Hardware Document Team 18

HARDWARE DESIGN DOCUMENT

Project:​ Metamorphobot
Task:​ Construct a robot that can decrease in size to fit through a tunnel, widen to go over a
bridge, identify coloured blocks while in a specified search area.

Document Version Number​: ​1.5

Date: ​07/04/18
Author: ​Tanbin Tahsin Chowdhury, Sarah Swanson

Edit History:
Version Date Author Section Summary
Updated

1.0 27/02/18 Tanbin Tahsin All Preliminary

Chowdhury Document
1.1 14/03/18 Tanbin Tahsin 1.0, 5.0, 6.0, 7.0 Initial Design
Chowdhury Phase
1.2 20/03/18 Sarah 6.0, 7.0 Added final
Swanson Robot Design
1.3 28/03/18 Sarah 6.0, 7.0 Final Robot
Swanson design details
1.4 04/04/18 Sarah All Major
Swanson reformatting
1.5 07/04/18 Tanbin Tahsin 1.0, 6.0, 7.0 Final robot and
Chowdhury prototypes

1
Hardware Document Team 18

1.0 Table of Contents

1.0 Table of Contents 2

2.0 Design Process 3

2.1 Objective 3

2.2 Challenges 3

2.3 Possible Solution Ideas 3

3.0 Constraints 4

4.0 Components 5

5.0 Design Initiation 5

6.0 Design Phase 6

6.1 Design Mechanisms 6

6.2 Design Workflow 9

6.3 Design Prototypes 13

7.0 Final Design 13

2
Hardware Document Team 18

2.0 Design Process

2.1 Objective
● The robot must be able to localize itself and navigate avoiding other robots
● The robot must be small enough to travel through the tunnel of given dimensions
● The robot must have a wide enough wheelbase to travel over the bridge since the
middle of the bridge has speed bumps
● The robot must be able to detect colour blocks

2.2 Challenges
● To look out for other robots that can possible come from any angle any time
● To align the robot with the tunnel or bridge while crossing the virtual river so that it can
pass successfully
● Have the wheelbase wide enough to pass over the bridge and avoid the center with the
speed bumps. Also the wheelbase has to be narrow enough with an overall small robot
dimension to be able to pass through the tunnel

2.3 Possible Solution Ideas

● For the ultrasonic sensor:
1. More than one Ultrasonic sensor could be used to widen the field of view
2. A motor could be used to rotate the Ultrasonic sensor to be able to see
everywhere

● For alignment issues with respect to the bridge and tunnel

1. To align the robot perfectly before it passes through the tunnel or over the
bridge, two colour sensors could be used at the front facing down. If both the
sensors see the same colour as the robot tries to pass it, it means it is aligned, if
not the robot could adjust accordingly. Moreover, the robot could use the
sensors to make sure both sensors detect the colour at the same time to ensure
it is straight.

● To meet the wheelbase requirements two possible approaches could be made:

1. Adjustable wheelbase​: The wheelbase could have a retractable design using

gears as shown in the diagram. This will allow the robot to meet both
requirements when necessary. However, friction will be encountered during the
process which needs to be managed

3
Hardware Document Team 18

Figure 1: Sketch of Adjustable Wheelbase

2. Double wheelbase​: Two sets of wheel bases could be implemented to meet

each scenario. With the tunnel preferred wheel base as the default, mechanical
movements could be used to bring in and out the second wheel base. However
only one wheel base can be operational at a time for which the other needs to
be off the ground. Both wheel bases need to have motor so that they can
operate independently.

Figure 2: Sketch of Double Wheelbase

3.0 Constraints
Refer to section 3.0 of Constraints Document.

4
Hardware Document Team 18

4.0 Components
Refer to section 3.0 of System Document

5.0 Design Initiation

Table 1.0 lists the pros and cons of the feasible solutions for hardware design.

