Capstone 1

Background Report

Aryan Jain

Tuong Thai

Zihan Lin

Zidi Meng

Anime Styled Humanoid Robotic Torso

Professor Kumar Abhishek

July 29th, 2022

Abstract:

The following research report explores on the design principles for building an anime humanoid robotic
torso for the purpose of meeting and greeting customers at anime conventions or outside anime stores. In
particular, the report focuses on the principles and research needed to design the arm of the robotic
systems. Therefore entailing the shoulder and elbow components. Additionally, it researches on the
feasibility of incorporating virtual reality (VR) controllers for the control of the robotic arms, while also
researching on the best material for the arms. In order to gather this information, the report analyses
literature reviews, various journal websites, and direct feedback from the client. Some of the key take
aways from research included that many robotic systems entailed two or three servo motors in each joint
to achieve multiple degrees of motion. Moreover, the majority of systems used servo motors instead of
stepper due to the complexity involved with programming stepper motors. In terms of controller boards
Raspberry Pi boards offer more features compared to the Arduino boards with almost the same price.
After gathering information for the VR controller, we found HTC vive to be most cost efficient and easy
to use, while also being precise, inside-out-tracking for the handheld controller and head mounted device;
outside-in tracking for the bases. Furthermore, the best materials for the arm modules of the robot would
be ABS and PLA due to the favourable mechanical properties they offer. After analyzing all the
information, the team concluded that servo motors shall be incorporated as the driving mechanisms for
the design of the shoulder and elbow components with two servo motors being attached to each other.
This would entail at least 4 degrees of freedom per arm. In addition, to control the servo motors,
Raspberry Pi boards should be used due to the benefits the board offers compared to its price and other
boards available. Furthermore, after researching, the best material for the robotic arms structure was ABS
plastic due to it being flexible, lightweight, cheap and widely accessible. However, for the connector
joints that assemble the components of the arm such as the shoulder and elbow joints, the best material to
use would be PLA due to its rigidity and strength. Lastly, the anime character that we will be replicating
and that meets our clients needs will be Hatsune Miku.
Introduction:

Our team is trying to design an anime humanoid robotic system for meeting and greeting customers. The
purpose of the robot is to essentially grab the customers attention and provide a friendly greeting
experience. Specifically, the robot is being developed to be showcased at anime conventions or anime
stores as our client is quite fond of this genre. In the anime genre there are multiple characters with our
robot replicating the famous character Hatsune Miku. After talking directly with our client from
Collabots, our team is mainly focused on creating the shoulder and elbows components of the robotic
system. In addition to this, we are looking to create the frame of the system in which the shoulders will be
attached. Overall each shoulder and elbow module should contain at least two degrees of freedom. The
driver mechanisms in the shoulder and elbow joints will not be required to lift any heavy loads as the
robot is purely for entertainment purposes. The only weight needed to be considered would be the weight
of the robotic arm itself. Both the elbow and shoulder component must move independently and be
controlled by either a virtual reality (VR) controller or any other feasible controller mechanism. The end
goal is allow the client to move the robot using the VR controller to remotely greet customers.

If we can build the shoulder and arm modules, we can move forward with helping our client integrate
neck mechanisms of the system and incorporate 2d facial projection of the head.
Some of the limitations of the project include the complexities of implementing VR technology and
achieving smooth arm movement of the robot without encountering lag or backlash of the motor. In
addition, challenges in programming the servo or stepper motor to perform concise movements. However,
as many proof of concepts exist, our team is hopeful and optimistic in the possibility of creating an anime
humanoid robotic system that conforms to our client needs and meets all of the client’s expectations.
Hence, this report explores and discusses the design principles, existing proof of concepts, and
components needed for design such as motors and controller boards. Additionally, it explores the anime
genre, the appropriate material for the shoulder and elbow components and the type of VR controller.

Research:
We did a lot of research in the preparation phase, the first things we investigated were existing products,
from which we hoped to get design inspiration. The first two robots we found in our survey of existing
products were NAO and Pepper from SoftBank Robotics. The NAO is a small robot with human-like
limbs [14] and the Pepper has a human-like upper torso and a cart-like rolling lower torso [13], and is
much taller than NAO, but still not comparable to an adult. SoftBank Robotics' incorporates a powerful
voice recognition technology and sensitive sensing system. Both robots have strong interactivity and are
now frequently seen in the service industry [13]. The joint parts of both robots are flexible, but
unfortunately their mechanical designs are hidden inside the torso. Both robots are still in use by
MassRobotic, so we were unable to disassemble their shells to take a closer look and study the inner
workings.
 Figure 1: The Pepper Robot [13] (Left) and NAO Robot [14] (right)

Fortunately, with the help of our collaborator Russell. We soon found another robot, Poppy, that we could
use as a mechanical reference. Poppy is also a small robot with a height of 83 cm and a weight of only 3.5
kg [12]. But different from NAO, Poppy uses 3d printing to make the shell of the robot. Additionally, the
internal mechanical structure is all exposed, convenient for us to observe. The Poppy Robot has helped us
inspire us tremendously in terms of mechanical design.

