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Your guide to Excel in First Lego League: Robot Architecture, Design,
Programming and Game Strategies. Copyright © 2017 Sanjeev Dwivedi and
Rajeev Dwivedi

All rights reserved. No part of this work may be reproduced or transmitted in any
form or by any means, electronic or mechanical, including photocopying,
recording, or by any information storage or retrieval system, without the prior
written permission of the copyright owner and the publisher.

LEGO®, MINDSTORMS®, EV3®, are trademarks of the LEGO Group, which does
not sponsor, authorize, or endorse this book.

First Lego League®, FLL® and USFirst® are trademarks of For Inspiration and
Recognition of Science and Technology (FIRST®), which does not sponsor,
authorize, or endorse this book.

World Robotics League® is a trademark of Satkriti Solutions LLC

The information in this book is distributed on an “As is” basis, without warranty.
While every precaution has been taken in the preparation of this work, the
authors shall not have any liability to any person or entity with respect to any loss
or damage caused or alleged to be caused directly or indirectly by the information
contained in it.
 To the next generation of innovators,
Hopefully we will see colonization of Mars in our lifetime
Foreword
We are glad to offer this book Your guide to Excel in First Lego League: Robot
Architecture, Design, Programming and Game Strategies to you. We believe that
new users as well as experienced participants will find this book very useful. This
book evolves from our experience over years of coaching and working with
multiple teams.

Using many of the guiding principles listed out in this book, our teams have not
only excelled through multiple levels of progression; they have done so with flying
colors. The awards won by our teams include prestigious regional championship
awards, robot performance awards at qualifiers, semi-finals, two state
championships with two representations at the World Championships. Additionally,
we have won multiple design awards, project awards and core value awards.

This book summarizes design principles including different kind of drives, elements
of robot architecture, design of robot as system. There are detailed explanation of
various programing elements including the flow structure, usage of various
sensors and design and programming for a consistent and more predictable
movement. A section is dedicated to the development of menu system that users
will find very helpful in organizing individual programs for various missions.

In addition to the technical information, the book has a section dedicated to

apprising teams, participants and coaches of many other issues that will help
them be better prepared for the competition.

The book also describes many mechanisms and fixtures used to reduce the overall
timing and repeatable performance. The book concludes with a section dedicated
to building a robot that encompasses many design features of well-balanced
highly reconfigurable robot.

Many programs described in the book are provided on our website:

www.FLLguide.com
While every care has been taken to provide accurate information, feel free to write
to us if you notice any discrepancies. We are also open to additional suggestion to
improve.

Happy building and good luck,

Go Lego

Sanjeev Dwivedi
Rajeev Dwivedi
August 15th, 2017
Table of Contents
Foreword
Table of Contents
Quick Introduction to FLL
Summary
Robot Architecture
Subcomponents of a Mobile Robot
Robot Design as a System
Guidelines for Robot Design
Other important considerations for overall Robot design
Summary
Mechanical System
Mechanical Drives
Gear Drives
Spur gears
Bevel Gears
Worm Gear
Rack and Pinion
Gear Trains and Combination gear trains
Chain and Sprocket Drives
Belt and Pulley
Mechanical Linkages
Composite Drives
 Summary
Pneumatic Systems
Pneumatic pump
Air Tank
Flow distribution accessories
Manometer
Pneumatic cylinders
Pneumatic Valve (switch)
Pneumatic mechanisms
Summary
Getting familiar with the programming environment
Introduction to the programming
Green/Action Blocks
Orange/Flow Blocks
Yellow/Sensor Blocks
Red/Data Operation Blocks
Royal Blue/Advanced blocks
Myblocks
Summary
Fundamentals of Robot Movement
Parts of the robot
Large Motors
Connection to Wheels
Caster
Bumper
Chassis
Moving Straight
Turning
 Exercises to reinforce basic robot movement
Summary
Basic Robot Navigation
Navigation Paradigms
Aligning the robot perfectly
Taking care of the Gear Slack
Starting Jig
Using wall and flat surfaces for navigation
Exercises with basic alignment
Wall Following using wheels
Summary
MyBlocks
Pre-requisite to Myblocks
Variables
Data Wires
Display Block
The Math Block
Exercises
MyBlocks for Moving Straight and turning
Summary
Basic programming blocks
The Single motor block
Flow Control Blocks
Flow Control: The Wait block
Flow Control: The Switch block
Flow Control: Programming mistakes with the Switch block
Flow Control: The Loop block
The Loop Interrupt
 Flow Control: Programming Mistakes with the loop block
Summary
Touch Sensor and the Brick buttons
Programming with the touch sensor
Mounting the touch sensor
Wall aligning with a touch sensor
Wall Following with a touch sensor
Exercises with the Touch sensor
Brick Button as a sensor
Summary
Ultrasonic Sensor
Mounting the Ultrasonic sensor
Examples of the Ultrasonic sensor use
Wall following with the Ultrasonic Sensor
Exercises
Summary
Color Sensor
Wait for color
Line squaring to color lines
Simple Line following with a color sensor
Calibrating the color sensor
Summary
Gyroscope Sensor
Basic Functionality
Summary
Motor Rotation Sensor and its use in conjunction with other
Sensors
Exercises
 Summary
PID algorithm for wall following using Ultrasonic and line
following using Color Sensors
PID line following
Summary
The Master Program
Display Program Names MyBlock
Summary
Some Design suggestions to improve accuracy and timing
Self-aligning features
Optimize motor usage by eliminating motorized
mechanisms and attachment by Robot Movement
Use passive non-motorized end effector for collecting
objects
Designs based on Out of box thinking for objects placed on
ground -effector for collecting objects
Save time by using single fixture for simultaneous multiple
deliveries
Robot need not go behind the wall
Axle based connectors for quickly switching static
attachment
Touch sensor Engagement
Use Level fix vehicle for aligning and make deliveries above
the ground level
Summary
Robot Mission and Path Planning Strategies for FLL
One at a time mission planning
Zone based mission planning
Path and Opportunity based Mission planning
 Island of Certainty
Overshoot your goal
Use techniques when you can be certain of them
Minimum number of segments on a path
Opportunistic Mission completion
Taking penalties as a strategy
Tying it all together
Summary
Appendix A: Winning Strategies at FLL - beyond Robotics
Appendix B: Things to remember for the competition day
Appendix C: The Essential kit for a successful FLL season
Appendix D: A FLL Robot
Quick Introduction to FLL
Started in 1999 through partnership between FIRST (For Inspiration and
Recognition of Science and Technology) and Lego group, First Lego League® or
FLL as it is commonly called, is a competition that focuses on STEM with a goal to
develop kids with a play nice attitude. Many or most people who have heard of
FLL associate FLL with robotics; however, it is key to understand the
differentiation.

