Archive for the ‘ 968 ’ Category

On the third day…

After calling many fabrication shops in Southern California within a radius of 45 miles, we ended up at the California Polytechnic University, Pomona shop. Our metal forming division was lucky enough to find the proper die to create the 45 degree bends on a 100 ton press brake.  Setting up the machinery and completing the bends took 6 hours.

Our newly acquired sponsor, TOMCO Products in Azusa, was able to perform the 90 degree bends with a very quick turn around.

Below are our newly trained press brake operators holding the first bent plate

Here’s one of our highly skilled operators hard at work(or hardly working)

Here’s a plate being formed

Here’s another photo of a plate being formed

Here’s our assembly and inspection division test fitting the formed pieces

Here’s where Jesus joins metal with all his might


Oh, for your enjoyment

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Oh, and uhh.. here’s the current status of the parts:

We currently have one fully welded base, two tacked bases, and one base waiting to be welded.

Jesus needs to take a break, so, he’ll be back on Friday to complete joining metal.

Finally, below is an artist depiction of our team’s weekly activities courtesy of our comic division:

 

The work of Jesus

Today, the battery boxes and superstructure sides were welded. We’re attempting to bend the base plates before we go ahead and begin to weld the drive base.

In the meanwhile, here’s some photos of Jesus and his special touch.

Jesus welding a battery box

The completed welds on the superstructure sides

 Here’s another shot of the superstructure sides

Here’s the battery box plates before they’re welded.

Attempting to center the battery connector tabs

Here’s the jig that we used

Here are two almost-complete battery boxes(tack welds need to be filled in)

In the hands of Jesus

The events portrayed in this post are from 10:30 PM to 6:47  PM. Events occur in real time. (Que 24 music)

10:30 PM: Kiet and Richard leave West Covina to meet Kirk in Kettleman, CA.

1:40 AM: Goods are exchanged (as pictured)

Loading the goods to the Prius

All the goods are accounted for

 

8:00 AM: Arrive at Ride and Show with robot parts.  Assemble  the superstructure sides and Jesus tack welds all 8 pieces.

Three superstructure sides that were just tack welded  

These superstructure sides cleaned up and ready to be welded

Jesus welding a superstructure piece

 

3:00PM: Shafts are picked up from Pacific Precision

3:30PM: Jesus welds 4 superstructure sides and the other 4 are ready for tomorrow morning.

Four fully welded superstructure sides

Four fully welded superstructure sides and the other four are ready to be welded

3:40 PM: Picked material to make the back tube for the robot chassis and will be machined later today.

4:00 PM: Shafts from Pacific Precision are picked up.

5:20 PM: Battery Box Side Plates are finished and prepped for welding tomorrow.

Battery Box Side Plates

Battery Box Parts

5:40 PM: The Battery Tabs are prepped to be drilled and tapped at Ride & Show tomorrow

Battery Tabs Queued For Machining

6:47 PM: Shafts are packaged and shipped to 254

Kiet will be escorting the box to shipment location

Additional Vertical Roller Testing

This was a test using dual 1/2″ rollers wrapped with duct tape. During the test, the rollers separated slightly after coming in contact with the ball once hitting the 3″ limit(simulates a spring loaded roller system).

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Lifting Arm Calculations

Review the PDF linked below for calculations for the lifting arm.  If the PTO is driven on the low gear side (14 to 64), then an additional reduction of approximately 8:1 will be required to drive the arm.  This is easily achievable in two stages.  If the PTO is driven from the high gear side (30 to 48), then an additional reduction of about 23:1 is required – still achievable in two stages, but requires rather large and small sprockets. With 4 CIMS, the lift can occur in about 1/2 second.  With only 2 CIMS, it could still work if geared properly (twice the reduction), but it would take twice as long.

The calculations below are presented in a fashion that should be understandable by the astute high-school student who has completed a Physics class.

Lifting_Arm_Calcs.pdf

Vertical Rollers Testing

During the previous two days, we attempted to design and prototype different roller orientations with minimal success. Before we were able to record a video of the horizontal roller setup, we determined that the setup held the ball well(going forward). While attempting to move the prototype backward, the ball would not stay in contact with the roller.

