Engineering Notebook Team India FGC 2024
Engineering Notebook Team India FGC 2024
Engineering Notebook Team India FGC 2024
Vision Mission
To make FIRST affordable, accessible and Build FIRST ecosystem by engaging
sustainable #FIRSTforALL and connecting governments, industry,
communities and STEM youth
ENGINEERING NOTEbook 1
Game Analysis & Objectives
The Feeding the Future Robotics Challenge is played on a 7 m by 7 m elevated platform. Six teams compete
with their ROBOTS on the PLAYING FIELD during the 2 minutes and 30 seconds (2:30) of play, with each
MATCH featuring a different randomized combination of teams
This year’s game involves a strategy that succeeds in performing all tasks presented in the Challenge.
Major Tasks are as follows:
• Loading large heavy balls on the robot
• Carry them to the Nexus Goals
• Lifting the heavy balls to low, mid and high Nexus goals
• Driving up the ramp with heavy load
• Parking on the Platform
Game Objectives:
• Maximise ranking points
• Optimise our drive train acceleration for short paths
• Optimise drive train for going over a ramp with heavy load
• Design mechanism to lift heavy balls to 3 different heights
• Design mechanism for delivery of heavy balls at the above 3 different heights
• Prioritise delivery of Water and Energy Balls from Regional Zone to Mid and Low Nexus goals under the
Warehouse
• Drive up the ramp with 4 Water and Energy Balls and deliver to the 3 High Nexus Goals near the ramp
• Intake and Collect Food Ball and get it back to the Regional Zone on the return path
2 ENGINEERING NOTEbook
Game Analysis & Objectives
Each match consists of two key phases. In the Regional Alliance phase, teams form groups of three, known
as regional alliances, and collaborate to transport and deposit water and energy balls into 12 distinct Nexus
goals. Successfully scoring in these goals triggers the release of a food ball, which must then be delivered to
the human player. In the Global Alliance phase, which takes place at the end of the match, all six teams join
forces to balance on the central platform, working together to achieve stability and coordination.
Game strategy:
1. The human player begins by placing 4 balls on the robot.
2. The robot then uses AprilTags for precise alignment with its target.
3. Employing a cascade elevator mechanism, the robot extends up to 120 cm.
4. A servo motor activates to drop one energy ball and one water ball into two separate goals, successfully
scoring all 4 balls.
5. The robot then uses its intake mechanism to collect the food ball produced, which it promptly delivers
back to the human player.
6. On receiving the food ball, the human player places 4 more balls on the robot and transfers the food ball
into the warehouse for storage.
ENGINEERING NOTEbook 3
Robot Specifications
4 ENGINEERING NOTEbook
Design Evolution - Drive
Mechanism
Chassis
a. Conceptual motors through gear with a ratio of
The chassis is the robot's foundation. It plays a 72:60, giving an overall reduction of
vital role in achieving manoeuvrability and speed 14.4:1 on each side of the chassis.
while having enough torque to climb the ramp to - Chain Drive System - The main
the platform area. output shaft is linked to the front
1. Initial Concept: Six-Wheel Drive wheels using sprockets and chains. A
- Wheel Configurations: A 6-wheel drive mechanical tension is added using a
system that uses traction wheels, omni shaft with spacers to control the chain
wheels, and grip wheels. tension by shifting it.
- Motor Placement - 4 motors individually • Result: Improved straight-line movement,
power the traction and grip wheels on eliminating drift.
both sides of the chassis. The omni
wheels are not powered and intend to 2. Grip Wheel Slippage
support and enhance the robot's turning. • Issue Faced: When going on to the ramp
to access the platform and for balancing
b. Trials and errors at the end of the game, the grip wheels
1. Non-Uniform Wheel Movement: (climbing, were slipping making the robot unable to
rotation, weight distribution climb up and access the 3 nexus goals.