FLL is a STEM (Science, Technology, Engineering and Mathematics) oriented

competition with a robotics component to it. It is, NOT a Robotics competition.
This differentiation is important to understand for most coaches to avoid
frustration and to better navigate the competition for great results and to win or
move from one level to another in FLL. Before we go deep into explaining how to
Win at FLL events, it is important to understand the format as well as the various
metrics that FLL judging occurs on. In our experience, even experienced coaches
quite often do not fully understand the dynamics of judging or even various parts,
so it is crucial to lay it out.

FLL as a competition has 4 parts to it:

Core Values - we like to call this teamwork. That is how team works together,
cooperates and exhibits gracious professionalism
Project - This is essentially a scientific research endeavor. The teams need to
identify a real-life problem, find a solution to it, or improve an existing solution
and share it with others.
Robot Design – Also referred to as technical judging is about the innovative
strategies, design and programing.
Robot Games - The robotics component where you get graded objectively based
on how well your robot performs in the competition.

In our experience, most participants love the robotics portion of FLL and that is
where they spend most of their time. Even though the FLL competition is heavily
weighted towards teamwork, project and robot design, most participants that we
have interacted with have a very positive experience that they gained out of the
robotics portion of FLL. Thus, we have decided to keep the majority of the book
dedicated to robotics with Lego and EV3 Mindstorms.

The central theme of this book is the robotics and programming that goes along
with FLL although we discuss some of the most important metrics needed to win
in FLL in the appendices. In this chapter, we setup the terminology and basic
concepts of FLL so that you can follow along in the rest of the book.

Figure 1: A sample FLL Robot Challenge Field, also called as

The Table shown for illustration purposes
For most of the teams, a FLL season runs from roughly the beginning of
September to Mid-December when the FLL Qualifiers take place. At the beginning
of each FLL season, FIRST, announces a challenge with a specific theme. The
challenge contains the description of the research area that the kids should work
in and more importantly, it contains the robotics challenge environment in which
the team’s EV3 robot must work in. The challenge environment is built with the
help of the FLL field kit that includes a mat and various models that are built with
the help of Lego pieces. As described in Figure 1, the challenge area is 45 in x 93
in with one area reserved as the Robot Base. The challenge area is surrounded by
single 2 x 3 stud (actual 1-1/2 in x 2-1/2in or 38mm x 64mm) walls on three sides
and double walls one side. During actual challenge two tables are placed next to
each other so that the walls are touching. The shared walls described in Figure 1
represent the second table.
Figure 2: A FLL table with the mat and the models shown. The
table is from the 2016 Animal Allies season.
 Figure 3: An FLL table shown with the base and a few models
On an actual challenge table (Figure 2), multiple Lego models are dispersed at
known locations on top of a printed mat and the robot needs to interact with the
Lego models and fulfill certain conditions. Each travel of the robot outside the
base in order to interact with one or more Lego Models to perform certain
objectives is known as a mission. The missions may include, push, pull, engage,
collect, redistribute or object launching tasks. While attempting a mission, the
Robot must be autonomous. Autonomy of the robot means that once the robot
exits the Robot Base, no member of the team may touch or aid the robot until the
robot returns back to the Robot Base on its own. Thus, as per the rules, the robot
can be touched only in the robot base. While in Robot base, the robot may be
reconfigured by changing the attachment and suitable program selected to
execute a mission. If due to some reason the robot is stranded outside the Robot
base, participants may accept a penalty point and pick the robot to bring it back
to base.

