Giordan

Team 22:
30 lb Combat Robot
“Thunderstrike”
Brandon Augustus, Kathryn Byerts, Giordan Pergola, Perry Rodrigue,
Trym Sandbakk, Kyle Stevens

Advisors: Dr. Hunter Gilbert, Dr. Jerry Trahan

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Project Objectives
• To meet requirements for, compete in, and win the 2nd
annual Bengal Bot Brawl and advance to the MomoCon
Robot Battles Featherweight Championship
• Customers
Primary Secondary

Competition Competition
Judges Audience

Capstone LSU College of

Design Team 22 Engineering

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Existing Technology

Near Chaos Robotics. “Nyx, 30lb Fighting Robot Re-Made.” Heatherington, Dale A. “Dale's Homemade Robots.” Couvillion, Trey. “LSU Hosts First Annual Combat Robotics
Competition.”

NYX Pushy Grabber Goliath

Robot Battles Robot Battles LSU Bengal Bot Brawl
Featherweight Champion Featherweight Champion Champion

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Functional Decomposition

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Qualitative Constraints
Constraint
Easily Transportable by hand
Durable
Operates Wirelessly
Needs no physical assistance
Passes inspection by competition judges
Safe
Easily repairable
Kathryn
Description
Safe to transport; not overly bulky or containing any sharp
edges
Able to take falls from the stage and minimize damage
taken by opponents
Able to send and receive signals from a speed controller
that controls the robot's movement
Able to fight without help from anyone to correct
movement; relies on electronic speed controller
Follow rules set out by the competition
Safe for the audience and be safe to handle for the team
Able to be fixed on the spot if certain parts fall off or it
takes fall damage
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Measurable Engineering Specifications

Specification Description
Weight [pounds] Must be 12-30 lbs 2.5%
Number of Parts [#] Total number of parts in completed robot
Total Price [USD] Must be under budget of $2000
Max Speed [ft/s] Maximum achievable speed, 7.5 ft/s
Stopping Time [seconds] Times to stop from release of accelerator over a range of speeds. This will depend
on whether or not a braking system is implemented.
Stopping Distance [feet] Distance from release of accelerator to rest. This will vary depending on the initial
speed.
Hull Strength [ksi] Strength of material used for hull, must account for strength of weakest points
Wheel Traction [lbf] horizontal force required to move static robot. This is related to the friction coefficient
of the wheels and the weight distribution of the robot.
Motor Power [Watts] Power supplied by chosen motor
Battery Life [minutes] Maximum life of battery when robot is in motion, >30 minutes
Turn Radius [feet] Minimum radius required for robot to turn
Input response time {Milliseconds] Time it takes robot to react to an input from controller
Time to Start Movement from [seconds] Time taken from power on to initial movement. Competition rules state that
Power On robot must move “within a reasonable time” at the discretion of the judge(s)
Maximum Fall Before Injury [feet] Maximum height from which robot can fall without sustaining damage.
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Concept Generation - Process

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Concept Generation – Tank Pusher

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Concept Generation – Pusher-Lifter

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Concept Generation – Wedge Stabber

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Concept Generation – Selection

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Product Architecture – Exploded View

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Product Architecture - Internals

Pneumatic pistons Air tank

Electronic speed
Sprockets
controller

Motors / gearboxes Batteries

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Pneumatic Weapon
• Analysis
• Minimum required force to move opponent
• Output force of pneumatic pistons
• Number of actuations
• Material Selection
• Pneumatic piston
• Air tank
• Check valve
• Solenoid valve
• Pressure regulator
• Tubing and fitting

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Pneumatic Weapon – System Layout

Check
Pneumatic piston Valve
1. 3-way fitting
2. Exhausted port
for pneumatic
Solenoid
pistons Air Tank 1 1 Valve

2
Pressure
regulator

Pneumatic piston
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Pneumatic Weapon – Force Analysis

Friction force = µ*N Weapon force
Friction force Opposing
= .8*30 lbs robot
= 24 lbs
Where,
µ = coefficient of friction between rubber on cardboard
N = normal force of robot

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Pneumatic Weapon – Output Force

Output force = (Pressure force)*(Area of Cylinder) – Spring Force
Where,
Area of cylinder = π*(Bore size/2)^2
Spring force = Manufacturer specified force of the return spring
Return Spring Air input

Pressure
Output
Pressure force Force
Force

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Pneumatic Weapon – Output Force

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Pneumatic Weapon – Number of Actuations