Figure 2: The Poppy Robot [12]

We finally found a robot with a design style very similar to ours: Hatsuki, an anime style robot made by
Waseda University in Japan [11], which was very close to our ultimate goal in many design areas, such as
the anime style appearance, the projected 2D expressions, and the VR control system [11]. Hatsuki
inspired us in component selection, mechanical and electronic control, and material selection.
 Figure 3: The Hastuki [11]

After investigating the existing examples, we had a certain idea of our target product. The next step is to
investigate the existing design principles to facilitate the further development of our design solution.

Existing Design Principles

Because our main goal is to make the arm part of the robot, we investigated some design principles about
the robotic arm. In order to make the robot arm as flexible as a normal human arm, the robot arm needs to
meet 4 degrees of freedom (DOF) [10]. This means that the arm can move arbitrarily in a limited
three-dimensional space. Of course, eventually, the joints of the robot arm need to be limited by the
degree of flexibility of the human joints. In order to meet the 4 DOF, two motors are added to each joint
(shoulder and elbow) to achieve this.
 Figure 4: Schematic Diagram of Joint Motor Principle Draw by Our Team

Controlling the robot arm also means controlling the parameters of the motor. Here we need to use the
knowledge of Forward Position Kinematics and Inverse Position Kinematics. Forward Position Kinematics is
used to find the arm position in the task space based on the joint parameters, while Inverse Position Kinematics
can be used to find the joint parameters required for the robot to be in that configuration [10]. Here, the
rotation angle of the motor and the length of the link between the motors are set as computational parameters
and brought into a 4x4 transformation matrix, and then the knowledge content of Forward Position Kinematics
and Inverse Position Kinematics is used to obtain the desired coordinates and motor parameter [10].

Figure 5: The Example for Define Parameters in 3 DOF Robotic Arm [10]

The team members do not know Forward Position Kinematics and Inverse Position Kinematics yet, so they
need to study them later. Moving forward with the design principles in mind, the next section displays research
on the selection of components.

Design components

Observing existing products, further analysis was required into the components needed particularly for
driving the robotic systems and the design principles. For our case, this included components needed to
drive the shoulders and elbow modules to move in 2 degrees of freedom each. After researching, it was
clear that there would be two pathways for driving or controlling each module: the usage of servo motors
or steppers. In each case, further research was conducted to understand how to connect the system
electronically using a controller board to control the position, speed delivered to fit our needs. Thus,
understanding how controller boards would be connected to the components and which ones to use for
our robotic system would be one of the key aspects we explored upon.

A paper written in 2011 published by the Institute of Electrical and Electronics Engineers (IEEE)
displayed that they could achieve the needed speeds, torques and mechanical power for a humanoid robot
with a “DC reduction servo motor”, which can be seen below in figure 6 [3]. The DC reduction motor
provided the ability to fix certain positions of the components. The servo was essentially controlled by a
controller board. The integration of the design seemed to be seamless by coding the positions and
movements required and preceding them into the servo motor. The only challenge seemed to be
calculating the correct values for the motor, such as the maximum speed and power rates. Some studies
used simulink to calculate the exact values whereas others used safety factors and overestimated the
parameters to ensure functionality [4].

Figure 6: DC reduction motor [3]

Additionally, a study written in 2021 by the Australian Journal of Engineering and Innovative Technology
also decided to create a humanoid robotic system with a usage of a servo and arduino controller board.
The servo motor and connection to the Arduino board can be seen below on figure 7 and 8. The study
outlined the common practice of using servo motors for robotic systems as they are highly reliable and
easy to use [5]. Moreover, servo motors provide the ability to lock certain positions of the motor, provide
high force and have a quick input reaction [7]. The engineers were able to control the servo motors
through the use of an arduino controller board. The program written inside the arduino would send signals
to the servo motor causing it to move in certain directions and dictate its position. On the contrary, the
study outlined how using a stepper would require an additional amount of programming making it
essentially more complicated to use.

