[Greg06] started learning electronics the same way most of us did: buy a few kits, read a few tutorials, and try your hardest to put a few things together. Sound familiar? After a while, you noticed your skills started increasing, and your comfort level with different projects improved as well. Eventually, you try your hand at making your own custom projects and publishing your own tutorials.
[Greg06’s] robot has a quadruped based, housed within a 3D printed spherical body. The legs are retractable and are actuated by tiny servo motors inside the body. [Greg06] even included an ultrasonic distance sensor for the obstacle avoidance mechanism. Honestly, if it weren’t for the ultrasonic distance sensor protruding from the spherical body, you might think that the entire robot was just a little Wiffle ball. This reminds us of another design we’ve seen before.
If that weren’t enough, the spherical head can rotate, widening the range of the ultrasonic distance sensor and obstacle avoidance mechanism. This is accomplished by attaching another servo motor to the head.
For many of us, movies are a great source of inspiration for projects, and the Star Wars films are a gift that just keeps giving. The D-O droid featured and the Rise of Skywalker is the equivalent of an abandoned puppy, and with the help of 3D printing, [Matt Denton] has brought it to life. (Video, embedded below.)
D-O is effectively a two-wheeled self-balancing robot, with two thin drive wheels on the outer edges of the main body. A wide flexible tire covers the space between the two wheels, where the electronics are housed, without actually forming part of the drive mechanism. The main drive motors are a pair of geared DC motors with encoders to allow closed-loop control down to very slow speeds. The brains of the operation is an Arduino MKR-W1010 GET on a stack that consists of a motor driver, shield, IMU shields, and prototyping shield. [Matt] did discover a design error on the motor driver board, which caused the main power switching MOSFET to burst into flames from excessive gate voltage. Fortunately he was able to work around this by simply removing the blown MOSFET and bridging the connection with a wire.
The head-on D-O is very expressive and [Matt] used four servos to control its motion, with another three to animate the three antennas on the back of its head. Getting all the mechanics to move smoothly without any slop took a few iterations to get right, and the end result looks and moves very well. Continue reading “Building D-O, The Cone Face Droid”→
By now we’ve come to expect a bountiful harvest of licensed merchandise to follow every Star Wars film. This year’s crop included many flavors of BB-8 so every fan can find something to suit their taste. At the top of this food chain is a mobile interactive “Hero Droid BB-8”. For those who want to see how it works, [TheMikeSenna] cracked open his unit to feed our curiosity.
Also called “Spin Master BB-8” for the manufacturer, this toy is impressively sophisticated for its price point. The video surveyed the mechanical components inside the ball. Showing how the droid travels, and how the head articulates.
The ‘Gonk’ droids from the Star Wars universe are easy to overlook, but serve the important function of mobile power generators. Here on Earth, [bithead942]’s life-size replica droid fulfills much the same purpose.
Cronk — functionally an oversized USB charging hub with a lot of bells and whistles — is remotely controlled by a modified Wii Nunchuck very controller similar to the one [bithead942] used to control his R2-D2. With the help of an Adafruit Audio FX Mini, an Adafruit Class D 20W amp, and two four-inch speakers, the droid can rattle off some sound effects as it blows off some steam(really, an inverted CO2 duster). An Arduino Mega acts as Cronk’s brain while its body is sculpted from cast-able urethane foam for its light weight and rigidity. It also houses a FPV camera, mic, and DVR so it can be operated effectively from afar.
We’ve been following [James Bruton]’s builds here on Hackaday for quite a while and he has built some impressive stuff. We love how he often doesn’t cover everything up, leaving enough room to admire the working bits under the hood. Just in time for the release of the new Star Wars movie, Rogue One, [James] put together an overview of his Star Wars robot builds.
The build summary includes his R6 droid, his GNK walking droid and the third revision of his BB-8 droid. [James Bruton]’s videos have tons of detail in them over many, many parts (for example, his BB-8 R3 playlist is 15 parts and his Ultron build currently has 26 episodes and counting!)
