Designing Tiny Motors Right Into The Robot’s Circuit Board

January 1, 2019 by Mike Szczys 10 Comments

Motors are not overly complex, but this one is downright simple. Carl Bujega has been working on a motor design that heavily relies on the capabilities of the printed circuit board (PCB) fabrication processes. His talk at the 2018 Hackaday Superconference covers how he built a brushless DC motor and speed controller into a PCB. You can watch the newly published video after the break.

There are two main parts of an electric motor; the stator is stationary while the rotor spins on bearings. Electromagnetic forces are used to cause that spinning action. In this case, Carl has built the electromagnets as coils on a 4-layer circuit board (six coils on each layer). When electrified, a magnetic field is generated that pushes against the rare-earth magnets housed in the rotor.

A couple of things are really interesting here. First, those coils are usually made of “magnet wire” (enamel covered wire that is very thin) wrapped around an iron core. Using the circuit board instead saves both physical space, and the time and expense of wrapping coils of wire in the traditional way. Second, Carl has been designing with manufacture in mind; you can see in the image show that his motor design is dead-simple to assemble by inserting a 3mm bearing in the PCB, inserting magnets into the plastic rotor and snapping it into place. The end goal is to make robot actuators that are part of the circuit board itself.

The genesis of this idea came from Carl’s interest in drone design, in fact, he jumped right into a drone startup immediately after finishing his EE. The company didn’t last, but his thirst for interesting designs is ongoing. When looking at reducing the total parts necessary to build a quadcopter he happened on the idea of PCB-based coils and he’s followed it to this motor design, and beyond to some very interesting flexible-PCB robot design work which you can check out on his Hackaday.io page, YouTube, and Twitter.

There are of course some trade-offs to this. The motor is low torque since it uses an air core and not an iron core. And he’s had trouble implementing a sensor-less Electronic Speed Controller (ESC) as the back-EMF from the coils appears to be too weak. Not to fret, he added a hall sensor and has succeeded in designing an ESC that measures just 14mm by 8mm. In fact, he’s holding up the ESC and motor in the image at the top of this article!

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Researchers Squeeze Out A New Breed Of Robot Locomotion

September 30, 2017 by Sonya Vasquez 24 Comments

Researchers have been playing around with various oddball forms of robot locomotion; surely, we’ve seen it all, haven’t we? Not so! Lucky for us, [researchers at Stanford] are now showing us a new way for robots to literally extrude themselves from point A to point B.

This robot’s particular motion for mechanism involves unwinding itself inside out. From a stationary base, a reel caches meters of the robot’s uninflated polyethylene body, which it deploys by pressurizing. Researchers can make full 3D turns by varying the amount of inflated air in outer control chambers. What’s more, they can place end effectors or even payloads at the tip of the growing end with their position held in place by a cable.

As we can imagine, any robot that can squeeze its way up to 72 meters long can have dozens of applications, and the folks at Stanford have explored a host of nooks and crannies of this space. Along the way, they deploy complex antenna shapes into the air, deliver small payloads, extinguish fires, and squeeze through all sorts of uninviting places such as flytraps and even a bed of nails. We’ve placed a video below the break, but have a look at Ars Technica’s full video suite to get a sense of the sheer variety of applications that they imparted upon their new creation.

Biomimetics tends to get us to cry “gecko feet” or “snake robots” without thinking too hard. But these forms of locomotion that come to mind all seem to derive from the animal kingdom. One key element of this soft robot is that its stationary base and vine-like locomotion both have its roots in the plant kingdom. It’s a testament to just how unexplored this realm may be, and that researchers and robots will continue to develop new ways of artificially “getting around” for years to come.

Thanks for the tip, [Jacob!]

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Robot Ants Wear Circuitry As Exoskeleton

March 16, 2017 by Steven Dufresne 36 Comments

[FESTO] keeps coming up with new tricks that make us both envious and inspired. Take their bionicANTs for example. Watching a group of them cooperate to move objects around looks so real that you’re instantly reminded of the pests crawling across your floor, but looking at them up close they’re a treasure trove of ideas for your next robot project.