Feasible Solutions Pros Cons

One non-adjustable ● Avoids the hassle of ● Wheels are too thick

wheelbase wheelbase change ● Too dependant on
design accuracy

Widen the wheels only ● Avoids the hassle of ● Difficult to design a

moving large motors mechanism
mechanically

Double wheelbase ● Simple design ● Motor limitation

mechanism avoiding ● Robot size limitation
gear methods ● Two wheelbase
cannot operate at the
same time

Adjustable wheelbase using ● Wheelbase adjustable ● Motor weight limitation

slider method to variable widths ● Complicated
mechanism
● Friction

Adjustable wheelbase using ● Simple and rigid ● Wheelbase alignment

gear method design if gear method ● Friction
can be applied
successfully
Table 1.0: Critical Analysis of Feasible Solutions

Based upon the analysis above, the best approach to move forward with is the
Adjustable wheelbase using slider method. ​The hardware design process and prototypes are
shown in section 6.0, and the final robot design shown in section 7.0.

5
Hardware Document Team 18

6.0 Design Phase

6.1 Design Mechanisms

1.0 Double Gear Method

The objective is to perform the wheelbase

adjusting function using one motor, therefore two
gears that are attached to the motors with wheels
must be rotated together. To put both motors with
wheels inwards the left one needs to turn clockwise
and the right one needs to turn anti-clockwise.
Strategically placing another gear between the two
gears in right angles allows it to do that.

Gears placed on the x-y plane provides

force in either the x and -x direction or the y and -y
direction. Gears placed in the y-z plane provides
force in either the y and -y direction or the z and -z
direction. Placing gears perpendicularly allows the
force of one to turn the others. Fig 1.0 illustrates the
idea.

​Figure 3.0: wheelbase adjusting function

2.0 Adjustable Wheelbase using Double Gear Method

Using two gears in the x-y plane for obtaining the force along the x axis for the motors,
and one gear in the y-z plane placed between the two gears to use the force along y axis to turn
the other two gears. The motor is connected to the gear in the y-z plane. The wheels are
attached to the gears in the horizontal plane using bars. Since the bar is allowed to move with
the point of attachment being the pivot, extra bars are placed around strategically to align the
bar with the motor in the desired way after rotation. The orange pointers mark the different
widths. Fig 2.0 and 2.1 illustrates the two scenarios.

6
Hardware Document Team 18

Figure 4.0: Wheel on the Inner Side ​ ​Figure 4.1: Wheel on the Outer Side

3.0 Elevation

In order to operate the wheelbase adjustment without friction, the

robot must be elevated from the ground by a small amount. The
elevation operation must be done using the one motor left for use,
therefore a gear method is required. Taking ideas from the expansion
method mentioned earlier regarding wheelbase adjustment, and from
the concept of differential gear, a gear arrangement can be made to
achieve elevation. Using two gears in the y-z plane with arms attached
to it, if the arms are made to rotate towards each other using the point
of attachment with the gear as a pivot, the friction with ground will
cause the pivot point to rise. Both the gears on the vertical plane (y-z
plane) can be turned using one gear in the middle in right angles (x-z
plane), similar to the gear method mechanism mentioned earlier.
Therefore using one motor to turn the gear on the x-z plane the two
arms can be made to rotate and use the ground to push up the gears
used as pivot, thus elevating the entire robot attached to it. Wheels are
used at the end of the arms for a smoother rotation while in contact
Figure 4.2 ​ with the ground. This is illustrated in ​Figure 4.0, 4.1, and 4.2

7
Hardware Document Team 18

Figure 5.1: Arms with Wheels Laying Flat ​ ​Figure 5.2: Push Up of Wheels

4.0 Slider

Gears when used for pulling or pushing does not always occur in either horizontal or
vertical direction, rather a combination. To restrict movement of the desired object in only one
direction a slider can be used. It prevents the undesired directional movements and guides to
move along in only one direction. The object is allowed to move along fixed rods.

