LEARN THE SCIENCE
Every part of Dusty is real science. Here is how each piece works, words to know, and something to try.
Good for the packet, the board, the judges' questions, and the build.
Crumbs and the robot that came first
Robot vacuums clean floors. Nobody built one for the table.
Ants and cockroaches find food by scouting. When one scout finds crumbs, it leaves a scent trail so the rest of the colony can follow. That is why the first step against bugs is always the same: clean up right after eating.
Most people brush crumbs off the table with a hand. The crumbs land on the floor. The mess did not leave the house, it just moved somewhere harder to reach. Dusty catches crumbs in a tray you dump in the trash.
The first Roomba robot vacuum went on sale in September 2002 for about $199. Before it was called Roomba, the team called it DustPuppy. It had three separate systems just to keep it from falling down stairs, because falling is the biggest danger for any driving robot.
The brain: micro:bit and code
A microcontroller is a tiny computer that does one job forever.
A laptop can do millions of different things. A microcontroller does one job, very reliably, using almost no electricity. There is one in a microwave, one in a car key, and dozens in the car itself.
The micro:bit is a microcontroller you can reprogram. Its 25 red LEDs can scroll sensor numbers, so you can read them at the table with no laptop. Button A runs random bounce and button B runs Spot Clean. When you load code, it stays. Switch Dusty on a week later and the program starts right away.
Code is a list of steps the computer follows exactly, in order. Dusty’s code uses three big ideas. A loop repeats steps forever. An if checks something and decides what to do. A variable is a box that remembers a number, like the threshold.
on button A pressedread the table, set thresholdforeverif a sensor reads above thresholdstop both motorsback up, spin a random amountelseboth motors forward at 40
Motors and the H-bridge
The micro:bit can point, but it cannot lift. The motor board does the lifting.
A micro:bit pin gives about enough electricity to light a small LED, roughly 1/100th of what a motor wants. Wire a motor straight to it and you get a broken micro:bit, not a slow robot.
The moto:bit board has a circuit called an H-bridge: four electronic switches in the shape of the letter H, with the motor in the middle. Close one pair and the motor spins forward. Close the other pair and it spins backward. The micro:bit only says which pair.
To run a motor at 40%, the board flicks the power fully on and off hundreds of times a second, on 40% of the time. The motor acts like it gets 40% of the power. This is called PWM. At 40%, Dusty drives about 7 centimeters per second.
The real board does this hundreds of times every second.
Wheels, steering and three feet
Dusty steers with no steering wheel. It just runs its two wheels differently.
Both wheels forward at the same speed: straight. One faster than the other: a curve. One forward and one backward: a spin in place. This is called differential drive.
Each N20 motor has a gearbox with a 298:1 ratio. The motor spins 298 times for one turn of the wheel. The gears trade speed for strength, so a tiny motor can push the whole robot.
Dusty stands on two wheels and one ball caster. Three points always sit flat, even on a bumpy table. Four wheels would rock whenever the table was not perfectly flat.
Seeing the edge with infrared
Shine light down, measure the bounce. No bounce means no table.
Each cliff sensor has two tiny bumps. One is an infrared LED that shines invisible light straight down. The other measures how much light comes back.
On the table, the light bounces straight back up. Past the edge, it shines into empty air and almost nothing comes back. That sudden drop is how Dusty knows the table ended.
The sensor works best about 3 mm above the table and gets unreliable past 6 mm. Two US pennies stacked up are almost exactly 3 mm, so they set the height. The sensors sit 62 mm in front of the wheels, which gives Dusty a head start to stop.
A black placemat is much closer to a cliff than white paper is.
Numbers, thresholds and calibration
Dusty measures the table it is sitting on, then decides for itself what a cliff looks like.
A button is digital: pressed or not, yes or no. The sensor is analog: it has a whole range of answers. The micro:bit turns it into a number from 0 to 1023. For Dusty’s sensors, a low number means lots of light came back, and a high number means almost none did.
A threshold is the line between table and cliff. On white paper the table might read 200 and the edge 900. Dark wood might read 650 on the table. A fixed line at 500 would make Dusty think the dark table was already a cliff.
So Dusty calibrates. Press A while it sits still, and it reads the table and sets the threshold 200 above that. Same code, any table.
Redundancy: the whisker
Two sensors that fail for different reasons.
The whisker is a small switch with a springy arm and a little wheel. The wheel rolls on the table and holds the arm pushed in. When the table ends, the arm drops, the switch clicks, and the motors stop.
