Parallax Penguin Robots in 2005
Penguin Robots: a Parallax mini R&D project
Fantastic Penguin Robot comments by Ken Gracey - Parallax
How it all began...
Ken Gracey 2005-05-20 21:27
https://forums.parallax.com/discussion/78698/penguin-robots-a-parallax-mini-r-d-project
Ken Gracey 2005-05-20 21:27
https://forums.parallax.com/discussion/78698/penguin-robots-a-parallax-mini-r-d-project
This is a picture of a couple of prototype "Penguins" made here at Parallax. Same concept as the Toddler but more advanced. These robots stand 3.5" tall and have the following features:
The robots are CNC machined from AL6061 and use GWS micro servos. The stride linkage (moves the legs foreward and backward) attached to the servo horn is a broached Delrin rod turned on a lathe. These robots walk very well and precisely compared to their larger counterparts.·They're part of·ongoing R&D·at·Parallax and will now be used to test a·future wireless programming/network interface. There are no formal plans to make them as a product at the·moment. Sincerely, Ken Gracey Parallax, Inc.
2005-09-03 04:11 I'd like to share with you the latest hardware revision on the Penguin robots. The latest design incorporates several design improvements to the mechanics. Improved precision, a new foot design and better integration with the BASIC Stamp system are some of the changes. In this picture you'll see the prior prototype (the clear aluminum one in back with the electronics) along with three new bodies. The parts are either nickel-plated or anodized red, black or blue. These new versions are not wearing any electronics yet. Meanwhile, we're working on a new PCB design which includes a USB mini-B (with a brand new FTDI chip, not even available to our customers yet!) and an RF module for PC-based control. Of interest is that everybody who sees these small robots assume they're less expensive to make than their larger counterpart, the Toddler. Actually, as a design gets smaller and more precise the cost of parts increases significantly. Machining isn't the only big expense - cost goes up with small servos, stainless steel hardware, mixed SMT/through-hole·boards, and components on both sides.·The cost of building these is almost twice that of a Toddler. Ouch.
BASIC Stamp 2px chipset
Hitachi HM55B digital compass
Mini blue seven-segment LED
for Penguin ID in group behaviour (or for program number)
Two photoresistors in R/C circuits
Two infrared emitters and a detector for near-field objects
3-pin socket for Ping)))
Speaker within the body, on the back of the battery PCB
CR123 camera batteries for 6V power supply
Pushbutton for reset
The robots are CNC machined from AL6061 and use GWS micro servos. The stride linkage (moves the legs foreward and backward) attached to the servo horn is a broached Delrin rod turned on a lathe. These robots walk very well and precisely compared to their larger counterparts.·They're part of·ongoing R&D·at·Parallax and will now be used to test a·future wireless programming/network interface. There are no formal plans to make them as a product at the·moment. Sincerely, Ken Gracey Parallax, Inc.
2005-05-21 16:43: We could put them into production, but CNC parts are not cheap. I like things to be affordable to our customers and this is not. This would have to be some kind of Parallax collector's edition robot.
2005-05-24 04:34: The programming port is a 4-pin header underneath the battery pack, on the back. There is no DB-9 on this robot becuase it would be as big as the top PCB. Ultimately it will have a USB mini-B connector with an FTDI chip or a wireless programming interface. The other Penguin referenced by pcrobot in which a BS2/BOE is held above the Penguin's head is an earlier prototype. That Penguin never got a brain mounted on his body, so I held it above him as he walked along. By the way, the Penguin walked for about eight hours today in our office. It looks like CR123 batteries can last for a long time, making them more cost effective (in terms of milliamp hours) than AA or AAAs.
2005-09-03 04:11 I'd like to share with you the latest hardware revision on the Penguin robots. The latest design incorporates several design improvements to the mechanics. Improved precision, a new foot design and better integration with the BASIC Stamp system are some of the changes. In this picture you'll see the prior prototype (the clear aluminum one in back with the electronics) along with three new bodies. The parts are either nickel-plated or anodized red, black or blue. These new versions are not wearing any electronics yet. Meanwhile, we're working on a new PCB design which includes a USB mini-B (with a brand new FTDI chip, not even available to our customers yet!) and an RF module for PC-based control. Of interest is that everybody who sees these small robots assume they're less expensive to make than their larger counterpart, the Toddler. Actually, as a design gets smaller and more precise the cost of parts increases significantly. Machining isn't the only big expense - cost goes up with small servos, stainless steel hardware, mixed SMT/through-hole·boards, and components on both sides.·The cost of building these is almost twice that of a Toddler. Ouch.
