Assembly manual Elektor Proton · PDF fileELEKTOR PROTON ROBOT ASSEMBLY MANUAL V1.2 Page 3 How...

V1.2

Bart Huyskens

Elektor Proton Robot

ASSEMBLY MANUAL

ELEKTOR PROTON ROBOT

ELEKTOR PROTON ROBOT ASSEMBLY MANUAL V1.2

Content:

How to solder wires together ..........................................................................................................3

IR distance sensors ..........................................................................................................................6

LCD ............................................................................................................................................... 11

Loudspeaker ................................................................................................................................. 14

Push buttons ................................................................................................................................. 16

Gripper brackets ........................................................................................................................... 18

Gripper assembly .......................................................................................................................... 19

Wheels + motors ........................................................................................................................... 24

Ball casters .................................................................................................................................... 26

Line follow PCB ............................................................................................................................. 27

Head ............................................................................................................................................. 31

Battery + main switch ................................................................................................................... 39

Motor driver PCB .......................................................................................................................... 44

Audio PCB ..................................................................................................................................... 47

Mother board PCB ........................................................................................................................ 50

Connecting all the cables............................................................................................................... 51

PIC board + programmer ............................................................................................................... 56

AVR board + programmer ............................................................................................................. 60

MASTER DEMO PROGRAM ............................................................................................................ 64

BLOCK SCHEMATIC ........................................................................................................................ 66


How to solder wires together

Soldering two wires together is not easy if you do it for the first time. This is a short guide on how I

do this.

Picture Description

Cut pieces of heat shrink tube of approx 2 cm in length

Put a heat shrink tube of 2 cm over each wire and slide it away from the place that you want to join the wires. The heat of the soldering may not reach the heat shrink tube.

Strip the wires of both cable assemblies over a length of 1.5 cm


Turn the wires into each other firmly. Make sure that the surface is quite smooth. This should be a firm connection, however, until it is soldered be aware that you do not pull these wires to hard, else they will come loose.


Solder the wires together.

Wait until the soldered joint cools off and now slide the heat shrink tube over the soldered joint.

Use a lighter or a soldering iron to heat the heat shrink tube. This tube will the shrink and firmly protect the joint for short circuits with other wires.


IR distance sensors

List of components:

Name Number Graphic

Plexi robot parts 1 of all


GP2Y0A21YK Distance sensors

3

Cable Assemblies with small connector that fits in the sensor

3

Cable assembly 3 wire 3

3

Bolts: M3x16 6

M3x16


Nuts: M3 6

M3

Spiral wrap 3

26 cm

HEATSHRINK tube 1.6mm

3 Pieces of 2 cm


Cable assembly:

Solder the two cables together as in the drawing. Be aware that colours of the wires

may not always be the same as on the drawing.

3

5V

SIG

GND

27cm To SHARP

IR SENSOR

1 of 3

TO MB

J5 = LEFT

J10 = FRONT

J12 = RIGHT

5V

SIG

GND

WELLER

Mounting instructions

Picture Description

Put the wire wrap round the cable assemblies.

Place the cable assemblies trough the correct holes.


Connect the cable assemblies to the 3 Sharp IR sensors

Mount the 3 sharp IR sensors with the M3x16 bolts and M3 screws.


LCD

List of components:

Name Number Graphic

LCD03 1

Cable assemblies 4 wires

2

4

Bolts: M2.5x16 4 M2,5x16

Nuts: M2.5 4

M2.5

3 mm black round spacer

4

Spiral wrap 1

23 cm


4 Pieces of 2 cm

Cable assembly:



Be sure to mark the LCD side with “LCD” to avoid switching both sides of the cable.

4 4

24 cmTo LCD

5V

SCL

SDA

GND

5V

SDA

SCL

GND

To MB

J11 = SER LCD

WELLER

LCD

MARK “LCD” !



Picture Description

Remove the jumper from the back of the LCD. This puts the LCD in I2C communication mode.

Mount the LCD in the square hole in the front of the plexi with the M2,5x16 nuts and bolts. A nice trick for this is to put the bolts in while robot is on it’s head and slide the robot further over the table every time you put one of the 4 bolts in.


