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BUILD JOURNAL: PROJECT REBUILT

"Every artifact we uncover holds a story."

MISSION ARCHIVE​

Season: FIRST AGE Operation: REBUILT Objective: Score Fuel. Cross Obstacles. Climb the Tower. Source Material: 2026 Game Manual, 2026 Team Update 00

KICKOFF UPDATE (Game Manual v0)​

  • Fuel: 5.91 in foam balls; unlimited control after start.
  • Timing: 0:20 AUTO -> 3 s scoring buffer -> 2:20 TELEOP (0:10 transition, four 0:25 SHIFTS alternating hub states, 0:30 endgame).
  • Hub status: winner of AUTO goes inactive in SHIFT 1; hubs alternate inactive/active until END GAME (both active). Fuel in inactive hub = 0.
  • Scoring: Fuel in active hub = 1 pt (auto/tele). Level 1 climb 15 pts in AUTO (table lists 10 pts TELEOP but 6.5.2 restricts to AUTO; watch for clarifications), Level 2 = 20, Level 3 = 30. Fuel counts up to 3 s after hub deactivates.
  • Bonus RP thresholds: Energized 100 fuel, Supercharged 360 fuel, Traversal 50 tower pts (thresholds may rise at DCMP/Champs).
  • Tower geometry: rungs at 27/45/63 in, 18 in spacing; only contact rungs/uprights/wall/support/fuel/other robots.
  • Evergreen updates: bumper gap allowed; crosslinked PE foam ok; Thrifty Bot Pulsar 775 added; several legacy motor controllers removed; new PD/radio power rules (no VRM/RPM on VH-109); re-weigh before playoffs; load-in limit 6; consent required for recording interactions.

ROADMAP​

WEEK 0: EXCAVATION & STRATEGY​

Lead: Strategy Team | Duration: Jan 11-17
Status: In Progress

Game Analysis​

  • Game Manual Review (Mech Lead + Strategy)
    • Score Fuel mechanisms and point values
    • Obstacle requirements and penalties
    • Tower climb specifications & scoring
    • Robot size/weight constraints (document in CONSTRAINTS.md)
  • Strategy Meeting (All teams)
    • Define priority order: Climb > Mobility > Scoring
    • Identify must-have vs. nice-to-have features
    • Create subsystem requirement matrix

Subsystem Planning​

  • Drivetrain (Drivetrain Lead)
    • Tank vs. Swerve decision matrix
    • Gearbox ratio calculations for obstacle traversal
    • Wheel selection (traction requirements)
  • Intake (Mech Lead)
    • Fuel geometry and flow analysis
    • Motor/gear requirements
    • Cardboard prototype sketch
  • Climber (Mech Lead)
    • Torque calculation for tower climb (125+ lbs load)
    • Mechanical advantage options (pulley, gear, rack-pinion)
    • Safety mechanisms
  • Vision (Software Lead)
    • Target tracking strategy
    • Camera placement requirements
  • Electronics (Electrical Lead)
    • Motor inventory check
    • Sensor requirements by subsystem
    • PDH/PDP power distribution plan
    • CAN bus ID allocation

Repository Setup​

  • Code Base (Software Lead)
    • Initialize WPILib project
    • Create subsystem structure (Drivetrain, Intake, Climber, Vision, Shooter)
    • Set up CI/CD pipeline (linting, build checks)
    • Create autonomous path tracking system

