Designing for FLL

with Lego Mindstorms

Hints and Tips
Presented by:
Team Unlimited, FTC0001
unlimited.syraweb.org
We acknowledge the efforts and copyrights of FIRST,
LEGO Education and LEGO with regards to the contents
of this workshop. Without their generosity, the FIRST
LEGO League would not exist!
Introduction

FLL season basics

NXT system basics
NXT robot chassis design
NXT robot navigation issues
NXT robot manipulator design
Questions & Wrap-up
NXT/G coding is beyond the scope of this workshop

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
FLL Challenges

Each fall, a new themed challenge

The 2011 FLL challenge : Food Factor
Past challenges
2010 – Body Forward
2009 – Smart Move
2008 – Climate Connections
2007 – Power Puzzle
2006 – Nano Quest
2005 – Ocean Odyssey
2004 – No Limits
2003 - Mission Mars
2002 – City Sights
2001 – Arctic Impact
2000 – Volcanic Panic
1999 – First Contact

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
FLL Challenges

Challenges include a series of robotic missions

Carried out on a custom mat on top of a 4 x 8’ playing
table, bordered by 2 x 4”s
Read all FLL Challenge documentation thoroughly!
Usually 8+ individual missions
Missions goals scored by object positions at end of 2.5
minute competition round
Technical presentation about the teams approach to the
challenge and their robot
Research Project presentation, as assigned
Core Values, as presented and/or demonstrated

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
FLL Accounting

Team Registration - $225.00 for 2011 season

https://gofll.usfirst.org/
Food Factor Field setup kit - $65.00
Basic LEGO Mindstorms NXT kit - $420
Can use retail or educational kit, reuse each season
Useful, not required
Extra NXT DC battery – $54.95
Extra NXT DC charger – $24.99
Extra NXT light sensor – $17.95
NXT color sensor - $34.95
Spare NXT motor - $18.95
Each tournament will have a team registration fee

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
LEGO Mindstorms NXT 2.0 kit

This essential and reusable core set is the recommended

package for teams who are newcomers to FIRST® LEGO® League.
NXT NXT/G Educational Software with a FLL Team license.
1 Intelligent NXT Brick
1 Rechargeable DC Battery
1 DC Battery Charger
3 Interactive Servo Motors (rotation sensor built in)
2 Touch, 1 sound, 1 light and 1 ultrasonic Sensors
1 USB computer to Brick cable
7 Connection cables of various lengths
3 Lamp bricks
3 Converter cables
1,000+ LEGO elements
2 Storage Boxes with Sorting Trays for organization
Can order at registration – p/n 979792
2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Useful Building Resources

Building Robots with LEGO Mindstorms NXT

David Astolfo, Mario Ferrari, Guilio Ferrari
Great overall reference for Mindstorms
robotics
Winning Design! LEGO Mindstorms NXT
David J. Trobaugh
More specific to addressing challenges
http://www.usfirst.org/roboticsprograms/fll/
http://www.techbrick.com/Lego/LEGO2011/
Resources/index.html
www.syraweb.org – links and resources
Many LEGO and FLL web resources available
Use Google keyword searches

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
LEGO NXT components allowed

LEGO electrical parts limited to :

One NXT microcontroller
Only 3 NXT Motors/with integrated rotation sensors
Total quantity brought to the competition table!
Cannot add in extra motors in detachable modules!
We really mean it!
Also, no pull-back mechanical motors
Maximum of 6 LEGO-manufactured sensors
Touch, light, color and ultrasonic sensors
Cables allowed as needed
All LEGO non-electric components are allowed
In any quantity – BrickLink Marketplace
LEGO pneumatics are allowed
2011/12 Building for FLL with LEGO - Hints and Tips Workshop
NXT, motors & sensors

NXT (NeXT)
4 Sensor inputs (plus rotation sensors on motors)
3 Motor outputs
LCD and control buttons
Sensors
Touch
Light
Sound
Ultrasonic
Motors

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot systems block diagram

Chassis
Computer
(microcontroller)
Motors
Power
Sensors
Communications/co
ntrol

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot systems – NXT Controller

Sensor ports - four input ports to

attach sensors - 1, 2, 3 & 4.
Motor ports - 3 output ports to
attach motors - A, B & C
USB port – for code loading
NXT Buttons
Orange button : On/Enter /Run
Light grey arrows: Used to move
left & right in the NXT menu Specifications
Dark grey button: Clear/Go back 32-bit ARM7 microcontroller
256 Kbytes FLASH, 64 Kbytes RAM
8-bit AVR microcontroller
LEGO attachment points 4 Kbytes FLASH, 512 Byte RAM
Bluetooth wireless (Class II V2.0)
Loudspeaker USB full speed port (12 Mbit/s)
4 input ports, 6-wire cable digital
3 output ports, 6-wire cable digital
100 x 64 pixel LCD graphical display
Loudspeaker - 8 kHz sound quality.
Power source: 6 AA batteries
2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot systems – NXT motors

