DIY a Christmas 'Danbo' Robot With Remote Control

This time we would like to share a new project made with Arduino: A Christmas Remote Control Robot Named 'Danbo'.

In this project we used 2x microcontroller boards that can be used as same as Arduino UNOs:

one for controlling the servos inside the robot to move the arms, the waist, and the head
while another one is in the remote controller together with a couple of wireless modules

Step 1: About "Danbo"

Danbo (ダンボー) is a fictional cardboard box robot character from Kiyohiko Azuma's manga series Yotsuba&!. In the ADV Manga English translation of the manga the name Cardbo was used, but the name was then changed to Danbo in the latest Yen Press English translation.

In reality, Danbo is merely a person inside of a costume made of cardboard, it's picked up as an Internet meme, and inspired various electronic gadgets.

Step 2: Things We Used to Make a Cute Danbo

Building a cute lovely Danbo isn't really some kind of rocket science. In fact, anyone can build it, as long as you have seen this instructable XD.

Check the items below to see what we've used to make Danbo:

Hardware:

Seeeduino V4.2 (Arduino Compatible
Base Shield
Grove – Servo * 5
Wireless communication module
Seeeduino Lotus (Arduino Compatible)
Grove – Button(p) * 2
Grove – Thumb Joystick
Energy Shield

Structure:

3mm wood
M3 support columns —— many
M3 flat heat screws —— 64 PCS
M3 nylon rivets —— 26 PCS
M2 screws —— 18 PCS
M2 nuts —— 18 PCS
M2 self tapping screws —— 5 PCS
Washed kraft paper
stapler
screwdriver

Step 3: First Thing First: Hardware Connection

At first, we should connect the electronic modules to each microcontroller:

To build the Danbo robot, we connect the Grove Servos and wireless communication module to Seeeduino v4.2, please refer to the table. 1
To build the Remote Controller, we connect Grove modules to the Seeeduino lotus, please refer to the table.2

Step 4: Upload the Arduino Code to "Danbo Robot"

Now we can upload the Arduino Code to our Danbo Robot :

1. Download demo code at https://github.com/Lee-Kevin/Danboard/

2. Click “Download zip” button on right side of webpage to download all codes.

3. Decompress the downloaded zip files to“C:\Users\Administrator\Documents\Arduino\” and remove “-master” in decompressed file name.

4. Launch Arduino IDE.

5. Click Sketch>Add file to add Robot.ino file from“C:\Users\Administrator\Documents\Arduino\ Danboard\Robot\”.

6. Click Tools -> Board and select “Arduino/Genuino Uno” and chose the right port, as shown in the picture below.

7. Press CTRL +U to upload codes to your board. Wait a while, there will be saying “Done uploading”.

8. Congratulations, you have already completed the robot side software work.

Step 5: Upload the Arduino Code to ''Remote Controller"

Then we upload the Arduino Code to the Remote Controller :

1. Download demo code athttps://github.com/Lee-Kevin/Danboard/

2. Click “Download zip” button on right side of webpage to download all codes.

3. Decompress the downloaded zip files to“C:\Users\Administrator\Documents\Arduino\” and remove “-master” in decompressed file name.

4. Launch Arduino IDE.

5. Click Sketch > Add file to add Controller.ino file from“C:\Users\Administrator\Documents\Arduino\ Danboard\Controller\”.

6. Click Tools -> Board and select “Arduino/Genuino Uno” and chose the right port, as shown in the picture below.

7. Press CTRL +U to upload codes to your board. Wait a while, there will be saying “Done uploading”.

8. Congratulations, you have already completed the controller side software work.

Step 6: Create a 3D Model

In order to make the skeleton create more easily, we need create a 3D model about Danbo's skeleton.

It would be easier for us to confirm every servo's position and angle of movement in the 3D model.

After creating the 3D model, we need to convert it to 2D for laser cutting.

Step 7: Laser Cutting

We used 3mm(thickness) wood to laser cut the Danbo skeleton.

As for the skin part, we laser cut washed kraft paper.

And the Christmas skin style, we laser cut some white cardboard to build it.

Here we've attached the files for laser cutting, which you can directlt download them to cut a Danbo robot for your own.

Step 8: Servo Installation

There are 2 servos on Danbo's neck, 2 servos for the shoulders, and 1 for the waist.

When installing, make sure to start with the boards that are used to fix the servos, and then go with other parts. Align the initial position when installing. Note that the servo is aligned with the initial position.

Step 9: Assemble the Body and Head

Fixed the head with support pillars and screws, then fixed neck and head.

Fixed the body with support pillars and screws too, then fixed waist and body.

Now, combine the neck and body with nylon rivets, do the same to the arms and the body.

Take out all the servo's cables from Danbo's back.

Step 10: Fixed Danbo's Heart

Connect all of servo's cables to Seeeduino v4.2, then put seeeduino into Danbo's body. Use nylon rivets to fixed them. Put all the cable's inside the body too.

Step 11: Make the Skin of Danbo

The laser cutting of the water-washed kraft paper are folded into the appropriate shape, you can use a stapler to fix the water-washed kraft paper. When it's done, dress up Danbo with those papers.

Step 12: Make the Christmas Hat and Beard

The laser cut cardboard, we use red marker make it red and fold it as a hat. Stick the beard to Danbo's face with a sticker, and cut the edge of the beard with scissors

Step 13: Fixed the Remote Control

Now we come to the part of the Remote Control.

Firstly lets fixed the Seeeduino Lotus onto the bottom plate, then put two Grove - Thumb Joystick on each side of it.. Now fixed two buttons on the side plate.

Connect all the parts, including the side boards, the top board and the bottom one with support pillars and screws.