Welding Robot Takes On A Hot, Dirty, Dangerous Job

November 6, 2018 by Adam Fabio 40 Comments

They used to say that robots would take over the jobs too dirty or dangerous for humans. That is exactly what [Joel Sullivan] had in mind when he created this welding robot. [Joel] designed the robot for the OSB industry. No, that’s not a new operating system, it’s short for Oriented Strand Board. An engineered lumber, OSB is made of strands (or chips) of wood. It’s similar to plywood but doesn’t require large thin sheets of lumber. To make a panel of OSB, a 5-inch thick matt of wood chips is mixed with glue and compressed down to 5/16″ at 7500 PSI and 400° F.

The presses used to make OSB are a massively parallel operation. 20 or more boards can be pressed at once. Thy press is also a prime area for damage. A nut or bolt hidden in the wood will dig into the press, causing a dent which will show up on every sheet which passes through that section. The only way to fix the press is to shut it down, partially dismantle it, and fill the void in with a welder. [Joel’s] robot eliminates most of the downtime by performing the welding on a still hot, still assembled press.

The robot looks like it was inspired by BattleBots, which is fitting as the environment it works in is more like a battleground. It’s a low, wide machine. In the front are two articulated arms, one with a welder, and one with a die grinder. The welder fills any voids in the press platen, and the die grinder grinds the fresh welds flat. An intel NUC controls things, with plenty of motor drives, power supplies, and relays on board.

[Joel’s] bot is tethered, with umbilicals for argon, electricity and compressed air. Air travels through channels throughout the chassis and keeps the robot cool on the hot press. Everything is designed for high temperatures, even the wheels. [Joel] tried several types of rubber, but eventually settled on solid aluminum wheels. The ‘bot doesn’t move very fast, so there is plenty of traction. Some tiny stepper motors drive the wheels. When it’s time to weld, pneumatic outriggers lock the robot in place inside the narrow press.

Cameras with digital crosshairs allow the operator to control everything through a web interface. Once all the parameters are set up, the operator clicks go and sparks fly as the robot begins welding.

If you’re into seriously strong robots, check out trackbot, or this remote-controlled snow blower!

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SMORES Robot Finds Its Own Way To The Campfire

November 2, 2018 by Roger Cheng 2 Comments

Robots that can dynamically reconfigure themselves to adapt to their environments offer a promising advantage over their less dynamic cousins. Researchers have been working through all the challenges of realizing that potential: hardware, software, and all the interactions in between. On the software end of the spectrum, a team at University of Pennsylvania’s ModLab has been working on a robot that can autonomously choose a configuration to best fit its task at hand.

We’ve recently done an overview of modular robots, and we noted that coordination and control are persistent challenges in this area. The robot in this particular demonstration is a hybrid: a fixed core module serving as central command, plus six of the lab’s dynamic SMORES-EP modules. The core module has a RGB+Depth camera for awareness of its environment. A separate downwards-looking camera watches SMORES modules for awareness of itself.

Combining that data using a mix of open robot research software and new machine specific code, this team’s creation autonomously navigates an unfamiliar test environment. While it can adapt to specific terrain challenges like a wood staircase, there are still limitations on situations it can handle. Kudos to the researchers for honestly showing and explaining how the robot can get stuck on a ground seam, instead of editing that gaffe out to cover it up.

While this robot isn’t the completely decentralized modular robot system some are aiming for, it would be a mistake to dismiss based on that criticism alone. At the very least, it is an instructive step on the journey offering a tradeoff that’s useful on its own merits. And perhaps this hybrid approach will find application with a modular robot close to our hearts: Dtto, the winner of our 2016 Hackaday Prize.

[via Science News]

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Low-cost Autonomous Rover Will Drive Your Projects

October 29, 2018 by Tom Nardi 3 Comments

[Miguel] wanted to get more hands-on experience with Python, so he created a small robotic platform as a testbed. But as such things sometimes go, it turns out the robot he created is a worthy enough project in its own right. With a low total cost and highly flexible design, it might be exactly what you’re looking for. Who knows, it might even bootstrap that rover project that’s been wandering around the back of your mind.

The robot makes use of an exceptionally simple 3D printed frame. No complicated suspension to worry about, no fasteners to hold together multiple printed parts. It’s just a single printed “L” shaped piece that has mounts for the motors and front sensor board. As designed it simply drags its tail around, which should work fine on smooth surfaces, but might need a bit of tweaking if you plan on taking your new robotic friend on an outdoor adventure.

There’s a big open area on the “tail” to mount a Raspberry Pi, but you could really put whatever board or microcontroller you wish here. In the nose is an HC-SR04 ultrasonic sensor, which [Miguel] is using to perform obstacle avoidance in his Python code. A dual H-Bridge motor driver controls the pair of gear motors in the front to provide propulsion and steering, and a buck converter steps down the 7.4V from the 2S LiPo battery to power the electronics. He’s even included a mini breadboard so you can add circuits or sensors as experimental payloads.

If you’re looking for a slightly more advanced 3D printed robotics platform, we’ve seen our fair share. From the nearly fully printed Watney to a tank that looks like it’s ready for front-line combat.

Robot + Trumpet = Sad Trombone.mp3

October 22, 2018 by Kristina Panos 13 Comments

[Uri Shaked] is really into Latin music. When his interest crescendoed, he bought a trumpet in order to make some energetic tunes of his own. His enthusiasm flagged a bit when he realized just how hard it is to get reliably trumpet-like sounds out of the thing, but he wasn’t about to give up altogether. Geekcon 2018 was approaching, so he thought, why not make a robot that can play the trumpet for me?

