Robot 2: Ball-on-Beam System

Description

Robot 2 is a center-pivot ball-on-beam dynamic balancing platform, developed specifically as an educational control-systems demonstrator for the Robotics Traveling Van. The system utilizes precision distance sensing to track ball position along the beam, a NEMA 17 stepper motor to provide instantaneous tilt actuation, and a highly tuned PID controller running on a Raspberry Pi Pico to actively stabilize the system.

Mechanically, the platform abandons standard off-center hinges in favor of a custom center-pivot architecture. This vital design choice drastically minimizes rotational inertia, allowing the stepper motor to react to the controller's feedback loop with zero hesitation. To meet the rigorous durability requirements of K-12 classroom environments, the chassis is optimized for small-batch manufacturability (DFM). It features high-tolerance 3D-printed components, heat-set M3 threaded inserts for robust structural rigidity, dedicated protoboard shelving for organized cable management, and protective housings to shield delicate electronics from direct student handling.

Educationally, Robot 2 bridges the gap between complex mathematics and physical reality. It allows K–12 students to interactively adjust the balance setpoint via a touchscreen and watch the system's behavior change in real-time. By observing how the ball moves, corrects, and settles on the beam, students gain an intuitive, hands-on understanding of feedback loops and dynamic stability.