There’s a quick overview of each of the three robot builds in this video, and it includes links to the playlists for each build for those who want more detail. This is just what you need to glimpse all of the clever design that went into these wonderfully crafted droids. And if you haven’t seen it yet, you should check out his series elastic actuators that he’s working on for the Ultron build, they give a robot some relief from rigidity.
Finally the workings of the official BB-8 that you’ve seen rolling around at various events have been revealed. Its makers [Matt Denton] and [Josh Lee] participated in an hour-long presentation at Star Wars Celebration Europe 2016 just this past week where the various views of its internals were shown in action. It’s since had BB-8 builders (yours truly included) analyzing the workings for new ideas. We also now have the official name for it, red carpet BB-8.
For the first half of their talk they went over how BB-8 was implemented for Star Wars: The Force Awakens. As we’ve long known this was done using 7 puppeted BB-8’s, though it was revealed that only 4 were actually used, including a stationary one called the wiggler whose purpose you can guess. Another thing we didn’t know is that they did consider building a working BB-8 for filming but decided they needed something bullet proof, that would work right every time without making a film crew wait for repairs, and so went with the puppets instead.
The second half of their talk contained the big reveal, the mechanism inside red carpet BB-8’s ball. It turns out to be pretty close to what many builders have been doing. If you’ve seen the DIYer’s guide to the different BB-8 drive systems then you’ll understand when we say it’s a pendulum drive (aka axle drive). That is, there’s a motorized axle that crosses the middle of the ball and the ball rotates on that axle. Meanwhile a large mass suspended below the axle acts as the pendulum mass.
Red Carpet BB-8 side with cables
Red Carpet BB-8 side with actuator
BB-8 builders have known the importance of keeping as much mass as possible as low down as possible for stability, but it was revealed the great extent to which that has been done in the red carpet version. Motors for the head’s pitch and yaw are located at the bottom and their motion is transferred up to the center using what are maybe best known as bicycle brake cables. Another big reveal was a linear actuator for the body roll, tilting the center stuff with respect to the mass lower down. The actuator itself is located in the lower section. Also, BB-8 builders have been mounting the drive motors for rotating the ball with respect to the axle, in line with the axle. However, in red carpet BB-8 the motor is also at the bottom and its motion appears to be transferred up to the axle via belt and worm gears. You may mistake the gold cylinders on either side of the central gimbal system to be motors but they’re actually Moflon slip rings.
Those are just a few of the insights gained so far from analyzing the video below. Doubtless people will be noticing a lot more in the weeks to come.
BB-8 is the much loved new droid introduced in the 2016 movie Star Wars: The Force Awakens, though in my case from the very first trailer released in 2014 I liked it for the interesting engineering problems it posed. How would you make a robot that’s a ball that rolls along, but with a head that stays on top while the ball rolls under it?
BB-8 in 1st Star Wars: The Force Awakens trailer
Hamster in hamster wheel
To make the ball roll, the answer most people found obvious at first was to use the analogy of a hamster wheel. The hamster running inside makes the wheel turn. In the BB-8 building world, which is quite large, the drive mechanism has come to be called a hamster drive, or just a hamster.
For the head, it seemed obvious that there would be magnets inside the ball, perhaps held in place near the top of the ball by a post extending up from the hamster. Corresponding magnets in attraction would then be attached to the underside of the head, and balls (also mounted under the head) would keep the head moving smoothly over the ball.
The magnet approach for the head has turned out to be the method used by all BB-8 builders that I’ve seen. However, the hamster has turned out to be only one of multiple solutions. Since the original debut many different methods have been used in builds and we’re going to have a lot of fun looking at each separate approach. It’s almost like revealing a magic trick; but really it’s all just clever engineering.
Note that for the actual movie, a combination of 7 or 8 props and CGI were used. The official working BB-8s that are shown at various promotional events were built after the movie was made and as of this writing, few details of their construction have been released. One notable detail, however, is that they aren’t using hamster drives.
Below are details of all the different BB-8 drive systems I’ve seen so far that have been built along with how they work.