Minitial,tank = Vtank x ρair, 200psi
Mfinal,tank = Vtank x ρair, regulated output psi
Mchange, 1 act. = Vpiston x ρair, regulated output psi
N = (Minitial,tank - Mfinal,tank) / Mchange, 1 actuation
Where,
Mtank = mass of air in the storage tank
Mchange = mass change of air in the storage tank due to 1 piston actuation
Vtank = Volume of the tank
Vchange = Volume change of the piston from actuation
ρair = density of air at certain pressures
N = number of actuations
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Pneumatic Weapon – Number of Actuations

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Pneumatic Weapon – Number of Actuations

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Pneumatic Weapon – Piston

• Pneumatic Piston
• ¾” bore with a 4”
stroke
• Single Acting, Spring
return
• Double end mounted
• Steel rod http://www.smcusa.com/products/NC(D)G-Cylinder-Single-Acting-Single-

• 1/8” input port

Rod-Spring-Return-Extend~53446

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Pneumatic Weapon – Air Tank

• Air Tank
• Paintball tank
• Rated psi: 3000
• Volume: 48 in^3
• Lightweight: 2.82
lbs
• Length 8.32”
• Diameter: 3.62”
https://www.ansgear.com/Ninja_Compressed_Air_Tank_w_Adjustable_Regulator_p/
ninjatank-48red.htm
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Pneumatic Weapon – Solenoid Valve

• Solenoid Valve
• 3 way (input,
output, and
exhaust ports)
• Spring return
• 12V DC https://www.mcmaster.com/#6124k271/=1a7bl1e

• Rated psi: 145

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Pneumatic Weapon – Pressure Regulator

• Pressure Regulator
• Ingersoll Rand
• Rated psi: 250
• Adjustable range: 0 to 140 psi

https://www.grainger.com/product/ARO-1-8-General-Purpose-Air-
Regulator-4PJG5

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Drivetrain – Decision Matrix

• Tank-style treads
• Powered by 2 motors in rear
• Decision Matrix: Table A2
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Drivetrain – Materials Selection

• Tracks
• Sprockets
• Motor
• Gearbox
• Motor Controller

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Drivetrain – Tracks
• Lynxmotion Modular Track
System, 3” width
• Decision Matrix: Table A6
• 1.07” pitch
• Modular system allows for
adjustments in track length

http://www.robotshop.com/en/lynxmotion-track-trk-02.html#Supplier-Product-Code
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Drivetrain – Track Testing

• Exact coefficients of friction not provided by manufacturer
• To be experimentally determined by Team 22

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Drivetrain – Sprockets
• Lynxmotion 15 Tooth Sprocket,
diameter 3.75” (Table A5)
• 3 per side (See 4WD vs 6WD,
Table A4)
• 6 mm hub

http://www.lynxmotion.com/p-1109-mts-12t-sprocket-6mm-hub.aspx

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Drivetrain – Motor
Analysis (RS-755)
• Nominal Voltage: 12V
• No Load RPM: 7000
• No Load Current: 0.65A
• Rated RPM: 6070
• Rated Torque: 10oz-in
• Linear Velocity: 119.2ft/s
• Stall Current: 43.9A
• Stall Torque: 125.69oz-in
Torque(g-cm) 31
http://www.robotshop.com/en/rs-775-motor-7000rpm-12v-7613oz-in.html
 Kyle

Drivetrain – Motor Decision Matrix

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Drivetrain – Gearbox Analysis

• Gear Ratios: 3:1, 4:1, 11:1,
13:1, 16:1, 38:1, 45:1, 54:1,
64:1
• 16:1 Gear Ratio
o New Rated Torque: 160.87oz-in
o New Rated RPM: 379.4
o New Linear Velocity: 7.45ft/s
• 38:1 Gear Ratio
o New Rated Torque: 382.06oz-in
o New Rated RPM: 159.74
o New Linear Velocity: 3.14ft/s
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Drivetrain – Motor Controller Decision Matrix

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Drivetrain – Motor Controller

• Sabertooth 60A
Regenerative Motor
Driver
• Nominal Voltage: 6V-
30V
• Continuous Current: 60A
• Peak Current: 120A
• 5V 1A Battery Eliminator
Circuit
Motor Controller User Manual

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Drivetrain – Motor Controller Thermal Analysis

• Left Wire Size – 12ga
• Temperature:
~37°C/98.6°F
• Right Wire Size – 8ga
• Temperature: ~30°C/86°F
• Selected 8ga wire size

Motor Controller User Manual

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Electronics – Transmitter/Receiver Decision

