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After you ve done all your research gone through those parts catalogs, know the rules, and are sure of the weight class you want your robot to compete in the next phase is coming up with the design sketch You don t need heavy-duty engineering computer aided design (CAD) software to create a basic design sketch Our work was done on an artist s sketchpad and on notebook paper The average builder won t have AutoCAD on his or her home PC, and it isn t necessary if you plan a simple robot design The photographs of my lightweight entry Chew Toy (Figures 14-1 and 14-2) show its simple design Chewie is a basic robot all the essential parts, such as the motors, batteries, and major weapons, were not that hard to lay out and assemble The robot s conception came out of the hypothesis, If I could use only a surplus store s catalog to get parts to build my robot, what would I design In reality, I use a lot more sources for parts However, I was curious Could I come up with an effective design by pretending I was limited in parts availability As you can see, Chew Toy has a simple structure It relies heavily on its 35-hp, four-stroke motor and those rather evil sharp saws to do its battle damage The
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Chew Toy with protective armor removed
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body frame the square steel tubing and the wire mesh used for the armor came from Home Depot, another great inexpensive supplier Chew Toy is something that all designers like a cheap entry The cost for this robot (everything but the speed controller) was about $500 (Instead of doing what I had initially conceived create a simple relay system I splurged on a Vantec speed controller for Chew Toy It cost about as much as the entire rest of the robot, but, because the speed controller is an item that can be reused in future designs, I looked at my extravagance as an investment In addition, it saved the time that it would have taken to construct and properly test the relay system I had devised in the early phase of Chew Toy s development) Once you figure out what you want to build, the next step is building the mockup I cut out a balsa wood frame and the parts into which the motor, the drive train, weapons system, and so on, will be fit Balsa is easy to work with, and any hobbyist who has done original designs of model airplanes, boats, or the like has probably done mockups in balsa wood Balsa wood is also cheap and readily available, and if you botch something in the mockup phase, you can redo it much more easily than if you were working in metal After your balsa wood mockup is within your parameters and everything looks workable, you are ready to spec out your final project The balsa wood project can be broken down into the component parts and used as guides for cutting the metal for the final project If you are doing your own metal cutting, you can take apart your mockup and use each piece as a template for your metal pieces I laid the pieces on top of the metal, traced the shape onto the metal, and then cut out the shapes That way I was sure all the metal shapes would be the exact size I specified, and when I cut and fit the bot together it would replicate the mockup
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Metal shops can also use your balsa template as a guide If a shop is also going to be doing all your welding, it is a good idea to give these folks your design sketch and review it with them so they understand exactly what you want your finished piece to look like Showing them the balsa mockup before you disassemble it for template parts is also useful, especially if you are working with people who have no prior experience with robotics
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