A New Beginning: The 17th Chapter; Back to the A-Town

Geez, how many times have I made this kind of post on this site? Seems like I change local environs quite often! Thus is the nature of fast-paced, action-packed entrepreneurship and #startupthuglyfe. In 2015, I left my position as an MIT instructor and set up at the Artisan’s Asylum. It’s hard to believe Sadbot is almost 5 years old, but indeed, I built its first version in the fall and winter of 2015, along with the first experiments in what would become Brushless Rage.

Just over a year later, my buddy Adam Bercu (of team Brutus) and I rented a somewhat very derelict old manufacturing building unit north of Boston, finally having a place we could call “The Shop”. From here, Equals Zero Designs went a lot bigger time, and we took on almost a dozen local consulting gigs and contract design/manufacturing jobs. And from there, as things tend to evolve, the “startup” I’ve been hinting at since 2018 or so was formed.

Now, for 2020, I’ve set up in yet another new location:

welcome to the #RobotTrapHouse

Don’t get too excited, I didn’t buy it….yet

The plot twist though? It’s in Atlanta, Georgia! So what’s the deal… did you bring the company with you? Quite the opposite, rather: After two and a half years of co-piloting the ship from its humble inception, I decided I was finally comfortable in leaving Boston for good. Equals Zero did travel with me (as the pile of Ragebridges in the dining room can attest to), and I still retain some equity in the company, so I’m extremely supportive of everyone there helping making it succeed.

charles on startups

Now is the time that I’ll finally reveal what it is I’ve been up to, what with over a dozen posts hinting at Product this and Company that. The company is Kiwi Technologies, the product is a giant-ass drone for agricultural payloads, and I was its founding and early stage CTO.

I have a lot to say about going through the whole motion of doing a venture-backed startup company, and it took some time and separation for me to really be able to put it in words and organized thoughts. The short story is, I wouldn’t hesitate to do it all over again, and I enjoyed greatly the “wild west” days of chasing the business case while also moving rapidly with a demoable, potentially saleable product from concept to testing. I could probably write a whole book, much less a blog post, on How to Your First Startup at this point. I do believe we did as many things “right” as possible, because both Adam and I had extensive experience working with, working for, or advising startups in Boston that ultimately crashed and burned.

There’s often a distinction in startup-world between a founding CTO and an operating or growth CTO. The first one is often a founder or co-founder and has to pull together many domains of knowledge in order to quickly advance product development. That, I felt, was where I shined the most. It was where I felt able to provide both the most value in terms of personal contributions, and (more importantly) to help organize and direct engineers’ efforts. But as the company’s needs grew from R&D and prototyping into becoming a more deployment and sales-centric organization, I definitely felt like my usefulness began to wane, as my interests were no longer aligned with the goals and needs of the company. That’s alright – this is why you hire good people, after all. We combed through our network hard, spearfishing for the people we thought would make for the best leaders in certain segments of the company, and eventually hired enough folks that could do my job(s) far better than I could – an actual electronics engineer, an actual software engineer with extensive firmware and controls experience, etc.

While I don’t like tooting my own horn (beep), I like to think that one of my personal traits that helped the company along is that I don’t really have an egotistical stake in anything. I don’t need to have my name be first anywhere, or be known as a revolutionary god-king or even feel the need to take credit for every accomplishment if we all contributed hard work to it. It meant, above all else, knowing when to stop, and that I think is something that a lot of engineers and inventor types have trouble with. In a way, this is also me admitting that I’ll never be an Elon Musk or Jeff Bezos kind of figure. But hey, you live and you learn more about yourself when challenged with things way outside of your usual modus operandi.

So we discussed my resignation and replacement in the middle of July 2019, and my last actions at the company took place more or less right after my Dragon Con trip – 30haul was the last thing I made in our shop, then we agreed that I would recuse myself from visiting or being around the company daily so as to help keep the leadership transition clean. After November, I would only visit to pack up and move out!

so what the hell did you build, anyway?