Figure 6: Slider Design

8
Hardware Document Team 18

5.0 Custom large gear

A gear has contact points on the edge. Turning it moves the contact point by a distance
in a rotational manner. A 180 degree turn moves the point to the other side which is the
maximum displacement. Having a larger distance between the opposite ends will allow to move
contact points by a greater displacement. While using gears for pulling or pushing forces using
contact points only and not turning further gears, the gear does not need to be round and have
features of a traditional gear. The main purpose is to have a rotational axel at the center and
have two contact points parallel to each other and on the same level.

Figure 7: Large Gear

6.2 Design Workflow

Week 1: approx 9 hours

Defining the problem and gathering data to understand the situation. Comprehensive
analysis to set the parameters, constraints, limitations, etc. Intensive research to generate
possible solutions. Gained extensive knowledge on mechanical design process online. Made
sketches of ideas (indicated in section 2.3).

Sample bridge and tunnel was not available yet to test theories. In addition no suitable
resources found online regarding adjustable design to take inspiration from.

Week 2: approx 12 hours

Sample bridge and tunnel received. Adjustments made to initial ideas and assumptions.
Carried out a comprehensive scenarios assessment and critical analysis on possible ideas to
turn them into feasible solutions. Further comparative analysis to select the best option to
approach with. Designed individual mechanism and made sample demos to present the ideas
(indicated in section 6.1).

9
Hardware Document Team 18

Figure 8.0, 8.1: The Bridge

Encountered new problem: Sensor limitation. According to the desired sensor functions,
5 sensors are needed; 1 ultrasonic for wall and block detection, 1 colour sensor for detecting
colour of the block, 1 light sensor at the back for localization and odometry, and 2 light sensor at
the front for alignment correction.

Since the sensors for alignment correction are not necessary during area search and the
color detection is also necessary only during the search, sensors could be reused. The
dedicated colour sensor for detecting colour of the block could be eliminated to meet the sensor
limitation of 4 sensors max, and instead the 2 sensors for alignment correction could be flipped
90 degrees to face front and reused for detecting colour of the block. However this mechanical
movement requires the use of a motor and the present approach taken uses up all 4 available
motors. Hardware wise the motor used for elevation could be designed to carry out the sensor
flip operation as well. Software wise the odometer could be made more accurate so that the
sensors used for alignment correction are not needed in the first place. Further research
required on the matter.

Week 3: approx 15 hours

Further research done to improve the wheelbase adjustment mechanism. Developed a

slider concept using one gear. Further improved the concept to make a compact slider base
(indicated in section 6.1). Built the wheelbase around it.

Encountered issue with gear operation. Using one gear could not contract and expand
the wheelbase to its full potential. The gears were not big enough to move contact points by
desired distance. Carried out extensive analysis and experimenting to come up with a custom
gear design the replicates the gear function but also meets the requirement (indicated in section
6.1). Motorized the gear function to build Prototype 1 (shown in section 6.3).

10
Hardware Document Team 18

The assumed friction encountered during sideways movement of the wheels during base
change was minimal, hence the idea of using a motor to elevate the robot during the adjustment
process was dropped. Minimal friction could be further reduced by using tape on the wheels.
Sensor issue left to be addressed later on.

Figure 9.0, 9.1

Figure 10: The Bridge Challenge

11
Hardware Document Team 18

Figure 11.0,11.1,11.2: Size of Robot versus Obstacles

12
Hardware Document Team 18

Week 4: approx 4 hours

Problems encountered with Prototype 1. The robot was too low hence the bottom of the
robot would rub against the bumps. The weight of the body rested on the wheelbase which was
allowed to move, therefore could not support the robot good enough. The robot was too
compact to have enough space for wires. The wheels would bend to an angle eventually after
experiencing the motor push force.

