Instructables

POLYRO (oPen sOurce friendLY RObot)

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This is an instructable on building a relatively low-cost wheeled robot platform for developing ROS applications. Think of ROS as an operating system for your robot (providing hardware abstraction, device drivers, libraries, visualizers, message-passing, package management, and more). THIS ROBOT IS NOT PLUG AND PLAY. ROS runs on Ubuntu, so you should feel comfortable working with Linux.

POLYRO, short for oPen sOurce friendLY RObot (yes I know, it's a bit of a stretch), is based off of the TurtleBot platform (from the good folks at Willow Garage) and inspired a great deal by Pi Robot (developed by Patrick Goebel). I designed this platform with Human-Robot Interaction (HRI) in mind. This is the first of many future iterations, so check for updates to the design. Please keep an open mind when following this tutorial. Many of the parts and tools can be substituted (or purchased for less) and there are many improvements to be made. As always, when working with power tools use the proper safety gear.
 
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Step 1: Suggested Tools and Parts

Picture of Suggested Tools and Parts

Tools
  • Dremel*
  • Clamps
  • Removable Double-Sided Tape
  • Screw Driver Set
  • Needle-nose Pliers
  • Jig Saw (or maybe a Scroll Saw)
  • Saw Horses
  • Drill Press (Dremel Work Station)
  • Dremel Sanding/Grinding Kit
  • Soldering Iron
  • Sponge
  • Glue Gun
  • Large Format Printer (Kinkos)
  • Metal Ruler
  • Safety Goggles
  • Work Gloves
  • Dust Mask

Parts List

10.1-Inch Netbook
1 x $150 to $300

iRobot Create® Programmable Robot
Item Number: 4400
1 x $129.99 – www.irobot.com

Kinect for Xbox 360 with AC Adapter (Refurbished)
1 x $119.99 – www.Gamestop.com

Wide 2" Gusseted Plastic Angle Bracket (pack of 8)
SKU/PNO:BRAC-GUS2
4 x $1.59 - www.budgetrobotics.com

Risers, Set of Four 1" Steel)
SKU/PNO:RISER-SET
4 x $1.69 - www.budgetrobotics.com

Gusseted Plastic Angle Bracket (pack of 8)
SKU/PNO:BRAC-GUS1
2 x $1.59 – www.budgetrobotics.com

White Expanded PVC 24" x 48" .120" Thick
Item #: 42485
1 x $12.85 – www.usplastic.com

White Expanded PVC 24" x 48" .240" Thick
Item #: 42488
1 x $27.86 – www.usplastic.com

Gray Expanded PVC 24" x 48" .120" Thick
Item #: 42501
1 x $16.50 – www.usplastic.com

250 Grams of ShapeLock
1 x $14.95 – www.shapelock.com

Bioloid Frame F3
Item #: M-300-B-BPF-F3
3 x $1.49 – www.trossenrobotics.com

Bioloid Frame F2
Item #: M-300-B-BPF-F2
1 x $1.49 – www.trossenrobotics.com

Dynamixel AX-12A Robot Actuator
Item #: FRS-B-AX-12A
11 x $44.90 – www.trossenrobotics.com

Robotis USB2Dynamixel Adapter
Item #: FRS-B-USB2D
1 x $49.90 – www.trossenrobotics.com

SMPS2Dynamixel Adapter
Item #: FRS-B-SMPS2DYNA
1 x $4.90 – www.trossenrobotics.com

Bioloid Bolt & Nut Set
Item #: M-300-B-BPF-BNS
1 x $23.40 – www.trossenrobotics.com

Bioloid 6-Port Cable Hub
Item #: FRS-B-6-PT-C-H
1 x $4.95 – www.trossenrobotics.com

3 pin Bioloid Servo/Sensor Cables (Set of 25)
Item #: FRS-B-CBL
1 x $34.90 – www.trossenrobotics.com

Logitech QuickCam E 3560 Refurbished
SKU: 130419
2 x $10.99 – www.microcenter.com

