Electronics Prototyping

Seen here is the integration of EAGLE PCB design with the ProE CAD model. Design in this fashion helps to ensure that the electronic assemblies mate with the mechanical design with the minimum of interference.

Old & New

Shown here are images of the older chassis (integrated with the PC104 and electronics) along with the new chassis (below). Shown in the lower photograph are the newly modified gearboxes, made from 2 components instead of 3.

Assembly

Shown here is the frame sub-assembly. Visible are the through holes for the PC fans. The rear sub-assembly is almost complete, so once the canopy sub-assembly is complete, final assembly will begin.

Manufacturing II

Shown here is an example of the typical manufacturing process for one section of the robot. Omitted is the first stage of this component (in this case the rear base of the robot) , in which several machining operations were done. Some components require machining on both sides, and this usually requires the use of fixtures and "clocking" to ensure accuracy, a very time-consuming process.

In this case, a profile of the component is machined in to a wooden "jig", and the component is then re-placed on the profile. This ensures absolute accuracy (taking into account the repeatability of the machine), and does not requiring clocking or fixtures.

The centre image shows a "roughing" machining procedure. At bottom is the completed component (top) as well as two other robot frame components.

Manufacturing

Here is the revised design for one of the frame sections. Shown in the picture are weight-reducing features, as well as a section machined out for one of the PC104's dual cooling fans.

Tail Assembly

Here is the pre-assembled tail unit. On top are the covers, beneath are the bearing supports, hinge shaft and swing-arm, with the magnetic jockey at the bottom.

Infra-red Camera

Shown here is a hacked apart Logitech QuickCam Pro 4000, that is going to be employed as an infra-red camera on teh robot. The basic premise is the removal of the infra-red filter (that comes standard on webcams) to allow the CCD chip to detect infrared. Normal light is filtered out with the use of a section of an ordinary colour negative.

If you are interested or want to know more, check out the webpage at: http://www.hoagieshouse.com