NHRL Housebots

My Role: 

- Lead all tasks related to design, testing and fabrication.

- Create CAD models, assemblies and generate production files.

- Wire, install and program full electrical and mechanical systems.

- Run regular functionality checks, keep maintenance logs and repair fleet of ten robots.

- Produce documentation and training materials for event-day staff.

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Project Overview: ​

During my time at National Havoc Robotics League, one of the largest projects I undertook was development of a new generation of House Robots. "Housebots" serve as a referee's in-cage proxy, and are regularly used to perform unsticks, disentangle competitor robots, and get a close up look at the action using on board cameras. More critically, housebots allow referees to assess and begin resolution of fire and uncontrolled robot situations without exposing staff to potential hazards. 

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When I started my contract with NHRL in 2022, the existing set of robots were each built as a "one-off" effort, often by different designers. This resulted in a fleet unified only loosely in aesthetic and rendered virtually unmaintainable due to their non-standardized assembly methods, component selection and maintenance needs; A fleet of robots that would not be capable of meeting the demands of the league as it grew.

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The average event at the time fielded around 180 competitors across 3 brackets, which could result in 300+ matches and up to 15 hours of active "fight time".  Due to the tight turnaround between matches, uneven distribution of operational-time across robots, and the need to consistently have functional units available for both tournament safety and competition integrity purposes, NHRL decided to phase out the old generation of robots and tasked me with bringing their new army of lovable block-heads to life.

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I set upon this task with reliability, serviceability, and ease of operation as the top-line priorities in all design decision making. Here is how those factors came into play during the design process.

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Reliability:

• Address regular failure methods/flaws in Gen 2 designs.

  • Intermittent communication loss​

  • Lid "decapitation"

  • Wheel well debris accumulation

  • Frequently failing light systems

  • Strain on wires from "floating" electronics

  • Debris easily collects in electronics

• Decrease robot downtime due to failures.

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Serviceability:

• Standardize design & component selection across all robots

  • Include consideration for larger bots Fluffy and Flo when possible.

• Select accessible off-the-shelf components.

  • Parts should require minimal modification/prep before installation

  • Chosen parts should be from reputable sources with consistent availability.

• Design considerations for easy mechanical maintenance

  • Drive system must be accessible without disassembling the robot​

  • Maximize fastener standardization

  • Minimize fastener count

  • 3D printable brackets rather than complex internal weldments

• Design considerations for easy electrical maintenance

  • Power distribution via busbar rather than hardwired harness​

  • Hot-swappable components with connectors

  • 3D printed racks for organization and wire routing

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Ease of Operation:

• Standardize control scheme across all units.

• Tune speed controllers for consistent and responsive drive

  • Consider PID vs. Duty Cycle

• Include monitors, alarms or other visual feedback systems that alert operators to non-functional sub-systems.​

• Build out training and documentation for event staff.

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For more information about Brett, Bart and Bert, check out the following photos from the build.