2521 SERT | 2024 Open Alliance Build Thread

Welcome back to team 2521’s Open Alliance build thread!

With 2023 having been our most successful year yet (and our first event win!), and coming off a successful off-season build and win at BunnyBots, we’re excited to be sharing what we do for a second year.

This year, our thread will focus mostly on the team’s technical work, particularly on strategy, design, and build. After reflecting on the effectiveness of our posts last year, we have decided that going forward we will post more frequently, and focus on keeping text blocks short while including plenty of pictures and videos. We hope that these changes can make our thread both more useful and more engaging for other teams.

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Onshape - 2024 Main

Happy kickoff eve everyone!

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Kickoff Weekend

MoSCoW Sort and Initial Game Thoughts

After some initial game analysis and brainstorming, this is where we ended up.

Our overall sense of the game’s cycling flow is that it’s important to be able to run cycles at both the speaker and the amp, allowing us to both amplify the speaker and take advantage of our own amplification for the highest point efficiency. Ground intake is a high priority for multi-piece autos, and source intaking is a nice-to-have, but unnecessary if it integrates poorly into our architecture. We will shoot into the speaker only from against the subwoofer.

The Trap

Our thoughts right now are that it’s highly valuable for the ensemble ranking point in quals, but doesn’t give a ton of point return for its difficulty. We think it’s a potential way to dominate qualification rankings, but aren’t willing to do anything outlandishly complicated to make it work. We will develop ideas both for robots that can’t score in the trap and for robots that can.

Obligatory:

It's a trap! | Star Wars Memes Wiki | Fandom

Initial Robot Concepts

We don’t have a clear direction yet and believe Crescendo tends towards exploring different architectures before committing to anything. Here are some of our ideas:

Slapdown intake that feeds into a kitbot-style shooter. Intake is either a pass-through into the shooter or can pivot up to score into the amp.

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Inspired by team 33 (2013), the slapdown mechanism is both the intake and shooter. The blue horizontal rollers actuate to free the shot path when shooting (as pictured) and actuate to act as rollers for the intake.

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Slapdown intake that passes off to a kitbot-style shooter. Intake can pivot up to score into the amp. This is fairly similar to the architecture Cranberry Alarm RI3D has been developing.

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AMP Testing

While we’ve been working on initial architecture sketches, we’ve found it difficult to know what positions can reliably score into the amp from below even using RI3D Testing videos as reference.

To get a better sense for the behavior of the amp, we put together a wooden version of it, along with a basic note manipulator prototype to do some testing. Our setup was fairly similar to the one used by Cranberry Alarm RI3D, but we wanted to test slightly different positions than they did.

We also used cim motors to drive our rollers, allowing us to provide more consistent power than we could with drills.

This is a video of the only angle/position range we were able to get to score consistently into the amp from below. Results for further positions were similar to what we saw from other testing online–somewhat accurate, but not great.

Here is our full testing folder:

https://drive.google.com/drive/folders/1nUXb_Ol5XgB6ChOtz8J4bgeAhZ0qXBqm?usp=sharing

Our conclusion is that while amp scoring from below seems like it can get plenty consistent, scoring from above will likely still be faster and less sensitive to alignment.

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Have you had the chance to test how this exact geometry intakes on the ground? Seems like pretty much any wheel placements will work, but intake that does amp is what 847 is planning atm as well.

Edit: Also, I’m curious whether you’re thinking od mounting an intake in-between modules, or to the outside of the frame? Like this:

Seems like being wider is nice, but does introduce a need to center the note.

We haven’t tested this outtake geometry on the ground yet, but with some basic sketching it looks very similar to intake prototypes I have seen work. At this point though, we are focusing on scoring in the amp from above as we believe it will be quicker, more consistent, and less sensitive to alignment.

If we make a deployable intake near the front of the robot like this, I am fairly confident we would mount it to the outside of the frame or on nut strips on our swerve modules.

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End of Week 1 / Beginning of Week 2

Choosing a Robot Architecture

Our team’s big goal by the end of week one was to have a locked-in decision on our robot architecture, so that’s what most of our late-week-one activity was focused on.

Even though our amp testing showed that we could likely shoot notes into the amp from below fairly consistently, we still ended up deciding that we wanted to score into the amp from above. Like we said in the amp testing update, we believe scoring into the amp from above will be quiker and less sensitive to robot alignment.

