Electronics and Robotics Merit Badges

Class 4 – Robot Subsystem Mechanics or

Building Robot Bases and Drive Trains

04/21/23 Electronics and Robotics Merit Badges - Class 3 1

Our kit! The SumoBot Kit

04/21/23 Electronics and Robotics Merit Badge Class 4 2

CHASSIS SUBSYSTEM

LET’S BUILD THE SUMOBOT

04/21/23 Electronics and Robotics Merit Badge Class 4 4

Step #1Install the Battery Box

Parts Required:• Battery Box• (2) 4/40 3/8" longflat-head countersunkmachine screws• (2) 4/40 nuts• SumoBot chassis

Stand the SumoBot on its PCB mounting ears. Install the plastic battery pack using two 4/40 3/8” flat-head screws and nuts. The screws will be countersunk into the battery pack when tightened and should be out of the way of the batteries.

MECHANICAL SUBSYSTEM

LET’S BUILD THE SUMOBOT

04/21/23 Electronics and Robotics Merit Badge Class 4 6

Step #2Install the Servo Motors

Parts Required:• (2) ParallaxContinuous RotationServos• (8) 4/40 3/8" longpan-head machinescrews• (8) 4/40 nuts• SumoBot chassis

Using four 4/40 3/8” pan-head machine screws and 4/40 nuts, attach each servo motorto the chassis. The easiest way to do this is to hold the nut with one finger whileturning the screwdriver with the other hand.

LET’S BUILD THE SUMOBOT

04/21/23 Electronics and Robotics Merit Badge Class 4 7

Step #3Install the Rear SumoBotPCB Stand-offs

Parts Required:• (2) 5/8" roundstandoffs• (2) 4/40 3/8" long panheadmachine screws• SumoBot chassis

Using a 4/40 3/8" pan-head machine screw, attach each stand-off to the rear of theSumoBot chassis.

LET’S BUILD THE SUMOBOT

04/21/23 Electronics and Robotics Merit Badge Class 4 8

Install the Front SumoBotPCB Stand-offs

Parts Required:• (2) 5/8" roundstandoffs• (2) 4/40 1" long panheadmachine screws• SumoBot PCB

Using a 4/40 1" pan-head machine screw, attach each standoff to the front mounting holes of the SumoBot PCB.

CONTROLS SUBSYSTEM

LET’S BUILD THE SUMOBOT

04/21/23 Electronics and Robotics Merit Badge Class 4 10

Step #5Mounting the PCBParts Required:• SumoBot PCB• (2) 4/40 3/8" longpan-head machinescrews• (2) 1-1/4" roundstand-offs• (2) Nylon washers• SumoBot chassis

Feed the ends of the 1" long pan-head machine screws through the front mounting holes on the SumoBot chassis. Secure the rear side of the SumoBot PCB to the 5/8“ standoffs with two 3/8" pan-head machine screws. Holding the chassis upside-down, place a nylon washer onto the end of each 1" long pan-head machine screw, then secure by threading on the 1-1/4" round standoff.

LET’S BUILD THE SUMOBOT

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Step #6Prepare the Wheels

Parts Required:• (2) SumoBot wheels• (2) SumoBot rubber tires

Stretch a "tire" of each wheel and adjust so that the"tire" is centered across the wheel.

LET’S BUILD THE SUMOBOT

04/21/23 Electronics and Robotics Merit Badge Class 4 12

Step #7Mount the Wheels

Parts Required:• (2) Preparedwheels/tires• (2) Black servo-hornscrews• SumoBot chassis

Carefully press each prepared wheel onto the servo splines. Secure each wheel with the small black Phillips head screw.

LET’S BUILD THE SUMOBOT

04/21/23 Electronics and Robotics Merit Badge Class 4 13

Step #8Mount the Scoop

Parts Required:• SumoBot scoop• (2) 4/40 1/4" long panheadmachine screws• (2) 4/40 nuts• SumoBot chassis

Using two 4/40 1/4” pan-head machine screws and 4/40 nuts, attach the scoop to the SumoBot chassis. Carefully center the scoop before tightening the screws and nuts.

SumoBot RulesThe Match:1) Flip a coin to determine who positions their robot first in the ring2) Place the ‘bot in the ring as directed by the referee3) Press the start button on the bot when directed by the referee. After 5 seconds the bot may begin moving (sound/light indicates robot working).4) Move back at least 3 feet from the edge of the ring5) Catch any bot that is out of the ring and turn it off6) Place the bot back in a holding area between matches. A contestant may make adjustments between matches, but may not leave the holding area.Basic Rules:1) One match will consist of three rounds, within a total of 3 minutes each. The team who wins two rounds out of three wins the match.2) The match will be stopped and a rematch will ensue when it is apparent that neither bot is making any progress for duration of about 4 seconds (as determined by the referee).3) If a part on the bot comes off that is less than 5 grams, the round will continue. 4) A player has 30 seconds to correct a problem between rounds.5) The referee has the final decision in a match.

