Consider this. An average human has hit points of 2/5 and armour of zero. A human-sized robot has hit points of 1/1 and armour of 4 (keep with craft design for the moment, and bearing in mind that if I got rid of the robot config, I would double the armour for most robots).
I don't think that is necessarily a reasonable comparison. First, how many soldiers go into battle with no form of armor. Even a leather jack gives them 1 point of armor. A bullet proof vest gives them 5 points.
I wouldn't assume the robot had an armor of 4 unless it was built for security. For an average domestic robot they typically have "jack" armor, which is only 1 point. If we stick to the 1/1, someone with a club could completely destroy a robot up 500 liters in volume (and weighing perhaps 1000kg) in two hits... one if they got lucky.

o: Try to picture that for a moment... big bad cargo lifter bot rolls up and a guy with police baton hits it hard once and it literally falls apart (2 points damage, destroying the bot)... are we doing hard sci-fi or comedy? At 100 liters with 2/5 hits this bot is not superhuman (which given that at 100 liters its bigger than most humanoid sophonts and yet only on par with them for resilience), but neither is it fragile either. This is one of my chief concerns about going the 1/1 hit route... results are going to be too prone to stuff that will simply blow disbelief and open the rules up to criticism. Done that way you *must* armor all bots, which then raises the question of why is RoboJeevs over there armored like a security droid? I don't see a domestic robot being armored (definitely not a pseudobiological which will present another problem to the 1/1 high armor... pseudos aren't supposed to have armor), its probably got a plastic body made to resist mild impacts and so forth. Look at how things are built today... I wouldn't expect a domestic bot to be any more resistant to damage than say your vaccum cleaner. The difference being that at 50 to 100 liters volume its a good deal bigger than your vaccum cleaner.
Let's ignore "exceptional success" for the moment, which tends to mean the victim is in a lot of trouble anyway. The 7mm rifle has penetration of 3 upto long range, and damage of three. If it hit a human, the bullet would do the three points of damage, rendering them unconscious. That same bullet would be reduced to 10% damage for the robot, a result of 0.3 which is rounded down to zero. So for this weapon, the robot is tougher.
Again, assuming it has 4 points of armor. You said your concern was that people would build "droid armies". Well, either with 1/1 of 2/5 hits, put 10 points of armor on there and droid armies become very viable assuming you can afford the expense. If you are building warbots or heavy security droids I'd expect them to have considerable armor. And this doesn't even consider the 20 ton warbot hiding in some dark corner of my brain. :devil:
But let's up rifle to a 9mm model. Now the penetration is 5 while the damage is still 3. The human is rendered unconscious as before. The robot now takes 1 point of damage (3 divided by two rounded down) and is also rendered inoperable.
Hmm... maybe we have diff editions, mine gives a pentration of 4. A 13mm hunting rifle has a pen of 5, damage of 4 (which again, would make a mess out of most of my robots in 1 or 2 shots, potentially destroying a 100 liter robot with mesh armor in just two shots, so again, I'm hardly suggesting robosupersoldiers). An 9mm ACR has a 6 if using a sabot round. Which with a sabot round against mesh armor (2 pts), poor RoboJeevs even with 2/5 hits is going down hard with one shot.
Given that Armour 4 with 1/1 damage vs. Armour 0 with 2/5 damage is reasonably equivalent but different in an interesting way, I am prepared to live with robots having lesser damage than humans for the sake of keeping the design sequence simpler and more in fitting with the existing sequence.
One apparent difference between myself vs you and Aramis is that you're assuming robots, even domestic ones, will have much more armor than I would allow. I'm converting straight from Book 8, so we have armor of 1 or 2 for most domestic robots and even a cargo lifter (industrial) still only has 2 points of armor. The only case where I see more armor would be for security droids and warbots, where it makes sense... and there, with sufficient armor 1/1 or 2/5 or 10/12... the problem isn't how many hits it can take but finding something that can even dent the armor. Going on my suggested rule, anything over 250 liters would be treated as a robotic vehicle and built exactly according to those rules, which for the hapless guy with a rife just makes things worse. Frankly, if you're going to build a warbot... why wouldn't it basically be a robot tank? I wouldn't want to spend 100s of thousands of credits on something that had a low survivability, would you? So my combat rated warbots would be several dTs+... all the way up to the 20 ton nightmare which would essentially be an automated heavy tank. Course you aren't going to find any of those in someone's apartment because they simply won't fit.
Lastly on the question of control. The way I have been handling it so far, robots are basically vehicles that require one operator / driver that has been replaced with a robot brain.
Yup and this would be one of the problems with the proverbial droid army... being able to control it. Course if you have coms that are reasonably secure from being jammed, and maybe some sort of special base ship with lots of controllers to command units... what the heck. Real world armies are using more and more drones now... I can easily visualize armies of the future using lots of drones and robots, perhaps more than was originally visualized for Traveller. I could especially see heavy infantry and commando units that had maybe one such robot as part of their squad, it gets all the really dangerous jobs and so has to be heavily armored, needs hits, etc. Need a machinegun nest taken out... Pvt Gears on the double... need a sachel charge tossed in a bunker... Pvt Gears front and center... need somebody to take point down that enemy tunnel.. Pvt Gears on point! You get the idea.
In 101 Vehicles the rule was given that a robot brain can replace one crewmember and/or computer, and gives a CP multipler of 250 per point of intelligence. With ED Quibell we have refined that for zero-intelligence robot brains (TL12 and below). Where a multiple-crew vehicle (e.g. a starship!) is to be fully automated, how brains, control panels, a crew stations work out is more of a problem. I am going to experiment with some starship designs to see if principles of design emerge in line with keeping it simple as possible while keeping interesting possibilities in mind.
Yup... another concern I have is that when you start trying to build robots on a scale that would be routinely encountered (again the "human sized" robots of 50 to 100 liters, things you'd find in someone's home or office, etc.) those vehicle rules will prove insufficient to the task... I just don't think they considered anything like this when they were designed. I haven't, however, yet had time to really dig into it.
Lastly, one more thing. An observer of this thread e-mailed to me a text file of a comprehensive draft for a robot supplement for Mega Traveller. It covers a lot of ground that I had not even considered yet. I think it is a complete waste if we don't use his excellent work for a fan-published supplement (by publish, I just mean lay out and circulate a free PDF) and of course we'd acknowledge his authorship.
Sure, ideas are good.