Deliverables: Strategy document, CAD skeleton, code repo ready

WEEK 1: BLUEPRINTING & DESIGN​

Lead: Mechanical Lead | Duration: Jan 18-24
Status: Not Started

Mechanical Design​

  • Drivetrain CAD (CAD Team)
    • Frame rail geometry finalized
    • Gearbox mounting points
    • Wheel base and track width dimensions
    • DELIVERABLE: DXF files for cutting
  • Intake Mechanism (Mech Team)
    • CAD model of Fuel path
    • Motor/roller specifications
    • Pivot point calculations (if articulated)
    • PROTOTYPE: Cardboard mockup built and tested
  • Climber Assembly (Mech Team)
    • CAD with force diagrams
    • Material selection (aluminum vs. steel)
    • Hook/attachment point design
    • Mechanical advantage calculations verified
  • Shooter/Scorer (Mech Team)
    • Launch velocity requirements (from game analysis)
    • Angle/trajectory analysis
    • CAD of shooter hood/flywheel

Electrical Design​

  • Wiring Diagram (Electrical Lead)
    • Motor allocation to PWM/CAN ports
    • Sensor connections (encoders, potentiometers, vision)
    • Power distribution layout
  • Electronics Enclosure Layout (Electrical)
    • PDP/PDH placement
    • Battery position
    • Airflow requirements

Software Foundation​

  • Subsystem Classes (All Programmers)
    • DrivetrainSubsystem skeleton
    • IntakeSubsystem skeleton
    • ClimberSubsystem skeleton
    • ShooterSubsystem skeleton
    • VisionSubsystem skeleton
  • Command Structure (Programmers)
    • Command templates for each subsystem
    • Basic drive command (Tank or Arcade)
    • Teleop structure

Deliverables: All CAD files, electrical schematics, code framework complete

WEEK 2: PROTOTYPING & VALIDATION​

Lead: Mechanical Lead | Duration: Jan 25-31
Status: Not Started

Mechanical Testing​

  • Drivetrain Prototype (Drivetrain Team)
    • Frame rails cut and welded
    • Gearbox installed and tested for free spin
    • Wheels mounted
    • TEST: Drive in straight line, verify no binding
  • Intake Testing (Intake Team)
    • Prototype built (wood/polycarbonate)
    • Roller speed tested (RPM verification)
    • Fuel flow smoothness tested
    • TEST: Feed 10 Fuel pieces in succession, measure success rate
    • Adjust geometry if needed
  • Climber Prototype (Climber Team)
    • Build first climbing mechanism
    • Load test with weight bag (125+ lbs)
    • Measure extension/retraction speed
    • TEST: Climb mock tower 5 times consecutively
    • Verify safety stops function
  • Shooter/Scorer Prototype (Shooter Team)
    • Build flywheel/launching mechanism
    • Test launch velocity with radar gun
    • Determine optimal angle through testing
    • TEST: Score 10 Fuel at goal, measure success rate & consistency

Electronics Assembly​

  • Power Distribution (Electrical)
    • PDP/PDH installed and wired
    • Battery connectors crimped and labeled
    • Breakers/fuses in place
    • TEST: Verify 12V output on all rails
  • Motor Controllers (Electrical)
    • Spark MAX/Victor SPX controllers mounted
    • Configured with proper CAN IDs
    • Firmware updated
    • TEST: Each motor spins independently via code command
  • Sensor Integration (Electrical & Software)
    • Encoders wired to each motor
    • Potentiometers for arm position feedback
    • Camera/vision system mounted
    • TEST: Read encoder/sensor values in code, verify accuracy

Software Development​

  • Drivetrain Code (Programmers)
    • Tank/Swerve drive implementation
    • Encoder feedback integration
    • TEST: Drive robot 10 feet, verify distance accuracy (±6 inches)
  • Subsystem Commands (Programmers)
    • Intake spin up/down commands
    • Climber extend/retract commands
    • Shooter fire command
    • Vision targeting command (basic)
    • TEST: Each command executes without errors
  • Telemetry/Debugging (Programmers)
    • Dashboard displays motor voltages, temperatures
    • Real-time encoder/sensor value display
    • CAN bus monitor for device health

Deliverables: All mechanical systems built & tested, electronics powered & responsive, basic commands functional

Success Criteria:
✓ Robot drives in straight line
✓ All subsystems respond to controller input
✓ At least 50% success rate on prototype tests

