An Insiders Have a look at BattleBots Group HyperShock

Editor’s Notice: The next was initially posted on the brand new Made in 3D community by Kyle Anwar of Group HyperShock. The MAKERS | Made in 3D neighborhood on 3DSwym is your home for all issues making – to attach with fellow makers, share your work, be taught suggestions and methods, and get impressed!


Hey all! We’re Group HyperShock from Discovery’s BattleBots, and we have now a brand new season beginning on January sixth at 8 pm EST. As a part of our relationship with SolidWorks, we’ll be sharing a few of our construct logs right here over the subsequent few months. That is the primary put up in that sequence, protecting the entrance armor mounting schemes we’ve tried, most of which you’ll see had been unsuccessful for one motive or one other.

  • Season 4 – 2019
    • The Season 4 wedge was probably the most profitable front-end we’ve placed on a HyperShock, however it was a nightmare to put in. For Season 3, we’d designed an enormous anti-horizontal wedge, however it weighed nearly 50lbs and we didn’t get the chance to need to determine it out at competitors.
    • The season 4 wedge had 12 pairs of holes for bolts and nuts to be mounted, however I don’t suppose we ever received greater than possibly 9 put in. Seems getting a number of items of AR to align after bending a few of them and all of the welding is kind of tough. A part of the issue was device and hand entry: we needed to float the screws in on the tip of a ratcheting device as a result of it was too tight to get any arms in. Comparable downside with the nuts, however we kinda managed with a little bit of grumbling. The larger problem was after a combat when the bolts had been half-sheared or bent, we needed to grind a few of them out or chisel them aside.
    • When the wedge took harm, the bolts would fail one by one, zippering off one facet, leaving the wedge hanging off the robotic and making driving harder. We had been too bold with the bends too, and the match was preloading the fasteners a lot that they’d typically get broken throughout set up.


[Season 4 wedge, back view]

  • We experimented with utilizing 6 lengthy metal pins as a substitute of 12 bolts at Robotic Rukus that yr and really made the state of affairs a lot worse. The pins had been simply lengthy sufficient that they grazed the bent a part of the wedge stepping into, so we needed to lever them by the primary gap. As soon as we had often simply 4 pins in, we’d bruise our knuckles jamming the cotter pins by the opposite finish. Including extra straw to the camel, the pins weren’t very onerous, so all of them received bent in each match, making it nearly unimaginable to take away the wedge with out reducing/breaking the pins.



[Season 5 front armor mount shown as-installed (highlighted)]

  • For Season 5 we determined to strive mounting the wedge from the entrance and making the mounts common. We designed each our entrance ends (pictured under) to suit the identical method. We had began by designing the system for carriage bolts after deciding that countersinking into only a quarter-inch of fabric can be a mistake. Whereas searching for the hardest carriage bolts in the marketplace, we got here throughout plow bolts, they’re like carriage bolts, however with a countersunk and keyed head quite than a dome. It was interesting to have an answer that didn’t protrude from the wedge; wouldn’t need tombstone or valkyrie to discover a seize level in any case. We had been again to coping with countersunk holes, however the engagement floor was smaller than we’d seen on any conventional flat heads.
  • We designed these delrin mounting blocks with sq. holes to retain the keying options of the plow bolts. We used 6 bolts and nuts one every mounting block and hooked up it to the robotic chassis at a couple of 30 diploma angle to lower the shear drive on the bolts.
  • The design intent was one individual might set up both entrance finish. The wedge was designed such that the mounts could possibly be balanced and pinned with the robotic the wrong way up with the wedge already hooked up. The shields had mounts hooked up on a regular basis and could possibly be swapped out by one individual in beneath 5 minutes. The design ethos for the whole thing of season 5 was centered on turning the robotic round in quarter-hour after the near-disasters season 4 with its two hour drive prepare meeting.



[Season 5 chassis, front iso view]

  • We bumped into issues instantly. S5 was most likely probably the most rushed construct and possibly the least prepared upon arrival. Didn’t assist that the precise robotic confirmed up a day and a half late resulting from transport shenanigans. Once we went to suit the wedge for footage and hero pictures, it was barely over-bent, so solely a few of the holes by the entrance of the wedge truly aligned. The chassis was additionally just a little splayed out, additional interfering with the mounting angles. We borrowed a forged iron sash clamp from Finish Recreation and compelled the chassis into compliance. Managed to get 4 bolts put in per facet and form of faked the opposite two nicely sufficient.



[Season 5 robot]

  • The mounting held up okay for a couple of fights, after which Finish Recreation sheared one off. We weren’t positive if it was the inner sharp corners or simply the large hit we’d taken, not that we had another answer. We additionally didn’t discover till later that they’d bent that facet of the chassis sufficient to raise the entrance wheels off the bottom. We began to see extra cracks within the mounts as we went by fights and concluded the geometry was improper.

