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#Open-source hardware (17)

How to Build a Humanoid Robot: A Seven-Layer Constraint Chain from Joint Modules to Sim-to-Real

How to Build a Humanoid Robot: A Seven-Layer Constraint Chain from Joint Modules to Sim-to-Real

A humanoid robot is not an assembly of seven modules but a stack of physics equations that set each other's boundary conditions. This article computes the whole-machine stack layer by layer: joint motor modules (declared torque versus real quasi-static CoP demand — knee margins across three vendors converge to 2.23-2.42x while BHL's knee has only 1.51x) -> IMU (lever-arm pseudo-acceleration is 21,752x the sensor noise floor, so mounting position matters four orders of magnitude more than the datasheet) -> materials and structure (three BOM revisions of AgiBot's X1 as a load-path history: every part entering the closed-chain drivetrain upgraded to 7075-T6 / TC4 / 17-4PH) -> sensors (fix the observation space before the shopping list) -> battery and BMS ('all joints at peak simultaneously' is physically impossible: G1's 46,062 W against a 421 Wh pack is 109 C) -> software control and the CAN-level low-side boards (22 nodes at 500 Hz on one bus is 130.9% load, so it must be split into four) -> simulation training and sim-to-real: domain randomization, sim2sim, zero calibration (ATOM01's 2.093 rad waist-yaw assembly offset, the |q| < 1e-2 rad acceptance gate, and write_motor_flash() being a no-op in three of the four motor drivers), plus 10 of 13 real failure modes being hardware calibration rather than simulation fidelity. Every figure comes from programmatic parsing of the five machines' public model files, deployment and calibration source, plus official vendor specifications, and is recomputable.

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HumanoidJoint modulesIMUBMSSim-to-Real