Figure 7 and 8 : Servo motor and servo motor connection to Arduino [5]

A major challenge with servo design is controlling “backstepping” or more simply the backlash and lag of
the motor. A study by the Journal of Bionic Engineering displayed that using dynamics principles and
calculating the energy conversions within a robotic movement, one could essentially figure out the “pulse
width modulation” required to adjust for the lag of the motor [6]. However, this study used a very
concrete and complicated method with lots of mathematical analysis involved. For the purpose of our
project, it provides proof that estimating inconsistencies within the motor and fine tuning the power
delivered to the motor would result in better performance from the servo motors.

As some of the other studies suggested overestimating parameters is a safer option to meet functional
requirements of the robot. Hence, looking at current technologies we will have to balance functionality
with price when selecting servo motors. For the purpose of our project where heavy loading isn’t required
a fairly smaller servo size may be considered. However, given the wide availability of servo and relatively
cheap prices, obtaining a high torque servo may be beneficial for the shoulder and elbow joints as the
weight of the structures and electronics inside the arm may amount to quite a bit of weight depending on
the material. Thus, selecting 20-25 KG servo motors would be ideal to ensure we are meeting the
maximum weight of the arm component.

On the contrary, steppers motors have been used in robotics. A study written by the IEEE in 2016
displayed that a team was able to build a “biped robot” with multiple degrees of freedom [8]. Although
the robot was made, the study noted that it was uncommon practice to use stepper motors due to the
higher complication in achieving the correct controls and also because stepper motors are more applicable
in “low-speed movements.” Even with the high precision that steppers provide, they still entail backlash
as seen by the servo. Thus, all advantages of the servo clearly outweigh the learning curve and
complications presented by stepper motors.

Further analysis is required to decide the controller board for the servo motors. There are two main
controller boards that are widely used in robotics and that we have been suggested to use by our client:
Arduino and Raspberry Pi. The study written in Australia presented before used Arduino for their project
as it is fairly easy to use and code due to the fact that Arduino is just a microcontroller. Whereas,
Raspberry pi is a single board computer (SBC) [9]. Arduino boards, though cheaper, are used for simpler
tasks that involve rudimentary movement due to the low scope of the program. Hence, these would
include simple tasks such as moving an arm up and down. However, Raspberry Pi boards offer more
scope due to the programming language being Python. Thus, there is a higher scope to input multiple
programs within the system and have multiple movements performed at once. In addition to this,
Raspberry Pi has the capabilities of achieving wireless connection with other components [9]. Therefore,
allowing us to incorporate virtual reality (VR) controllers or any other wireless controllers with ease.

In figure 9 below we can see the Arduino used in the Australian study, incorporated one USB port, power
supply port and multiple connection pins also known as GPIO pins. It is a fairly simple controller board.
Whereas, in figure 10, we can see the Raspberry Pi 4B which offers multiple hdmi ports, USB ports, and
more. It also has multiple GPIO pins. Essential for the servo motor, there are 3 connection pins with one
being a negative wire, the other being a positive wire, and the last wire being connected to the GPIO pin
for pulse width modulation signals from the controller board. Both the boards have the capability of
providing these features.
 Figure 9: Aruino AT MEGA 2560 [5]

Figure 10: Raspberry Pi 4B controller board [15]

In the next section we analyze VR controllers and how to integrate them into our design.

Remote Control (VR)

 Figure 11 VR controller [22] .

Figure 12: Joystick controller [23]

For remote controller systems, we are mainly considering Virtual Reality (VR) controllers. Different from
direct virtual controllers, our maximum aim is to see what our robot sees, and make the robot copy our
movements as much as possible. VR controllers (or human posture-based control) make the
humanoid-robot’s body directly controlled by human-operator’s movement, and is widely used in
humanoid robotics. It allows the operator to better communicate their intentions to the robot than joystick
controllers or keyboards.
 Figure 13: VR Control Based on Pollen Robotics [24]

VR motion capture includes 3 captures: head capture, limbs capture, and facial motion capture to
completely control the major moving parts of the robot. For the first two captures, there are existing
signal receiving solutions including infrared cameras used by HTC Vive and Oculus “Touch”, visible light
LEDs tracker used by Playstation VR, and magnetic tracking used by Sixense’s Razer Hydra. At present,
there are three main motion control methods for VR humanoid robots. They are “keyframe technology”,
“motion capture technology” and “approaches based on simulation” [25].

For head capture, a work on the HMD in 2014 created the Oculus Tracker v2 board that can increase the
“sampling rate to 1000Hz”, and “reduce sensor delay to 2ms”, better synchronize the real world
movement and the video feedback to the screen in the head-mounted device (HMD) [26].