Without divulging too many insider details, the early days of “the company” in 2017 was still more of an Equals Zero side project. There was a lot of experimentation in trying to create a low-cost, high-thrust/high efficiency propeller pod using commercial, off the shelf (COTS) and especially hobby-grade parts, without just spamming outrunners and small props. We were, back then, intent on taking on the many Silicon Valley based aerial taxi/personal VTOL companies, places I called (openly, to our potential investors, maybe to the chagrin of everyone else) “Daddy’s Money Companies” referring to Larry Page bankrolling a lot of them.

As we prowled the network, agricultural application (“crop dusting”) entered the realm of possibilities and quickly revealed itself to be an industry worthy of transformation. Conceptual work solidified in 2018 with a first flying prototype (still looking kind of like a personal rideable VTOL, since we already designed that), and in 2019 with the first customer-targeted prototype using much bigger gear. The object seen on the website today is another iteration based on customer’s needs and feedback.

Again, maybe in due time, one day, I’ll go back through my photos and make some “build reports”. But as one of the biggest lessons I learned while part of this grand experiment was some times you have to shut up about what you’re doing in order to preserve its value to others, I’ll simply present one photo of what I was most proud of:

That there is an eight hundred pound all-electric quadcopter with a 120kW powertrain. The tank on top is a 50 gallon agricultural spray tank. All I can say is, I have a lot of personal business in this realm that’s unfinished, and one day I hope to revisit it.

anyways, back to the #RobotTrapHouse

The observant will notice that I had a post gap in the middle of the Vantruck restoration this summer, between late July and late September. That was largely attributable to me hustling the project along while making sure the loose ends were getting tied off at the shop, while making transition documentation. Then there was a gap until late November – during this time, I made a van trip to Atlanta to scout out housing and interview in-person at a few job candidates.

I was real excited to find this place in particular because it’s very close to a massive shopping center/retail area in an inner suburb, not out in McMansionland like what is very easy to get in Atlanta otherwise. It’s an older 3 bedroom, 2 bathroom house with a half-basement in the “split level” style, with a detached (!) 25 foot square, 2-car sized garage building in the back yard. It stood out so much against other housing candidates that, after visiting, I decided to open loop move: that I will capture it first, job offers be damned, because I could always try and run a consulting gig from the workshop!

So I actually laid out quite a bit of cash here – as I wasn’t employed at the time, I negotiated with the owner to pay up front the first 3 months. I figure if I couldn’t find employment or start something by then, it was never meant to be.

The move itself was held in 2 stages starting December 15th. First, I (with the help of many) packed up all of my mountains of robot junk and life needs (one vastly outweighing and outsizing the other…. guess which) and re-enacted this very common scene:

Then after puking everything inside and pretending to live like a human being for a few days, I flew back to Boston to retrieve my white elephant, which held some other less critical life goodies. This ended about as well as you’d expect:

So how on earth did you make it all the way to Dragon Con and back? Whatever.

I got close enough (mid-Virginia on I-81) that a friend and I were able to chain AAA tow benefits to drop it off in my driveway (!!!) where it can hang out unmolested. I’ll deal with YOU later.

Anyways, I spent the first couple of weeks getting a handle on the new environment and new job & coworkers, working on finishing Overhaul 3’s design (you know what’s coming next!) and most importantly…

Building up the future home of Overhaul and friends. I constructed a few workbenches and a 4 x 8 foot rolling worktable and ordered more shelves, as well as some other toys:

This time, I pledged to not buy anything that weighed several thousand pounds which could not also move itself. While this opens the floor up to more vans, it meant I was going to keep my machinery small. I haven’t had a personal tinylathe since the MIT IDC days, and since then the market structure has changed significantly. There’s a ton more options now! What you see here is an “8×16” model, basically the 7 inch lathe with a 1 inch spacer on everything. I was fine with this since it gave me the additional diameter I would need to turn even some Overhaul-sized parts. This machine is worth a Beyond Unboxing post as a tour – one of many back-posts I need to make now that life has finally collapsed its wavefunctions and I feel some sense of normalcy™.

Wait! Did I say “more vans”? Because this is how you get more vans:

 

Yup. This is how you know I’ve finally snapped: I bought a Real People Car.

Ladies and gentlemen, welcome the current-events-relevant-named #Coronavan to Big Chuck’s Auto Body.

After starting my new job in January, I now have a Real People Commute – it’s 20 miles one way, which isn’t bad by Atlantese standards, but is much more than the 4-5 miles daily of life back in the denser inner suburbs of Boston. After Mikuvan crested 250,000 miles one day coming home….