In the FLL Robot game where the robots are driven using autonomous programs
by kids, two tables are placed next to each other (Figure 4) and two teams run
their robot on them simultaneously. It is key to note that even though two teams
are running their robots simultaneously, there is limited impact they can have on
each other. The two tables have one wall touching each other and a shared model
is placed on this double wall. In the 2016 Animal Allies season, scoring points on
the shared model would grant points to both the teams irrespective of which team
was the one that took on that mission. Apart from the shared models, the scoring
as well as running of the robot on the two sides is completely independent and
does not impact the other team.
Figure 4: Two tables placed in the competition setting with the
shared model overlapping the two walls. Note that there are
quite often loose pieces in the base which are required to
finish some missions. During the competition, you may move
them off the competition table and onto a small stool placed
next to the table for keeping the spare pieces. Apart from the
one shared model between the two walls, the two sides are
completely independent of each other.
Summary
In this chapter, we quickly touched upon some core concepts of FLL. The most
exciting thing that participants find in FLL is the robotics and the Robot Games.
The Robot Game is performed on top of a 45inchx93inch table which, contains a
mat and lots of Lego Models. The participating team builds and programs a robot
to go and interact with the models in an autonomous way within a 2 minute and
30 seconds timeframe. Each autonomous run of the robot is known as a mission
and usually involves the robot interacting with multiple models using a variety of
techniques. With this introduction, we are ready to delve in the world of Lego
based robotics.
Robot Architecture
Ever wondered what a Robot is? Fundamentally, a Robot is a machine. We see all
manners of machines around us. There are machines that help us with
transportation, machines that help make our live more comfortable, machines that
help us explore and machine that help us manufacture and produce goods. So,
what differentiates the Robots from all the rest of the machines?

Come to think about it, most of the machines that we see around us, and use are
dedicated to a single task. They perform the same task over and over. A juicer
mixer grinder - makes juice and grinds food. A car transports us from one place to
another. A drilling machine drills and similarly a washing machine washes
clothes. What differentiates these machines from Robots?

Robots are special kinds of machines distinguished by following three

characteristics:
1. Robots are multifunctional machines
2. Robots are Reconfigurable machines and
3. Robots are reprogrammable machines

Contrary to most of the machines, the Robot can perform many different
functions. Attach a welding torch to a Robot and it welds to join two pieces of
metal. Attach a gripper to the Robot and it can perfectly pick and place and sort
items. Attach a surgical implement to a Robot and it can perform surgery just like
a skilled surgeon. Attach a laser to the Robot and it can custom cut a piece of
cloth to be sewn into a great dress. Let’s take the multi-functionality to the next
level - attach a baseball bat to the Robot and it can hit perfect homeruns. In fact,
some enthusiasts have configured Robots to paint and mock sea-surf. For each
different task, the Robots needs a different attachment. The unique attachment
for the Robot required to perform a specific task is also referred to as an end
effector.

This takes us to the next subject, that is, the reconfigurability. Think of your arm,
it is a perfect multi-functional implement. Hold a brush to paint, hold a bat to hit
home runs and hold a fork to enjoy a perfect meal. It is worth noticing that, in
order to perform a task, we need to configure our arms in a certain
manner. Similarly, for a robot to perform different tasks, robot needs to configure
its shape accordingly.

All the robots used for specific functionality, industrial applications, entertainment
and education, are classified into two categories:
1. Mobile robots
2. Non-mobile robots

Non-mobile robots are used in manufacturing and assembly industries where the
raw material(s) arrive near the Robot and Robots picks and assembles, solders or
welds pieces. By contrast, Mobile robots are used for material movement and
exploratory purposes; Mars rover is a popular example of a mobile robot.