Our 3 main ronbot architecture options reflected this:

Option 1

Slapdown intake that hands off to a pivoting shooter

The idea was loosely inspired by this early-season CAD. We liked that this architecture featured mostly mechanisms we were familiar with, but weren’t as happy about the idea of two servoed degrees of freedom interacting for a handoff.

Option 2
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Tall, single stage elevator with a pivoting intake that passes through to a shooter

This was the only one of our 3 options that could score in the trap, and definitely the most complex. The climber is integrated into the elevator, with passive hooks at the bottom of the base stage and a set of hooks on the carriage, which saves a little complexity, but we still felt like this architecture would push our team’s limits, especially on the programming side for the elevator’s passthrough logic. We also didn’t feel 100% confident that this architecture would actually score in the trap, despite looking like it, as there are a lot of chain interactions that might not go as expected.

Option 3:

Under-the-bumper intake feeds to a large, pivoting shooter

This option is sort of a combination of team 95’s intake and the Unqualified Quokkas Ri3D. The under the bumper-intake felt unfamiliar, but we really liked how simple and robust it seemed, while still allowing us to have a full-width intake. This architecture does require a large mass to pivot to score in the amp, but we think that there’s plenty of room for ballast if it comes down to it.

Decision

After a team discussion on friday, we decided on option 3, which means we aren’t going to score in the trap. We think that by going for a less complex robot, we will be able to make a more polished robot that scores more points at the end of the day. We are aware that this will likely make it difficult to rank highly at our events, but still feel that the tradeoff is worthwhile.

Prototyping

We’ve been snowed in for the past four days (and maybe more to come), so we haven’t done a ton of prototyping, but we were able to get in one test to verify the geometry of our 95-style intake.

The intaking looked good, but the note got stuck against the ground when we tried to eject it. We unfortunately didn’t get video of this, and didn’t test further out of fear of damaging our only note, but we hope to run more tests once we get more notes. Our current guess is that moving backwards while ejecting will fix the issue.

CAD Progress

The CAD isn’t entirely done, so I won’t be going into too much detail on each subsystem yet, but here are the links to our CAD documents, along with some pictures:

Main

Drivetrain & Intake

Pivot Structure

Shooter

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A couple of things to note on our designs so far:

  • We haven’t done any design for our climber yet, but the current plan is to use one telescoping climber on either side of the robot for a basic chain climb that can reach the high parts of the chain
  • The power transmission for the 95-style intake ends up being somewhat complicated (but not too bad). We’re currently using 4 timing belts and 2 polycord reversals.
  • We opted to build our shooter out of HDPE. We wanted higher rigidity than polycarbonate, without the weight of aluminum, and enough thickness to counterbore mounting holes. As a bonus, notes slide well on HDPE, so we don’t expect to need to line our shooter with any other material.
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Week 3 Update

Prototyping

After missing a week due to ice, we finally got back into our shop last Saturday, with a focus on prototyping, particularly with shooters.

While our original CAD had a side-by-side flywheel shooter, we suspected that top-bottom shooters were better than we initially thought, based on other teams’ prototyping, and our most successful prototype confirmed it:

This shooter uses 8 80a 4” stealth wheels with .5” of vertical compression, and 2” of horizontal compression.

Unfortunately, we don’t have good footage of repeated testing, but it was quite consistent and made straight shots from distance.

CAD Update

Due to our success with the top-bottom flywheel prototype, we updated our shooter in CAD and added centering wheels to our intake. We opted to replace a roller from our second set of intake rollers with a sheet of HDPE to guide the note into the centering wheels. This reduces the grip on the note from the intake as it enters the centering wheels, allowing it to be easily centered. We will also experiment with various amounts of (or lack of) grip tape to allow for ease of centering.

Our updated note path looks like this:

Here’s a video of this geometry being tested:

Inspired by Team 3467, we also decided to change the construction of our arm pivot from dead-axle SplineXL with an off-axis encoder to live-axle MaxSpline with hex endcaps and hex bushings to allow for an on-axis encoder. The hope is that this will make assembly and maintenance of the setup easier, along with reducing encoder backlash.

