Hardware
High-Current Safety Switch
Engineered and established manufacturing for a high-current safety switch for combat robotics, now widely adopted.
Project Overview
Engineered and established a manufacturing process for a revolutionary high-current safety switch specifically designed for combat robotics applications. The innovation addresses a critical need for reliable, accessible power control systems handling extreme current loads while maintaining structural integrity under combat conditions. This design has become a standard solution adopted by numerous robotics teams.
Technical Implementation
- Electrical Design: Developed a robust electrical contact system using precision-machined copper plates and a specialized copper bolt mechanism, achieving continuous load handling of 160A.
- Thermal Management: Implemented an innovative thermal solution using high-temperature modeling clay for superior heat dissipation and electrical isolation.
- Manufacturing Process: Created a streamlined production methodology incorporating precise copper fabrication, specialized threading, and optimized 3D printing (TPU) for the enclosure.
Technical Specifications
- Continuous Current Rating: 160A
- Sustained Operation Time: 3+ minutes at max load
- Protection Rating: Impact-resistant TPU enclosure
Impact and Recognition
- Widely adopted by multiple combat robotics teams across competitions.
- Created reproducible manufacturing process enabling widespread adoption.