…and after Vantruck got rear-ended a second time coming back from the local monthly car show, this time a hit-and-run…

…I decided that once and for all that having my meme fleet serve daily duty, especially a rare and unusual thing like Mikuvan for which parts are not readily available, was just too much risk. That was a crash which would have likely totaled out Mikuvan. Granted, I barely felt it and thought I hit a pothole or speed bump I didn’t see.

(Seriously, how do people miss the wall of Miku slowing down in front of them? I watched the guy pull an illegal turn and drive away with his front bumper hanging off, so I hope I got at least his radiator or something!)

Anyhow, I’ve been “meaning to” get a Real People Car as a next step, but figured it would be after a few months of Trial Edition on my new life. That schedule got advanced, and I decided to keep it pain-free and go for the Amazon Prime car buying experience of using Carvana, after being recommended it by a few friends. I can definitely vouch for the painlessness of the process. Maybe I could have saved a thousand dollars or two by playing hardball with local dealers, but I was in no mood to (with Overhaul’s build going full-speed at the time), and figured if I can’t earn a few thousand dollars equivalent over a few years, again, maybe something wasn’t meant to be.

I decided that any Charles RPC I got had to replicate Mikuvan’s functions as much as possible. I was leaning towards a reasonably sized truck, like a Nissan Frontier or similar. But really after hashing out the things I regularly tote around, keeping it #vanlyfe made far more sense. I also have rented enough Grand Caravans to know that Stow-n-Go seating is a blessing from the automotive gods – in under 2 minutes I can convert #coronavan from 7-seater to a long-bed compact truck.  So here I am, having gone from rad to dad.

Anyhow, that’s the story of my life for the past 5 or so months – which is pretty insane to think about how much has changed since November. I even have trouble grasping it really today, and think it’ll take a lot longer to fully sink in.

where to go from here?

Honestly? I don’t really know!

It is truly a strange feeling now that it’s “happened” and I’m no longer in Boston and nearby MIT. I have plenty of friends and a reasonable network here in the area from high school and from friends that went to Georgia Tech. Atlanta isn’t a startup hub (yet) like the Northeast tech corridor or Silicon Valley, but it does have a healthy maker scene and several smaller startup and tech incubators, a few of which I’ve gotten to know during the course of my networking and introductions back in October.

I currently work at the Georgia Tech Research Institute, basically GT’s Lincoln Labs, in the UAV division working with several different projects. They are all well summed up by “Putting fancy hats on drones”.

Everything’s changed so much that I’ll probably take at least this couple of months to just level out and work on little things, maybe get back to my electronics side. I’d like to leverage having #Coronavan now to take Mikuvan offline for longer periods of time and address issues here and there that have gone neglected. Maybe even do its Vantruck-esque exterior restoration this coming summer or fall.

In the mean time, for all of you, brace for incoming Overhaul 3 content!

Robot Ruckus at Orlando Maker Faire: How to Somewhat Scale-Model Test Your BattleBots

Hello everyone. Here’s a photo of Überclocker 5 experiencing Waffle House for the first time, alongside Earl of Bale Spear team, who makes a better “BIG CHUCK” figure than I ever will.

Let that image never fade from the collective knowledge of mankind.

Anyways, as Robot Ruckus approached, I had to figure out how to get my bots all the way to Florida. Taking a week or so to drive there and back was kind of out of my realm of possibility at the time, so I decided to run a little bit of a relay race with the HUGE team.  They’re in Connecticut , which is either a suburb of New York or Boston depending on who you talk to.

I delivered Sadbot, Clocker, a tote of spare parts, and a toolbox to them one fine Sunday afternoon. They were then going to drive everything – Huge included to Earl in New Jersey (if you recall, Earl also brought Overhaul to Battlebots in 2018!) upon which he will travel to Florida. So after the delivery, I had plenty of time to do Other Stuff before flying down to Orlando.

Upon my arrival, I obviously had to grab a rental car. I figured that I’d get the shittiest econobox possible since I wasn’t going many places, just to the event and a hotel room. Well, when I got the reservation and headed over to the rental car garage, it turns out the company was out of shitty econoboxes.

