1. The Art of LEGO Design Jason Geist Original version by Michael Rosenblatt September 10, 2003

2. Sources The Art of LEGO Design, by Fred G. Martin LEGO kit instructions Internet ME! And other TA’s, of course.

3. Goals: Build better robots –Minimize mechanical breakdowns –Build robots that are easy to control –Encourage good design strategy –Strive for elegant, clever solutions

4. Know your Materials Quick facts: –Plastic bricks since 1949 (wooden blocks prior) –On average, 2100 different parts each year –Manufacturing tolerance: 1/1000 of an inch –Number of ways of combining six 8-stud bricks: 102,981,500 –Widely used by scientists and engineers as a rapid prototyping tool

5. Geometry 1-stud brick dimensions: exactly 5/16” x 5/16” x 3/8” (excluding stud height 1/16”), This is the base geometry for all LEGO components Three plates = 1 brick in height

6. Structure Common pitfall when trying to increase mechanical robustness:

7. Structure The right way:

8. Structure The right way:

9. Connector pegs Black pegs are tight-fitting for locking bricks together. Grey pegs turn smoothly in bricks for making a pivot

10. Structure LEGO bricks are finicky: –They HATE duct tape. –They HATE hot glue. –They HATE super glue. –They HATE epoxy. You should never need adhesives to build reliable LEGO structures

11. Help!!!

12. Drivetrain LEGO Gears 8T 16T 24T 40T 24T Crown 1T Worm Bevel

13. Worm Gears Pull one tooth per revolution 1 2 3 4 Result is a 24:1 gearbox Not back driveable!

14. Motors 9V Gear Motor ~ 150 mA 300 RPM (no load)

15. Motors 9V Micro Motor 20-30 RPM Internal two stage orbital gearbox (wow!)

16. Mounting Motors Note Bulge under motor

17. Mounting Motors Add a gear:

18. Mounting Motors Use special 2x1 stud plate with “wing”

19. Build for good control Slow vs. fast? Gear backlash Stability Skidding

20. Wires Take pride in your wires!!! Wire management: use zip ties!!

21. Design Strategy Incremental –Test components parts as you build them Drivetrain Sensors, sensor mounting Structure Don’t be afraid to redesign KISS

22. Design Strategy Drivetrain driven Chassis/structure driven Modular?

23. Testing Don’t wait until you have a final robot to test –Interaction of systems –Work division (work concurrently) Develop test methods Repeatability

24. Philosophy Have fun Be creative, unique Strive for cool solutions, that work! Aesthetics: it’s fun to make beautiful robots!