Matrix

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Electronics – Transmitter/Receiver
• Futaba 6J 6-Channel 2.4 GHz S-
FHSS
• Receiver:
• Power requirements: 4.8-7.4V
• Current drain: 80mA (@ no signal)

http://www.robotmarketplace.com/products/0-futl7606.html http://www.robotmarketplace.com/products/0-futk6000.html

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Electronics – Battery Decision Matrix

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Electronics – Battery
• Turnigy nano-tech 2700mAh 4S 65~130C Lipo Pack w/XT-60
• Capacity: 2700 mAh
• Voltage: 4S/4 Cells Series / 14.8 V Nominal voltage
• Lifespan: 300+ Cycle
• Discharge rating (Current): 65 C Continuous / 130 C Burst
• 175.5 A Max Continuous Current
• 351 A Max Burst Current (a few seconds)
• Max Charge Rating: 8C
• 21.6 A Max Charging Rate
• Two batteries to power:
• Motors
https://hobbyking.com/en_us/turnigy-battery-nano-tech-2700mah-4s-65-130c-lipo-pack-xt-60.html?___store=en_us
• Solenoid valve
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Chassis
• Designed around components
• Motors → width
• Sprockets → length
• Air tank → height
• Protection
• Accessibility

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Chassis – Material Selection

• Al 7075-T6: Aircraft grade

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Chassis – Deflection Analysis

• Drop test
• 4 ft
• 90° & 45°
• No damping

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Chassis – Deflection Analysis

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Chassis – Deflection Analysis

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Chassis – Deflection Analysis

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Chassis – Deflection Analysis

• Max stress << yield stress
• Max. deflection ≈ 0.03"
• Clearance = 0.125"
• Added weight will increase damage
• Multiple falls → compounding deflections
• Solutions:
• Reinforce armor
• Increase clearance
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Manufacturing Plan
• Chassis:
• Water jet cut aluminum
• Bolt together using brackets
• Drivetrain:
• Assembly by hand of modular track system
• Weapons:
• Build restraints for components
• Attaching tubing to fittings
• Motors:
• Connect components via 8g wires (solder if needed)
• Check firmware of ESC, make adjustments
• Calibrate ESC with transmitter

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Testing and Validation Plan

• Weapon: • Motor:
• Test number of actuations at various tank and • Temp of motor & ESC via IR
output pressures thermometer for continuous current
• Test pushing force on 30 lb mass operation, 5-25 min in increments of 5
min
• Drivetrain • Torque & RPM performance with load
• Friction testing
• Max speed vs theoretical max speed
• Chassis
• FEA
• Battery: • Scale model tests
• Charge to max voltage (4.2 v/cell) and connect
to a load, determine capacity from current
discharged
• Testing temperature during continuous current
• Voltage (at different rates of discharge) vs Time

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Safety Considerations
• Weapon:
• Components must operate under their rated pressures
• Battery
• No high temperatures (under 140 F)
• No very cold temperatures
• Fireproof container for charging, discharging, storage
• Electronics:
• Ensure temp of ESC & motor within reasonable range for continuous operations
(same as battery)
• Emergency kill switch on ESC
• Drivetrain:
• Speed limited to controllable range (~7.5 ft/s)
• Drivetrain protected by plating on each side to prevent damage from attack

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Budget Miscellaneous
10%

Drivetrain
Fasteners
27%
8%

Drivetrain
Electronics
Raw Materials
Pneumatic System
Pneumatic System Fasteners
20% Miscellaneous

Electronics
Raw Materials 25%
10%

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Timeline- Major Milestones

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Timeline- Major Milestones

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Appendix
• Figure A1: Rated Torque, RPMs vs. Gear Ratio
• Figure A2: Steering Decision Matrix
• Figure A3: 4WD vs 6WD Decision Matrix
• Figure A4: Sprocket Diameter Decision Matrix
• Figure A5: Track Width Decision Matrix
• Figure A6: Pneumatic Piston Stroke Length Decision Matrix
• Figure A7: Pneumatic Piston Bore Size Decision Matrix
• Figure A8: Actuations for 3" Stroke
• Figure A9: Actuations for 5" Stroke

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Figure A8: Actuations for 3" Stroke

Figure A9: Actuations for 5" Stroke

Figure A1: Rated Torque, RPMs vs. Gear Ratio

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 Figure A2: Steering Decision Matrix

Figure A3: 4WD vs 6WD Decision Matrix

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Figure A4: Sprocket Diameter Decision Matrix

Figure A5: Track Width Decision Matrix

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Figure A6: Pneumatic Piston Stroke Length Decision Matrix

Figure A7: Pneumatic Piston Bore Size Decision Matrix

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