• Issue Faced: The initial design involved • Impact: It restricted the robot to the
powering the front and middle wheels nexus goals accessible from the mat,
individually using 4 separate motors, reducing the scoring ability of the robot.
leading to the wheels not moving • Solution Implemented: Reconfigured
uniformly, causing the robot to drift Wheel Setup
towards the side that moved faster. - The grip wheels were removed from
• Impact: This drift compromised the the chassis and we transitioned to a
robot's ability to move straight and four-wheel drive system.
required the drivers to correct it manually. - New Configuration - Front wheels:
This also led to slower cycle times. Powered traction wheels
• Solution: Switched to a gearbox that Rear Wheels:
unifies two wheels onto one output shaft. Unpowered Omni wheels.
- Gear Reduction - Each of the REV • Result: Reduced the slippage of wheels
HD Ultra Planetary Motors uses a 3:1 on the ramps and allowed the robot to
and a 4:1 stage, resulting in a 12:1 access the platform.
reduction per motor. The gearbox
then combined the output of the
ENGINEERING NOTEbook 5
Design Evolution
- Drive Mechanism
3. Difficulty in Turning
• Issue Faced: The traction from the grip wheels on the carpet hindered thet smooth turning, and
added strain on the drive motors.
• Impact: Decreased efficiency in navigating the field and precise movements
• Solution Implemented: SAME AS ABOVE PROBLEM
• Result: Improved turning capabilities with quick point turns, assisting with alignment with nexus
goals.
4. Weight Distribution Leading to Tipping
• Issue Faced: When accelerating forward or backward, the robot tips, posing a risk of falling over
completely.
• Impact: The instability adds difficulty in balancing on the ramp and can also possibly lead to the
robot falling over.
• Solution Implemented: Implementing a Programming Fix
- The robot’s default maximum speed was reduced to prevent sudden accelerations that could
lead to tipping.
- If maximum speed is necessary, the driver can override by pressing down the joystick while
pushing it forward to drive at the true maximum speed.
Final Design:
Our finalised chassis is a four-wheel tank drive system. It features a drive system that utilises four REV HD
Ultra Planetary Motors, each with a total gear reduction of 12:1. The motors are paired to drive each side of
the robot To combine their output, a gear ratio of 72:60 between the motor output and drive shaft is kept to
give an overall reduction of 12:1 x 72/60 =14.4:1. This provides the necessary torque needed for climbing and
manoeuvring.
The wheel configuration consists of two pairs of powered 6-inch trancion wheels at the front of the robot,
connected to the drive shaft using sprockets and chains. Additionally, mechanical tensioners made of shafts
and spacers are used to maintain chain tension. For the rear wheels, two pairs of dead 6-inch omni wheels are
used, which act as supports.
The chassis frame is made from the C-channels, since they provide a more robust structure compared to that
made from extrusions.
6 ENGINEERING NOTEbook
Design Evolution
- Three Stage Cascade Elevator
Cascade
a. Overall design
The cascade elevator is the most innovative as well as an important mechanism of our robot. It
underwent significant iteration and had the purpose of lifting the delivery mechanism to deliver the water
and energy balls into the nexus goals
b. Initial concept:
Power mechanism- Chains will be used to power the elevator as they are stronger and more capable of
lifting heavy loads. Secondly, chains proved to be more reliable than string as a power mechanism, which
meant that it would be much more rugged and require less maintenance.
Frame structure- Cross members between the two vertical extrusions would lead to a more stable
mechanism in which the weight would be distributed. The length of the cross member was minimised to
occupy the least possible space on the robot.
Motor placement- The motor would be mounted at the bottom of the elevator and a 125:1 gearbox was
attached to provide the high torque needed to lift the weight of the stages.