Infrared can be fooled by a black placemat. The whisker cannot, because it touches instead of looking. Having two different systems do the same job, so one can catch what the other misses, is called redundancy.
The test: cover both infrared sensors with tape. If Dusty still stops at the edge, the whisker works on its own.
Gears: trading speed for strength
The brush gears make the roller 5.4 times slower and about 5.4 times stronger.
When two gears touch, their teeth pass one for one. The motor gear has 12 teeth and the big gear has 36, so the motor goes around 3 times for one turn of the big gear.
A small 10-tooth gear is stuck to the big gear. It drives the 18-tooth roller gear, which slows things down again by 18 ÷ 10 = 1.8. The two slow-downs multiply: 3 × 1.8 = 5.4.
The 130 motor spins about 8,000 to 10,000 times a minute. Divided by 5.4, the roller turns about 1,500 to 1,800 times a minute, with enough turning strength to push through a pile of cereal.
Power: volts and the power bank
A power bank holds a steady 5 volts until it is empty.
Volts are like the push behind electricity. Four AA batteries start near 6 volts and fade as they run down, so Dusty would get slower all day. Speed is what the experiment measures, so a steady 5 volts keeps the test fair.
Battery size is measured in milliamp hours (mAh). The bank holds 5,200 mAh and Dusty uses about 450 milliamps. 5,200 ÷ 450 is about 11 hours, but the bank loses some energy changing its voltage, so plan on 6 to 7 hours.
The power bank is a lithium battery. Never crush, pierce or drop it. If it gets hot, swells or smells, a grown-up takes it out.
3D printing and PLA
A 3D printer builds a part like a stack of very thin pancakes.
PLA is a plastic made from plants, usually corn or sugarcane. The printer pushes a thread of it into a nozzle at about 220°C, where it melts like hot glue, and draws one layer 0.2 mm thick. Then it draws the next layer on top.
The base plate is 28 mm tall. 28 ÷ 0.2 = 140 layers. All 19 printed pieces use about 101 grams of PLA.
The screw holes print a little smaller than the M2 screws, 1.8 mm instead of 2 mm. The screw cuts its own thread as it turns. The small print in Batch 1 checks that holes come out the right size before the long print.
Stopping distance
The faster you go, the more room you need to stop.
Nothing stops instantly. A robot keeps rolling while its code notices the edge and while the motors slow down. A faster robot covers more ground in that time and has more motion to get rid of.
Dusty’s sensors are 62 mm ahead of its wheels. That head start is the room it has to stop. The prediction: at slow speed it needs about 8 mm, and at full speed about 38 mm, so it should never fall.
The experiment tests four speeds (25, 50, 75 and 100), 20 runs each, measuring how far the sensor goes past the edge and counting falls. If the numbers climb toward 62, the chart can predict the speed where Dusty would finally fall.
If a bar ever reaches the pink one, Dusty falls.
Search patterns: bounce or rows
Simple random driving works. Rows work better on a small spill.
The first Roomba had no map. It drove straight, turned a random amount at an obstacle, and drove again. Bounce around long enough and you cover the whole room. It sold about a million a year. That is Dusty’s button A.
Spot Clean on button B sweeps a 1 foot square in rows, like mowing a lawn. The brush is 52 mm wide and the rows are 40 mm apart, so each row overlaps the last by 12 mm and no stripe is missed. 305 mm ÷ 40 mm is about 8 rows.
The spill race: 5 grams of cereal in a taped square, Spot Clean against random bounce for the same time, then weigh what each caught.
Running a fair test
Change one thing, measure what happens, and keep everything else the same.
In the speed test, the thing you change is motor speed. The things you measure are stopping distance in millimeters and falls out of 20. Everything else stays the same: the table, the charged power bank, the 3 mm sensor height, and the running start.
To find an average, add up the runs and divide by how many there are. Then make a chart with speed along the bottom and stopping distance up the side.
Saying "Dusty cleans pretty well" is an opinion. Saying "Dusty picked up 3.8 grams out of 5, which is 76 percent" is a measurement. Science runs on measurements.
How engineers invent
Ask, imagine, plan, create, test, improve. Then do it again.
Dusty has used every step: asking how to keep crumbs off the table, imagining a list of cleaning robots, planning the design, and now building it.
Once a design is locked, changes go through a change order. It says what changes, why, what else it touches, and who said yes. Dusty has had two so far: the USB-C power bank (MOC-001) and Spot Clean on button B (MOC-002).
Testing always finds problems. That is good. Keep notes and photos of what went wrong and how it got fixed. Judges love that.
All the words
Use these in the packet, on the board, and when the judges ask questions.