Chain breaker (reference Mcmaster Carr # 6015K15) Wir

1
Robot Quick Build Session
Pre-Kickoff PreparationsProduced byEd Latimer,
Team 476Ken York, Team 476Ron Markum, Team
1750Special Thanks to Oklahoma State
UniversityCollege of Engineering, Architecture,
and Technology
2
Overview

• What is the Robot Quick Build Session (RQBS)
• Facility requirements
• Tool and material requirements
• Personnel requirements
• Time requirements
• Pre-kickoff communications with teams
• Rewards

3
What is the RQBS

• Last year in Oklahoma we had 24 rookie teams and
  only a few veteran teams to mentor them. In
  years past, weve received calls in the third or
  fourth week of build season from rookie teams
  who, after being overwhelmed by the newness and
  initial complexity of the process had simply been
  staring at the KOP since kickoff, and still had
  not put one nut on a bolt. We had to do
  something to answer questions early in the season
  and get our rookie teams off to a good start or
  we would be constantly on the phone, or worse, on
  the road helping our new teams get over the steep
  initial learning curve.. Where do I start???
  was the universal question. To which our
  universal answer is Build the kitbot. If we
  tell teams on the third week of build season to
  build the kitbot, why not tell them on the first
  day. Further, if we tell them on the first day,
  why not show them how its done! That is how the
  RQBS was born!
• We planned the RQBS to happen immediately after
  our kickoff lunch. Being in the central time
  zone, the NASA broadcast is usually over by 1100
  AM. This gives us an hour for the teams to
  brainstorm, issue the KOP and prepare for lunch,
  and for the RQBS presenters go through the KOP to
  determine if there are any surprises. In the
  past Oklahoma State University has provided lunch
  so we can keep everyone on site and begin the
  RQBS promptly at 100PM. Last year we had over
  700 attend with 28 teams (four helper teams)
  staying for the RQBS. By 530 that afternoon we
  had 24 rolling robots and a room full of highly
  excited and energized students, not to mention
  several veteran mentors who were greatly relieved
  at the possibility of having time to mentor their
  own teams during the build season.
• In short, the RQBS is a four to five hour process
  whereby teams can build, test and drive the
  kitbot under direct supervision of experienced
  mentors.

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The Goal !
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Facility Requirements

• Depending on the size or your kickoff your will
  need four areas that will accommodate the
  following.
• A Main Assembly Area. Everyone starts here for
  the first 30 minutes of instruction. The Frame
  and transmission teams, usually two to 10 persons
  per team, work here. (A second room for
  transmission assembly is desired, but not
  necessary) This area needs to have at least one
  table per team, full audio visual and PA
  capability to show the assembly process on a
  screen. Internet access to view the AndyMark.biz
  assembly videos is required. In Oklahomas case,
  this is the same large room where the kickoff
  broadcast is viewed and the KOP is distributed.
  Immediately after the RQBS introduction, this
  room transforms into the Frame and Transmission
  Assembly area.
• An Electrical Wiring Area. This room should be
  large enough to provide each team with at least
  3 x 6 work table and space for several students
  per team. Full audio visual capabilities, PA,
  along with 120VAC power for team laptops are
  needed. Drilling the base plate will be done in
  this room (unless a separate area is designated)
  so some method to protect the table tops should
  be considered. Also, when the base plate is
  assembled, bolts will be exposed on its bottom
  and may scratch the table surface.
• A Programming Area where two to four persons per
  team will install, upgrade and train on the new
  programming software. Again AV and PA capability
  is needed along with internet access.
• A Team Training Area where team members and
  mentors that do not have a specific task in the
  RQBS can go for training on team building,
  preparing for awards and judging, team fund
  raising, and many other topics that would benefit
  young teams.
• Two other areas are necessary. A cutting area
  for trimming the frame channels to length.
  Depending on the method chosen for cutting, this
  area may need to be isolated from the general
  public and hearing protection provided. A drive
  area where the completed robots will be tested
  should have adequate room (15 x 15) and
  protection for the operators and public should a
  robot decide to behave badly.

