1. The Engineering Design Process & Notebook
Competitive robotics requires iterative design documented through an official Engineering Notebook:
- Problem Formulation: Breaking down game manuals and field constraints into verifiable engineering requirements.
- CAD Modeling (Onshape): Modeling the chassis, brackets, and gearboxes in cloud CAD before cutting aluminum extrusion.
- BOM (Bill of Materials): Budget calculations, weight budgets (under 42 lbs for FTC), and spare parts planning.
2. Mechanical Architecture & Drivetrains
Detailed analysis of mobility platforms used in robotics:
Standard Tank Drive (Skid-Steer)
4-wheel or 6-wheel drop-center configurations. Highest tractive force and push power, with predictable odometry slip characteristics.
Mecanum Wheel Drivetrain (Holonomic)
4 rollers angled at 45°. Allows instantaneous lateral strafing (X-Y translation) independent of chassis heading. Requires vector matrix motor mixing.
UltraPlanetary Gearbox Tuning
Cartridge-based planetary gear reductions (3:1, 4:1, 5:1). Students calculate motor stall torque, free speed RPM, and optimal gear ratios to lift arms without stalling or burning motor coils.
3. Control Hardware & Power Distribution
- REV Control Hub: Integrated Android-based computer and motor/servo controller running Qualcomm Snapdragon with built-in 5 GHz Wi-Fi.
- REV Expansion Hub: Daisy-chained via RS-485 to double available motor channels (up to 8 DC motors, 12 servos, and I2C buses).
- Power Distribution: 12V 3000mAh NiMH battery, 20A main breaker, XT30 connectors, and voltage sag compensation during high-torque motor maneuvers.
4. Programming & Autonomous Control
Teaching Java and Blocks programming within the FTC SDK:
- Teleoperated Mode (TeleOp): Mapping dual-analog gamepad joysticks to exponential motor drive curves with deadzones.
- Encoder Odometry & RoadRunner: Using 2048-count optical dead-wheel odometry pods to track robot Cartesian position $(X, Y, heta)$ with millimeter precision.
- Computer Vision (AprilTags & OpenCV): Camera pipeline detecting field target markers to automatically align intake grippers during autonomous periods.