We’ve been working on a fun new robot we call Metalbot. Our goal was to build an autonomous rover with a unibody design that was machined out of a single block of metal. We started with this 13” x 9” x 1.75” block of 6061 aluminum:
When the machining was done, the robot’s body looked like this. It’s a hollowed-out shell that is about 1/8” thick with holes, slots, and pockets for the motors, LEDs, sensors, and other electronics.
Once Metalbot was assembled with the internal components, it looked like this:
What do you think? We think it’s pretty cool looking. Do you like it?
In this first picture (which was taken through the polycarbonate enclosure), we clamped the part vertically in the vise and we’re using an 1/8″ end mill to machine the detail on the front of the nose. In a previous operation we clamped the stock flat and machined the top of the robot, so that work is already done. Because this part has features on every side, machining it required us to clamp the stock in the vise in 8 different orientations: top, left side, right side, back, front, 45-degree left nose, 45-degree right nose, and bottom.
In this next picture, we’re on the last setup, machining out the large pocket on the underside of the robot. This turned the aluminum block into a 1/8” thick shell. The large pocket appears to be glowing because the ring of LEDs we installed around the mill’s spindle are shining into the coolant that has filled the pocket. We’re using a 25mm (.98”) modular end mill here, which is designed to remove material fast. Of course, there were a lot of metal chips, but it’s important to remember that aluminum is easy and efficient to recycle.
In this picture we’re half way done digging the pocket and we have the machine take a break from the hard work to chamfer the outside contour:
Once the body is machined, we screwed in the wheels, motors, and electronics, which are screwed upside down on the underside, where they are easy to access when the robot is turned over. We will install a bottom plate later.
Then we did the wiring and soldering:
Here is the underside of the robot with most of the electronics installed. We’re using an Arduino Mega and a 4-channel Motor Controller, along with 4 Pololu gear motors to drive the mecanum wheels, which will allow the robot to strafe. The robot is also equipped with 6 Ping ultrasonic sensors for autonomous object detection, a LIPO battery, a main power switch, 6 NeoPixel RGB LEDs to indicate the state of each sensor, an Xbee Radio, and a panning servo (black thing in the middle). The robot will also be equipped with an MP3 module and speaker for sound, but those haven’t been installed yet.
The robot’s finished body is 8” wide and 12” long. The rover can be fitted with either the mecanum wheels shown or CNC-machined conventional wheels (not shown). Our original goal was just to machine a cool looking rover out of a single piece of metal, but as we went along, we decided to add some flexibility into the design for future enhancements in case we wanted to do more with it. The robot has been designed with a central spine of holes and ridges for attaching future add-ons, including a servo mounted in the center, which will support a pan-tilt turret for a camera, gun, or arm. We have designed the pan-tilt turret to utilize the Actobotics ecosystem, but other pan-tilt mechanisms could also be used. There are also holes on the front and rear of the top deck that are compatible with the full range of Actobotics components such as brackets, hubs, and channels, which really adds a lot of flexibility.
The next step is to work on the sensors and software programming. With its mecanum wheels, it should be able strafe like a champ very soon.
Here are a few more pictures of Metalbot so far. Let us know what you think. Do you like the overall design?