Your robot is able to move

using up to 3 servo
motors.
Turning speed is from 100-
170 rpm
NXT servo motors have an
integrated rotation sensor
Two motors can be
synchronized so that your
robot will move in a
straight line

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot systems – NXT power

Batteries are placed inside of the NXT microcontroller

Flash memory – programs not lost when battery removed
6 AA cells or 1 Lithium Ion rechargeable battery
Two different battery packs, AC or DC charger

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot systems – NXT sensors

Sensors are used to provide Light

information about the environment
to the microcontroller
Light sensor – used for line tracking, a
color with filter
Touch
Touch sensor – used to sense collisions
Ultrasonic sensor – sense proximity
(distance without touching)
Color sensor – sense colors, line
tracking
Color

Ultrasonic
2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Bricks & Beams

Standard LEGOs – bricks, hold together by friction only

LEGO Technics – standard beams, hold together by
friction and/or pins
LEGO Technics – studless beams, hold together by pins

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Liftarms & Pins

Studless beams also

come in “bent” shapes
Some connectors are
crossed for axles,
others round
Pins are different
lengths & tightness –
the light grey ones will
rotate in the holes

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Axles & Angle Connectors

Axles can be used for more

than just connecting
wheels.
With angle connectors, light
frameworks can be built

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Gears & Drive Trains

Gears are designated by # of teeth

Motor speed starts at ~ 125 rpm
Smallest (8t) & largest (40t) give a 5 to 1 ratio
Gearing down (small to large) increases torque (power) and
decreases speed
Gearing up (large to small) decreases torque and increases
speed

Spur Gears

40 24 16 8
2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Technic Gears

Spur gears
8t, 16t, 24t, 40t
Crown gear
Double bevel gears
Single bevel gears
Worm gear
Clutch gear

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Technic Gear trains

Gear up/gear down

Up for speed
Down for torque
Idler gears
Only first and last gear
affect ratios
Single stage gearing
Ratio between # of teeth
Multi stage gearing
Multiplicative
3:1 plus 3:1 becomes 9:1

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Worm Gears, Bevel Gears & Pulleys

Worm gear w/gear rack –

equivalent of 1t gear
High torque
Difficult to back drive!
Crown & Bevel gears
Use to change angle of
rotation (90°) Pulleys bridge distance
Low torque capacity (bands slip)

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
LEGO Wheels

Avoid tracks
Low friction/high slippage
Motion/turns not easily reproducible
Large wheels go farther per revolution
Friction varies with different tires
Consider how well they pivot for turns, as well as straight
forward motion
Wheel-axle support
More support – less wiggle/sag
Support from both sides is best

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Wheel Stability

1. Not Stable
3. More Stable

2. Stable 4. Most Stable

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot Design and Construction

Planning – what does the team want to achieve and

how will they achieve it? Let the kids do it!
Design iteration
Brainstorm (what to build)
Design (how to build it)
Build it!
Test it!
Repeat until it’s perfect (or good enough)
Trade-offs: Good, Quick, Cheap – pick two (at most)!
Quality – Schedule – Budget

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot Design Considerations

Size – navigate obstacles on board, motor power

Ruggedness – maintain structural integrity
Center of Gravity – avoid tipping with slopes, sharp
turns or stops, or in collisions
Chassis style
2 wheel
Balancing skid is usually fine if no ramps to climb
3 wheel
Caster wheel can change robot course (supermarket carts)
4 wheel
Usually one pair is without tires to slide while pivoting)
6 wheel
Larger than most FLL robots, smaller base this season

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
General Robot Chassis Design

The chassis (body) of the

robot is built using LEGO
Technic components.
It should be stable and
rugged, so it does not fall
apart under use.
Remember – after it is built,
you still need to get to the
battery compartment on the
bottom of the
microcontroller.

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
General Robot Chassis Design

Two basic designs (many that are more complex)

Differential Drive
“Tank-like” steering, one motor connected to each side
Powerful, easy to turn in place
Can be a challenge to go straight
Steering Drive
“Car-like” steering, one motor to drive a pair of wheels,
another motor to steer
Less power (steering motor doesn’t add drive power), hard to
turn in place
Not often used in competition

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot systems – NXT motors

Each motor has a built-in Rotation

Sensor to control the robot’s
movements precisely. Rotations
are measured in degrees or
rotations [+/- one degree].
1 rotation = 360 degrees, if you
set a motor to turn 180 degrees,
it will make half a turn.
Slack in the internal gear-train
makes precise movements difficult
to reproduce exactly
The built-in Rotation Sensor in
each motor also lets you set
different speeds for your motors
[set different power parameters in
software].

