We saw both kinds of "nesting" that you described.
We only found the type of nesting where the upper frisbee tries to go out the output slot in front of the lower frisbee to be a problem.
If the frisbees nested so that the upper frisbee was between the "plunger" and the frisbee in the "chamber" we noticed that when the plunger was fired the upper frisbee would slide at an angle upwards and the lower frisbee would slide into the shooter just fine.
As per how we solved the other kind of nesting:
Quote:
Originally Posted by JChang
We added a lip on the exit side, so only the bottom most Frisbee lay flat, the rest sits on the lip. When the bottom one exits, the diagonal length allow the second Frisbee to fall through, getting it into position.
Edit: After thinking how it worked on our robot, I realized that the animation is somewhat inaccurate. The back piece should be angled a little towards the exit so that it realistically works.
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We use something very similar that I can advocate for.
What we have is that the bottom frisbee is shifted about 1/2" off center from the other frisbees. Then, the other frisbees lay on top of it at an angle.
When you push one frisbee out of the "chamber" another slides down into the chamber with the other frisbees still resting at an angle to the frisbee in the chamber. The key here is that this "chamber" only be small enough for only one frisbee to fit in at a time, but large enough so that a frisbee will slide into it from a position "staged" above it when no frisbee is in the chamber.
Also, vibration of the entire plate from the shooter wheel, or from the bot driving is more than enough for any loose frisbees to fall into place.
Sorry I don't have any good pictures of the device and the kids took the prototype apart. If you have questions, please ask.
Best of luck.