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Consider ways to lighten your heavy robots, but without sacrificing strength. This can be done by selecting a different construction material and/or by using different construction techniques. For example, instead of building the base of your robot using solid 1/8inch (or thicker) aluminum sheet, consider an aluminum frame with crossbar members for added stability. If you need a surface on which to mount components (the batteries and motors will be mounted to the aluminum frame pieces), add a 1/16-inch acrylic plastic sheet as a skin over the frame. The plastic is strong enough to mount circuit boards, sensors, and other lightweight components on it. Aluminum and acrylic plastic aren t your only choices for frame materials. Other metals are available as well, but they have a higher weight-to-size ratio. Both steel and brass weigh several times more per square inch than aluminum. Brass sheets, rods, and tubes (both round and square) are commonly available at hobby stores. Unless your robot requires the added strength that brass provides, you may wish to avoid it because of its heavier weight. Ordinary acrylic plastic is rather dense and therefore fairly heavy, considering its size. Lighter-weight plastics are available but not always easy to find. For example, ABS and PVC plastic popular for plumbing pipes can be purchased from larger plastics distributors in rod, tube, and sheet form. There are many special-purpose plastics available that boast both structural strength and light weight. Look for Sintra plastic, for example, which has an expanded core and smooth sides and is therefore lighter than most other plastics. Check the availability of glues and cements before you purchase or order any material. (See 8 for more on these and other plastics.)
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For robots that have additional decks, like the bot shown in Fig. 16.1, select construction materials that will provide rigidity but the lowest possible weight. One technique, shown in the figure, is to use 1/2-inch thin-wall (Schedule 125) PVC pipe for uprights and attach the decks using 8/32 or 10/24 all-thread rod. The PVC pipe encloses the allthread; both act as a strong support column. You need three such columns for a circular robot, four columns for a square robot. Unless your robot is heavy, be sure to use the thinner-walled Schedule 125 PVC pipe. Schedule 80 pipe, commonly used for irrigation systems, has a heavier wall and may not be needed. Note that PVC pipe is always the same diameter outside, no matter how thick its plastic walls. The thicker the wall, the smaller the inside diameter of the pipe. You can readily cut PVC pipe to length using a PVC pipe cutter or a hacksaw, and you can paint it if you don t like the white color. Use Testor model paints for best results, and be sure to spray lightly. For a bright white look, you can remove the blue marking ink on the outside of the PVC pipe with acetone, which is available in the paint department of your local home improvement store.
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A critical issue in robot frame design is excessive weight that causes the frame to sag in the middle. In a typical robot, a special problem arises when the frame sags: the wheels on either side pivot on the frame and are no longer perpendicular to the ground. Instead, they bow out at the bottom and in at the top (this is called negative camber ). Depending on which robot tires you use, this can cause traction errors because the contact area of the wheel is no longer consistent. As even more weight is added, the robot may have a tendency to veer off to one side or the other.
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