I’ve been a merit badge counselor for several years, and I now work for the BSA as a District Executive.
By far the easiest way to teach Robotics Merit Badge is with LEGO EV3/Mindstorms. MARS has a couple kits that I usually borrow. Depending on the setting, I typically ask them to create a robot that will complete a very simple task. I.e. “move this water bottle from one end of the table to the other.”
I work with them through the process of building a stable base, but you can also have them make one of the pre-designed kit bases, again depending on the setting and the time.
Then, we go through the problem-solving process. With the water bottle example, they always try to design a complicated arm to pick up the bottle before moving it. This allows us to go into more in-depth problem-solving skills, asking questions like “did it say we need to pick it up off the table?” and “what is the simplest way we can solve this problem?”
As far as the team helping, I haven’t gotten them involved as much as I would like, because it is typically easier to teach when there is only one or two counselors, and I’m usually either teaching in the middle of build season or in the summertime when our outreach calendars are already full. I’m not typically in a setting in which the team can bring a robot to demonstrate, but for Requirement 6 (competitions), I have them watch match video, game animations, etc. and walk through how our team and other teams solved the game challenges.
Feel free to PM me if you want to discuss more. As a District Executive and a FIRST mentor/volunteer, I’m always looking for creative ways to get FIRST involved in the Scouting program.