2005-09-05 15:32 These will be available in November for purchase. We just launched production for the robot bodies and hardware and the electronics are in their last prototype. It's a limited run, too. Only 50 nickel-plated robots, 50 anodized blue and 50 anodized red. No target price yet, but under $250.
2005-10-05 03:43 I'm using aluminum because I can machine it to exact tolerances, it looks good and can be anodized a variety of colors. This is a high-quality "low-volume" desktop robot, so plastic was not considered as a material. Once you get a chance to hold a Penguin you'll see how the aluminum provides the perfect mass of well-balanced material. The update is that the Penguin hardware is in production at a local machine shop. The electronics are in a final prototype and have not gone to production. The new PCB includes an RF receiver for PC control, a USB port for programming, HM55B compass, speaker, infrared, Ping))) socket, 7-segment blue LED, photoresistors and a power switch. We're still aiming for mid-November, but no promises.
2005-10-06 00:33 We'll be selling it somewhere around the cost of materials and assembly. This should be about $250. Okay, we'll probably make fifty bucks. It's a special robot that we are making to provide as a gift to key distributors, but it will also be for sale in limited quantities (don't believe me? You will when we're out of stock :). It will be 100% manufactured in the USA, with the best QA/QC we have available. I consider it an experiment in quality, precision hobby robotics. There is one business benefit of low-volume manufacturing in the USA. Machined parts can be made in low quantities, without tooling. Minimums can be reduced with high-end products. Inventory levels can be much lower. And considering we're currently swimming in a pool of continuous rotation servos this is an important point at Parallax. Now you will want to become a distributor to get a free one.
2005-12-01 17:26 The Penguin is on the cover of Servo Magazine this month.
"Parallax will offer 1,000 limited edition Penguin kits for purchase starting Q1 2006"
2005-12-01 22:56 The small Penguin was made using a Wabeco F1210 CNC desktop mill. I use FlashCut signal generator (Mach2 with Gecko drives is more popular, though) and CAM work was done with OneCNC. I also used a Wabeco D6000 CNC lathe to turn a small part you can't see, which is the stride linkage between the legs. The specific part is 1" long and has a ball on each end which fits within the leg slot so the bottom servo can be used for stride control. Additionally, this part (which is Delrin) was drilled and broached with the shape of the servo spline. To broach it, I made a tool with a sideways-mounted rotary table. Using a small V-cutter, I machined a drill blank rod with 21 cuts to match the servo spline. Then, this tool was used to punch the shape into the Delrin.
The other tools I used include end mills, drills, and lots of coolant. I also used a benchtop sander to clean up any tabs which I left on the aluminum parts from CNC (to avoid making fixtures for the parts). The CNC tools·I used are among the more expensive for desktop machines, but·a Sherline machine could certainly do the same. A Taig mill could also make the parts. In fact, you could make them with a bandsaw and drill if you were careful (especially if you used acrylic). The drawings are posted, so·you're welcome to try to make one.
2005-12-12 01:46 The only part not shown is the 5/8" machined standoff which holds the servos in place. It's nothing more than a 4/40 5/8" long round aluminum standoff with the middle milled flat. Then, tap a 4/40 hole in the middle of the flat spot and this will be used to mount your servo.
2005-12-15 02:57 The servos mount on two 5/8" round standoffs to the 1/8" holes on the Penguin body. The DXFs should provide the exact detail you need, from which you are free to extract dimensions. We're just finalizing the PCB. As this is not a revenue-generating product we've not been in much of a rush. We're only making 1,000 units and you'll never see it again after that. The reasoning is that the product is entirely USA manufactured and machined, so the cost is truly through the roof.
Other comments
A common ACAD output format. See this, which is particularly helpful:
Lots of free tools are available to convert DXFs to something you can read.
Feb. 2006, still waiting for the Penguin robots
https://forums.parallax.com/discussion/83652/penguin-fact-or-fiction
Ken GraceyKen Gracey Posts: 7,295 2006-02-24 06:03 edited 2006-02-24 06:03
Zax- It's for real - I promise! While you've been waiting we've been making some design improvements to Penguin's PCB. Now you have a USB mini-B for programming and a nice socket for RF/Ping additions, not to mention an HM55B compass which is no longer affected by the presence of servo motors. Not being an "official" Parallax product it has to be finished on our free time. In this case, these silly·RoHS requirements (new lead-free rules)·have caused a·delay·so we could make a few PCB updates to other products. And to answer your other question - it's really expensive to make but that won't stop us from making it available for general sale.·There was no value engineering on this product and it's all made in the USA. No release date on the kit, but I saw that the final prototype PCB was sent off today! That means I'll have pre-production units late next week. Ken Gracey Parallax, Inc.
