Crazy Frog 3-lb BattleBot

Crazy Frog was my first attempt at building a competitive combat robot, designed specifically for the 3-lb Beetleweight class. The robot features a unique in-hub weapon motor architecture, divided into two independent drive modules and a central weapon subframe. The vertical spinning disc was laser-cut from AR500 steel to maximize tooth hardness and impact durability. While 3D printed TPU drive units and water jet aluminum uprights make up the main chassis. As a first-time build, Crazy Frog performed successfully, achieving a 2–1 record at a National Havoc Robot League event.

The in hub weapon drive utilized a off the shelf stator from a brushless outrunner motor, the rotor and magnet ring however were heavily modified to be pressed into a central hub that would bolt to the weapon. The stator of the motor was also drilled out to accept a 10mm hardened steel shoulder bolt that would replace the entire shaft of the motor. With the rotor hub riding on 2 over sized ball bearings. This allowed the entire assembly to be extremely resilient not having any gears or belts as points of failures. During Crazy Frogs last fight taking an extremely heavy horizontal hit to the blade, both the 1/4" aluminum uprights and 1/4" AR500 disk bent. However the weapon drive was still functional spinning the blade to full speed.