Figure 5: The Robot path may comprise of a set of linear,

circular or a task specific profile as indicated by the differently
colored (or solid vs dashed) arrows. The robot environment
above is from the FLL 2016 Animal Allies Season.
The Robots used in FLL are mobile Robots. That is, they need to move from one
location to another. As shown in Figure 5, the movement of a robot may comprise
of linear segments, circular arcs; or need based unique path profiles. Different
attachments on the Robot help the robot complete mission tasks. In FLL, the
maximum number of allowed motors are limited by the availability of ports on
EV3/NXT module. Therefore, significant reusability of attachments as well as easy
and quick reconfigurability of the Robots is critical to solving maximum number of
missions in fixed time window. Typically, the Robots are multifunctional since the
variety of problems that are solved may range from push, pull to pick and place,
engage and actuate among others. The end effector connected to the robot helps
solve various mission problems.
Each mission and reconfigured design of the robot may go hand in hand with a
specific program.

Figure 6: Typical mobile Robot used in FLL

A configuration refers to the arrangement of various elements of a mechanism or
mechanical system. In context of FLL, let us refer to the examples shown in the
Figure 6. The core mobile Robot comprises of the Chassis and motors for the
Robot to travel. Additional motors are attached to the robot for attaching the End
Effectors.
 Figure 7: Various end effectors for range of missions
Figure 7(a)-(h) show different end effectors ranging in complexity and
configurations. Each end effector is unique and corresponds to a mission. Figure
7(a) is a pusher mechanism that allows access across a tall structure. Figure 7(b)
and (c) show mechanisms for delivery of items above the ground level. Figure
3(d)-(f) show end effectors for collecting items. Figure 7 (g) shows a rack and
pinion based actuator and Figure 3(h) shows a robot with attachment for aligning
a Robot. While an end-effector may be used for a specific task, many end
effectors may be configured to perform multiple tasks.

When designing an end effector, it is highly recommended that the designer

consider using it for multiple tasks. One may also design an end effector such that
with minimal changes and adjustments, the same end effector can be used for
multiple missions. As illustrated in Figure 8, a scoop like attachment, used for
collecting objects, can be made multifunctional by attaching an axle to hang the
mission pieces with loops. Similarly, as described in Figure 9 an alignment end
effector can be easily converted to a collection end effector using a simple drop-in
and remove wall.
Figure 8: Configuring a scoop for multiple usage by attaching
an axle

Figure 9: Configuring an alignment end effector to collection

end effector by using a simple add on wall
Subcomponents of a Mobile Robot
As described in the Figure 5, typical mobile Robot, in addition to the onboard EV3
computer, comprises of following units:
1. Vehicle (the robot body) - this is what most coaches and teams will term as the
base robot. This robot has the basic chassis with two large motors for moving
the robot as well as one or two other motors to operate the end effectors or
attachments.
2. End effector (the attachments) - these are detachable mechanisms that will be
attached/mounted on the robot to perform one or more actions e.g. pick a
piece, drop a piece. You would want to design a mechanism on the robot body
so that multiple attachments can be attached and detached with relative ease
and minimal time involvement since all FLL competitions have multiple
challenges which can usually not be solved by a single attachment. Additionally,
the challenges are time constrained to 2 minutes and 30 seconds, so any time
spent changing the attachments is down time where your robot is not scoring
points.
3. Sensing unit (the sensors) - even though we list this as a separate item, the
sensing unit is the various sensors that you will attach to your robot. In
general, the sensing unit is a permanent part of the robot and is attached
rigidly to the body of the robot. The sensing units are attached to the robot
with structural components such as pegs and axles and attached to the brick
with a cable. In EV3 Mindstorms world, the sensing unit consists of up to 4
sensors of type touch, ultrasonic (for distance), color, Infra-Red distance
measurement sensor, and gyroscope - for measuring angles.
Robot Design as a System
First of all, it must be emphasized that every design has opportunity to improve
and secondly, a design is perfectly acceptable as long as it performs a task with
reliability and within specified constraints of time and space. However, there are
some fundamental rules of design that need to be addressed for a reliable and
efficient performance.

Let us discus few fundamental of physics and geometry that will help us
understand as well as implement the robot kinematics.
1. A minimum of three-point support is needed to fully constrain the motion of
an object.
2. The Robot support points at the wheels must work in a synchronized, well
defined manner.
3. The lesser the redundancy, the higher the accuracy of the Robot navigation.
 Figure 10: Physics of object support points
To elaborate the first idea, let us refer to an example shown in Figure 10. A 3D
object, when supported on one point may tilt along any of the multiple axes
passing through the support point. The same object, when supported on two
points, may tilt about the axis passing through the two points. By contrast,
the object when supported on three points is fully constrained. The reason behind
this is that at any given point of time there are only three points on which the
object is supported, and any additional support introduces redundancy.
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