On Stage Foam Ball-Type Mic Windscreen (Blue)
2 x $4.95 – www.amazon.com

Wall Mount Bracket Dock Stand for Kinect
SKU: 267-363-001
1 x $9.99 – www.meritline.com

USB to PDA 9-pin Serial Adapter
SKU: 173369
1 x $29.99 – www.mircocenter.com

6” Novak Heat Shrink Tubing Assortment 24 pcs
1 x $3.74 – www.amazon.com

High-Tech Rosin Core Silver-Bearing Solder (1.5 Oz.)
Model: 64-013
1 x $5.79 – www.radioshack.com

25-Position Male Solder D-Sub Connector
Model: 276-1547
1 x $2.29 – www.radioshack.com

Schmartboard 201-0001-01
1 x $5.00 – www.schmartboard.com

USB 2.0 4 Port Hub – (Black)
SKU 502880
2 x $2.99 – www.microcenter.com

0.33μF and 0.1μF capacitors
2 x each

Voltage regulator 12V 1A
2 x each

22 AWG wire (red and black)

Machine Round Head w/Nut (4-40 x 3/8)

USB extension cable

Velcro tape (optional)

White model paint (optional)

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TimPayne (author)  MovieMaker3 years ago
Thanks MovieMaker! The first place winners were pretty awesome.
Great project! Do you actually use the feedback that the servos are capable of returning? Or would I be able to get away with a more basic servo? Thanks for your help. I would really like to give this a try.
TimPayne (author)  scottieboy06303 years ago
Thanks Scottieboy0630. The design files which are included with this tutorial were made specifically around the AX-12 servo. At this point, Polyro's arms are primarily for communication purposes (no feedback required). Some minor changes to parts in the arms and head would allow you to use standard hobby servos instead of the Dynamixel AX-12's.

The Dynamixel servo was chosen because of it's many features (including feedback). Instead of USB2Dynamixel, I initially wanted to use an ArbotiX robocontroller with PyPose. Using PyPose would allow you to easily create motion sequences simply by posing and capturing...
Thanks. I will figure something out. Would you happen to have any sample code so that I can get an idea of what the code should look like when I am done, or is the Turtlebot code enough to get Polyro running after the build is finished?

Thanks for all your help
TimPayne (author)  scottieboy06303 years ago
With Turtlebot, you will be able to do teleoperation, SLAM map building and autonomous navigation of a known map. There are examples of code found in the ROS tutorials (I would highly recommend going over them).
http://www.ros.org/wiki/ROS/Tutorials

I am using Dynamixel servos, so I have also installed nodes and drivers from the ROS package 'robotis' from Georgia Tech Healthcare Robotics Lab. This allows me to operate, query and control Dynamixel servos.
http://www.ros.org/wiki/robotis

Once you complete the ROS Tutorials I would also like to recommend a great Head Tracking tutorial.
http://www.pirobot.org/blog/0016/
LucasOchoa3 years ago
hey bro i need your help on the garden photo contest congrats on making second place!
TimPayne (author)  LucasOchoa3 years ago
Thanks! I voted for your project yesterday. Good luck!
doncrush3 years ago
(removed by author or community request)
It's not really very polite to post on someone's instructable to say that your one is better...
I was not attempting to make a statement about "better", just lower cost.

Sorry bout that.

Thanks!
:)
TimPayne (author)  doncrush3 years ago
It is a nice robot. I wish you the best luck in the competition!
Pretty darn good!
TimPayne (author)  Computothought3 years ago
Thanks Computothought!
bhylak3 years ago
Hey UglyBuddha,

I got your solution for charging. (I built a telepresence robot off of a Roomba, which charging method can be adapted to the Create) First, take the barrel jack directly to the docking pads, while still having it connected to the PCB inside. (But don't let the pcb be connected to the docking pads) Then, purchase a 22v to 12v converter. You can then use a Inverter for the Laptop. (But get a universal laptop power adapter, 4 amps, and hook it up to the dock)

Hope it helped,

Ben
TimPayne (author)  bhylak3 years ago
Thanks Ben! That is a great solution. Do you recommend a specific 22v to 12v converter?
bhylak TimPayne3 years ago
I have detailed instructions and pictures in my Telepresence robot instructables. Search the site for "Maya Telepresence"
TimPayne (author)  bhylak3 years ago
Awesome! Maya is a really cool robot. Great job on the Instructable as well. The pictures in Step 5 are really helpful.
bhylak TimPayne3 years ago
Thanks.