ENGINEERING NOTEbook 7
Design Evolution
- Three Stage Cascade Elevator
height of the elevator would reach more than the constraint of 50cm for the highest level to reach the
level of the highest nexus goal. To mitigate this issue, we thought of cutting 1 stage by the required
length. However, another problem arose. Since it was a cascade elevator, to reduce the overall length
by 1cm each of the stages had to be reduced by 1cm. To summarise this we developed a formula:
Total extension= delta extension per stage * number of stages.
This meant that a 1cm reduction in the length of the elevator would reduce our extension by 3cm.
Solution Implemented: We conducted a trial and error procedure for several different lengths
of stages. We noticed that to minimise the initial length, all of the stages needed to be of similar
length. This method was enhanced by the use of CAD where we were able to test several different
combinations.
Result: We were able to design the elevator such that it was capable of extending to highest nexus
goal as well as fit in the robot constraint of 50cm.
Frame Number Length Height Extension
0 300 300 0
1 345 345 287
2 345 390 287
3 345 435 287
8 ENGINEERING NOTEbook
Design Evolution
- Four Ball Delivery Mechanism
c. Solution
• Mounted control and expansion hub higher up
ENGINEERING NOTEbook 9
Design Evolution
- Intake Mechanism
a. Design
The intake mechanism is positioned 30 cm above the ground and extends/retracts using a Core Hex
motor. A shaft runs through both sides of the motor, with a 10-tooth sprocket mounted at both the ends.
This sprocket drives a chain, which is affixed to an extrusion, enabling the intake mechanism to smoothly
slide in and out. We have utilized a linear slide motion kit to mount an additional extrusion onto the main
structure. A smart robot servo is attached to the additional extrusion, which rotates a shaft loaded with
compliant wheels. These wheels are designed to grip and compress the game element, sucking it into the
intake mechanism.
b. Prototype
In the initial phase, we began with a basic chain and sprocket mechanism to extend the extrusion, which
operated effectively. Then, we developed an intake system using a shaft with compliant wheels mounted
on it, which also functioned well as a standalone component.
10 ENGINEERING NOTEbook
Electrical Control System
ENGINEERING NOTEbook 11
JoyStick Mapping
JoyStick Mapping
GAMEPAD 1 GAMEPAD 2
4 Left Joysick Y-axis - Robot 4 Left Joystick Y-axis - 9 Square - Right Side Flap
Forward/Backwards Cascade Up/Down Up
10 Right Joystick X-axis: Robot 10 Right Joystick Y-axis - Rear 3 Dpad Right - Left Side
Rotation Flap Up/Down Flap Up
4 Left Joystick Press: Speed 8 R1 - Right Front Flap Up 3 Dpad Left - Left Side Flap
Boost Down
7 R1 - Slow Button 11 R2 - Right Front Flap Down
11 R2 - Intake Roller In 1 L1 - Left Front Flap Up
13 M1 - Intake Slide Out 18 L2 - Left Front Flap Down
18 L2 - Intake Rolleer Out 9 Circle - Right Side Flap Down
19 M2 - Intake Slide In 19
12 ENGINEERING NOTEbook
Programming
CASCADE Elevator:
To prevent our cascade system
from over-extending and putting
pressure on the motors; we
used magnetic limit switches.
By putting the limit switch near
the bottom of the slider and
the magnet at the top, we could
identify when the slider reached
its lowest position by detecting
the magnet.
DELIVER: TELEMETRY:
The numerous servos of the delivery system were very hard to control. For fast debugging and problem-
Since we wanted the capability of manually adjusting each angle while solving of our code and robot,
driving, and also the speed of preprogrammed positions, we combined we implemented an in-depth
both. By having preprogrammed sequences which would take each telemetry system which would
servo to the right position at the right time to grasp and release the record every single detail about
balls we achieved speed. By dedicating many buttons of the gamepad the robot at all times allowing
to individual control of each servo we achieved accuracy and control. us to quickly and accurately
diagnose problems.
ENGINEERING NOTEbook 13
Programming
INTAKE:
Due to the large amount of buttons required for the delivery we had to smartly use the remaining ones for our
intake but we still required precise control. By creatively using the triggers we were able to achieve this.
