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Thread: Ensign Wedgeley Crusher (FW Sportsman)

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  1. #1
    McMullet
    Guest
    Quote Originally Posted by Ocracoke View Post
    It is heartening to see a few newcomers come into this sport, go out to achieve something and then coming out with something that actually looks like the design they envisaged, so well done. It can be quite a learning curve to get to grips with what works and what doesn't. I guess it being in the Sportsman event would have come back (hopefully) in one piece?
    Thanks!

    Yep, we didn't have too much damage; just enough dents and scratches to feel like we'd "been there", and a slightly busted up motor after one fight.

    Quote Originally Posted by RogueTwoRobots View Post
    Well that was a really enjoyable read. I'm not on here often much anymore but glad I had a look-in today.

    Great job on getting your first bot together so quickly and as Ocracoke said, looking very close to your original design. The funny thing about wonky holes and such is that you know exactly where they are, but to most observers, they couldn't spot them. Looking at your final pic before leaving for the event, everything looked like it was where it was supposed to be. Almost every robot has a wonky something (with exception of the Nippers and the Dutch guys probably ) so don't worry too much about it!

    Looking forward to seeing how it evolves
    Cheers, glad you liked it! And thanks for the inspiration, I think there's more than a little hint of Coyote in EWC.

    I think the only really wonky bit was the front of the wedge, because the front plate is misaligned from the base by about 10 mm (curiously that's also the thickness of the HDPE, it's almost like *someone* measured it wrong then didn't have time to fix it). Other than that you're probably right, it's only noticeable to use because we've spent so long looking up close...


    Next, quick lowdown on the Robodojo event...

    We arrived just after 830, still stressed from the day before and mostly excited about the prospect of an egg butty from the van outside (they offered the addition of a hash brown to the egg butty for a small fee, which was a cause of great excitement).

    Still, we were technically there for ROBOTIN', not eating fried food, so we staked out a quarter of a table and set out the Ensign for tech checking. This went fine in the event; turns out the AR610 does shut down the drive on loss of signal, or maybe the FeatherTwo does or something, but in any event the wheels stopped turning when the Tx went off so GOOD TIMES. We just needed a locking bar for the weapon, which was swiftly bodged from a piece of scrap HDPE (we took all the offcuts with us, I'm gonna claim for things like that, it was really because I couldn't be arsed to unload the car the night before). After that, we put the spare battery (bought from HK 3 days earlier) to charge, and obtained an egg butty with a hash brown in it which lived up to ALL my expectations. It was then a matter of waiting for the first fight, and chatting to our fellow competitors (who were all excellent folks). We drew straws to see who would drive; Simon lost, so he had to do it.
    EDIT: in the finest Scrapheap Challenge tradition, we also spent this time decorating the robot (using sharpies).

    FIGHT 1: Tantrum
    Tantrum was a really quite intimidating thwackbot, with a nasty chunk of broken saw blade as a weapon. If one were to stretch to the assumption that Wedgeley's weapon and drive would function exactly as intended, there wasn't much for us to grab onto and Tantrum's tyres were huge and grippy, so grabbing was unlikely to give us much control.
    Anyway, here's the fight:

    Fair play to Simon here, no one had ever driven this machine before and his credentials for the job consisted of "had driven his nephew's RC car at Christmas". Managing to exact some semblance of control was quite an achievement, but the conclusion was probably inevitable given how twitchy the robot was to steer.
    Nevertheless, in this fight the robot demonstrated effective basic functionality - drive wheels made robot move, weapon control (sometimes) made weapon move. (Sometimes the weapon just didn't seem to respond, which is annoying; sometimes the relay switch just doesn't seem to react. Still investigating that...)

    After the fight, Eoin (Barróg) made a helpful suggesting, to add some wheely bars to the back of the robot to get a bit more control. We dug into the offcuts bag again and, with some manual reshaping came up with these:
    DSC_0591.JPG
    Note also the gouges on the bottom corner, courtesy of Tantrum...

    FIGHT 2: Midas
    This was another robot that looked pretty scary, a 1500N lin-ac driven crusher that looked about 4 times the size of our machine (more on this later). Becky lost the coin-toss and was selected to drive this time. I think the rear skids helped a bit but Ensign Crusher was still pretty undriveable:

    In the pub the night before, Simon set us the objective for the weekend of at least starting the second fight. So at this point we had achieved our goal for the weekend, and anything else from hereon was a bonus...

    We'd also had a sweepstake between the three of us on the drive up as to how heavy the robot was. We'd very roughly estimated around 8 kg, based on the time-honoured engineering technique of rounding everything up. Sometime around here, Dave the tech checker asked how much the robot actually weighed. I said I didn't really know, but it was probably a bit underweight, so we went to put it on the scales. At this point I became irrationally paranoid that it was going to be massively overweight; turned out I needn't have concerned myself, as Ensign Crusher tipped the scales at a puny 3.2 kg - we could literally have built 3 duplicates and entered them as a FW cluster. That explained the controls being so twitchy at least.

    Fight 3: Mattock

    At this point I was starting to wonder if I'd offended someone, as we kept getting drawn against all the really mean robots. Mattock is pretty beefy looking and has a really nasty pickaxe. By elimination it was now my turn to drive, so I took the controls with some trepidation. At least I had the second-hand experience of watching Simon and Becky try to drive it.

