In this making and tinkering module, our team has faced numerous challenges in designing and constructing Ball-E. Throughout this process, we acquired invaluable knowledge and skills and experienced the thrill of innovation. Here are eight takeaways and quotes that defined our journey, highlighting the lessons learned and the growth we achieved as a team.
1. Working in a Diverse Team:
"Collaborating with teammates from different backgrounds and areas of expertise was eye-opening. We discovered that the fusion of diverse perspectives drives creativity and leads to breakthrough ideas." – Luc, Mechanical Engineering
Our team comprised members from various science and engineering majors, each bringing their unique expertise to the table. Working collaboratively across disciplines allowed us to leverage each person’s strengths and tap into a diverse range of perspectives. We quickly realized the power of teamwork in problem-solving, as different insights and approaches led to innovative solutions.
2. 3D Modeling and Printing with Fusion 360:
"Learning Fusion 360 opened up whole new possibilities for our design process. It allowed us to transform our ideas into tangible objects and pushed the boundaries of our creativity to overcome size and utility constraints of our purchased parts" – Dylan, Materials Engineering
To bring Ball-E to life, we immersed ourselves in the world of 3D modeling and printing using Fusion 360. This software empowered us to create intricate designs and visualize the robot’s components before actual fabrication. Mastering Fusion 360 expanded our design capabilities and enhanced our understanding of geometry and spatial relationships.
3. Robotic Part Assembly and Engineering Calculations:
"Assembling the robot's parts required meticulous attention to detail. It taught us the importance of precision and engineering calculations to ensure the functionality and safety of our creation." – Kanghowe, Electrical and Electronic Engineering
Assembling the robotic parts was a meticulous process that required attention to detail. We had to ensure the compatibility and suitability of each component, considering factors such as size, weight, and functionality. Making accurate engineering calculations played a crucial role in determining the structural integrity and performance of Ball-E. This hands-on experience deepened our understanding of mechanical systems and strengthened our problem-solving skills.
4. Arduino Software for Motion Control:
"Programming Ball-E using Arduino was like giving life to our creation. We were amazed by the level of control we had over its movements, turning our vision into a reality." – Kanghowe, Electrical and Electronic Engineering
Controlling the motion of Ball-E was made possible through Arduino software. Learning to program the robot’s movements and interactions with its environment allowed us to fine-tune its functionality. We explored various commands, sensor integration, and control loops to optimize the robot’s performance.
5. Computer Vision for Self-Piloting:
"Integrating computer vision technology was a game-changer for Ball-E. Witnessing the robot autonomously navigate its surroundings using image recognition was both thrilling and awe-inspiring." – Luc, Mechanical Engineering
Integrating computer vision technology was a turning point in our project. Through computer vision algorithms, Ball-E gained the ability to navigate and perform self-piloted inspections. This breakthrough elevated the robot’s autonomy and expanded its potential applications.
6. Building Resilience and Embracing Challenges:
"Throughout the project, we encountered numerous setbacks and faced moments of doubt. But we didn't give up. We embraced each challenge, knowing that failure is simply a stepping stone on the path to success." – Gavin, Environmental Earth Systems Science
The journey of constructing Ball-E was not without its share of setbacks and failed prototypes. However, we viewed these challenges as opportunities for growth and learning. We embraced failure as an integral part of the iterative design process. With each setback, we analyzed, adapted, and persevered. This resilience fueled our determination to acquire new skills, explore alternative approaches, and ultimately succeed in bringing Ball-E to life.
7. Seeking Feedback and Recursive Improvement:
"Seeking feedback was instrumental in refining our design. The input we received from peers, tutors and industry experts helped us identify blind spots and make iterative improvements, bringing us closer to the final product." – Dylan, Materials Engineering
Feedback played a critical role in shaping the development of Ball-E. Regularly seeking input from peers, instructors, and industry experts from General Motors allowed us to refine our design and address potential flaws. We embraced an iterative approach, continuously improving and iterating on the robot’s design based on feedback received. This recursive improvement process instilled in us the importance of embracing critique and constantly striving for excellence.
8. Effective Documentation and Communication:
"Documenting our progress and communicating our ideas effectively ensured everyone was on the same page. It fostered clarity, collaboration, and a shared direction throughout the entire project." – Bryant, Biological Sciences
Throughout the project, we realized the significance of effective documentation and communication. Keeping detailed records of our design decisions, test results, and lessons learned enabled us to track progress and share knowledge within the team. Additionally, clear and concise communication facilitated collaboration, ensuring that ideas and instructions were effectively conveyed.
We firmly believe that learning comes both through setbacks and success. These are several setbacks that we faced throghout the project:
First test run
This was our first attempt to get a preprogrammed Ball-E to move. Ball-E was set to move after a 5 minute timer (to allow time to assemble the ball), but after an adrenaline filled 5 minutes where we scrambled to assemble the Ball-E, Ball-E was completely stationary. Despite the initial confusion, we identified several possible points of failure:
The code was non-functional
Torque provided by the DC motors were insufficient to move the ball
The battery was close to being flat
The on/off switch malfunctioned
After disassembling Ball-E, we tested the individual components and deduced that the insufficient torque was the root cause. As such we decided to purchase motors with higher torque to be fitted into Ball-E.
Overdischarged battery
The bulging battery on the left is over discharged
View from another angle
Measuring battery voltage
The overdischarging occurred when we were trialing the joystick control for Ball-E. After running Ball-E for an extended period of time, a soft pop sound was audible and Ball-E stopped functioning. We immediately disassembled Ball-E and found that the battery has been discharged completely. From this lesson, we learnt to perform routine checks on the battery’s voltage using a multimeter/battery capacity checker before each trial run, and fully charge our battery’s whenever the capacity drops below a threshold (~9V).
Wifi bug
Our group encountered another bug when we attempted to set up the Wifi for joystick control, where the joystick control for Ball-E worked initially, but stopped after a period of time. In our troubleshooting process, we connected Ball-E to an oscilloscope to observe the input voltage to the wifi receiver. In this video, the Wifi receiver received stable voltage initially as seen by the constant input voltage displayed on the oscilloscope, but the voltage received became very unstable after 2 seconds, as seen by the subsequent intermittent voltage peaks. We hypothesized that the bug was caused by several potential issues:
Back EMF from the motors induced voltage fluctuations in the power source, which affected the voltage received by the Wifi receiver which shared the same power source
Loose wiring
Power supply was not stable for constant operation
We stabilised the power supply using a voltage regulator, as previously, the wifi was powered by the arduino, which provided insufficient current. This solved the issue of the unstable wifi connection.