For limbs capture, there are sensors such as an accelerometer and gyroscope in the device. Positional data
can be generated from DIY slimeVR trackers etc. A Youtube channel, Virtual Reality Oasis, recorded a
group of people controlling a Pollen Robot in London from Paris.

Expression capture includes eyeball tracking and facial muscular capture. Rawal etc. introduced
ExGenNet, which is a new framework for facial expressions of their real Furhat Robot Alfie and
Elenoide. In their future work, human-computer interaction experiments will allow robots to recognize
human facial expressions and generate their own facial expressions [27].
 Figure 14: Facial features from human and robot training images [28].

Figure 15: Examples of VR Motion Control System in Quadrupedal Robots [29].

The diagram above is an example of the non-controller VR motion capture, similar processes will be
applied to our control system. An example is the Leap motion controller, integrated hand-tracking sensor
into its VR headset, include 2 cameras and 3 IR LEDs. But tracking latency is a big issue. Other than the
non-controller solution, we studied wearable controllers. Most of the available products include
components of HMD, hand held controller, and software. Bases are used in more high-end devices for
accuracy improvement, Valve index is using it as “lighthouse tracking”. More general solution is inside
out tracking where the only peripherals are HMD and hand held controller. HTC Vive Pro integrate both
lighthouse tracking and inside out tracking.
 Figure 16: The Two Major Tracking Procedure [30].

Products Price

HTC Vive Pro (2 bases+handheld+HMD) 1399

HTC Vive (2 base+handheld+HMD) 749

Valve index (2 bases+handheld+HMD) 1189

Leap motion controller (desktop device) 169

Playstation VR (a base+handheld+HMD) 399

Oculus Rift and Oculus Touch 499+109.9

Table 1: Price from Amazon [31]

Problems of general VR controllers in the market are, tracking accuracy, material reliability, and holding
comfortability. Problems with our project regarding the controller include, limit of remote distance and
movement degree of operator, portable power supply, and the position of the motor attached into our
robot. While incorporating VR controllers, we will be exploring these challenges and trying to solve
them. In the next section we discuss the material choices for the shoulder and elbow components of the
design.

Material
For the anime robot that our group is developing, we are looking for a material that doesn’t need to be
extremely hard because it doesn’t have to carry any heavy weight or perform extreme tasks that could
result in breaking or damaging the plastic parts of the robot. However, the material must be lightweight
but steady because the tasks of our robot are mostly interacting and greeting the users, ideally, from anime
conventions. There will be a lot of movement for the robot from morning to night and these movements
could be non-stop since the convention is always packed with participants. As a result, the lighter and
steadier the material, the better it helps extend the lifespan of the robot. Furthermore, even though our
client expects parts to be removable and replaceable, the chosen material must be cost-effective because
there are many parts to be printed. Two of the most popular 3D printing plastic materials are ABS and
PLA. They are popular because of the way they turned into a softer state when they are heated and
quickly harden when they are cooled, while those characteristics are exactly how 3D printing mechanism
work.

Figure 17: Material properties between ABS and PLA[16]

According to “Plastic Materials,” ABS plastic has high impact resistance, good stiffness, and good stress
cracking resistance [17]. These are all the important characteristics that we are looking for. In our daily
life, ABS plastic is used to create most electronic housing products; it was also really widely known as the
material of LEGO bricks. ABS is also one of the three main materials made up of the Pepper robot [18].
Similar to ABS, PLA plastic is also very steady with tensile strength up to 37 MPA while ABS is
approximately 27 MPA based on figure 17. Also from figure 17, in term of density, PLA is roughly 1.3
3 3
𝑔/𝑐𝑚 compared to around 1.0 - 1.4 𝑔/𝑐𝑚 in the density of ABS which makes no major difference
between those two materials. However, there is a big difference in the melting point of these two
materials. The melting point of ABS plastic is 200 °C [19] while the melting point of PLA is only 173
(from figure 16). The higher melting point means a longer heating process and slower cooling period for
ABS which will make the printing time not as fast compared to PLA. Lastly, the price of PLA is a little
more expensive at around 22.99 USD for 1kg/1.75mm; for ABS it would cost a dollar cheaper [21].
Eventhough the price differences are not significant. However, because we are trying to build a
human-size robot, there will be different prototypes until we get our final design. The price factor might
also affect our final decision in the future.

Overall, both PLA and ABS meet the requirements of our material’s goal for the anime robot which are
lightweight, steady, and idealistic for 3D printing. In the following section we explore the anime style
genre.