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Facility Requirements

• Cutting Area. Two of the aluminum channels in
  the frame kit must be cut to length. This
  process needs to happen as soon as possible and
  as quickly as possible. There are several method
  to cut the channels to length. The simplest way
  is have the teams use a hacksaw and cut the
  channels at their table or at a designated area
  where the chips can be easily cleaned. Last year
  we used a horizontal band saw in an enclosed
  trailer located in the parking lot. The saw and
  trailer were provided by one of the veteran team.
  This produced smooth and square cuts but was not
  a fast process. This year we will use a
  motorized miter saw (chop saw) with a fine tooth
  carbide blade. Two channels can be cut in a few
  seconds and the quality of the cut is excellent.
  A jig-stop can be set on the saw so all the
  channels are cut to the same length without
  measuring each piece. This process is quick and
  of good quality but it produces more noise than
  previous methods. Hearing protection and safety
  glasses should be provided. Power tools should
  only be operated by trained and skilled adults.

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Facility Requirements

• Drive Area. Teams will need at least a 15 x 15
  area to test drive their robot. Because robots
  can behave in unexpected ways, this area should
  be large enough to accommodate the students and
  spectators at a safe distance. Also, any
  furnishing that can be damaged should be removed
  and the area should be located far enough away
  from walls so that the robot can be stopped
  before it hits them. Consider laying down the
  same floor playing surface as used in the game.

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Tools

• Each team will need to bring with them the
  following tools.
• Safety glasses for each team member and mentor
• A charged, cordless drill
• ¼ Drill bit
• 3/8 Drill bit
• 2 phillips screwdriver
• 2 Phillips screwdriver bit for drill
• 3/16 Allen bit for drill
• 3/16 Allen wrench
• 5/32 Allen wrench
• A small and medium sized flat screwdrivers
• A non-marring hammer. (plastic or leather head)
• 3/8 combination wrench
• 7/16 combination wrench
• 10mm combination wrench
• Chain breaker (reference Mcmaster Carr 6015K15)
• Wire cutters
• Wire strippers
• Wire crimpers

• Needle nose pliers
• Drift punch 1/16 dia.

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Tools

• A bare thumb drive (no auto run programs) with
  only the following files on it.
• DSUD_PKG.BIN available at (the download file
  will need to be renamed)
• http//www.usfirst.org/community/frc/content.aspx
  ?id10934
• The Labview or WindRiver upgrades available at
• http//joule.ni.com/nidu/cds/view/p/lang/en/id/118
  0
• http//first.wpi.edu/FRC/frcupdates.html
• An Ethernet cable.

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RQBS Site Supplied Hardware

• Note The numbers at the end of the descriptions
  are the McMaster Carr part number.
• As the RQBS coordinator you will need to acquire
  the following materials.
• A 17x37x3/16 thick base plate of polycarbonate
  or other insulating material (plywood, masonite,
  etc.) that accepts sticky-back Velcro.
• An 8x32x3/16 or thicker plate for the drivers
  station. Material should accept sticky-back
  Velcro.
• A box of ¼-20 Nyloc nuts. 5 per team. Mounts the
  120 amp breaker electrical board. 90640A129
• Several ¼-20 x 1-3/4 SHCS bolts. 3 per team and
  the rest for spares. 92196A548
• A box of 10-32 x 1 machine screws. 2 per team.
  Mounts cRIO 93075A833
• A box of 10-32 Nyloc nuts. 2 per team. Mounts
  cRIO 90633A411
• Boxes of 10-24 x 1 self tapping screws. 12 per
  team. Mounts sprocket to wheel. 90087A247
• Hook and loop dots. (Velcro) Mounts all small
  control system parts to base plate. Teams will
  need to permanently mount the control system
  parts to their legal base plate once they get
  home. Each team will need approx 50 pairs of
  dots. 9736K195, 9736K315
• A box of ¼-20 x 1 SHCS bolts. 2 per team.
  Mounts the 120 amp breaker. 92196A542
• Wire 10 stranded wire. For spare. 71245K51
  Black, 71245K54 Red
• Wire 14 two conductor stranded wire. For low
  power hookup spare. 9697T3
• 24 zip tie. 1 per team for securing battery.
  7130K932 (or 2, 12 zip ties as an alternative)
• Rolls of masking tape. Holding the drill
  templates in place. 1 roll for every 4 teams.
• 1 can or tube of wheel bearing grease. This is
  enough for all teams.
• Magic Markers for teams to label their parts.

