Autonomous Mower Hits Snag

February 28, 2022 by Bryan Cockfield 10 Comments

Interfacing technology and electronics with the real world is often fairly tricky. Complexity and edge cases work their way in to every corner of a project like this; just ask anyone who has ever tried to operate a rover on Mars, make a hydroponics garden, or build almost any robotics project. Even those of us who simply own a consumer-grade printer are flummoxed by the ways in which they can fail when manipulating single sheets of paper. This robotic lawnmower is no exception, driving its creator [TK] to extremes to get it to mow his lawn.

[TK] actually had a platform for his autonomous mower ready to go thanks to a previous build using this solar-powered robot to explore the Australian outback. Adding another motor to handle the grass trimming seemed simple at first and he set about wiring it all up and interfacing it to the robot. After the first iteration he found the robot was moving too fast to effectively cut the grass, so he added a more powerful cutting motor and a gearbox to help the mower crawl more slowly over the lawn. Disaster struck when his 3D printed mount for the steel cutting blades shattered, but with [TK] uninjured he pushed on with more improvements.

As it stands right now, the mower can effectively cut the grass moving forward even with the plastic-only cutting blades that [TK] is using now for safety reasons. The mower stripped its reverse gear so there still are some improvements to make before this robot is autonomously cutting the lawn without supervision. Normally we see lawnmowers retrofitted with robotics rather than robotics retrofitted with a lawnmower, but we’re excited to see any approach that lets us worry about one less household chore.

Thanks to [Rob] for the tip!

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Resin-Printed Gears Versus PLA: Which Is Tougher?

February 10, 2022 by Lewin Day 33 Comments

When it comes to making gearboxes, 3D printing has the benefit that it lets you whip up whatever strange gears you might need without a whole lot of hunting around at obscure gear suppliers. This is particularly good for those outside the limited radius served by McMaster Carr. When it came to 3D printed gears though, [Michael Rechtin] wondered whether PLA or resin-printed gears performed better, and decided to investigate.

The subject of the test is a 3D-printed compound planetary gearbox, designed for a NEMA-17 motor with an 80:1 reduction. The FDM printer was a Creality CR10S, while the Creality LD02-H was on resin duty.

The assembled gearboxes were tested by using a 100 mm arm to press against a 20 kg load cell so that their performance could be measured accurately. By multiplying the force applied to the load cell by the length of the arm, the torque output from the gearbox can be calculated. A rig was set up with each gearbox pushing on the load cell in turn, with a closed-loop controller ensuring the gearbox is loaded up to the stall torque of the stepper motor before letting the other motor take over.

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Keynote Video: Jeremy Fielding Wants To Help You Get Moving

December 23, 2021 by Tom Nardi 7 Comments

For many DIY hardware projects, the most movement it’s likely to see is when we pick the assembled unit up off the workbench and carry it to wherever it’s destined to spend the rest of its functional life. From weather sensors to smart mirrors, there’s a huge array of devices that don’t need to move one millimeter to function. But eventually, you’re likely to run into a project that’s a bit more dynamic. Maybe you’d like to motorize your window shades, or go all out and build a remote controlled rover. With these more active designs comes a whole slew of new problems you may never have encountered before.

Luckily for us, folks like Jeremy Fielding are out there and willing to share their knowledge. In his fascinating presentation for the 2021 Hackaday Remoticon, Building Hardware that Moves: the Fundamentals that Everyone Should Know, he took viewers on a whirlwind tour of what he’s learned about designing and building complex machines from his years of professional experience. Whether its a relatively simple articulated workbench for the shop, a gargantuan earthmoving machine, or a high-dexterity robotic arm, each project he’s worked on has presented unique challenges that needed to be solved.

Not all of Jeremy’s machines will fit in your average workshop.

A lot of the projects that Jeremy has worked on are on a much larger scale than what your average hobbyist is ever going to run into. When there’s an arrow pointing out the tiny human in a picture of you and the machine you’re currently working on, you know things are getting serious. But as anyone who’s watched his YouTube videos knows, he’s got a real knack for taking these high-level concepts and distilling them into something more digestible for the home gamer.

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Cheap Big Servo For Robot Arm

November 19, 2021 by Lewin Day 10 Comments

[Skyentific] is looking to push the hobbyist robotics state of the art. Motors and their gears, the actuators, are typically the most expensive part. For his build, he realised he needed big servos capable of delivering plenty of torque. Thus, he set about creating a 3D-printed design to get the job done on a budget. (Video, embedded below.)

Stepper motors are the order of the day here, chosen for their low cost compared to brushless solutions, particularly when taking control hardware into account. In this design, the stepper motor drives a sun gear as part of a bigger planetary gearbox with a high gear ratio. Cross-roller bearings are used to allow the servo to effectively handle both radial and axial loads. The servo as a whole is designed to fit neatly into the joints of the robot arm itself, and has external mounting points provisioned as such.