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot Chassis Design
Differential Drive - dual wheel pivot

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot Chassis Design
Differential Drive - single wheel pivot

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Navigation – Design Issues

Wheelbase – narrow turns easily, wide goes straighter

Like fighter jets, stability is less maneuverable
Weight – heavy yields less tire slip
Weight placement affects balance, ability to turn
Wheel support – flexing of axles makes erratic motion
Support from both sides, if possible
Batteries – constant power levels are key
Replacement batteries are key
Match motors for performance
Build jig to compare rotation speeds
Works best if you have many motors to choose from

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Navigation – Design Issues

Wall following
Horizontal guide wheels, approach wall at shallow angle
Line following
Use the light generated by the light sensor itself
For greatest accuracy, box light sensors to eliminate (as
much as possible) ambient light
Calibration can help to reduce the effect of changes in
external lighting, but is hard to eliminate
Light sensors tend to hunt – pivoting on one wheel (instead
of two) tends to be less jittery and make faster progress
Take advantage of knowing the proper course for the
mission – not a general-purpose line follower

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Navigation - Design Issues

Uncalibrated light ranges from ~30 to ~70, 50 is a good

center of the midrange
Look for a range, look for < & >, not equal to a single value
Single light sensor line following
Following a grey value between the black line and the
white border
Dual light sensor line following
One follows the black line, the other follows the white
border
Triple light sensor line following
The middle one follows the black line, the outer ones
follow the white borders
2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Navigation - Design Issues

Reorientation after turns

Squaring against walls can restore a known angle
Push for a time, or use twin touch sensors
Contact surface of robot and wall must be smooth
Movement to a fixed point should be careful not to base only on
rotations – a timer can save the robot from never arriving at the
final distance value
Dual light sensors can be used to align along a line on the mat
Arrival
Touch sensors can detect impact
Ultrasonic sensor can detect an approach without contact
Successful designs tend to use a combination of movement
controlled by rotations and timers and sensor-based movement

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Demo robot from “Winning Design” book
used for examples

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Demo robot enhancement

Adding an attachment connection

Snap-on or slip-on
Use long black friction pins 0
They don’t pull out easily when the
attachment is removed

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Demo robot enhancement

Adding a third motor on reverse end

Snap-on / snap-off
Cable to motor port A

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot Manipulator Design - no motors

Simple pusher design – “bulldozer”

Flat surface
Snap-on or slide-on
Move game elements independently or in a container

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot Manipulator Design - no motors

Simple plow design –

“cowcatcher”
Angled surfaces
Snap-on or slide-on
Move game elements out
of robot’s path

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot Manipulator Design – motors optional

Fork and Hook

attachments
Can be combined with
power assist
to lift or sweep

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot Manipulator Design – motors optional

Object trap
Box opens only inward
Capture objects to return
to base

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot Manipulator Design - with motors

Only three motors

allowed in FLL
Two are used for
propulsion
Third motor is best
attached to chassis
Attachments would be
designed to connect to
the fixed motor

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot Manipulator Design - with motors

Carabineer arm
Passive clip open/close
Spring or band tensioned
Principle can be used for grabbers. etc.
Powered arm to raise/lower

attach to motor
with axle

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot Manipulator Design - with motors

Lifting hook attachment

Vertical pivot from
attached motor
Similar design could
pivot horizontally as a
grabber

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Robot Manipulator Design - with motors

Forklift attachment
Uses worm gear, resists being back-driven
Gearing is often used in powered attachments
Can provide extra torque or slower motion
Simultaneous motion (grabber arms coming together)
Can redirect angle of motion

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Testing FLL Robots

Test robots in mission environment

Table/mat/mission objects
Properly oriented and secured
Time missions
Speed is important, but consistency is even more critical
Only 2.5 minutes total, include in-base time
Modify design one change at a time
Too many variables can confuse issues
Don’t change code before you verify battery strength
Weak batteries cause performance issues

2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Practicing with FLL Robots

Practice in mission environment

At first, just the individual mission
Then, in combination with others
Time in base for change-over is critical
Best to practice in assigned pairs
Plan for contingencies
When to grab robot and try again (or move on)
One of pair can follow robot down-field (quick grabs)
Alternate plan in case of difficulties
Murphy’s Law (and its many corollaries)
Whatever can go wrong will go wrong, and at the
worst possible time, in the worst possible way
Murphy was an optimist!
2011/12 Building for FLL with LEGO - Hints and Tips Workshop
Questions & Wrap-up

Resources linked at our Sharon Youth

Robotics Association website
Including this presentation

www.syraweb.org/Resources.htm

2011/12 Building for FLL with LEGO - Hints and Tips Workshop