    My take-aways from this fight were, a) we lasted more than a minute and b) we got pushed out of the arena rather than driving out under our power. That's PROGRESS!
    However, the robot got pretty banged up in this fight; one of the motors was damaged and had to be swapped out, and one of the wheels got pushed off its hub, requiring some gentle re-positioning using a large G-clamp (I think Chris from Luna-Tic lent me the clamp, so ta!). In addition, though we didn't realise it, the weapon gearmotor was toasted in this fight due to a Good Hit from Mattock. More on this later!

    Fight 4: Chimera's Revenge
    Sadly Chimera's revenge had to retire from the contest, so we won this one by default. It would've been preferable to have the fight, even though we'd have struggled against another big chunky thwackbot, but I suppose the silver lining is that we had a win of some sort from the weekend...

    Fight 5: 8-way rumble
    There was some talk of us getting a final whiteboard fight to make up for missing our 4th fight, but in the end we participated in a final melee of all the Sportsmen (Sportspersons? Sportsrobots?), which sounded like more fun anyway. I lost the dice roll so drove again. There were 8 robots in the arena for this one:

    Unfortunately we got flipped after a couple of minutes and couldn't self-right. I think the gearmotor could've flipped us back over if it'd been in good condition, but (as I'll show in the next post), it was not in a condition I would describe as good. The last driving gear in the box had sheared in two, hence the sporadic waggling seen at 1:49 - every half turn of the driving wheel, it would catch and turn the shaft, then slip back again.


    Overall, we had a fantastic time at Robotdojo. I was really chuffed that we managed to get there with something that worked, regardless of how well we did. I think the Sportsman competition was a great idea; I can't see that we'd ever have gotten around to building a robot otherwise. It's not just that we didn't have to worry about taking the robot home in a bin bag, I also like the fact that the pressure to perform is not too high - it's specifically meant for beginners, so you don't feel like there are too many expectations. That's a great relief when you're not even sure you'll have a robot, never mind a good robot or the ability to drive it competently. So thanks to all the people involved in running the event!
    Last edited by McMullet; 4th February 2019 at 10:05.

  2. #2
    McMullet
    Guest
    Today I got around to stripping the robot down to look at the damage done.


    First up, the previously-seen weapon arm flapping issue:


    Pulling this apart, I found a smashed up gear (already spoiled above). The broken half had embedded itself in a lump of grease at the top of the 'box, which I suppose was lucky:

    Not much I can do about this right now, but it's actually quite a nice little piece of kit so might try and replace that bit some day, if I can.
    P2023779.jpgP2023781.jpg

    I'm not sure if this was caused by Mattock or my cack-handed overtightening of the bolts securing the weapon to the shaft:
    P2023789.jpg

    Also within the weapon subsystem, for curiosity here is the BEAUTIFUL rework I did on the relay switch:
    P2023777.jpg
    I know what you're thinking, what rework right? There's no visible bodging on there AT ALL.


    Next, drive. Both sides were pretty messed up. My bodged-together wheels just about survived the day, but I think some refinement is needed. First, there's not enough contact between the reverse-threaded screw that holds them in place and the inside of the hub, so one of them just came undone by the frankly rather unsubtle means of stripping the thread. I mean, rude or what.
    P2023767.jpgP2023765.jpg

    The other problem is, press-fit components can obviously be un-press-fit, with sufficient application of force:
    P2023783.jpg
    Sufficient forces were evidently applied. This wheel was also hard to get off, since obviously the motor can turn when you try and unscrew it. In the end I jammed something against the motor fan to hold it still and then it came off.

    Both motors were a bit wobbly. They sit in a hole drilled in the side of the chassis and a U shape in an internal bulkhead, then there's some complicated clamping gubbins to grab hold of the various protuberances on the gearbox and motor to hold them both steady.
    P2023771.jpg
    The big flangey screws (1) sit in the slots in the motor mounting face (A) to stop the whole thing slipping axially, while the two countersunk screws (2) sit in the slot in the top of the motor (B) to stop it rotating.

    Two blocks on the base stop the gearbox from rotating:
    P2023769.jpg

    Again, this worked pretty well but a few things need refining. First, Argos are not so kind as to make all their motors the same:
    P2023786.jpg
    Don't think a 4mm screw head will fit in that slot...

    Second, the axial restraint puts a lot of force on the flangey screws, which has damaged the slot in the motor, and on the bayonet-style fitting from between the motor and 'box, resulting in breakage, and consequent wobblage:
    P2023772.jpgP2023773.jpg

    All in all though, this would probably keep trucking for a few more fights (maybe with some extra duct tape to be sure).


    Finally, a couple of shots I never took while building, the wiring, including battery mounted for combat, and location of the F2 ESC:
    P2023775.jpgP2023776.jpg


    A few lessons learned:
    • Mount the wheels and drive motors better - those things take some whacks.
    • Cheap eBay gearmotors cannot take direct impacts (who'd have thunk it). If we want to go clampy, we may need to go big cogs or preferably linear actuator.
    • Do a proper mass budget. Although in some ways I was happier not knowing the first time around.
    • Sort out the mixing on the Tx so the robot doesn't rotate faster the Magnetar's drum when you try and go around a corner (thanks again to Eoin for the hint there - I'll have to look through the Tx manual)
    • Give the robot a shorter name - understandably, it rapidly became known as just "Wedgeley".



    We've definitely got the bug for this so expect to see us again at Robodojo (probably in May) with something bigger and better (or failing that, heavier and repaired).

    Cheers for reading!

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