Be aware that you put the black 3mm spacers between the plexi and the LCD.

Put the wire wrap round the cable assembly.

Connect the cable assembly to the LCD (with the connector marked “LCD” on the LCD side)


Loudspeaker

List of components:

Name Number Graphic

Loudspeaker 1


1 2

Bolts: M3x16 4

M3x16

Nuts: M3 4

M3


4

Spiral wrap 1

18 cm HEATSHRINK tube 1.6mm

2 Pieces of 2 cm



Picture Description

Solder the two wires of the cable assembly to the 2 connections of the loudspeaker. Polarity is not important. Be careful not to heat the connections of the loudspeaker to much – else it could be damaged. Put the wire wrap round the cable assembly.

Mount the loudspeaker in the correct place in the front of the plexi. Make sure the you place the 3mm black spacers between the loudspeaker and the plexi.


Push buttons

List of components:

Name Number Graphic

Red push button 1

Black push button 1


2

2

Spiral wrap 2

16cm


Cable assemblies:

WELLER

2

17cmTO MB

J35 = SWR

WELLER

2

17cmTO MB

J17 = SWB


Picture Description

Solder the push buttons to the cable assemblies. Put the wire wrap round the cable assembly.

Screw the push buttons in the 2 holes in the front of the clear plexi. RED = RIGHT BLACK = LEFT


Gripper brackets

List of components:

Name Number Graphic

Gripper bracket 2

Bolts: M3x16 4

M3x16

Nuts: M3 4

M3


Picture Description

Note that you can move the gripper-brackets inward or outwards by using the other holes. We will use the most inside position to start with.

Mount the gripper brackets to the front of the clear plexi as in the picture. Use the M3x16 nuts and bolts


Gripper assembly

List of components:

Name Number Graphic

Servo motors 2

Red plexi gripper parts

4

Black plastic servo extensions

2

20 mm black Hex spacer

6

M3 x 20


Black nylon drive fastener

8

M3 x 8 Hex bolt 12

M3x8

Screw 2.2x6.5 4

Spiral wrap 2

20cm



Picture Description

Unscrew the 4 long screws on the bottom of the servo. Be aware that the servo does not fall apart.

Fit the black plastic servo extension to the bottom of the servo – so that the round cylinder is in line with the axis of the servo. Screw the 4 long screws back on (but be careful with screwing them on with too much force).

Place the bottom red plexi gripper part over the servo wire.


Mount the top red plexi gripper part on top of the servo with the 4 plastic drive fasteners.

Mount the 3 black 20mm hex spacers on the gripper with 6 M3x8 Hex bolts.

Mount the whole gripper into one of the gripper brackets in front of the robot. You might need to pull the brackets open a bit to fit the servo in. It is a very tight fit. Be careful not to break anything! Turn the shaft of the servo – so that it stands in its center position.


Use two small 2.2x6.5mm screws to screw the servo to the bracket. Do exactly the same for the other gripper, but be aware that this needs to be the mirror of the first gripper.

Put some spiral wrap round the two servo cables.

Pull the servo cables into the body.


Wheels + motors

List of components:

Name Number Graphic

RD02 – Robot drive system

1

M3 x 6 6

M3x6



Picture Description

Mount the motors to the chassis of the robot.

Mount the wheels to the axis of the motor. Use the long inbus key that is in the RD02 package.


Ball casters

List of components:

Name Number Graphic

Ball casters 2

M2x16 (Do not use the bolt that come with the ball casters – they are not long enough)

4

M2x16


Picture Description

Use the M2x16 bolts to mount the ball casters to the front and back of the proton robot. (Do not use the bolt that come with the ball casters – they are not long enough) There are two spacers in the ball caster package - Use the thin spacers between the ball caster and the chassis. Test it and make sure that both ball casters do not touch the ground at the same time. The large wheels should always touch the ground – even if the surface is not perfectly even.


Line follow PCB

List of components:

Name Number Graphic

Linefollow PCB 1


2

5

Bolts: M3x16 2

M3x16

Nuts: M3 2

M3


4

Spiral wrap 1

24cm HEATSHRINK tube 1.6mm

5 Pieces of 2 cm

Cable assembly:



5

5

25 cmTo

LINEFOLLOW

PCB

5V

CNT

LFT

GND

RGT

To MB J3 =

LINE SENS

WELLER



Picture Description

Connect the cable assembly to the linefollow PCB.