The exoskeleton is 3D printed but they then use the outer surface of that exoskeleton as a circuit board for much of the circuitry. The wiring is “painted on” using a 3D MID (Molded Interconnect Device) process. While FESTO didn’t give specifics about their process, a little research shows that 3D MID involves the 3D printed object being made of a special non-conductive metal material, a laser then “drawing” the traces in the material, and then dipping the object in various baths to apply copper, nickel and gold layers. We mortal hackers may not have the equipment for doing this ourselves in our workshops but seeing the beautiful result should be inspiration enough to get creative with our copper tape on the outer surfaces of our 3D printed, CNC’d, or hand-carved parts.

We also like how they took a the mouse sensor from under a regular computer mouse and attached it to the ant’s underside, pointing down for precision dead reckoning. For the legs they used three piezo bending transducers. However, these give a deflection of only 1.5mm in both directions, not enough for walking. They increase this to over 10mm with the addition of a plastic hinge, another idea to keep in mind when building that next tiny robot. And there are more ideas to be taken advantage of in their ants, which you can see being built in the video below.

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Soft Robot With Microfluidic Logic Circuit

September 7, 2016 by Steven Dufresne 17 Comments

Perhaps our future overlords won’t be made up of electrical circuits after all but will instead be soft-bodied like ourselves. However, their design will have its origins in electrical analogues, as with the Octobot.

The Octobot is the brainchild a team of Harvard University researchers who recently published an article about it in Nature. Its body is modeled on the octopus and is composed of all soft body parts that were made using a combination of 3D printing, molding and soft lithography. Two sets of arms on either side of the Octobot move, taking turns under the control of a soft oscillator circuit. You can see it in action in the video below.

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Hackaday Prize Entry: Robotic Prosthetic Leg Is Open Source And 3D-Printable

May 25, 2016 by Moritz Walter 19 Comments

We’ve been 3D-printing parts for self-replicating machines before, but we’ve been working on the wrong machines. Software and robotics engineer [David Sanchez Falero] is about to set it right with his Hackaday Prize entry, a 3D-printable, open source, robotic prosthetic leg for humans.

[David] could not find a suitable, 3D-printable and customizable prosthetic leg out there, and given the high price of commercial ones he started his own prosthesis project named Drakkar. The “bones” of his design are made of M8 steel threaded rods, which help to keep the cost low, but are also highly available all over the world. The knee is actively bent by a DC-motor and, according to the source code, a potentiometer reads back the position of the knee to a PID loop.

While working on his first prototype, [David] quickly found that replicating the shape and complex mechanics of a human foot would be too fragile when replicated from 3D-printed parts. Instead, he looked at how goat hooves managed to adapt to uneven terrain with only two larger toes. All results and learnings then went into a second version, which now also adapts to the user’s height. The design, which has been done entirely in FreeCAD, indeed looks promising and might one day compete with the high-priced commercial prosthesis.

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Smartphone-based Robotic Rover Project Goes Open Source

May 17, 2016 by Donald Papp 4 Comments

[Aldric Négrier] wrote in to let us know that his DriveMyPhone project has been open sourced. The project is a part telepresence, part remote-controlled vehicle, part robotic rover concept on which he says “I spent more time […] than I should have.” He has shared not just the CAD files, but every detail including tips on assembly. He admits that maybe a robotic chassis for a smartphone might not seem like a particularly new idea today, but it was “an idea with more potential” back in 2010 when he first started.

The chassis is made to cradle a smartphone. Fire up your favorite videoconferencing software and you have a way to see where you’re going as well as hear (and speak to) your surroundings. Bluetooth communications between the phone and the chassis provides wireless control. That being said, this unit is clearly designed to be able to deal with far more challenging terrain than the average office environment, and has been designed to not only be attractive, but to be as accessible and open to repurposing and modification as possible.

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Forty-Year-Old Arcade Game Reveals Secrets Of Robot Path Planning

April 28, 2016 by Dan Maloney 20 Comments

What’s to be gained from reverse engineering a four-decade-old video game? As it turns out, quite a lot, and as you’ll learn from [Norbert]’s recent talk at the ViennaJS meetup, it’s not just about bringing a classic back to life.

The game in question is Kee Game’s Sprint 2, a monochrome 2D car race that allowed two players to compete head to head. The glorious Harvest Gold and Burnt Orange color scheme just screams 1970s, and it might be hard to see why this game was once a popular quarter-eater. But it was quite engaging for the day, and [Norbert] was interested in reverse engineering it. That he did, using JavaScript to build a faithful browser-based emulation of the game. And he took it further, creating a 3D first-person version of the game.

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