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RQBS Site Supplied Hardware

• The hardware on the previous slide will need to
  be packaged, before kickoff, into team bags.
  This allows all the supplied hardware to be given
  out in the shortest time.
• The site supplied hardware can be distributed at
  the same time as the KOP.
• For a complete description of the contents of
  each bag, see the 2009 Kitbot Assembly Set-up
  word document.
• The two base plates, one for the electrical
  components and one for the drivers station, need
  to be cut to size before kickoff.

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RQBS Supplied Printed Materials

• Printed items. Print one copy for each team.
• Sections 1-5 of the 2009 Control System Manual at
• http//www.usfirst.org/community/frc/content.aspx?
  id10934
• This is also included in the Printed Materials
  folder on the CD.
• Drilling templates for Robot base plate. Two
  sheets per team, front and rear. These are shown
  in the Electrical Assembly procedure and are
  included, to scale, in Autodesk Inventor format
  in the Printed Materials folder on the CD. These
  are 11 x 17 size and will take a special printer
  to produce.
• FRC 2009 rules. Many sections of the rules will
  be made public before the kickoff. Have these
  preprinted and in 3 ring binders. As soon as the
  unlock code is broadcast on kickoff day, have a
  volunteer(s) print the remain sections and
  install them in the binder. This is no small
  task and is usually about 250 pages. One copy
  per team. This gives each team a copy of the
  actual rules to look at during the RQBS.
• FRC Checklist by Benjamin Heaivilin. This is a
  good overview of the control system setup.
• One copy each of the Frame, Transmission, and
  Electrical Assembly Powerpoints.
• http//www.usfirst.org/uploadedFiles/Relay20Cable
  20Memo.pdf PWM cable modifications.

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Personnel

• The RQBS coordinator(s) will gather all the
  materials and personnel. They will conduct the
  opening introduction and make sure everyone is on
  schedule. They should become thoroughly familiar
  with the RQBS process and areas. They will
  basically be in charge of the session.
• The RQBS can not happen without informed
  volunteers and presenters. Each of the four
  areas need a presenter(s) that is thoroughly
  familiar with the materials and procedures to
  accomplish their tasks. The materials in this
  information release should be made available to
  them as soon as allowed by FIRST (signed NDAs,
  etc.). They should, after the KOP has been
  released on kickoff day, familiarize themselves
  with the location of all the parts in the KOP
  necessary for their area. They should be
  comfortable showing and explaining the PowerPoint
  slides for their session.
• Several mentors that are comfortable with the
  tasks associated with an area should be
  recruited. Usually you will need one mentor (in
  addition to the presenter) for every 5 teams.
  Veteran team leaders and mentors are good
  choices.
• Print materials volunteer. This volunteer will
  get all the printed materials ready for
  distribution.
• Machinist. This person will be in charge of
  setting up the area and tools necessary to cut
  the frame channels to length. This process will
  be explained in the frame assembly procedure. If
  the band saw or miter saw method is chosen, this
  person must be responsible for the safety of the
  machine operators and the students waiting for
  their service. NO STUDENTS ARE TO OPERATE THE
  CUTTING EQUIPMENT.
• Lunch Coordinator. In past years we have served
  lunch on site. This gives teams more time to
  brainstorm and work on their Kitbot. However,
  this year with over 1100 attending our kickoff we
  will plan a 2 hour lunch period so team can go
  and get lunch (our building does not allow for
  non approved food items to be brought in.) Your
  circumstances will direct how you can best handle
  lunch.

