Segway Build You Can Do Yourself

We’ve seen lots of Segway variants on Hackaday, but they don’t always have detailed instructions on how they made it… Well lucky for us, [Bob] from [Making Stuff] just finished his extensive Segway project with tons of videos of the build!

Inspired by other self-balancing scooter projects he had seen online, [Bob] wanted to try his hand at building one. So he took bits and pieces from designs he liked, and came up with his own solid looking Segway clone design. Using Google Sketchup he drew up the frame, and from there it was all hands on deck. A bit of TIG welding later and it was time for the components.

Some small slight mechanical hiccups aside, the longest part of the project was the electronics and software — getting it to work like a real Segway. After writing his own code he ran into a few roadblocks, but luckily he was able to get some help from someone at his local Maker meetup which saved a lot of troubleshooting on his end.

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Self Balancing Vehicle Inspired By Bicycles Of Yesteryear

[XenonJohn] is not a newcomer to the world of self balancing vehicles. He was part of the Medicycle team and a semifinalist for The Hackaday Prize. Working on the Medicycle had exposed some opportunities for improvement of the design, the most significant being the single wide wheel supporting the vehicle and rider. The unicycle design was more difficult to learn to ride than that of a two-wheeled nature. [XenonJohn] wanted to make an improved self balancer and this new one will have two wheels that are independently controlled.

Although the finished product looks like it started with a bike frame, the self-balancer’s frame is actually completely custom. The handlebars and banana seat were purchased new as aftermarket parts for old-style bicycles. Powering the two wheels is a pair of 24v brushed motors, conveniently each one came with a 6:1 reduction gearbox pre-installed. The wheels are a complete compilation of parts not intended to go together. The BMX bike rims were laced to mountain bike front hubs. The hubs have provisions for a disk brake but [XenonJohn] mounted a large toothed pulley there instead. A belt then connects the drive motor gearboxes to the pulleys completing the drive train.

The LiFePO4 battery kit was purchased off eBay and puts out 24v and 15AH using eight cells. These batteries alone were a hefty percentage of the projects cost, costing nearly $300. Controlling the vehicle is an Arduino Mega that makes use of the FreeSix IMU library. The Mega receives inputs via I2C from a Sparkfun SEN-10121 board that contains both accelerometers and gyroscopes along with turn switches connected to the ‘brake’ levers on the handlebars. The Arduino then sends commands to the 25 amp Sabertooth motor controllers to keep you balanced as you buzz around town.

Video below.

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Impressive Homemade Segway Is The Real Deal

[Kristian] just put the finishing touches on his full size Segway built from scratch.

Back in 2012, he made a small balancing robot using a gyroscopic sensor and a PID controller — you can see the original post here. The cool thing is, he’s basically just scaled up his original project to create this full-size Segway!

It uses two 500W 24V DC motors (MY1929Z2) on an aluminum check plate frame, with the rest of the structure made from steel plumbing and fittings. What we really like is the steering linkage; similar to a real Segway, you pull the handle in the direction you want to turn. He’s accomplished this by putting another length of pipe parallel to the wheels which is connected by an elbow fitting to the handle bar. It’s supported by two pillow block bearings, and in the back is a fixed potentiometer — when you lean the handle bars one way, the pipe rotates, spinning the potentiometer. To make it return to neutral, he’s added springs on either side.

There’s an impressive build log to go along with it, and a great demonstration video after the break.

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