DRIVE:
For our drive we wanted absolute control and accuracy while maintaining speed. In order to achieve this we
creatively used the different joysticks along with the Joystick button. Through this we were able to drive at
high speeds while maintaining accuracy at important moments.
14 ENGINEERING NOTEbook
Team Outreach
India’s current demographic profile presents both a challenge and an opportunity. With a large and
growing youth population, there’s a significant need to focus on STEM education and skills development.
We fiercely advocate that by empowering the youth with STEM skills it will propel them to be leaders and
innovators that the world needs. And FIRST GLOBAL gives us the opportunity to engage with various
stakeholders with 5 main initiatives
Advocacy
Engaging the
to the
youth in STEM
government
Connecting Collaboration
Connecting
with with FIRST
with Industry
Communities Partners
ENGINEERING NOTEbook 15
Advocacy To The Government
16 ENGINEERING NOTEbook
Engaging STEM Youth
ENGINEERING NOTEbook 17
Engaging STEM Youth
18 ENGINEERING NOTEbook
Connecting With Communities
ENGINEERING NOTEbook 19
Connecting With Industry
20 ENGINEERING NOTEbook
Collaboration With FIRST
Partners
ENGINEERING NOTEbook 21
FTC Kit of Parts
O needs.
22 ENGINEERING NOTEbook
Corporate and Crowdfunding
1. Everest Masala:
Everest Masala is a renowned
Indian brand with quality spices
and culinary excellence. We
went to the head office and
had an interactive session with
the director of the company
Mr. Sanjay Shah. He inspired
us about how automation is
used in packaging masalas at
the rate of 130 packets per
minute.
ENGINEERING NOTEbook 23
Final Thoughts
Final Thoughts
Over the course of 4 months, we evolved from a team of robotics to a force for change and a voice for
empowerment of the youth with STEM skills to be the leaders of today and tomorrow.
With FGC social media challenges, we formed global friendships, learned new skills of developing a
marketplace for banana waste disposal, learnt to code, build and drive a robot. Above all it was more about
problem solving, creative thinking, collaboration, exchange, and much more. We reached out to a diverse
audience to spread the message that FIRST Global is using robots to build kids that have the self-confidence,
skill sets, imagination, courage, and vision to do important things.
As we all are from different schools in Mumbai and Goa we have displayed teamwork and time management
in all our initiatives. Our mentors have guided us with management tools of KAIZEN, PDCA and FISH BONE
ANALYSIS. Interacting with diverse communities and industry has made us realise that hands on learning
and STEM needs to be made accessible and affordable. At the core of all our initiatives we uphold Gracious
professionalism and Coopertition and Indian belief of “Vasudhaiva Kutumbakam” which means that the
world is a family, we strive to uplift the community through STEM. We imbibed skills that are essential both in
and outside of STEM fields. There is only one way forward and that is evolution of ourselves to be agents of a
positive change in our community using STEM and FIRST as a tool.
We take pride in things we do and things we make, the trends we set and the results we achieve.
WE HAVE
• ADVOCATED TO GOVERNMENT FOR ROBOTICS AS A SPORT
• INSPIRED THE START OF 12 FTC EAMS
• HOSTED 2 STEM COMPETITIONS
• PROMOTE KOP TO MAKE FIRST ACCESSIBLE & AFFORDABLE
• RAISED FUNDS $6000 FOR FGC INDIA TRUST
• ENGAGED WITH INDUSTRY & COMMUNITIES
All this as we
• REJOICE in the FIRST GLOBAL CHALLENGE -AS A TOOL TO BE CHANGEMAKERS
• And will continue to do so!
24 ENGINEERING NOTEbook
Impact of Outreach
ENGINEERING NOTEbook 25
External help and Newspapers
26 ENGINEERING NOTEbook