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Blog Post

Animatronic robot soldier

08 Feb 2018
0 Comment
Vedran Relja
Build Log

I like making robots and animatronic stuff, so whenever something like that comes to my plate, I get really enthusiastic about it. Few months ago, I was commissioned to make an animatronic skeleton of the soldier robot for the museum purposes. And yes, it supposed to be big :)

Animatronic robot 37

I didn’t had much time, so I didn’t take preparation photos as usual. This will be the first time we’ll move fast forward onto the roughly finished thing. The whole construction was cut and welded, and the base was supplied from another workshop.

Animatronic robot soldier

I didn’t get the exact specification for the space between the arm and body, so I designed it to be adjustable for dressing it up in the future.

Animatronic robot soldier

The initial wiring test.

Animatronic robot soldier

The angle of the forearm was also made to be adjustable.

Animatronic robot soldier

Those enclosed massive bearings came in handy because they are actually rose joint-ed, so even more alteration of the figure was possible.

Animatronic robot soldier

For the motors, I used WV wiper ones, and here you can also see the templates for the marking during the fabrication of the motor mounts.

Animatronic robot soldier

Thread cutting process. Multiple holes allow further adjustability.

Animatronic robot soldier

Figuring out where to mount the sensor switch that tells when the arm is extended or retracted.

Animatronic robot soldier

All the parts were zinc plated, to protect them against the rust.

Animatronic robot soldier

The wiring detail – this is a two-speed motor, but I was using only one. Speed, not the motor 😀

Animatronic robot soldier

The next step was the electronics. I mounted the mounting plate to the laser cut and fabricated the frame with rubber shock absorbers, so it can reduce a vibration from machine operating.

Animatronic robot soldier

PWM speed controler for the arm.

Animatronic robot soldier

The final assembly at 0 °C.

Animatronic robot soldier

Using Loctite on all the bolts, so they don’t come loose from the vibrations.

Animatronic robot soldierExplaining the robot his purpose, the meaning of life, and similar stuff.

Animatronic robot soldier

Detail of the arm, there are also two small bearings inside the wrist.

Animatronic robot soldier

Working on the secondary motor that is located in the base.

Animatronic robot soldier

Goga showing off with some cool angles.

Animatronic robot soldier

A PVC pipe was cut to make a protective shield for the mechanism.

Animatronic robot soldier

A finished top part. All except the spear holder that will be done by another workshop.

Animatronic robot soldier

Zinc plated detail of the arm.

Animatronic robot soldier

Ball bearing detail. Also, I used the lubricating nipple thread so I can lock the rose joint in final position.

Animatronic robot soldier

A view from the back, the shoulders are now locked in place.

Animatronic robot soldier

A few more details and close-ups.

Animatronic robot soldierShoulder bearing is also locked in place by a bolt.

Animatronic robot soldier

The bottom mechanism was connected to a spear the same way I would make a knife handle.

Animatronic robot soldier

The whole base was powder coated of course.

Animatronic robot soldier

A connector detail.

Animatronic robot soldier

The base from the back, where you can see the control switches.

Animatronic robot soldier

The part of the build that I’m really proud of is this custom fabricated back panel, and all the wiring for the electronics.

Animatronic robot soldier

There’s a fan for moisture / heat expelling.

Animatronic robot soldier

I left some more wiring and mounting space that will be eventually used to connect it to the Arduino system which will control the whole machine.

Animatronic robot soldier

A detail of the controller.

18

From the front.

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From the back.

19

And here it is in all his glory! The project is still not completely done, it went to another studio for further refinement. Here’s also a video:
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