grade robotics framework built in Rust for real-time performance and memory safety.

This is a batteries included system which aims to have everything you might need available out of the box. [neos-builder] said their vision is to create a robotics framework that is “thick” as a whole (we can’t avoid this as the tools, drivers, etc. make it impossible to be slim and fit everyone’s needs), but modular by choice.

[neos-builder] goes on to say that HORUS aims to provide developers an interface where they can focus on writing algorithms and logic, not on setting up their environments and solving configuration issues and resolving DLL hell. With HORUS instead of writing one monolithic program, you build independent nodes, connected by topics, which are run by a scheduler. If you’d like to know more the documentation is extensive.

The list of features is far too long for us to repeat here, but one cool feature in addition to the real-time performance and modular design that jumped out at us was this system’s ability to process six million messages per second, sustained. That’s a lot of messages! Another neat feature is the system’s ability to “freeze” the environment, thereby assuring everyone on the team is using the same version of included components, no more “but it works on my machine!” And we should probably let you know that Python integration is a feature, connected by shared-memory inter-process communication (IPC).

If you’re interested in robotics and/or real-time systems you should definitely be aware of HORUS. Thanks to [neos-builder] for writing in about it. If you’re interested in real-time systems you might like to read Real-Time BART In A Box Smaller Than Your Coffee Mug and Real-Time Beamforming With Software-Defined Radio.

A round, 3D-printed motor housing is shown, with one flattened side holding a fan mount. A circular plate is mounted above the face of the housing, and a cord runs around it and pulleys on the side of the housing.

Tying Up Loose Ends On A Rope-based Robot Actuator

January 5, 2026 by 9 Comments

One of the perennial challenges of building robots is minimizing the size and weight of drive systems while preserving power. One established way to do this, at least on robots with joints, is to fit each joint with a quasi-direct-drive motor integrating a brushless motor and gearbox in one device. [The 5439 Workshop] wanted to take this approach with his own robot project, but since commercial drives were beyond his budget, he designed his own powerful, printable actuator.

The motor reducing mechanism was the biggest challenge: most quasi-direct drives use a planetary gearbox, but this would have been difficult to 3D-print without either serious backlash or limited torque. A cycloidal drive was an option, but previous printable cycloidal drives seemed to have low efficiency, and they didn’t want to work with a strain-wave gearing. Instead, he decided to use a rope drive (this seems to be another name for a kind of Capstan drive), which doesn’t require particularly strong materials or high precision. These normally use a rope wound around two side-by-side drums, which are difficult to integrate into a compact actuator, but he solved the issue by putting the drums in-line with the motor, with two pairs of pulleys guiding the rope between them in a “C” shaped path.

The actual motor is a hand-wound stator inside a 3D-printed rotor with magnets epoxied into it. The printed rotor proved problematic when the attraction between the rotor and magnets caused it to flex and scrape against the housing, and it eventually had to be reinforced with some thin metal sheets. After fixing this, it reached five Newton-meters of torque at one amp and nine Newton-meters at five amps. The diminishing returns seem to be because the 3D-printed pulley wheels broke under higher torque, which should be easy to fix in the future.

This looks like a promising design, but if you don’t need the output shaft inline with the motors, it’s probably easier to build a simple Capstan drive, the mathematics of which we’ve covered before. Both makers we’ve previously seen build Capstan drives used them to make robot dogs, which says something for their speed and responsiveness.