WEEK 3: INTEGRATION & TUNING​

Lead: Mechanical Lead | Duration: Feb 1-7
Status: Not Started

Mechanical Integration​

  • Chassis Assembly (Full Mech Team)
    • Attach drivetrain to frame
    • Mount intake assembly
    • Mount climber mechanism
    • Mount shooter
    • Verify no interference between subsystems
  • Weight & Balance (Mech Lead)
    • Weigh each subsystem
    • Verify total weight < 125 lbs
    • Check center of gravity for stability
    • DOCUMENT: Subsystem weight breakdown
  • Cable & Pneumatic Routing (Electrical & Mech)
    • Route all power cables with proper gauge
    • Organize with cable ties (no rubbing)
    • Pneumatic lines (if applicable) secured
    • Verify no strain on connectors

PID Tuning​

  • Drivetrain Tuning (Programmers + Driver)
    • Tune wheel slip compensation
    • Test straight-line driving (±2 degrees)
    • Test turning radius at various speeds
    • DELIVERABLE: Final PID constants documented
  • Subsystem Tuning (Programmers)
    • Intake speed optimization (balance speed vs. consistency)
    • Climber speed tuning (smooth extension/retraction)
    • Shooter RPM tuning for consistent launch velocity
    • Vision tracking smoothness

Autonomous Baseline​

  • Path Planning (Programmers + Strategy)
    • Map obstacles on field
    • Plan Path A: Cross obstacle -> Score pre-load
    • Plan Path B: Score -> Mobility bonus
    • Generate path trajectories in code
  • Vision-Based Targeting (Vision Programmer)
    • Implement goal detection algorithm
    • Test tracking at various distances
    • Auto-aim functionality
  • Auto Routines (Programmers)
    • Implement Path A (cross obstacle, score)
    • Implement Path B (score, exit zone)
    • Test both paths 10 times each
    • SUCCESS CRITERIA: 80%+ success rate per path

Driver Training Begins​

  • Control Scheme (Drivers + Programmers)
    • Finalize button mapping
    • Test dead zones and sensitivity
    • Practice with team on mockup obstacles
  • Practice Sessions (Drivers)
    • 2×/week practice minimum
    • Record video for analysis

Deliverables: Robot fully integrated, subsystems tuned, 2 autonomous paths tested

Success Criteria:
✓ Robot weight < 125 lbs
✓ Straight-line driving ±2 degrees
✓ All subsystems respond smoothly
✓ 80%+ autonomous success rate

WEEK 4: OPTIMIZATION & RELIABILITY​

Lead: Mechanical Lead | Duration: Feb 8-14
Status: Not Started

Mechanical Optimization​

  • Stress Testing (Full Team)
    • Run robot continuously for 30 minutes
    • Monitor for overheating, loose fasteners, hydraulic leaks
    • Check wear on critical components
    • FIX: Replace or reinforce any failing parts
  • Cycle Time Optimization (Mech Team)
    • Time Intake -> Score -> Repeat cycle
    • Identify bottlenecks
    • Modify geometry to reduce cycle time by 10%+
    • TARGET: Sub-5 second scoring cycle
  • Intake & Shooter Consistency (Shooter Team)
    • Test 50 Fuel pieces through intake -> shooter
    • Record success rate, launch consistency
    • Adjust geometry for minimum bounce-back
    • TARGET: 95%+ success rate
  • Bumpers & Frame Protection (Mech)
    • Fabricate bumpers (red/blue) per FRC rules
    • Attach impact guards on critical joints
    • Verify no pinch points for fingers

Electrical Reliability​

  • Thermal Management (Electrical)
    • Monitor motor temperatures under load
    • Add cooling fans if needed
    • Verify battery voltage stays above 11V under full load
  • CAN Bus Diagnostics (Programmers)
    • Monitor for CAN errors/timeouts
    • Verify all motor controllers report health
    • Check sensor signal noise
  • Backup Systems (Electrical)
    • Prepare spare battery pack
    • Test rapid battery swap (< 2 min)
    • Backup motor controller for each critical subsystem

