Open Source Controller For Old And Expensive Industrial Robots

October 4, 2025 by Maya Posch 3 Comments

The Zynq-7000 usage at the core of the robot controller. (Credit: Excessive Overkill, YouTube)

Industrial robots like robotic arms are basically everywhere, albeit usually out of the public’s eye in factories. This also means that they get replaced and scrapped all the time, making for many opportunities to snap up an industrial robot that once cost as much as a pretty fancy car for essentially peanuts. Over the years the bloke behind the [Excessive Overkill] YouTube channel did this a lot, which also revealed the main issue with these ‘cheap’ robots: the electronics and associated software, with the manufacturer rarely going out of their way to appease to hobbyists trying to fix up one of these units, never mind for free.

That said, if you’re persistent enough, you can reverse-engineer these beasts to the point where you can develop your own controller hardware and software solution. This is exactly what was done, resulting in an open source controller, found on the ExcessiveMotion GitHub page, that should allow you to control many of these industrial robots. At the core is a Zynq-7000 hybrid FPGA-ARM SoC chip, running real-time Linux (with preemptive scheduling patch) on the SoC side and custom HDL on the FPGA side to handle the hard real-time tasks.

The controller during testing. (Credit: Excessive Overkill, YouTube)

The controller is made to be modular, with a backplane that can accept various interface cards in addition to the current RS-485 and RS-422 interfaces that are commonly used in industrial settings, such as here for controlling the individual servo drives of the robots. To make assembly and testing interesting, the first controller and integration with a robot was made ready for display at the Open Sauce 2025 event, requiring things to be rushed along, including reverse-engineering the servo protocol for a small-ish industrial robot suitable for public display and use, as well as developing the kinematics for the robotic arm.

With the controller now demonstrated, clearly this is the perfect time to rush out and get one of these fun industrial robots for a few hundred bucks. Currently the controller is still being finalized, with the author asking for feedback on what it should be able to support. If you have a particularly unusual industrial robot lounging around without the requisite controller, this might be your chance to revive it.

Thanks to [Hans] for the tip.

Continue reading “Open Source Controller For Old And Expensive Industrial Robots” →

Unitree Humanoid Robot Exploit Looks Like A Bad One

September 30, 2025 by Donald Papp 11 Comments

Unitree have a number of robotic offerings, and are one of the first manufacturers offering humanoid robotic platforms. It seems they are also the subject of UniPwn, one of the first public exploits of a vulnerability across an entire robotic product line. In this case, the vulnerability allows an attacker not only to utterly compromise a device from within the affected product lines, but infected robots can also infect others within wireless range. This is done via a remote command-injection exploit that involves a robot’s Bluetooth Low Energy (BLE) Wi-Fi configuration service.

While this may be the first public humanoid robot exploit we have seen (it also affects their quadruped models), the lead-up to announcing the details in a post on X is a familiar one. Researchers discover a security vulnerability and attempt responsible disclosure by privately notifying the affected party. Ideally the manufacturer responds, communicates, and fixes the vulnerability so devices are no longer vulnerable by the time details come out. That’s not always how things go. If efforts at responsible disclosure fail and action isn’t taken, a public release can help inform people of a serious issue, and point out workarounds and mitigations to a vulnerability that the manufacturer isn’t addressing.

The biggest security issues involved in this vulnerability (summed up in a total of four CVEs) include:

Hardcoded cryptographic keys for encrypting and decrypting BLE control packets (allowing anyone with a key to send valid packets.)
Trivial handshake security (consists simply of checking for the string “unitree” as the secret.)
Unsanitized user data that gets concatenated into shell commands and passed to system().

The complete attack sequence is a chain of events that leverages the above in order to ultimately send commands which run with root privileges.

We’ve seen a Unitree security glitch before, but it was used to provide an unofficial SDK that opened up expensive features of the Go1 “robot dog” model for free. This one is rather more serious and reportedly affects not just the humanoid models, but also newer quadrupeds such as the Go2 and B2. The whole exploit is comprehensively documented, so get a fresh cup of whatever you’re drinking before sitting down to read through it.

WALL-E’s Forgotten Sibling Rebuilt

September 28, 2025 by Al Williams 5 Comments

Do you remember the movie WALL-E? Apparently, [Leviathan engineering] did, and he wasn’t as struck by the title character, or Eva, or even the Captain. He was captivated by BURN-E. His working model shows up in the video below.

We’ll be honest. BURN-E didn’t ring a bell for us, though we remember the movie. He grabbed a 3D design for the robot on the Internet and planned out holes for some servos and other hardware.