Beginning Assembly and Fabrication

After making these changes to our CAD, we finally began fabrication and assembly at the end of this week. After finding so much success with it during bunnybots, we are implementing kitting and cut lists again. These allow us to get all the parts we need for a subsystem together before we begin assembly, allowing a lot more people to work in parallel and making everything go quicker.

*Each box is for one subsystem

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Smooth. And appreciate the box system for subsystems. We actually do something similiar, with Monday.com as our main project tracker, has part numbers for parts that need machined, are completed, and which subsystem they go to. Then there is a subsystem part number build list to track. Excited to see the build come alive!

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Week 4 Update

Wiring and Assembly

This week, we went through almost all of the fabrication, wiring, and assembly on our robot. All that’s left is to add our climbers and finish up wiring, so we’re hoping to make a complete handoff to our software team within the next few days to give them plenty of time with the robot before our “week 0” scrimmage on February 18.

Below are some photos of the current state of our robot:

Considering we already missed a week of our season due to ice, I’m fairly happy with where we’re at. I hope to be able to share lots of testing videos soon.

CAD Update

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Since last week, we’ve added two more vision cameras to our CAD, for a total of three. The image above shows the sight cones of these cameras. The two facing to the left are intended only for software vision. They will be able to see the speaker apriltags and either the friendly amp or opponent source apriltags, depending on our alliance. The camera on the right was added as a driver-view camera but uses the same Arducam we use for our vision cameras, so it may allow us to see additional apriltags for localization.

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Great work! Congratulations on finishing up so quickly. I’m eager to see your robot in person in Salem next month.

Week 5.5 Update

Intake Iteration

After the initial testing of our intake geometry, we found that our front roller was too close to the ground due to our robot sinking (~3/16 inch) into the carpet. We adjusted our intake accordingly by raising our front roller 1/4in and our back roller 3/16in and are satisfied with the new geometry.

Here’s the old geometry, with 1.875in (in CAD) between the leading roller and the ground:

And here’s the new geometry, with 2.125in between the leading roller and the ground:

Notably, we’re only using grip tape on the center of our leading roller. The goal was to keep the other rollers low-friction for better centering, and we’ve had no problems with it so far. Testing may lead us to change this, though.

Robot Testing

After updating our intake, our programming team got the robot driving and cycling notes into the speaker from subwoofer range for the first time today.

We’re hoping to get our pivot working soon, along with finally getting our climbers on once some bolts we need arrive, but here’s what we have for now:

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To add to our intake fix explanation:
We also had to change our ratio from 21:24 to 15:30 with 1.5in rollers to prevent stalling

Big Pre-Scrimmage Update

Climber Installation and Testing

After finally receiving some bolts we were waiting for, the climber arms got installed and tested.

Here’s us testing our hang time after a theoretical match end:

We found that we stay off the ground for ~10 seconds but we will most likely change our max planetary ratio after scrimmage from 12:1 to 20:1 to increase our hang time.

To avoid putting the entire robot weight on one climber arm, we created two separate climbing commands. One is an “initilization” command with a very low current limit (5A) to bring the arms down without lifting the robot off the ground. The arms winch down until they contact the chain. Once we are initilized we execute our climb sequence which lifts our robot off the ground. This process will hopefully help us in harmonizing with other robots where we have to climb to either side of the chain.

Continued Robot Testing

After installing the climbers, we got our pivot working and tested our amp scoring position.

As you can see we don’t have bumpers on and we plan to retune the arm positions once we have bumpers available.

We then tested to see how tippy the robot is while driving around and pivoting our arm up and down.

We also got our podium scoring shot position up and running.

As well as a wing line shot position.

We also weighed the robot (no battery or bumpers) and it was surprisingly accurate to the weight in CAD. It will be a little heavier once we swap our intake plates from polycarbonate to aluminum.

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Robot Reveal
It’s been a while since the last update, but for the first time in a few years we were able to produce a robot reveal for our first competition! We’ll compete this weekend at the Oregon State Fairgrounds district event.

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how thick is the grip tape you’re using? does it add any compression?

This is the grip tape we use. There’s no thickness on the listing but we estimated it’s about 0.05in thick, so we sketched our rollers as 1.6in diameter (the polycarbonate tubes are 1.5in). We’ve also recently added the grip tape to our bottom roller to help worn notes intake more easily.

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