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POLYRO (oPen sOurce friendLY RObot)

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 1Suggested Tools and Parts

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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74 comments
1-40 of 74next »
May 22, 2012. 6:55 PMchewy3939 says:
How much did this end up costing you in the end?
Feb 16, 2012. 7:02 AMarjun0520 says:
which webcams did u use to make the eyes
and can i use roller sakets and make 2 curcit for the legs to move and which software should i download for my ideas to work help ubuddha
Feb 15, 2012. 7:49 PMarjun0520 says:
we are trying to modify and make polyros (our version) i want 2 know about the movement and the charge of the mainframe
Feb 15, 2012. 5:41 AMarjun0520 says:
dear u buddha
i wanted to know where have u got the parts from and r they avalable online?
hope for a quick response
Feb 15, 2012. 5:50 AMarjun0520 says:
dear ubuddha
i wanted to know where can we get the required material and is it AVALABLE ONLINE
Jun 24, 2011. 9:59 AMKaydenST says:
What was the final cost for POLYRO?
Jul 1, 2011. 7:29 PMMovieMaker says:
The main expense that is killing me are the 11 actuators. phew!

Do you think that this would work with a Roomba 530 instead of a create?

And just go through the serial RIO
Nov 17, 2011. 8:30 AMMovieMaker says:
UBuddha,

Thanks for the reply. I have since burnt up my roomba 530. I got a factory cable from irobot. It was made overseas. It had a big glob of solder on the inside shorting out the whole thing. I plugged it in to the 530 and it fried the motherboard of the 530. IT would cost me around a hundred dollars that I do not have to get it going again. :-(

But, I have worked with other units and I am having fun. But, none looks as cool as your design.

When you get some code, please post it.
Jun 24, 2011. 11:00 AMKaydenST says:
Thanks! Now another question: Is this robot able to do stuff like navigate through homes and interact with people? And how would you program it? Is that what the netbook is for, your programming console?
Jun 24, 2011. 12:28 PMKaydenST says:
Thank you for explaining! This is a great project, and looks like it has a bunch of potential!
Jun 24, 2011. 4:36 PMKaydenST says:
If you're not too busy, would you mind posting a video of POLYRO, so I can see what POLYRO can do and how he behaves? You don't have to if you don't want to... and can POLYRO "speak" and does he have voice recognition and stuff like that?
From,
Your personal skeeter lol
Jun 26, 2011. 12:49 PMKaydenST says:
Thank you for answering all of my questions!
May 8, 2011. 4:36 PMmkopack says:
Great project! I've been wanting to build a robot using similar hardware (Create/Kinect/Webcam/Laptop.) Thanks for pointing to the WillowGarage turtlebot. I've gotten that code all installed on 2 machines and have been able to start it up (just waiting on the battery for the Create to charge up.)

Any idea what Gyro unit they're using for the Turtlebot? They list one in the specs, but it isn't listed on the preorder page.

Can't wait to see more about how you mounted the body to the base and what the support structure looks like.

My only concern with the Turtlebot code is that it seems like it's using the onboard netbook simply as a control interface and it's just passing all the data off to a workstation to do all the computational tasks. For my needs, I want the robot's computer to do 99% of everything, and just expose an API or web interface to do the controlling.

Also, how does one go about installing the uvc webcam package
May 9, 2011. 10:56 AMmkopack says:
Great! Thanks!

I managed to get ROS talking to the roomba last night, and was able to use their Teleop Keyboard control interface to drive the roomba around. I have to say though, it's going to need some adjusting because it was VERY jerky (seems like there's no speed control, it's just 0% or 100% which will make for a very wobbly robot prone to fall overs since the speed doesn't gradually build up or reduce. It's either stopped, or driving full speed!)

Tonight I'm going to try to test the Kinect to make sure it's talking to that properly.

I'm going to be using this setup mostly for telepresence experimentation between 2 offices, so I really want to make the control interface something that doesn't require software installation, and keep most of the robot's brains and ROS specific stuff on the robot itself. (Just maybe make the robot act as a web server to provide the API/interface to whatever machine/client hooks to it.)

Also, I asked on the Turtlebot user's mailing list about the Gyro they're using and found out that it's one of these:

http://www.sparkfun.com/products/9059

Unfortunately, they didn't tell me how it's hooked up to the system, and I don't have the EE background to know how to wire it up.