Continue reading “WALL-E’s Forgotten Sibling Rebuilt” →

Robot Bartender Is The Life Of The Party

September 26, 2025 by Bryan Cockfield 9 Comments

As the old saying goes, when the only tool you have is a 6 DOF industrial robotic arm, every problem looks like an opportunity to make it serve up adult beverages. [benkokes] found himself in this familiar predicament and did what any of us would do, but his process wasn’t without a few party fouls as well as a few head-scratchers.

One of the common problems that people who suddenly find themselves with an old industrial robot have is that there’s usually no documentation or instructions. This was true here with the added hiccup of the robot’s UI being set to Chinese. Luckily no one had changed the root password, and eventually he was able to get the robot up and working.

Getting it to make drinks was a different matter altogether. [benkokes] needed a custom tool to hold the cup as well as shake it, and 3D printed a claw-style end effector with a lid. Out of his multi-colored pack of party cups, however, the orange cups were different enough in dimension to cause problems for the shaking lid which was discovered when the robot spilled a drink all over the table.

Eventually, though, the robot was successfully serving drinks at a party. One of [benkokes]’s friends happened to be a puppet maker and was able to outfit it with a tailored tuxedo for the party as well, and he also programmed it to dance in between serving drinks, completing the AI revolution we have all been hoping for. Perhaps unsurprisingly, this is a common project for people who suddenly come to posses a large general-purpose industrial robot, while others build robots specifically for this task alone.

Continue reading “Robot Bartender Is The Life Of The Party” →

Robot Balances Ball On A Plate

September 22, 2025 by Lewin Day 26 Comments

Imagine trying to balance a heavy metal ball bearing on a cafeteria tray. It’s not the easiest thing in the world! In fact, it’s perhaps a task better automated, as [skulkami3000] demonstrates with this robotic build.

The heart of the build is a flat platform fitted with a resistive touchscreen panel on top. The panel is hooked up to a Teensy 4.0 microcontroller. When a heavy ball bearing is placed on the touch panel, the Teensy is thus able to accurately read its position. It then controls a pair of NEMA 17 stepper motors via TCM2208 drivers in order to tilt the panel in two axes in order to keep the ball in the centre of the panel. Thanks to its quick reactions and accurate sensing, it does a fine job of keeping the ball centred, even when the system is perturbed.

Projects like these are a great way to learn the basics of PID control. Understanding these concepts will serve you well in all sorts of engineering contexts, from controlling industrial processes to building capable quadcopter aircraft. Continue reading “Robot Balances Ball On A Plate” →

For A Robot Claw, The Eyes Have It

September 21, 2025 by Al Williams 3 Comments

Have you ever wished your hand had an extra feature? Like, maybe, a second thumb? A scope probe pinky maybe? Well, if you are building a robot effector, you get to pick what extra features it has. [Gokux] has the aptly named Cam Claw, which is a 3D printed claw with a built-in camera so you can see exactly what it is doing.

The brains are an ESP32-S3 and the eyes — well, the eye technically — uses an OV3660 camera. There’s even a light in case you are in a dark space. A servo drives it, and the printed gear train is pretty fun to watch, as you can see in the video below.

This project is all about the mechanics. The electronic hardware is trivial. A battery, a power controller, and a servo complement the ESP32 and camera. Six LEDs for light, and the job is done.

Obviously, the gripping power will only be as good as the servo. However, we really liked the idea of putting eyes on a robot hand where they count. Of course, the claw you really want a camera on is in the arcade. We’d like to see cameras on some other robot appendages.

Continue reading “For A Robot Claw, The Eyes Have It” →

Reverse Engineering A Robot Mower’s Fence

September 10, 2025 by Jenny List 22 Comments

There are a variety of robot mower systems on the market employing different navigation methods, and [Eelco] has the story of how one of these was reverse engineered. Second hand Roomba lawnmowers kept appearing for very low prices without the electronics driving the buried-wire fence that keeps them from going astray. The story of their reverse engineering provides us with a handy insight into their operation.

The wire fence is a loop of wire in the ground, so it was modeled using a few-ohm resistor and the waveform across it from a working driver captured with an oscilloscope. The resulting 3 kHz waveform surprisingly to us at least doesn’t appear to encode any information, so it could be replicated easily enough with an ESP32 microcontroller. An LM386 audio amplifier drives the loop, and with a bit of amplitude adjustment the mower is quite happy in its fake fence.

Robot mower hacking has become quite the thing around here.