He scoured the internet and found that someone else had taken pains 20 years ago to imitate embouchure with a pair of latex lips (think rubber glove fingers filled with water). Another soul had written about measuring air flow with regard to brass instruments. Armed with this info, [Uri] and partners [Ariella] and [Avi] spent a few hours messing around with air pumps, latex, and water and came up with a proof of concept that sounds like—and [Uri]’s description is spot-on—a broken robotic didgeridoo. It worked, but the sound was choppy.

Fast forward to Geekcon. In a flash of brilliance, [Avi] thought to add capacitance to the equation. He suggested that they use a plastic box as a buffer for air, and it worked. [Ariella] 3D printed some fingers to actuate the valves, but the team ultimately ended up with wooden fingers driven by servos. The robo-trumpet setup lasted just long enough to get a video, and then a servo promptly burned out. Wah wahhhh. Purse your lips and check it out after the break.

If [Uri] ever gets fed up with the thing, he could always turn it into a game controller a la Trumpet Hero.

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Teardown: Sony’s New Aibo Goes Under The Knife

October 22, 2018 by Drew Littrell 22 Comments

In a complete surprise, Sony has moved to release the latest version of their robotic dog series, Aibo, in North America. The device is already out in Japan, where there are a number of owner’s clubs that would rival any dedicated kennel club. Thanks to the [Robot Start] team, we now have a glimpse of what goes into making the robotic equivalent of man’s best friend in their teardown of an Aibo ERS-1000.

According to Yoshihiro of Robot Start, Aibo looks to be using a proprietary battery reminiscent of the Handycam camcorders. Those three gold contacts are used for charging on the rug shaped power base that Aibo will periodically return to in order to take a”nap”. There are a couple of square OLED screens behind those puppy dog eyes. They are full-color OLEDs somewhere in the one-inch ballpark. Between the screens is a capacitive touch sensor that wraps around to the top of the head that are also pressure sensitive.

According to Sony’s press release, the fish-eye camera housed in Aibo’s snout is used to identify faces as well as navigating spaces.

Laying out all the major parts out together certainly drives home the complexity of the latest Aibo. It’ll be interesting to see the progression of this device as all of them come equipped with 4G LTE and 802.11 b/g/n WiFi that connect to Sony’s servers for deep learning.

New behaviors are supposed to download automatically as long as the device is under the subscription plan. While Sony has no current plans to integrate with any voice-activated virtual assistant, we can still look forward to the possibility of some expanded functionality from the Hackaday community.

For the rest of the teardown photos make sure to head over to [Yoshihiro]’s write up on Robot Start. Also just in case anybody cared to see what happens when the first generation Aibo ERS-111 from 1999 meets the 2018 Aibo ERS-1000, you’ll find the answer in the video below:

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SandBot Happily And Tirelessly Rolls Patterns In Sand

October 18, 2018 by Donald Papp 1 Comment

The patience and precision involved with drawing geometric patterns in sand is right up a robot’s alley, and demonstrating this is [rob dobson]’s SandBot, a robot that draws patterns thanks to an arm with a magnetically coupled ball.

SandBot, SCARA version. The device sits underneath a sand bed, and a magnet (seen at the very top at the end of the folded “arm”) moves a ball bearing through sand.

SandBot is not a cartesian XY design. An XY frame would need to be at least as big as the sand table itself, but a SCARA arm can be much more compact. Sandbot also makes heavy use of 3D printing and laser-cut acrylic pieces, with no need of an external frame.

[rob]’s writeup is chock full of excellent detail and illustrations, and makes an excellent read. His previous SandBot design is also worth checking out, as it contains all kinds of practical details like what size of ball bearing is best for drawing in fine sand (between 15 and 20 mm diameter, it turns out. Too small and motion is jerky as the ball catches on sand grains, and too large and there is noticeable lag in movement.) Design files for the SCARA SandBot are on GitHub but [rob] has handy links to everything in his writeup for easy reference.

Sand and robots (or any moving parts) aren’t exactly a natural combination, but that hasn’t stopped anyone. We’ve seen Clearwalker stride along the beach, and the Sand Drawing Robot lowers an appendage to carve out messages in the sand while rolling along.

Laser Cut Cardboard Robot Construction Kit Eases Learning And Play

October 18, 2018 by Donald Papp No comments

It has never been easier to put a microcontroller and other electronics into a simple project, and that has tremendous learning potential. But when it comes to mechanical build elements like enclosures, frames, and connectors, things haven’t quite kept the same pace. It’s easier to source economical servos, motors, and microcontroller boards than it is to arrange for other robot parts that allow for cheap and accessible customization and experimentation.

That’s where [Andy Forest] comes in with the Laser Cut Cardboard Robot Construction Kit, which started at STEAMLabs, a non-profit community makerspace in Toronto. The design makes modular frames, enclosures, and basic hardware out of laser-cut corrugated cardboard. It’s an economical and effective method of creating the mechanical elements needed for creating robots and animatronics while still allowing easy customizing. The sheets have punch-out sections for plastic straws, chopstick axles, SG90 servo motors, and of course, anything that’s missing can be easily added with hot glue or cut out with a knife. In addition to the designs being open sourced, there is also an activity guide for educators that gives visual examples of different ways to use everything.

Cardboard makes a great prototyping material, but what makes the whole project sing is the way the designs allow for easy modification and play while being easy to source and produce.