@henilX0

Just wrapped up designing and routing the custom dual-layer PCB for my ESP32 Smart Robot in KiCad!Took quite a bit of time to get all the pin mapping and trace routing clean without messy crossovers. Here’s what’s packed onto the board:ESP32 DevKit footprint & MPU6050 IMU connectorPin headers for motor driver, ultrasonic sensor, and dual servosPower circuitry with DPDT switch, filter capacitors, and status LEDsChecked everything in the 3D viewer and all the component clearances look clean. Next up: exporting Gerbers and getting this board fabricated!

Finally back on track after taking about a week off due to some medical/health reasons! Today, I finished designing the complete rack-and-pinion servo gripper in Onshape and integrated it into the full mobile robot assembly. The CAD model is now 100% complete, including the multi-tier chassis, ultrasonic sensor mount, motor driver, and gripper mechanism. Since all the CAD designs are ready, I really need 3D printing grant support/help now to get these physical parts printed so I can start assembling the hardware!

Redesigned the spur gear and rack profiles in Onshape to get a better tooth fit and pitch alignment. Spent time tweaking assembly mates and testing how the mechanism converts servo rotation into smooth linear movement for the gripper arms. Still fine-tuning, but getting closer to the final assembly!

Spent time in Onshape experimenting with different gear profiles and rack designs for the gripper! Tested tooth counts and pitch alignments to figure out how to convert the servo’s rotation into smooth linear motion. Still tweaking the design, but getting closer!

Modeled the gripper base plate in Onshape with integrated guide rails and gear clearance for the servo horn. Also mounted the HC-SR04 ultrasonic sensor to the top deck! Still working on finishing the moving gripper arms, but the base structure and sensor placement are locked in.

Designed a custom H-shaped bracket in Onshape to mount the SG90 gripper servo directly onto the front chassis. Integrated precise cutout & screw mounts, aligned everything, and successfully mated the part into the main robot assembly!

Worked super hard today to completely redesign the robot chassis from scratch in Onshape! My main goal was to optimize material usage, keep the structure lightweight, and make physical assembly as easy as possible.The best part about this new design is all the open space ,there’s so much room from every side now. Routing wires, tuning components, or swapping parts like the ESP32 and motor driver will be totally effortless. Spent hours fine-tuning the component placement and layout, and everything fits together perfectly now!

Designed a custom mounting bracket for the HC-SR04 ultrasonic sensor in Onshape today! Created the front casing to hold the sensor, added filleted edges for structural rigidity, and integrated a bottom mounting arm to attach it to the servo motor.

Fine-tuned chassis dimensions in Onshape and modeled two structural components: designed a precision grid of internal screw bosses on the base plate for component mounting, and created a custom plate with filleted edges and corner screw holes.

Updated the chassis dimensions in Onshape for better alignment! Also designed and mounted the bracket connecting the ultrasonic sensor to the SG90 servo motor.

Designed the top cover plate for the robot chassis in Onshape today! Added a custom honeycomb mesh pattern for weight reduction, integrated an exact cutout for the SG90 servo motor, and added corner screw bosses to mount it securely to the chassis.

Updated the robot chassis dimensions in Onshape today! Arranged 3D models for components (motors, wheels, battery holder, and electronics) inside the frame to verify fitment and component spacing. Will keep tweaking dimensions as physical assembly progresses.

Worked on the robot chassis CAD design in Onshape today! Added a custom pattern and configured the motor mounting dimensions so everything fits properly.

Fixed the MPU6050 power drop issue today by properly wiring it with the capacitor setup on the PCB. After fixing the power, started designing the initial robot chassis base in Onshape to fit all components!

Fixed a short circuit today by replacing a damaged capacitor. Got the MPU6050 setup fully working and tested it with code. Also started drafting the 8cm target logic for the servo and ultrasonic sensor,will code the full logic tomorrow!

Wired and soldered the buck converter power setup. Ran into a short circuit issue whenever the ESP32 was connected and spent the entire session testing voltages and debugging (still in progress).

Finished soldering and hardware connections for the MPU6050 sensor today! Added this sensor so the robot can measure precise turning angles to face target objects accurately. Next step is writing the code for it!

Updated the robot’s code in Arduino IDE today! Fixed a few compilation errors in the logic and tweaked some code settings so everything runs smoothly now. Next step is testing it live on the chassis!

Wrote some new code in Arduino IDE today and wired up the ultrasonic sensor! I set the motor speed to 50% so it moves slow and doesn’t crash while testing. Right now, I’ve added a simple logic where as soon as the sensor detects an object in front, the robot moves towards it. Step by step getting it to work!

Finally built the first working prototype today! I mounted the ESP32, motor driver, and BO motors onto a temporary MDF board chassis to check wiring and component balance.Wrote custom code in Arduino IDE to handle motor control, flashed it to the board, and successfully verified basic movement!Next steps:Integrate the ultrasonic sensor for obstacle avoidance.Connect the servo motor for the gripper mechanism.