Electronics and Robotics Merit Badge Class 3

LET’S BUILD THE SUMOBOT

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Step #9Install Line SensorWires

Parts Required:• (2) 10" 3-pinextension cables• SumoBot chassis

Carefully feed each 10" 3-pin extension cable through the center chassis slot.

LET’S BUILD THE SUMOBOT

04/21/23 Electronics and Robotics Merit Badge Class 4 16

Step #10Install the QTI LineSensorsParts Required:

• (2) QTI line sensors• (2) 4/40 1/4" longpan-head machinescrews• SumoBot chassis

Using two 4/40 1/4” pan-head machine screws, attach the QTI line sensors to the 1-1/4" round stand-offs. Connect the ends of the 10" 3-pin extension cables to the QTI line sensors, noting the polarity markings B[lack]-R[ed]-W[hite] on the QTI sensors.

POWER SUBSYSTEM

LET’S BUILD THE SUMOBOT

04/21/23 Electronics and Robotics Merit Badge Class 4 18

Step #11Make the Connections

Plug the servo motors and QTIsensors into the SumoBot PCBconnectors as indicated below.Note that the "B" pin on eachconnector is for the black wire.

X7 = Left Servo MotorX6 = Right Servo MotorX5 = Left QTI Line SensorX4 = Right QTI Line Sensor

Connect the battery pack wires to SumoBot PCB connector X1. The battery pack's white-striped lead connects to the + terminal.

LET’S BUILD THE SUMOBOT

04/21/23 Electronics and Robotics Merit Badge Class 4 19

Step #12Powering the SumoBot

The SumoBot PCB has a three-position power switch. The state of each position is shown below. The three-position switch has a middle position that powers the entire circuit except the servos. A complete schematic of the SumoBot PCB follows. Also note the new Li-ion Boe-Bot Power Pack-Charger.

Position 0 – No PowerPosition 1 – Power PCBPosition 2 – Power PCB & Servos

COMPLETE SUMOBOT CIRCUIT DIAGRAM

04/21/23 Electronics and Robotics Merit Badge Class 4 20

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Robotics merit badge requirements        

1.Safety. Do each of the following:a. Explain to your counselor the most likely hazards you may encounter while working with robots and what you should do to anticipate, mitigate and prevent, and respond to these hazards. Describe the appropriate safety gear and clothing that should be used when working with robotics.b. Discuss first aid and prevention for the types of injuries that could occur while participating in robotics activities and competitions, including cuts, eye injuries, and burns (chemical or heat).

2.Robotics industry. Discuss the following with your counselor:a. The kinds of things robots can do and how robots are best used today.b. The similarities and differences between remote-control vehicles, telerobots, and autonomous robots.c. Three different methods robots can use to move themselves other than wheels or tracks. Describe when it would be appropriate to use each method.

3.General knowledge. Discuss with your counselor three of the five major fields of robotics (human-robot interface, mobility, manipulation, programming, sensors) and their importance to robotics development. Discuss either the three fields as they relate to a single robot system OR talk about each field in general. Find pictures or at least one video to aid in your discussion.4.Design, build, program, test. Do each of the following:

a. With your counselor's approval, choose a task for the robot or robotic subsystem that you plan to build. Include sensor feedback and programming in the task. Document this information in your robot engineering notebook.b. Design your robot. The robot design should use sensors and programming and have at least 2 degrees of freedom. Document the design in your robot engineering notebook using drawings and a written description.c. Build a robot or robotic subsystem of your original design to accomplish the task you chose for requirement 4a.d. Discuss with your counselor the programming options available for your robot. Then do either option 1 OR option 2.

(1) Option 1. Program your robot to perform the task you chose for your robot in 4a. Include a sample of your program's source code in your robot engineering notebook.(2) Option 2. Prepare a flowchart of the desired steps to program your robot for accomplishing the task in 4a. Include procedures that show activities based on sensor inputs. Place this in your robot engineering notebook.

e. Test your robot and record the results in your robot engineering notebook. Include suggestions on how you could improve your robot, as well as pictures or sketches of your finished robot.

5.Demonstrate. Do the following:a. Demonstrate for your counselor the robot you built in requirement 4.b. Share your robot engineering notebook with your counselor. Talk about how well your robot accomplished the task, the improvements you would make in your next design, and what you learned about the design process.

6.Competitions. Do ONE of the following.a. Attend a robotics competition and report to your counselor what you saw and learned about the competition and how teams are organized and managed.b. Learn about three youth robotics competitions. Tell your counselor about these, including the type of competition, time commitment, age of the participants, and how many teams are involved.

7.Careers. Name three career opportunities in robotics. Pick one and find out the education, training, and experience required for this profession. Discuss this with your counselor, and explain why this profession might interest you.