Addressed the issues and made improvements. The robot has been strengthened to
support the weight. The motors for the wheels have been lowered raising the robot body. Made
more space for the wires. Overall design made as rigid as possible to avoid undesired wheel
movements, leading to form Prototype 2 (indicated in section 6.3).

Week 5: approx 12 hours

Prototype 2 still experienced wheel flex which changes the track and affects navigation
accuracy. Faced a critical design decision point. Carried out comprehensive analysis and
experimenting. Testing showed driving over the speed bumps does not affect the robot as much
as anticipated. Considering all these factors alongside time constraints, made a decision to
move forward with a more software intensive approach and redesign a simpler robot without
wheelbase changing function. The robot would drive over the bridge bumps and relocalize to
correct odometry.

13
Hardware Document Team 18

Started building a new robot from scratch. The main focus was to make the robot strong
and rigid with a wide base and lower center of gravity to ensure the robot does not flip over
while driving over the bumps. The new robot met the design parameters and requirements. The
ball bearings were opted out for wheels since they tend to cause problems while driving over
junctions of the board as well as cracks on the bridge. 4 wheels at the front and 2 wheels at the
back for stability. No additional motos used for any mechanical movements.

Sensors issue addressed. Mandatory ultrasonic sensor and colour sensor used at the
front. The two light sensors planned at front for alignment and correction are put at the back.
They could be used for X-Y axis localization method, or turn one of them off and use one during
localization using the present method. Prototype 3 (shown in section 6.3) was completed and
only minor changes are anticipated on top of this to form the final design.

14
Hardware Document Team 18

Week 6: approx 3 hours

Minor changes made on Prototype 3. Only two wheels used at the front as the other two
were not much necessary and helped improve track measurements. Two wheels at the back
had the rubber tires removed and taped to better localization as tape over the wheels caused
too much sliding. This hampers driving over the bridge also. They could then again be replaced
with a single ball bearing for accurate localization. This would cause problems driving over the
bridge, however localization has been given priority for which driving over the bridge has been
compromised in either situations. Colour sensor at the front has been removed as search
objective was decided to be compromised due to time restrictions. Two sensors at the back for
localization and alignment correction have been substituted with only one for localization.
Improved odometry in software made alignment correction unnecessary. The final design
(shown in section 7.0) is a simpler robot with no mechanical movements or additional
improvement functions but cleverly built to be really strong, compact and has met most of the
requirements. Most trials have been successful and no hardware changes expected.

Due to time restrictions, all design requirements could not be met and only important ones have
been met successfully. Given more time, all of the persisting issues could be successfully
solved. Search objective could be tested and made more accurate. Driving over the bridge
could be solved by having the inner wheels instead of the outer wheels at the front motors to
make the robot go over bumps instead of the higher rails. Moreover a motor could be used to
bring down a wheel and lift the bot to the same level or higher to cross the bridge and have it
pulled back off the ground again after the bridge has been crossed. However these operations
are dependant on editing or adding more to the software and testing for which they have not
been attempted.

6.3 Design Prototypes

Prototype 1 Prototype 2

15
Hardware Document Team 18

Prototype 3

7.0 Final Design

The final design is built around the EV3 brick which is the core of the robot. The main
components include two large motors, one colour sensor and one ultrasonic sensor. The
sensors and motors are attached to the EV3 using the lego bricks and connected using ethernet
cables. The design is made such that the robot has a wide base and a low center of gravity so
that it is more stable. The built is rigid and strong. The two motors with wheels are attached two
the sides to drive the robot with support at the back to balance it. The colour sensor is placed at
the center in the back facing down. It is used for localization. The ultrasonic sensor is placed at
the front to detect walls necessary for localization. Dimensional parameters have been met. The
hardware is perfectly compatible with the software and can accurately perform localization,
navigation, and driving through the tunnel as intended. Driving over the bridge and search
operations have been compromised due to time restrictions, thereby no hardware design
needed for those operations have been implemented.

16
Hardware Document Team 18

17