So what now, do I get a free bicycle instead? Nope. Free upgrade time! The garage handlers throw me a key fob which I assume was to the small dorky crossover nearby.

Nope, behind that:

Thanks, I hate it.

Let me be very clear: I’ve forgotten how to drive. No, not in general, but remember what I’m mentally calibrated and trained to for years: Being high up and on top of the front axle, and having a very short or nonexistent hood.  THIS WAS NEITHER. You cannot see out of these. Not out the sides, not out the back, and barely out the front.  I guess that’s the trade for prioritizing looking cool and edgy. For yours truly, stepping into any modern car requires some zen and meditation, and a constant reminder that I now have a front.

I am always terrified of automatically failing over into “van mode” while driving anything rental, and going full Unintended Acceleration into a store or dumpster or fire hydrant as I try to park 1 foot away from something.

How fast does it go? Greater than Van. I dunno man, I don’t have a good sense for How To Fast. My friends who work at GM (who had to listen to me complain about it in real-time) said it likely has the rental-car spec turbocharged 4-cylinder Ecotec engine, which may explain why I was experience what I swore was turbo lag, but more likely might be several inter-related drive feel variables like any economy modes it was stuck in.

2019 Chevrolet Camaro: Faster than a 1986 Ford Econoline.

 

Also, this interior panel fell off while I was heading back from the event at one point. It snapped back in, of course, but seriously?

The trip from the airport to my hotel was made in complete darkness, in the rain. Great. So I’m sitting 2 inches off the floor behind 8 feet of snout, unable to see anything, trying to figure out why every new car is a forsaken spaceship simulator inside, and mingling with other equally lost tourists trying to figure out their own rental cars on the fly. Through several construction zones, to boot. I guess I’m glad I went ahead and got the full-plausible-deniability add-on.

When I arrived at the event the next morning, I found Uberclocker like this.

 

Aaaaaaaaaaaaaawwwwwwwwwwwww. Earl took it in a South of the Border restaurant apparently, and they had these convenient accessories available.

 

I unloaded totes and began setting the bots and infrastructure up for safety inspections.

Sadbot

Sadbot was up first against the multibot Crash and Burn, built by Fingertech Robotics (incidentally, a Ragebridge dealer!) and which has done very well at Robogames events. They were running in kind of a reduced functionality state for this event, so it was more or less a pushing match. Sadbot is obviously a great shape to get pushed around, so it went about as expected with the exception of me getting a few good shoves in. At one point, I took a huge gouge out of the railroad tie side bumpers with the log splitter tip. It definitely did its job.

In the first 30 seconds of the match, the lifter controller popped. Uh oh!

 

It was a pre-production 12-FET brushless Rage board that I pulled out of a bucket labeled “SAD RAGEBRIDGES” and wired up. I probably deserved this.

It would appear I neglected to solder some of the pins on the MOSFET packge. Quality control! That probably popped as soon as it saw any heavy load. I replaced it with a “production model” I brought along in the pile of Equals Zero wares.

What’s more important, though, was the powertrain holding up great for that entire match of me running around and into things. The C80/100 drive motors were lukewarm, and so was the aluminum heat spreader plate in the electronics deck. And even better? I loved driving the damn thing. I mean, saying it handled like Overhaul 1 would be cheeky. Obviously from the video, I took a while to get re-engaged with bot dynamics. But afterwards, it felt like driving a big 30lber, which is my desired effect. Big wheels and conservative gearing seems to be holding up so far.

Sadbot’s next match wasn’t going to be until Sunday at this point, so I decided to take the opportunity to go to Home Depot and grab some….

…masking tape, a big wire brush, and some spraypaint.

This thing has always needed a paint job, and I wanted to paint the frame pastel purple to match the Miku blue and pink attachment aesthetics. Well what better time than now? It was a bright and only somewhat windy day outside and around 70-something degrees. I brushed off the accumulated rust and grunge on the outside and had at it. Paint+Primer, you say? I dare you.

So there you have it. Sadbot will be purple from now on.

My next match was against the other multibot, Macaroni and Cheese. The matchups are “DETERMINED RANDOMLY”, or so I am told. Maybe the random quantum computer just really likes seeing multibots get thrown around.