Any cheap Universal Laptop Adapter will work, but make sure it can supply the correct amperage for the laptop at 22v. Also, the modification on the dock is necessary, it will just flick on and off without it.

Ben
bhylak TimPayne3 years ago
http://www.jameco.com/webapp/wcs/stores/servlet/ProductDisplay?langId=-1&storeId=10001&catalogId=10001&pa=212531&productId=212531&keyCode=WSF&CID=GMC

(Screw Terminals, 12v 4.2a output, 18-36v input)

TimPayne (author)  bhylak3 years ago
Thanks for the link!
MovieMaker3 years ago
Your Project is AWESOME! I however have been to the ROS site. It is ALL greek to me. I installed Ubuntu without a hitch. It was easy. But, I have tried three times to install ROS without success.

Looking forward to more software and hardware updates.

Thanks for the Quick Reply. I installed Ubuntu 10.10 four times. It always installed quickly and nicely.

I tried to install ROS each time and it Never completed. It would go to around 99% and then tell me an error. I forgot what the error was. I was putting it all on a 32 gig flash drive because my main operating system is windows.
TimPayne (author)  MovieMaker3 years ago
Did you install Lucid or Maverick? Also, did you configure your Ubuntu repositories to allow "restricted," "universe," and "multiverse?"
I never got that far.
TimPayne (author)  MovieMaker3 years ago
Try to configure your Ubuntu repositories before installing ROS (for Maverick).

https://help.ubuntu.com/community/Repositories/Ubuntu
Thank you so much for the reply. I will do this as soon as I can. My fastest most powerful computer 9300 Quad core, with the most memory got hit by lightning last night. So, with no insurance and no money, I will have to cool it until I can fix my best computer. Thank God I had a spare 3800 dual core on hand. At least I can get my emails.
I always installed Maverick. Lucid would not install for me.
TimPayne (author)  MovieMaker3 years ago
ROS is a bit intimidating initially. I would suggest going through the tutorials here:

http://www.ros.org/wiki/ROS/Tutorials

Also, what exactly is the problem that you are running into while installing ROS?
LucasOchoa3 years ago
this is actualy awesome i dont understand why it only has 150 views... there has to be some sort of trick... im subbing hopfully you can check out my channel i have an animetronic hand u might be interested in.
TimPayne (author)  LucasOchoa3 years ago
Thanks, I checked out your animatronic hand and it was really cool.
thanks man... yeh btw i advertised your ible on facebook cause im sorry it deserves way more than 350 views
also my instructables account really needs some help getting off the ground i would really appreciated it if u subscribed.
TimPayne (author)  LucasOchoa3 years ago
Absolutely
TimPayne (author)  LucasOchoa3 years ago
Thank you, I really appreciate it.
WayneS23 years ago
Cool Robot. I'm looking forward to more construction details as you continue your developement. Open source is DEFINITELY the way to go.
TimPayne (author)  WayneS23 years ago
Thanks Wayne, I will have more construction details up later today ;-)
mrbadr3 years ago
Nice one, I was planning on building a 170cm full humanoid with hands and actuated with air muscles for this contest but unfortunately I didn't finish it yet, I'm planning to use ROS as well and got the minuro webcam for stereo vision
Good project and wish you the best of luck with the MakerBot contest
TimPayne (author)  mrbadr3 years ago
That sounds awesome! I can't wait to see it.
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