Cover.png

Flywheeler

 

What’s the winning strategy and how might we design those capabilities in a robot?

Flywheeler is a robot designed and built for 2.007, MIT’s Design and Manufacturing I class. This class culminates in an end-of-semester robotics competition and in 2017 the game course and competition theme was “May the Torque Be With You”. The Star Wars inspired challenge was designed to have robots face off against each other in a 2-minute 1v1 match to score the most points.

Flywheeler is a robot that consists of a driving chassis, a spinner wheel that engages the flywheels on the game course and spins them to score points, and a 4-bar linkage pusher to tilt a weighted game piece to score a point multiplier.

 
 

The Game and Strategy

The game is played on a game course split into two sides: red and blue. At the beginning of the match, the robots start in the starting zone and have 30 seconds of autonomous play to score double points. Then the 90-second manned-operation period starts and students try to score the more points than their opponent to win and move to the next round.

The game course is a X-Wing flying craft. Robots may play on both the ground level, or they can also ascend the elevator to access game play on the top level.

Game Board.jpg

The several methods of scoring include:

  • Spinning the X-Wing thrusters (weighted flywheel) as fast as you can (higher maximum RPM scores more points)

  • Pulling the “Carbonite-frozen Han Solo” to a certain height

  • Pushing stormtrooper figurines into a pit

  • Placing stormtrooper figurines on a high ledge

  • Tipping the lightsabers over to score a point multiplier

  • Knocking over Darth Vader

Given that each match is only 2 minutes long, my strategy was to pick only one thing to do, and to do it extremely well. I chose to spin up the thrusters because it gives the most points and didn’t require taking the time to get up to the upper level of the game course. As I build the robot, I realized that I would have room to put another mechanism on the robot, so my strategy evolved to include a 4-bar linkage pusher that could help me tip the lightsaber to score up to a 3x point multiplier.

Strategy.jpg

My three stage strategy proved to be an effective use of time. A simple autonomous maneuver helped me align to thruster. While I did not score double points in the autonomous period, this starting strategy left me the full 90 second left to score points.

My strategy helped me score a maximum of 146 points. In the end-of-semeter robotics competition, this was enough to land me a spot in the top 16 and a chance to compete in the finals.


The Robot

Flywheeler is built to prioritize the efficiency of the spinner wheel since that is key to scoring the most points. The spinner is mounted on a 2-axis suspension system which provides a spring-loaded normal force on the thruster, and additional compliance to absorb vibration. To get the robot to the thruster, a maneuverable but fast drive train was required to move the robot in position. The 4-bar-linkage pusher was added last as a “nice to have” in the event that I had enough time in a match to score the multiplier points.

 

The rubber tread on Flywheeler’s spinner wheel engages with the tread on the thrusters. A 2-axis suspension system helps to hold the spinner against the thruster and combat any vibration from the slightly eccentric rotation of the thrusters.

Spinner Subsys.jpg
 

My original spinner concepts utilized multiple points of contact for stability and redundancy in case one spinner wheel slipped.

spinner concepts.png

I prototyped and tested one of the modular small spinners. I was so convinced that this was the correct architecture and I had designed in enough compliance and redundancy to ensure good contact with the thruster flywheel, however my prototype did not work. The small wheel barely moved the thruster.

I went back and looked at the math to see where I had gone wrong. If I assumed a no-slip condition, my spinner wheel and the thruster flywheel should act like gears. The problem was that I needed a bigger “gear”. I increased my spinner wheel to have the biggest diameter that could still fit within the robot size limits to create a 2:1 “gear” ratio.

However, with a bigger gear, the torque on the motor would increase. Then, the motors could not operate near no-load speed. I solved this by using multiple motors and gearing them up to increase both torque and no-load speed.

geared motor realization.png
 

Video of final spinner design being tested.

Each time I tested the spinner prototypes, I noticed that it took a lot of strength to hold the spinner and gearbox still. The slightly eccentric thruster flywheel and the small unevenness in the tread create vibrations that make it hard to maintain good contact between the two wheels. From this, I realized that mounting the spinner would not be so easy. I designed a suspension system to provide compliance so that the spinner had a better chance of staying in contact with the flywheel.

 

Early design of 2 axis suspension system and the final design.

The threaded core has pockets designed to snugly hold the electrical components in this lamp. This prevents any electrical components from coming loose, and also helps keep all the LED lights oriented so all of the light shines toward the shell of t…
DSC_5907.jpg
 
 

The 2 axis- suspension system consists of a set mounting plates and a set of carriers. The axle of the spinner wheel is secured to the carrier. The carrier then floats in a pocket of the mounting plates and is held by springs at their neutral length. This design allows the carrier to move in both X and Y directions within the plane of the mounting plates.

DSC_5889.jpg

The 4-bar linkage pusher is mounted to the back of the robot. The design intent is for the robot to drive up next to the lightsaber on the upper level of the game course and then extend the pusher to push the hilt of the lightsaber. This would tip the lightsaber far enough to score a 3x point multiplier. However, in gameplay, there was never an occasion where I had enough time to complete the maneuver.

 
 
DSC_5903.jpg

The drive train is a simple tank-style drive train. One DC motor drives the center gear on each side, and a series of idler gears transfer the motion to the two wheels on that same side. To drive straight, current is applied equally to both motors. To turn, one motor runs in reverse and the other runs forward. This simple drive train preserves the high speed of the motors selected, and as a result this robot was very fast maneuverable, earning it an award for fastest robot in the class.

 

Bottom view of the Flywheeler. Electronics are mounted on the bottom for easy access and to save space to mount the other subsystems on the top.

DSC_5895.jpg
Cover.png

Designed and built by Annie Zhang

 

This curve represents the skills I practiced and strengthened through my work on this project.

This curve represents the skills I practiced and strengthened through my work on this project.