I went a little more hard-headed in this match with the added confidence of the previous fight, more actively chasing as well as trying to back off from engagements. I stayed to a “I weigh more than thee” strategy instead of trying to capture with the pokey dingle, and managed to drive both halves in the wall a good few times, including propping them both up by the end.

One of these power charges had the unfortunate side effect of making Sadbot somewhat droopy.

Ah well. This match was a much more aggressive one from the stick perspective. I purposefully drove like the maniac I should be driving like, to see if I could get anything to upset itself. The motors got warmer, but not concerningly warm, and I unfortunately neglected to take a controller temperature.

I asked Earl to use Farmer Force™ to straighten out the pokey dingle a little – the upside of it being slightly bent was it at least touched the floor.

 

Sadbot’s final matchup was against Kraken, the actual BattleBots entry. This was finally a chance to drive a match against an opponent of equal weight, and what an intense driving match it was – I went full hard as if it the Giant Nut depended on it. This thing also perfectly fit in Kraken’s trap, as I found out. I kept the pokey dingle at a height to engage Kraken “in the jaws”, and did it once and drove it into the corner. However, once we recovered, Kraken got a better bite on the lid, which led to…

Oops. That’s the outrunner’s wires getting squashed into the rotor. One of the downsides of using external rotor’d motors is you have to pay a lot of attention to where your wires are going. It would have been better to make this a side-exit mounting instead of top-exit. Overhaul, if I keep this drive setup, will definitely have an external shield over the rotor to prevent this.

The wires took a little while to get chewed through, during which it was shooting sparks out the side of the bot which I thought was the controller exploding. I lost this side of drive around 75% of the way through the match, so had to play defense and pivot to keep facing Kraken. Anyhow, I couldn’t find any explosion signs on that Brushless Rage, but I also didn’t feel like repairing this at the event after the Heavyweight bracket ran out of time – originally, each bot was supposed to get 4 matchups, but only we had three in the end. This will be a forensic investigation for later!

Überclocker

Clocker got off to a …. great? Memeful? start by fighting “Marty”.

I’m going to let the video explain itself. Well, I found out it’s definitely front heavy, but it’s also compounded by the fact that Marty is enormous. I also found out this match that Clocker gets stuck on the floors very easily here – they’re plate steel laid on wood foundation, and definitely were shifting around as the event wore on. That’s one of the foils to having a super low wedge in BattleBots – the arena floor will only get shittier, and you’ll definitely regret missing your charges. It’s a tradeoff – possibly get stuck or bounce off a seam, but have weight on the ground.

After I parked the bot at the end of the match, I noticed when picking it up that the lifter was actually seized. What on earth?

It would seem that I #HardParked it maybe a little too much, and the P61 bent in half.

Uh oh. This is maybe an engineering oversight, but the failure mode is also a little infuriating. See, the P6x series shafts neck down to 10mm no matter what diameter you order them as, to pass through the bearings which are of limited size to support the mounting hole pattern. They’re also made of stainless steel.

 

This last part I don’t really get, but basically the shafts are rather soft. So once the preload on the screws is overcome, the whole thing will buckle. Maybe I should have secured them with a 2nd plane or backup plate of some sort. Or maybe I should have used a face-mount technique instead so there’s no “gear climbing” force. Or maybe…

Okay, whatever. I didn’t need the full torque that the 45:1 ratio was going to give – I more did it for a limited lifter speed, but I suppose that’s why I took the care of engineering clutches into Overhaul, and Clockers Past, so it didn’t consume itself.

That’s why you might have noticed the bot split in two for service during Sadbot’s segment. I managed to get a P60 from another team that was the 16:1, two stage ratio, so I had to fiddle it into the bot. This involved cutting the height spacer down in length because the mounting pattern changed. Luckily, I anticipated something dumb like this happening, and the bottom rail has both the 2:1 and 3:1 pattern.

The only downside of going 16:1 is the lifter will be almost hammer-speed. But this could be entertaining in its own right!

Clocker’s next fight was against Ascend, a very powerful 30lb pneumatic flipper. This was going to be a durability test!