[Damaged front armor mount]

  • We hadn’t confronted a big horizontal and thus hadn’t wanted the total wedge but, however we had been within the ICEWave bounty, so we began prepping it and a chassis for it. The highlight-only combat with Sporkinok is once we realized one of many chassis was ruined, however the different had a wedge poorly hooked up, so swapping wasn’t an possibility. Three teammates spent two days solely messing with a chassis (certainly one of 3) to ensure we had a wedge+single disc possibility for ICEWave. For higher or worse, we had been eradicated earlier than that wedge noticed a combat.
  • We found partway by the bounties that neither of the ‘clear’ chassis had been actually that nicely aligned, so the wedge must be floor down flat after putting in it. Wasn’t supposed to be floor scraping, however one edge at all times was anyway.

[Season 5 robot, sideview]

  • Season 6 – 2021
    • We began designing for Season 6 with no particular entrance armor plan. We knew we needed to make one thing floor scraping and wanted to make it considerably adjustable. The frequent theme up till this level had been difficulties with mounting {hardware}; we simply by no means actually thought that half by.
    • We had been speaking to a possible machining sponsor who needed to point out off their potential to make giant, advanced components with plenty of inside options. Appeared fairly good, we love difficult our machinists with “it really works in CAD!” What we appreciated about S5 was the massive module system. The heart of the robotic had been a single detachable unit, good in idea, however required a four-person operation to put in into the robotic. We appreciated that the wedge and weapon system had been additionally unbiased modules that could possibly be prepped 98% on a bench.
    • We began brainstorming this large entrance finish billet so all the weapon and wedge meeting could possibly be labored on individually from the remainder of the chassis. The concept was we might have three or 4 of those able to go and swap a extremely broken entrance finish out and switch the robotic round in half an hour. For higher or worse, that firm determined they didn’t need to commit assets to a sponsorship, forcing us to revise the entrance finish design intent.
    • We determined to take a lot of the options from the mega-billet and simply combine them into the chassis or not less than their mounting. We separated the weapon motors from the remainder of the chassis so that they could possibly be put in with out having to feed something by a slot or in any other case contort our arms contained in the ever-shrinking chassis. We took the strong, box-like entrance corners from the S4 chassis and separated them from the weapon mount.



[Season 6 chassis, shown with top plate, front view]

  • We had come to the conclusion that one of many issues holding us again was how anemic our weapon hits had been, largely since we didn’t have good drive switch from the ground into our opponent. We had been principally attempting to uppercut somebody whereas standing on a trampoline, losing drive mashing our tires into the ground. We’d been attempting to enhance on this since season 3, however hadn’t fairly gotten it proper. Our answer was to have a steady billet from the underside of the weapon shaft to the ground. As soon as we began enjoying with wedge mounting, we determined it must be all one piece. A bit additional alongside, we determined we had to surrender the weapon axle clamp system we’d used for the prior seasons since there wasn’t a fantastic answer for {hardware}. We’d had points yearly with the bolts within the clamp ultimately stripping, so factors towards it there. Round this time we determined to start out calling them the “Billettes” since they had been shrunken variations of what we’d initially deliberate for.



[Season 6 “Billetes” as-installed, front view. Some hardware suppressed]

  • These Billettes solely wanted 8 bolts every to be put in and held the weapon shaft, wedge mounts, and the invertibility horns. Most significantly, we now had a really stable connection between the weapon and the ground.
  • The wedge mounts we selected had been so simple as we might get: 4 large suspension bushings with bolts by them. We took the wedge bracket geometry from season 4 and simplified it to make alignment simpler. The vital distinction this time was having time to weld the wedge up with it put in into the chassis. We additionally benefited from a simplified sub-structure for the wedge, so there have been fewer weldments to go improper. This model didn’t have any adjustable options, so we knew we’d be grinding the wedge to ground-scrape.



[Season 6 wedge, back view]

  • On the final minute, we determined to offer in to the prevailing technique and designed a set of forks. We primarily based them on the considerably efficient arms we had in season 3, however made them a lot beefier. The unique had a 4-part lattice of three/16” AR500, these new forks had been only a single profile in half-inch AR500 held collectively in pairs with thick standoffs. We slotted the highest mounting gap and had been cautious to not overtighten the bolt so that they’d passively ground-scrape. Perhaps it was laziness, however we simply trusted the Billettes to be inflexible sufficient to make use of as a aircraft reference, so we weren’t apprehensive an excessive amount of about how the forks would naturally settle alongside the ground.



[Season 6 forks, some hardware suppressed]

  • The forks and wedge had been held on with nothing greater than bolts and lock nuts. We needed to get just a little intelligent since we forgot to account for the thickness of the washers and the heads interfered with the weapon path. Happily, Hijinx had a lathe and allow us to use it to show down the bolt head, fixing that promptly.
  • One ultimate consideration for the Billettes was how uncovered they had been once we had been operating forks. With the wedge on, they had been just about lined; something getting by that wedge was posing larger issues. We needed to make them considerably thicker than we had beforehand designed the shaft clamps so they may survive some harm if it occurred. We’d shifted the weapon place barely ahead since we didn’t need to rely on chassis geometry to help it anymore, so the edges of the disks had been extra uncovered than ever earlier than.

[Season 6 partially assembled]

BattleBots Season 6 begins airing on January sixth, 2022 on Discovery and Discovery+ within the US and Canada. We want all of the bots and their groups the most effective of luck this season!

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