Oy. We determined that his was definately a problem. Horizontal roller utilizing a 1/2″ diameter round shaft will not meet our required specifications.

We moved onto an idea that our student design group envisioned… dual vertical rollers.

The vertical roller test(s) utilized the following parameters:

1. One roller spinning at half speed, one at full

2. One roller with rotational resistance, one roller at half speed(This test demonstrated the best results)

3. Both rollers spinning at full speed

We determined that the vertical roller setup requires that the ball is only pulled into the prototype under a specific set of conditions. (It doesn’t really work…..)

Please note that this is a proof of concept test.

 

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The artist depiction below displays the team hard at work on new prototypes.

Revised Launcher Assembly

Ball launching assembly launches ball out of the field when set at the high power position. 

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Ball launcher assembly launches ball 44ft on the low power setting.

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Here’s the hit spread photo after a few test shots.

Vacuum Suction Testing

Since the ball may only roll 3 inches into the robot, we wished to study the plausibility of a vacuum holding system.  In the 2008 Overdrive game, Team 1771 successfully used a mini shop-vac impeller driven by two Fisher Price motors, to posses and lift the 8lb track ball.  For our test today, a Shop-Vac brand “Hang-Up Mini” model was used.  This is a 120VAC 6.2A model.  As shown in the picture below, the impeller is approximately 4 inches diameter, one half inch thick, and very light weight.

After reassembling the vacuum, a plastic funnel of approximately 4 inches diameter was affixed to the hose.  A small basketball and a rubber exercise ball were used for the test (no soccer balls available at testing location).  No seal was used around the lip of the funnel.  The vacuum held the small basketball very well, and the large exercise ball moderately well.  While seams in the balls did not greatly affect the holding power, we speculate a larger funnel with a lip seal/gasket would improve the results greatly.

A video of the test is shown below:

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We have not yet determined exactly how a mechanism like this might integrate with a kicker.

We also observed the suction power directly from the impeller housing:

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The testing revealed the vacuum produced greater suction and holding power than expected, and could potentially be a successful  soccer-ball holding device.  Further tests would have to be done to power the impeller with KOP motors (such as two Fisher Price motors, as 1771 did in 2008).

Ball Launcher Prototyping

Earlier today, RAWC students and mentors brainstormed ideas while at the high school, coming up with a few mechanisms to launch a soccer ball.  A few of those ideas were actually plausable(we went forward with one).  We built a launcher frame that takes into account the size restrictions placed on teams(Ball can only be 3″ inside the ‘bot, Launcher mechanism can only protrude 2″, Ball must stay in contact with the floor).

Here’s a photo of the launcher.

Here’s the release mechanism:

Here are a few videos:

Long Range (Corner to Corner) Preset Test. This test was setup having the launcher’s frame(the size of the 2009 base) touching the wall of an alliance station. The frame was also pointed toward the opposite corner(diagonally). After launching the soccer ball using the long range setting, the ball landed approximately 2 feet away from the opposing alliance’s home zone.

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Mid Range (Corner to Corner) Preset. This test was setup having the launcher’s frame(the size of the 2009 base) touching the wall of an alliance station. The frame was also pointed toward the opposite corner(diagonally). After launching the soccer ball using the mid-range setting, the ball landed close to the midfield divider.

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Ramp Contact Testing. This test was configured in a way that a KOP tote was placed in varying distances from the front of the soccer ball. We tested the following scenarios: Tote 4FT from ball(long range), Tote 4FT from ball(mid range), Tote 2FT from ball(long range). During our testing, we determined that the ball does not come close to touching the tote in all of the configurations. We performed one additional test that was not documented; the tote was placed 2FT from the ball and the launcher was set into the mid range position. The ball clearly comes in contact with the tote, altering the trajectory of the object.

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Additional ramp contact testing. These videos include a plane that is angled to a 45 degree slope. In addition, the ball is in contact with the inclined plane. This test was to demonstrate the launcher’s capability to launch a soccer ball accurately in the case that it was touching the ramp.

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Angled ramp contact testing. This test is to demonstrate the effects of using our launcher while being offset from the ramp.

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Ball Launcher

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