Dash's Big Helper Adventure

Complete Step-by-Step Project Plan for CoBot Prototype PHASE 1: PROJECT DEFINITION & DESIGN (Weeks 1-3) Step 1: Finalize Your Project Scope Based on your budget(~$200-250) and constraints, define EXACTLY what "100% success" means: · Success Criteria 1: Robot A autonomously moves light load (<500g) from Point X to Point Y · Success Criteria 2: Robot A detects heavy load (>500g), stops, and broadcasts help request · Success Criteria 3: Robot B receives request, navigates to Robot A · Success Criteria 4: Robots dock (magnetically/physically) and move heavy load together · Success Criteria 5: Complete task within 3 minutes maximum Step 2: Detailed System Architecture Create these documents before buying ANY components: 1. Block Diagram showing each robot's components 2. Communication Protocol Specification (exact message format) 3. State Machine Diagram for each robot's behavior PHASE 2: COMPONENT SELECTION & PROCUREMENT (Weeks 3-4) Step 3: Final Hardware Selection Based on your constraints,I recommend: Option A (Lower Cost, Easier Programming): · Controller: ESP32 Dual Core ×2 ($10 each) - Use PlatformIO/Arduino IDE · Chassis: 2WD Smart Car Chassis Kit ×2 ($25 each) · Motor Driver: L298N ×2 ($3 each) · Weight Sensor: HX711 + 5kg Load Cell ×2 ($5 each) · Distance: HC-SR04 Ultrasonic ×2 per robot ($3 each) · Line Following: TCRT5000 IR Sensor Array ×2 ($5 each) · Power: 18650 Battery ×2 + Holder ($8 per robot) · Docking: Neodymium Magnets ($5) **Total:~$180** Option B (More Professional, Mesh Capable): · Controller: RAK4631 + RPi Pico ($45 each) for Zephyr RTOS (Same other components) **Total:~$250** Recommendation: Start with Option A (ESP32) - more tutorials, easier debugging. Step 4: Order Components with Contingency Order 20%extra of: · Jumper wires · Voltage regulators · Fasteners · Create a shared spreadsheet tracking delivery dates PHASE 3: HARDWARE ASSEMBLY (Weeks 5-7) Step 5: Sequential Assembly Process Follow this EXACT order to avoid damage: 1. Week 5 - Base Assembly: · Assemble chassis without electronics · Mount motors and wheels · Test mechanical movement manually 2. Week 6 - Power System First: · Install battery holders · Add voltage regulators (5V for sensors, 3.3V for ESP32) · Add power switch · CRITICAL: Test voltages at every connection point 3. Week 7 - Component Integration: Day 1: Mount ESP32 and connect motor drivers only Day 2: Add load cell and test independently Day 3: Add ultrasonic sensors Day 4: Add IR sensors for line following Day 5: Install docking magnets Day 6-7: Cable management and stress testing PHASE 4: SOFTWARE DEVELOPMENT (Weeks 8-12) Step 6: Development Environment Setup · Install PlatformIO VSCode extension · Create separate folders: Robot_A, Robot_B, Shared_Libraries · Set up serial monitoring for debugging Step 7: Modular Code Development (TEST EACH MODULE) Week 8 - Motor Control: ```cpp // Test pattern: Forward 2s, Stop 1s, Backward 2s // Verify: Motors respond correctly, no overheating ``` Week 9 - Sensor Validation: · Load cell: Test with known weights (100g, 500g, 1000g) · Ultrasonic: Test at known distances (10cm, 30cm, 50cm) · IR sensors: Test on black vs white tape Week 10 - Communication Protocol: Use ESP-NOW(simpler than Bluetooth Mesh for prototype): ```cpp // Message structure: struct RobotMessage { uint8_t robotID; uint8_t messageType; // 1=HELP, 2=ACK, 3=POSITION float positionX; float positionY; uint8_t loadWeight; }; ``` Week 11 - Navigation Algorithm: Implement PID-controlled line following: ```cpp // Pseudo-code: error = left_sensor - right_sensor; adjustment = Kp*error + Kd*(error - last_error); left_speed = base_speed - adjustment; right_speed = base_speed + adjustment; ``` Week 12 - Integration & State Machine: ```cpp enum RobotState {IDLE, MOVING, HEAVY_LOAD, REQUESTING_HELP, WAITING_HELP, DOCKING, COOPERATIVE_MOVE}; ``` PHASE 5: TESTING & REFINEMENT (Weeks 13-16) Step 8: Systematic Testing Protocol Create a testing checklist: 1. Individual Robot Tests: · Robot follows line for 5m without deviation · Weight detection accurate within ±20g · Ultrasonic detects obstacles at 15cm · ESP-NOW communication range >10m 2. Communication Tests: · Message delivery success rate >95% · No interference between robots · Help request timeout mechanism (30s) 3. Collaboration Tests: · Docking alignment success rate · Cooperative movement synchronization · Undocking mechanism reliability Step 9: Failure Mode Analysis Prepare solutions for these common failures: · Communication Failure: Implement retry mechanism (3 attempts) · Docking Misalignment: Add IR proximity sensors for fine alignment · Battery Depletion: Implement low-battery warning system · Line Following Errors: Add recover