Anime Style
Anime or アニメ is an extremely famous term describing the Japanese version of a cartoon. Characters
from anime are loved and endorsed not only by Otaku, referring to an anime/manga lover, but also by
people of any age. They were loved not only because of their unique characteristics but also because of
their standout appearances. As we mentioned earlier, our anime robot is planning to appear at anime
conventions or events to interact with fans. As the result, we are looking for a female character that is
familiar with most of the Otaku but also has a strong and interesting character that is already loved by the
fans and can also attract other convention attendees. There are two characters that we are interested in
bringing to real life which is Hatsune Miku and Nezuko from Demon Slayer.

Figure 18: Hatsune Miku

Figure 19: Nezuko

“Hatsune Miku was developed as a Vocaloid software voicebank” [20]. She is known as a virtual idol
from Japan and quickly becomes popular because of her unique appearance and multiple hit songs not
only in Japanese but also in English. Unlike Miku, Nezuko is a character from an anime called Demon
Slayer which was extremely famous in 2019. The story is about the journey of protecting people from the
human-eating demon of the two siblings Tanjiro and his sister who is Nezuko. Nezuko is popular because
of her cute moments in the show and breathtaking abilities. She is very recognizable because she always
has bamboo on her mount. This can be an advantage in our robot design because without designing a
movable mount, Nezuko can still be lively because of the nature of her character.
Discussion and conclusion:

For the design of the shoulder and elbow. In order to achieve 4 degrees of freedom, we will put two
motors at each joint. We will refer to Poppy Robot's design for the internal mechanical and electrical
structure. The specific parameters of the motor movement angle will be set and adjusted after the arm
structure is completed. The shell will be modeled according to the purchased mannequin as a reference.

After looking at the research for servo motors and steppers, it seemed clear that servo motors had higher
benefits than steppers. The advantages included high accuracy, high torque output and lower level of
complications when implementing into electronics/controller boards due to the ease of programming a
servo motor compared to a stepper. In addition, servo motors are widely accessible and a cheaper option
making them more suitable for our project. Hence, for our project we will be selecting servo motors as the
driving mechanism of the joints instead of steppers. While choosing a servo motor, overestimating
parameters seems to be ideal for deciding what servo to choose. A servo with a torque output of 20-25
KG is more than enough for the scope of our project. 8 servo motors will be necessary for both the
shoulder and elbow modules.

In regards to the controller boards, both Arduino and Raspberry Pi have the scope to control servo motors
and perform tasks. Generally, Arduino boards are easier to work with and contain a much simpler
programming language to control components when compared to using python for Raspberry Pi boards.
However, Raspberry Pi boards provide a larger scope with the ability to program multiple movements and
tasks whereas the arduino board only allows for a singular task to be performed. In addition, for the price
of the board, the Raspberry Pi boards offer more ports and a faster processor. A major factor for selecting
the Raspberry Pi instead of the arduino would also be the opportunity to connect VR controllers to the
shoulder and elbow components of our robot. Hence, to meet client needs and design specifications,
Raspberry Pi boards will be used to drive and control the servo motors, regardless of the higher difficulty
in programming.

In terms of material choices, we are planning to use ABS plastic for the outer shell of the robot and PLA
for the inner components and the frame of the robot. According to Hubs, “engineers often go for ABS as
it has better ductility than PLA. ABS has higher flexural strength and better elongation before breaking
than PLA” [21]. As the result, it is a perfect material for the outer shell of the robot for all the elbow and
shoulder parts of the robot since we would prefer making them hollow so that we can insert boards,
motors, and wires. If we pick a material with higher flexural strength, we can avoid fracture and breakage
during the assembling and operating process. On the other hand, inner components require materials with
higher tensile strength which make them a better fit for PLA.

For remote controller, the VR controller HTC Vive with 2 bases, a HMD, and 2 handheld controller is
going to be used in our project. Facial motion capture is a bonus point since they are in still in lab-test
phase. For the HTC vive, technology of inside-out-tracking from the limbs capture device and head
capture; outside-in tracking in the bases is providing a more precise position detection than non-base
controllers.
Through our discussions between the team and also our client, a robot with movable mouth is preferable.
As the result, eventhough the style selection is not finalize, Hatsunee Miku will be the style that we are
aiming toward.

In conclusion, after looking at all the research, the best method to create an anime humanoid robotic
system would be to incorporate servo motors with a Raspberry Pi controller board. In doing so, we will
have to adjust the pulse width modulation signals to account for the backlash of the motor and to achieve
smooth movements from the motor. Additionally, we must incorporate VR controllers through the use of
wireless technology on the Raspberry Pi and controller set to create a replication of the Hatsune Miku
character from the hip upwards. The robotics arms will be made from ABS plastic.

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