It's been a while

So, that break was a little longer than I expected.. but don't worry, I'm still working on it.

I kind of got sidetracked on how I was going to fabricate the pieces, I started focusing on building a CNC router.

Now, I'm back to working on WALL-E. I went ahead an ordered some parts for the audio components such as a music shield, amplifier, and speakers. Audio will be stored on a microSD card and played through the music shield via a 3.5mm jack. I have that connected to the amplifier which powers 4 10-12 watt (RMS) speakers. I hooked it up and it doesn't sound too shabby. Until I get my hands on an oscilloscope, I don't want to push the speakers too much to the point it'll blow. The amp seems to be drawing about 200-300mA at the moment which isn't too bad since it's rated for a little above 3A.

As for my 3D model, I'm still working on the legs and the suspension. Once that's completed, I'm going to go back and re-work on the head - optimizing the components for weight, fabrication, construction, and maintenance. This goes the same for all the other components as well.

I'll still be working but my updates will be less of a daily thing and perhaps more of a weekly update.

No New Updates

I am going to take a break for a couple of days. I'll be thinking about this project but I want to give myself some rest before continuing on.

Almost Done With The Hands

I went back and touched up the hands again before I start on the thumb. Once the thumb is done, I'll begin working on his legs, starting with the treads. Since the legs are well documented, it should be easier to model than the other parts. Once that's done, I'll go back to the arms and begin creating the real version with the appropriate movement mechanisms inside. Then, I'll head back to the legs.. and then finally, I'll work on the body.

I still have plenty of work to do but it seems to be going a lot faster than I imagined. When I first started, I thought it was going to take 2-3 years to build WALL-E, but at this rate, I'm hoping that I'll be completed by the end of the year?

It'll take a few more weeks to finish up the 3D model, then I'll have to work on my CNC router. Then I'll have to fabricate my pieces, which will take some time as I optimize each component such that they are able to be fabricated... Then, I'll have to build WALL-E and install all the electronics. Finally, I'll have to work on the software for both WALL-E and for the computer control.

Alright, here's an obligatory render from behind, and that's it for today.

No Updates For Today

I am officially burned out. No updates for today.

Edit: Never mind. I decided to work just a little bit on the hands. I'm just trying to get a general feel of it so there aren't any details.

Arm Update

So, I began working on the arm today.

I decided to change my strategy for designing WALL-E. At first I wanted to design it with the mechanisms in mind, but now I decided to first create a relatively accurate model of WALL-E. Then, I'll go back and try to design the movement. It should be easier since I'll know the amount of space I'll have to work with.

Here's a short 360 view of the model so far:

Edit 2: Added the clevis for the hand. Now it's time for The Walking Dead and then sleep.

No Major Updates Today

Unfortunately, I was busy for most of the day and was still pretty sick. Now I have a cold and a major headache, so I wasn't able to get any modeling today.

I was able to finalize the audio design, component-wise. It will have 4 internal speakers: (1) Front charge panel, (2) Rear side vents, (1) Neck/Body joint opening. It will be powered by a 12V 200W MOSFET amplifier which I just ordered tonight. Frequency-wise, the speakers are capable of 130Hz-20kHz. Because of that, I was thinking of adding a small woofer but price-wise, only a 70Hz woofer was available. I ran a high and low pass filter to see how the audio would sound and it didn't too bad or noticeable. So, unless it sounds really bad when I use the real speakers, I'll just stick to the 4 full range speakers for now.

Basic Body Completed!

I went ahead and finished up the rear body of WALL-E. So, with the exception of the front bumpers, the rear bumper/exhaust vents, and the logos/solar level, I am done with the body shell-wise.

I just realized that the lunchbox hanger is missing so I will finish that up tomorrow. Also, I have not yet checked the dimensions for accuracy yet so it may be off a little bit.

I'm still sick and feeling a little groggy so I'll end it here for tonight.

Quick Body Dimensions Comparison

So here is a comparison between my model and the real WALL-E.

Not too bad. I suppose it could be better but I think that's good enough for now.

Edit: And here's the final update for today:

For the body, I still need to work on the following:

- Rear components

  - Piston/Cylinders

  - Upper panel

  - Main panel

  - Lunchbox Hanger

- Main chassis and support brackets on the inside of the body (eek..)

- Front charge panel electronics

I think that I will just finish the rear compartment and then go on to the arms or the legs. Then I'll work backwards towards the body and how these two components mount to it. Then I'll finish up with the inner chassis.

Considering that I was sick all day with the cold, it was actually a pretty productive day. I have work tomorrow but it's going to be Friday!

Uh Oh

So, I found a little problem with my model. The edge where the lower and upper panels meet on the side has an lip in mine.

I could try and fix it but the only geometry that would fit would be a faceted surface. If I kept this design, I might be able to sand the lip a little bit and hide it with some paint. Hmm... I don't want to continue with the design if I'm going to change this panel because the other pieces won't fit correctly. Decisions, decisions...

In any case, here's the model so far:

Another difficulty I'm having right now with modeling is the front lower right and left bumpers. I'm having trouble due to the fact that there are several components with complex surfaces and angles that the bumpers need to mate to. Obviously I plan on creating these bumpers but I will probably have to use modeling clay and carve it by hand. Then create a urethane mold/cast afterwards. So, even though I didn't model it, it will be there!

Edit: Updated model

Here's an updated view of the model. After looking at some high resolution movie posters, it looks like the rear bumpers house vents. I can do one of two things with this. The first option would be to use these two openings for left and right speakers. I wanted another speaker(s) location besides the front panel for better and louder audio. The second option would be to add fans to cool the electronics inside WALL-E - eventually, I will probably need some sort of cooling option...

Small Body Update

After taking a second look, I had to change a part of the body where his hands are stowed.. I had to increase the depth.

That's about it for now.

Edit: Here is WALL-E with his new front and side panels (without the bumpers).

I'm a little sick right now because of a cold so no more updates for today. Time for some NyQuil and sleep...