Since you're using the Turtlebot code for your bot, did you use their Calibration routine? And if so, how did it behave without having the Gyro in there?
May 10, 2011. 12:44 PMmkopack says:
Yup, saw that blog before. Partially what got me thinking down this path. Where I work, we have one main site in NJ where most of the people work, and then 3 small satellite offices around the country that were part of an acquisition several years ago. I work in one of those outlying offices, and we regularly experience the "out of sight, out of mind" situation because we aren't able to easily socialize with the people at the main office. We also have problems with interacting in meetings because we can't see each other, see what the others are writing on whiteboards, get left out of discussions that take place after meetings break up, etc.

So, trying to build something like a combination between the procrastineering robot, yours, and the TurtleBot.. Ideally I'd like it to be something that could be manually controlled, but also have capabilities where you could allow the operator to say "drive to this conference room and beep me when you get there, that way I can go do something else in the mean time" and the user doesn't have to manually drive it there. Additionally, capabilities like "follow this person" would e automated so you can focus on the conversation rather than the driving.

My coworkers and I have some other ideas as well about how to incorporate other functionality, and use this platform for some HRI research that we do here...

I like the idea of using ROS because they have such a rich library of components to build upon. I'm just a bit of a newb with it so I'm still learning a lot and just getting my feet wet.

The body you are using for yours is interesting, but not necessary for my needs right now, although we have talked about scenarios where having some sort of arm on the robot would be good for allowing actions like pointing at objects and such.

Anyhow, right now I'm just trying to get the basic system up and running with mapping and such and then temp mount it all onto the create to demonstrate a basic capability to management so we have something to use to convince them to fund us to get better hardware and some time to build a more robust setup for actual use. They need to be convinced that a setup like this would be useful first. At a minimum I'm going to need a better computer on the robot than I have right now.
Aug 25, 2011. 12:20 PMmkopack says:
Ok, I'm back... I promised I'd report on progress and such...

First off, here's some pictures of what we ended up with:

http://i185.photobucket.com/albums/x200/crazybiker_ga/7da54e04.jpg
http://i185.photobucket.com/albums/x200/crazybiker_ga/f53ffc3e.jpg
http://i185.photobucket.com/albums/x200/crazybiker_ga/133c439a.jpg
http://i185.photobucket.com/albums/x200/crazybiker_ga/496d7540.jpg
http://i185.photobucket.com/albums/x200/crazybiker_ga/c90ae6c1.jpg

We're calling it TED - Telepresence Experimentation Device

We have switched out the webcam in those pictures for a better Logitech HD model, and the mast in those photos was U-shaped Aluminum, which has been replaced with box aluminum (I would have prefered to use 80/20 T-slot but couldn't find any place local that I could just go in and pick it up.) We had to replace the U-bar with box to eliminate serious torsional twisting that would take place whenever we had the robot turn (the monitor would just wobble back and forth like crazy.)

Anyhow, it works pretty well. We're able to do SLAM right on the robot itself, we have 2-way video working, the monitor is a DoubleSight DS-90U 9" USB powered + signal monitor and it's very light weight, as is the speaker. Since most of the weight of the whole unit is down low, and we were able to use lightweight materials up top, it's still relatively stable.
Nov 17, 2011. 8:27 AMMovieMaker says:
MKOpack, could you share some code with us?
Sep 2, 2011. 10:07 AMDancesWithRobots says:
Your robot is probably the most refined and "complete" of the approachably priced robot projects I've seen. It matches a typical persons concept of a robot. It looks like it can actually "do" something. It looks well built and commercial quality. I'm impressed.
Jul 27, 2011. 7:35 PMwamj says:
Love It! Just a thought for the second prototype, you could use Maker Beam   for the frame
Aug 10, 2011. 6:38 PMwamj says:
I think that is the point of the design, because there are all of these compatible parts out there so people can mix an match the makerbeam with other products and hardware
Jul 20, 2011. 3:25 PMpnangle iv says:
I don't see how this was beaten by "Bookshelf." This just LOOKS cool! And it probably works great!
Jul 1, 2011. 7:31 PMMovieMaker says:
I don't see what this got 2nd place instead of 1st place! This project rocks! Who got first place? They must've been remarkable.
May 6, 2011. 6:58 AMscottieboy0630 says:
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.
May 31, 2011. 7:35 AMscottieboy0630 says:
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
1-40 of 74next »

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