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Personnel

• One of the most important mentors that you must
  recruit is the Electrical - Control system
  expert. The complexity of setting up the new
  control system is not a quick or easy task for a
  novice. There are several detailed procedures
  that MUST be followed in order to configure the
  Driver Station, set up the IP addresses,
  configure the wireless router and bridge, flash
  the Driver Station, Image the cRIO, Upgrade
  Labview It is absolutely essential that someone
  with experience (a Beta Test team mentor, or
  veteran team mentor familiar with this years
  system, or NI representative) on the system be
  available at the RQBS. The Electrical and
  programming sessions will be by far the most
  challenging aspects of the RQBS. The actual
  assembly of the components onto the base plate
  and their wiring should not take much more than
  an hour. But setting up the tethered and
  wireless communications, flashing the DS, and
  imaging the cRIO will take the majority of the
  time.

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Time - Schedule

• The RQBS should commence as soon as possible
  after the kickoff.
• Allow at least 5 hours for the session.
• RQBS Time Line
• After kickoff Inform teams to have break their
  students into four groups, one group for each
  area.
• Lunch
• 0 hour Introduce RQBS, distribute RQBS parts,
  locate KOP parts for each of the four sessions.
• 030 All groups with their parts should be in
  their areas.
• Each area shows the PowerPoint presentation and
  assembles their part of the kitbot.
• 3 hour The Electrical - Control System group and
  the Frame Transmission group reunite.
• The basic kitbot is assembled and readied for
  driving. Complete the tethered and wireless
  bench top tests.
• 4 hour Basic robot should be ready for driving.
  Troubleshoot as necessary.
• 5 hour Finish up, clean up.
• 6 hour Go home and crash.

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Pre-Kickoff Communications

• Get a count of the teams that wish to attend the
  RQBS so you will know how much material you need
  to purchase.
• As soon as possible inform teams of the tools
  they need to gather and bring with them to the
  RQBS.
• Inform teams of the extra room needed to haul the
  KOP and robot back to their shop.
• Inform teams that the RQBS will last
  approximately 4 hours (in addition to the
  kickoff).
• Those teams that already have their control
  system should have the completed the following
  before arriving at the RQBS. Refer them to the
  FRC Control System Checklist by Benjamin
  Heaivilin and the 2009 FRC Control System Manual
  on FIRSTs web site.
• Load the Labview WindRiver Software and install
  the mandatory upgrade.
• Complete the out of the box bench test as
  described in the 2009 FRC control system manual.
• Update firmware in the Drivers Station.
• Update firmware on cRIO and set team number.
• Set up the system and laptop for wireless
  communication and completed the associated tests.
• Teams that do not have an early control system
  must immediately, after receiving the KOP, find
  the control system box, get the software DVDs and
  install the software before the RQBS session
  starts. They may have to work through lunch.
  Remind them to have upgrades on the thumbdrive.

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Rewards

• The rewards will be completely evident as soon as
  the first team drives their robot.
• The RQBS is designed to answer as many questions,
  up front, before a rookie team has time consider
  the impossibilities of actually building a robot
  from this massive kit of parts.
• Veteran team mentors will have much fewer
  question to answer during build season from
  rookie teams and can focus on their students.
• RQBS teams get a tremendous start to the season.
  Its almost like getting a two week head start.
• RQBS gives rookie teams a more level chance in
  the competition with veteran teams.
• RQBS shows new students they can actually build a
  robot. If we can build this in four hours, just
  think what we can do in six weeks!

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Other Thoughts

• Inform teams to prepare to carry the completed
  kitbot and the KOP boxes home with them. This
  requires considerable vehicle space and should
  not be overlooked. Although it may be good
  advertising for a team to drive through their
  town with the robot strapped to their cars top
  carrier, its probably not the best method for
  getting the robot home. -)
• The RQBS will take most of the afternoon. Thats
  a long time for kids (and especially hard working
  mentors) to go without food or drink. Consider
  providing and mid afternoon snack.
• Be safe when driving the robot. Have the mentors
  constantly remind the students of safety. One
  accident can ruin the day.
• Don forget to reserve help to get the building
  cleaned up afterwards and the demo field
  disassembled and in storage.
• Be calm. Things will not go completely as
  planned. One knee jerk reaction can spoil a lot
  of labor and excitement.
• Have fun and enjoy watching kids light bulb
  turn on.