PROJECT: Miniature Hero

Oldbitcollector (Jeff)

Having played with the Propeller for the last couple years,
I'm finally taking the plunge into some robotics experimentation.
This may be a unrealistic, but I thought I'd take a shot at building
a small hero replica (minus the arm) with a target budget of $150.

So far the project incorporates 2 continuous rotation servos,
a couple of standard servos, a ping sensor and a propeller board.
Still have to run down some minor parts, including a small keypad.

Any ideas on inexpensive fabrication of plastic panels?

OBC

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New to the Propeller?

Getting started with the Protoboard? - Propeller Cookbook 1.4
Updates to the Cookbook are now posted to: Propeller.warrantyvoid.us
Got an SD card? - PropDOS
Need a part? Got spare electronics? - The Electronics Exchange

erco

Interesting goal. Hero 1, not Hero 2000, right? The original panels were injection-molded polystyrene/ABS. If you find someone with vacuum- forming equipment, you can make a wooden pattern to pull sheet styrene over. That's actually a fun job, using not much more than a band saw, drill press and disk sander. Fabricating two panels out of individually-cut styrene panels would be a nightmare.

http://en.wikipedia.org/wiki/Vacuum_forming

http://www.ipfrontline.com/printtemplate.asp?id=453

http://www.build-stuff.com/001book_vacuum_forming.htm

http://distributionbizwiz.wordpress.com/2007/10/02/diy-vacuum-forming-machine/

http://www.warmplastic.com/q_a.html


Do you plan to use differential drive, or stick with Hero's lovingly-flawed tricycle drive? That was the weakest link in Hero's ability to get around.

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·"If you build it, they will come."

RobotWorkshop

Actually, I've already got a project like this underway as one of my HERO robot projects. It is still in the early stages but looks promising. If you are interested in getting an early one let me know. In the past I've done some early kits at a discounts and incorporated feedback into the final docs.

Robert

Oldbitcollector (Jeff)

Getting a kit feels a little like cheating at this point.. [noparse]:)[/noparse]
Yes, I'm basing the design on Hero 1.

I could really use some pictures and measurements (height, etc) to base my design from.
Most of the pics I'm finding on the internet are fairly poor.

I'm thinking that 1/5 scale will be movable by the servos (I hope, now waiting for more parts)

I'm using some "Erector" parts to form the frame to save on costs.
I'm really shooting for a design which would allow someone with a Propeller
protoboard to replicate the base very inexpensively.

I always wanted my own hero, but the prices were always wayyyy out of my range,
and it's worse now that it's a collectible.

Has anyone got digital copies of the hero features/documentation that would be
willing to share?

OBC

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New to the Propeller?

Getting started with the Protoboard? - Propeller Cookbook 1.4
Updates to the Cookbook are now posted to: Propeller.warrantyvoid.us
Got an SD card? - PropDOS
Need a part? Got spare electronics? - The Electronics Exchange

RobotWorkshop

The manuals for the HERO are not available in digital form. I had obtained the rights to them when I bought the HERO line years ago. I offer a select few in electronic format for some of the new robot options but that probably isn't what you'd be looking for. Most of the hard copy manuals are on hand and available. If you are interested in many manuals just send me a PM.

There are also a lot of spare parts (original and reproduction) available to keep the robots going. One of the latest was a USB Interface. It's pretty cool to see Windows XP find a "HERO robot" when you first plug it in.

Robert

Post Edited (RobotWorkshop) : 5/28/2008 4:43:56 PM GMT

Oldbitcollector (Jeff)

Wow.. Nice vacuum- forming links! {EDIT: book ordered! Looks very doable!}

It can't possibly be that easy... Looks like a small vacuum former would be pretty
straight forward to replicate. I'm curious what the hole size is in the bottom of the
form plate. I'll add that book to my shopping list!


I'm going for a three wheel design. Two continuous rotation servos and one steering servo.

OBC

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New to the Propeller?

Getting started with the Protoboard? - Propeller Cookbook 1.4
Updates to the Cookbook are now posted to: Propeller.warrantyvoid.us
Got an SD card? - PropDOS
Need a part? Got spare electronics? - The Electronics Exchange

Post Edited (Oldbitcollector) : 5/28/2008 8:11:40 PM GMT

erco

FYI, in the toy biz, we make virtually 100% of our prototypes out of polystyrene. It's a very versatile material and great for fabricating robots and models in general. I'm surprised that more people don't know about it and use it. Sheets come in a variety of thicknesses, and they are very easy to work with. Beyond vacuum forming, only basic tools are necessary to cut, machine, and fasten styrene. You can go far with a bandsaw, drill press, and a disk sander. Surprisingly, sheet styrene up to 0.125" can be snapped VERY cleanly after scoring with an X-acto knife. It drills beautifully and holds a thread (tap or self-tapping screws) fairly well. It's OK as a light-load bearing surface if you use silicone lube. To "glue" it together, we usually solvent-bond it with MEK (Methyl Ethyl Ketone), a fairly noxious solvent that melts the styrene into inself. CA glue (aka Superglue) works well on styrene too, especially the thicker gap-filling type, used with spray-on accelerator.

A VERY useful modelmaking trick is the use of thin (watery) superglue with baking soda. Alternating layers of these two, you can build a strong, thick, rock-hard fillet, screw boss, hole-filler, bracing rib, almost·anything. Anywhere that needs strengthening can be shored up on the inside this way. You can actually make strong, solid parts out of nothing but superglue and baking soda. In an emergency, I have hand-made GEARS this way to keep a model going. Sort of old-school rapid prototyping.

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·"If you build it, they will come."

MSDTech

erco,
You forgot to mention that there are a wide variety of polystyrene shapes available. As a model railroader, I have used it in many different construction projects. If you want an idea of the type of scratchbuilding supplies available in styrene, try:
http://www.plastruct.com/Home.html

erco

MSD:·guilty as charged. Thanks for your post. Another·good supplier is http://www.evergreenscalemodels.com/
They have all sorts of plastic rods, tubes, extrusions, I-beams, as well as·thin plastic·sheets with various textures for decoration.

While I'm mentioning materials suppliers, I'd be remiss if I didn't mention K&S metals, available at·most hobby shops: http://www.ksmetals.com ·All sorts of wonderful sheet metals and tubing.

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·"If you build it, they will come."

Oldbitcollector (Jeff)

Just got more of my parts in today.. As well as that book that "erco"
sent the link on vacuforming.. It looks VERY doable! I'll be starting
work on a small forming unit very soon.

Has anyone else here ventured this direction yet?

OBC

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New to the Propeller?

Getting started with the Protoboard? - Propeller Cookbook 1.4
Updates to the Cookbook are now posted to: Propeller.warrantyvoid.us
Got an SD card? - PropDOS
Need a part? Got spare electronics? - The Electronics Exchange