It’s a neat servo that somewhat apes those used on full-sized industrial designs, at least in the sense of being an integrated part of the joints of a robot arm. It also comes in at a relatively-cheap $32 based on the materials used by [Skyentific].

We’ve seen some related work from [Skyentific] before, too – like this interesting cable-driven joint. Video after the break.

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A Simple LEGO Automatic Transmission

July 22, 2021 by Lewin Day 9 Comments

The automatic transmission in your average automobile can be a complicated, hydraulic-y thing full of spooky fluids and many spinning parts. However, simpler designs for “automatic” gearboxes exist, like this Lego design from [FUNTastyX].

The build is based around a simple open differential but configured in a unique way. A motor drives what would typically be one of the output shafts as an input. The same motor is also geared what would normally be the main differential input shaft as well. In these conditions, this double-drive arrangement would sum the speed input and lead to a faster rotational speed at the other shaft, which becomes the output.

However, the trick in this build is that the drive going to what would be the usual differential input is done through a Lego slipper clutch. This part, as explained by [TechnicBricks], allows the outer teeth of the gear to slip relative to the shaft once torque demand is exceeded. What this functionally does is that when the output of the “automatic gearbox” is loaded down, the extra torque demand causes the clutch to slip. This then leads to only one input to the differential doing any work, changing the gear ratio automatically.

It’s likely not a particularly efficient gearbox, as there are significant losses through the very simple clutch, we suspect. However, it does technically work, and we’d love to see its performance rated directly against other simple Lego gearbox designs.

It’s a little confusing to explain in text, but the video from [FUNTastyX] does a great job at explaining the principle in just a few minutes. We’ve seen plenty of crazy Lego gearboxes over the years, and we doubt this will be the last. Video after the break.

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Differential Drive Doesn’t Quite Work As Expected

June 6, 2021 by Bryan Cockfield 10 Comments

Placing two motors together in a shared drive is a simple enough task. By using something like a chain or a belt to couple them, or even placing them on the same shaft, the torque can be effectively doubled without too much hassle. But finding a way to keep the torque the same while adding the speeds of the motors, rather than the torques, is a little bit more complicated. [Levi Janssen] takes us through his prototype gearbox that attempts to do just that, although not everything works exactly as he predicts.

The prototype is based on the same principles as a differential, but reverses the direction of power flow. In something like a car, a single input from a driveshaft is sent to two output shafts that can vary in speed. In this differential drive, two input shafts at varying speeds drive a single output shaft that has a speed that is the sum of the two input speeds. Not only would this allow for higher output speeds than either of the two motors but in theory it could allow for arbitrarily fine speed control by spinning the two motors in opposite directions.

The first design uses two BLDC motors coupled to their own cycloidal drives. Each motor is placed in a housing which can rotate, and the housings are coupled to each other with a belt. This allows the secondary motor to spin the housing of the primary motor without impacting the actual speed that the primary motor is spinning. It’s all a lot to take in, but watching the video once (or twice) definitely helps to wrap one’s mind around it.

The tests of the drive didn’t go quite as planned when [Levi] got around to measuring the stall torque. It turns out that torque can’t be summed in the way he was expecting, although the drive is still able to increase the speed higher than either of the two motors. It still has some limited uses though as he notes in the video, but didn’t meet all of his expectations. It’s still an interesting build and great proof-of-concept otherwise though, and if you’re not clear on some of the design choices he made there are some other builds out there that take deep dives into cycloidal gearing or even a teardown of a standard automotive differential.

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A Stackable Planetary Gearbox You Can Print At Home

May 14, 2021 by Lewin Day No comments

In one little corner of YouTube is a small but vibrant community sharing videos about gearboxes of their own design, particularly those with very high ratios or other quirky features. Adherents of the subculture are known as gearheads, and [Let’s Print] is among them. His latest creation is a 3D printed planetary gearbox design with a focus on easy assembly and versatile ratio choice. (Video, embedded below.)

The gearbox came about as [Let’s Print] grew weary of designing bespoke geartrains for each of their individual projects. The planetary design they landed on has the benefit of being stackable, with each reduction block fitted adding a 1:3 stepdown to the train.

For testing purposes, four stages were ganged up for a total reduction ratio of 1:81. The resulting gearbox was able to lift 40 kg before its output coupler failed, no mean feat for some plastic squirted out of a hot nozzle. It’s a common problem with huge ratio gearboxes made out of plastic – often, the very components of the gearbox can’t hold up to the huge loads generated.

Regardless of the limitations of the material, we’re sure the gearbox will prove useful in future projects from [Let’s Print]. We’ve seen other tough 3D printed gearbox builds before too, such as this anvil-lifter from the aptly-named [Gear Down For What]. Dive into the online gearbox subculture yourself.

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