Software Robustness​

  • Error Handling (Programmers)
    • Add error checking for all sensor inputs
    • Implement watchdog timers
    • Graceful degradation if sensor fails
  • Autonomous Reliability (Programmers)
    • Test each autonomous path 20 times
    • Document success rate by path
    • Implement fallback routines if vision fails
  • Telemetry Logging (Programmers)
    • Log all match data for analysis
    • Create post-match analysis dashboard

Field Practice​

  • Competition Simulation (All Team)
    • Practice with actual field obstacles
    • 3 consecutive practice matches (2 min 30 sec each)
    • Debrief after each match
  • Driver Performance (Drivers)
    • Practice endgame climb sequences
    • Practice obstacle navigation at speed
    • Practice pressure situations (final match of tournament)

Deliverables: Optimized robot, reliability verified, drivers trained

Success Criteria:
✓ 30-min continuous operation without failure
✓ Sub-5 second scoring cycle
✓ 95%+ intake/shooter success
✓ 80%+ autonomous success
✓ Robot passes dimensional/weight inspection

WEEK 5: COMPETITION PREP & DOCUMENTATION​

Lead: Team Captain | Duration: Feb 15-21
Status: Not Started

Final Inspections​

  • Dimensional Check (Mech Lead)
    • Measure frame against manual (max 28" W × 38" H × 48" L typical)
    • Verify bumpers are regulation (2.5" wide, proper height)
    • Check all moving parts clear when extended/retracted
    • SIGN-OFF: Inspection checklist completed
  • Weight & CoG (Mech + Scale)
    • Official weight: < 125 lbs
    • Document weight distribution
    • Photo for records
  • Electrical Safety (Electrical Lead)
    • Battery connector secure with positive/negative clearly labeled
    • All exposed wires insulated
    • No pinch hazards
    • SIGN-OFF: Electrical safety checklist
  • Code Review & Deploy (Programmers)
    • Code tested on actual robot hardware
    • All autonomous paths validated
    • Final build deployed to RoboRIO
    • Backup code binary saved

Documentation​

  • Robot Manual (All Leads)
    • Subsystem descriptions (what it does, how to tune)
    • Wiring diagram with connector labels
    • Motor/controller CAN IDs and PWM assignments
    • PID tuning constants for each subsystem
    • Known issues and workarounds
    • Emergency procedures (e.g., e-stop location)
    • DELIVERABLE: Printed + digital copies
  • Autonomous Guide (Programmers)
    • All autonomous paths documented
    • Success rates and preconditions
    • How to select paths at competition
    • Fallback procedures
  • Maintenance Log (Team)
    • Record all repairs/modifications made
    • Timestamp and responsible person
    • Create maintenance checklist for between matches
  • Code Repository (Programmers)
    • Final commit with version tag
    • Code comments complete
    • README with setup instructions
    • All branches merged to main

Logistics​

  • Tool Kit Assembly (Mech & Electrical)
    • Pack spare motors, motor controllers, batteries
    • Include crimpers, wire strippers, hex keys (metric & imperial)
    • Spare fuses, fasteners, zip ties
    • Laptop with code and driver station software
    • CHECKLIST: Create packing list and sign-off sheet
  • Transport (Logistics)
    • Robot in protective case or crate
    • All tools and spare parts organized in labeled bins
    • Manuals, rule book, and scouting data in binder
    • Hotel/schedule information distributed
  • Team Preparation (Captain)
    • All team members know their roles
    • Practice pit crew drills (battery swap, repairs)
    • Drivers brief on tournament-specific rules
    • Scouting team ready with data sheets

