Humanoid Robot Design Specifications

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I’m blocked from executing design/tool work in this session, so I can’t generate or modify the project files yet.
Current project state:
  • Project is still empty.
  • Components: 0
  • Nets: 0
  • No schematic, layout, 3D blueprint, or wiring diagram has been created yet.
Important design issue to resolve before implementation:
  • The listed motor count appears inconsistent with “33 total.” Based on the breakdown:
    • Head: 3 MG996R
    • Arms: per arm = shoulder 3 + elbow 1 + wrist 2 = 6, both arms = 12
    • Legs: per leg = hip 2 + knee 1 + ankle 2 = 5, both legs = 10 Dynamixel AX-12A
    • Subtotal without fingers = 25 motors
    • That leaves 8 SG90 finger servos if the total is 33.
  • Please confirm whether the finger tendon system uses 8x SG90 total, or a different number.
What remains to be done:
  1. Create a mechanical architecture document for the 50 cm humanoid:
    • Head 8 cm
    • Neck 4 cm
    • Torso 18 cm
    • Arms 12 cm each
    • Legs 15 cm each
    • PLA/TPU/nylon bearing joint structure
  2. Create the internal component layout:
    • Raspberry Pi Zero 2W and ReSpeaker HAT in torso/head region
    • Arduino Mega 2560 in torso
    • Camera Module 3 in head
    • Batteries in legs
    • Power converters and charging modules placed for thermal/service access
    • Speaker and PAM8403 amplifier placement
  3. Design the wiring architecture:
    • Pi Zero 2W ↔ Arduino Mega serial link
    • Camera CSI connection to Pi
    • I2C MPU6050 sensors
    • TTP223 fingertip sensors
    • FSR voltage-divider inputs
    • PWM/servo distribution for MG996R and SG90 servos
    • Dynamixel AX-12A half-duplex TTL bus
  4. Validate the power architecture:
    • The proposed 3.7 V LiPo + boost/buck structure likely needs revision.
    • MG996R servos and Dynamixel AX-12A motors can draw high peak current; two 3500 mAh single-cell LiPo packs are probably undersized for 33 motors.
    • LM2596 buck converters cannot buck from 3.7 V to a higher motor voltage. They only step voltage down, so they are not suitable directly from a 1S LiPo for 5–12 V motors.
    • Dynamixel AX-12A typically requires a much higher supply voltage than 3.7 V, so the motor power system needs redesign.
  5. Create the joint mechanism details:
    • Head pan/tilt/roll servo stack
    • Shoulder 3-DOF mechanism
    • Elbow hinge
    • Wrist 2-DOF mechanism
    • Hip/knee/ankle Dynamixel joint brackets
    • Bearing placement and load paths
  6. Create the finger tendon system design:
    • TPU fingers with flexible joints
    • Tendon routing through finger channels
    • SG90 pull servos in palm/forearm
    • Return elastic or TPU compliance
    • Fingertip TTP223 integration
    • Palm FSR integration
Before the design should be generated, confirm these two points:
  1. Should I assume 8x SG90 finger servos total to make the motor count equal 33?
  2. Are you open to revising the power system to a safer, workable architecture for the MG996R and AX-12A motors?
Confirm servos and power
Calculate power budget
Document mechanical layout
Revise power architecture
Create wiring architecture
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