It was hard to get under using conventional means, so I mostly had to drive around it and hope to catch it vulnerable post-flip. I also spent an infuriating amount of time trying to get out of a floor seam.  Clocker went flying several times in the fight, which was the shakedown test I wanted.

Near the end, it got stuck upside down because the retaining bolt for the lift axle on the left (gear) side actually backed out and fell out somewhere!  So the gear just skipped as I tried to put it back upright. I managed to get one good grab-and-lift and a couple of other pushes, but didn’t prevail in the decision.

What was cool was I actually got a wheel nibbled off from a direct flipper shot in the first 30 seconds, then drove the entire rest of the match on 3 wheels. Just fine.

This was very exciting. To me, this means if I can keep the chain and inner hubs on, I can treat the wheels very disposably. Not that I’d do it as an explicit tactic, but as get out of jail cards if the situation forced it.

In Overhaul, I’d likely keep the inner wheel tightly retained while the outers are left to float on plastic/shear-rated hardware. I have a few ideas of how to do this for Clocker itself come Motorama.

Another downside of just coupling your actuator to the bot lazily: When your actuator suddenly has 3 times the power, it’s gonna start consuming itself! Remember I put a 42mm brushless on the leadscrew drive instead of the usual 500-class drill motor.  Overhaul has a dedicated trunnion on the lift hub, this is just me not wanting to bother redesigning everything after the lift gear to use a 30lb-scaled one.

The lift motor didn’t blow itself up this time, and in a way I found the lessened torque to be more tolerable. I still clearly had grab and lift ability, but now with the weight of the bot having more leverage against the motor, I noticed I could “trim” the bot better in that match. I’d stick-down just a bit, and gradually the thing finds its self-levelling point. I could then periodically stick-down to refresh it, in a way.

All patched up after wheel service.

Clocker’s 3rd and last fight was against BEEESS???!! (You must only say its name with the upward questioning inflection). I found it hard to get a grab on with his defensive tines sticking out everywhere, so this match was just a lot of driving practice.

And that’s it. Sadbot came away 1/2, and Clocker ended up 2/1! After the event was packed up, I sent the bots back up north with Earl and picked them up from Connecticut again the week after.

Well, not before getting up to some shenanigans in the dark behind the building.

Sadbot, being “Extremely robot shaped” as we termed it, was used as a test dummy by a few teams with lifters/grabbers. Here is a future possible BattleBots entry, Claw Viper, tuning lift motor settings using Sadbot as a dead weight.

The Real Giant Nut was the Lessons We Learned Along The Way

So I’ll do a  more in-depth discussion of the implications for Overhaul separately as its own design series. But here were my two biggest takeaways from this event:

  • If I can make the equation “Overhaul 3 drives like Sadbot drives like Overhaul 1” work, then I feel far more confident bringing sexy back in the arena. I’m satisfied with this powertrain setup, consisting of the single 80mm brushless motor on a Brushless Rage, geared conservatively for about 13mph, and back riding on big blobby wheels.  What I’d probably do is use this as an initial design path, but have a failover ESC solution (VESC controllers have grown up a lot in the past 2 years) as well as a failover brush DC solution. I have some candidates in mind for the latter which I tested over these few months and think are a good idea. More on that later!
  • Clocker was a great architectural test beyond what I intended to accomplish. I definitely wasn’t counting on losing a wheel here! The bot was vastly easier to maintain, even replacing the lift gearbox with a different ratio. I now know that the frame should get longer to better grab and lift – part of the issues stemmed from having to move the front wheels so far back. The small poker wedge legs worked out reasonably, but I’d probably want to make several kinds because of the arena floor. There’s only minor changes and mods I want to make before Motorama. For one, it needs to test the DETHPLOW architecture for Overhaul, and maybe implement my 2-stage breakaway wheels.

One thing to note about Clocker is that I should have dropped the Angerbox clamp drive system to a single stage. I’ve basically done away with the requirement that either Clocker or Overhaul can crush stuff. The clamp should therefore be fast to close, something it wasn’t really at this event. Clocker and Overhaul will likely run single-stage gearing into their clamps for future events.

Between these two major differential tests, I think I have a good handle on what Overhaul 3 has to be.

Namely, it should be Sadbot, but with a grabber and lif….. wait a minute. #holup I swear I’ve built this bot before.