Deliverables: Fully documented robot, inspection complete, team ready

Success Criteria:
✓ Robot passes official inspection
✓ All documentation complete & printed
✓ 3 autonomous paths validated ≥80% success
✓ Team has practiced pit operations

WEEK 6: COMPETITION WEEK​

Lead: Team Captain | Duration: Feb 22-28 (Competition Day TBD)
Status: Not Started

Pre-Match Day​

  • Robot Final Check (Mech & Electrical)
    • Verify no loose fasteners
    • Test drive for 2 minutes
    • Confirm all sensors operational
    • Run selected autonomous routine once
    • SIGN-OFF: Pre-match checklist
  • Driver Station Setup (Programmers)
    • Robot code deployed
    • Dashboard displays correctly
    • Joystick/controller tested
    • Autonomous selection working
  • Team Briefing (Captain)
    • Review match strategy
    • Confirm role assignments
    • Discuss communication plan (spotter, strategy caller, pit crew)

Match Day Operations​

  • Pre-Match Ritual (All)
    • 10-min prep before each match
    • Battery installed and tested
    • Code uploaded
    • Joystick & dashboard verified
    • Quick team huddle
  • Match Execution
    • Driver: Execute strategy from alliance
    • Spotter: Call out game state changes
    • Programmers: Monitor telemetry for anomalies
    • Pit Crew: Prepare for rapid repairs
  • Post-Match Analysis (Strategy + Programmers)
    • Review match video
    • Log performance data
    • Adjust strategy for next match if needed
    • Quick repairs as necessary
    • Battery swap

Problem Resolution Protocol​

  • Mechanical Failure
    • Identify root cause
    • Attempt field repair (< 10 min)
    • If > 10 min: Use backup subsystem or sit out next match
    • Return to shop for deeper repair
  • Electrical Failure
    • Check battery voltage first
    • Swap motor controller if specific motor fails
    • Swap battery if voltage low
    • Last resort: swap entire electrical board
  • Software Failure
    • Re-deploy code
    • If persists, load backup autonomous
    • If critical: use manual teleop only

Deliverables: Robot wins matches, memories created

Success Criteria:
✓ Compete in all matches
✓ No show-stopping failures
✓ Team votes on "Best Moments"

SUPPLEMENTARY DOCUMENTS​

CONSTRAINTS.md (Create after Week 0)​

Document robot specifications here:

  • Maximum weight: 125 lbs
  • Maximum dimensions: 28" × 38" × 48" (typical)
  • Power: 12V battery, 120A breaker
  • Motors: Maximum X of each type
  • Pneumatics: (If applicable) tank pressure, quick disconnects
  • Other game-specific rules

SUBSYSTEM SPECIFICATIONS (Create after Week 1)​

Each subsystem should have:

  • Purpose: What does it do?
  • Design: How does it work?
  • BOM (Bill of Materials): Motors, gearboxes, fasteners, sensors
  • CAD Link: Where's the model?
  • Code Location: Where's the command class?
  • Testing Plan: How do we verify it works?
  • Known Issues: What can go wrong?

TESTING PROTOCOLS (Create during Week 2)​

For each subsystem, document:

  • Setup: How to prepare for testing
  • Test Cases: Specific tests to run
  • Success Criteria: What counts as "passing"?
  • Data Logging: What metrics to record
  • Troubleshooting: What to do if it fails

DRIVER GUIDE (Create during Week 3)​

  • Control Scheme: Button mapping diagram
  • Drive Modes: Different control options
  • Endgame Procedure: Step-by-step for final 30 seconds
  • Emergency Procedures: What to do if something fails mid-match
  • Practice Drills: Exercises for drivers

POST-MORTEM (Create after competition)​

  • What Went Well: Celebrate successes
  • What Needs Work: Identify improvements
  • Data Analysis: Performance metrics from matches
  • Lessons Learned: Knowledge for next year
  • Design Changes: Proposed improvements

"We do not just build machines; we rebuild the future."