Use 2 x 2 3 mm spacers to determine the correct position of the linefollow sensors. Use 2 M3 x 20 bolts. (not 4) Pull the cable assembly trough the rectangular hole into the body of the Proton.

Mount the linefollow PCB – using only 2 M3 nuts and bolts. (this is enough)


M3x20M3x20

REFLECTING SURFACE

1-5mm

Use the 3mm spacers to position the PCB so that the sensors are exactly between 1 and 5 mm from the reflecting surface (the ground). (between 2 and 4mm is even better)


Head

List of components:

Name Number Graphic

Servo pan and tilt kit

1

red plexi plexi part (back of the head)

1

Set of 4 different plexi parts + Head PCB.

1 red 3 milk 1 PCB


2

2


Cable assemblies 4wires

2

4

M3 x 16 4

M3x16

M3 Nuts 6

M3

M2.5 x 8 3 M2,5x8

M2.5 3

M2,5

M3 x 30 2

M3x28

M3 acorn locking nuts

2

M3

Spiral wrap 1 1

36cm

15cm


6 Pieces of 2 cm


Cable assembly:



Make these cable assemblies as long as possible (38-40cm is OK)

4 4

40 cm To HEAD PCB

J3 = I2C +

Power

12V

SDA

SCL

GND

12V

SDA

SCL

GND

To MB

J20 HEAD

WELLER

2

2

40 cm To HEAD PCB

J1 = CONN

SOUND

TO MB

J4 = AUDIO

WELLER

Picture Description

Screw the largest black metal bracket to the servo. Use only these specific holes. Use two small metal black tapping screws from the pan & tilt package. Be aware of the position of the metal bracket on the servo – it should be exactly as on this picture.


Mount the smaller metal bracket on the large metal bracket using the black bolt, black spacer and black nylon acorn locking nut. Place the black spacer between the two brackets – so that – when they turn – they do not touch each other. Turn the locking nut quite tightly, but not too tight. The servo still needs to be able to position this bracket.


Use two small screws from the pan & tilt kit to screw the other side of the bracket to the white part of the servo. Make sure to fit it so that the bracket can move up and down. (use the centre-one of the 3 holes in the white servo piece for the screws)

Mount the pan & tilt kit to the top of the Proton. Use M3x16 nuts and bolts. Take your time and do not get frustrated – there is not much place for your fingers and screwdriver, buts as you can see here – at the end – you will succeed.


Place the “left-right” servo in the ‘facing left’ position to determine what maximum cable length they need. Mark the connectors in some way that you know them apart afterwards (up/dn – lft/rgt) Use 15 cm spiral wrap to tie them together. !! for some reason, not all servo’s come with the same length of cable. In some cases it will be necessary that you make the cable of one of the servo’s a few cm longer. – in that case – make it just as long as the other servo cable. This is best done by cutting them and soldering a few pieces of wire in between.

Use 3 M2.5 x 8 nuts and bolts to mount the red backplane to the black servo bracket.


Take the 4 plexi parts and the head-PCB as shown on the picture

Connect the two cable assemblies to the 4pin and 2pin connectors on the head PCB as shown in the picture. Use 36 cm spiral wrap to tie them together.


FRONT –

RED –

3m

m

MIL

K –

4m

m

MIL

K –

3m

m

PCB –

HEAD 2

mm

MIL

K –

Bac

k –

10m

m

Bac

k –

RED –

3m

m

Use 2 M3x30 bolts and 2 M3 Nuts to screw all these parts to the red backplane part that’s already connected to the pan&tilt kit. The M3 acorn locking nuts have just an esthetical value. Be aware that all these parts have a certain position in the head.


Battery + main switch

List of components:

Name Number Graphic

Battery HGL1.3-12V 1

Switch 1


1

2

Extra wires (black and red) 10cm

1 black 1 red

HEATSHRINK tube 1.6mm RED 5cm BLACK 5cm

1 red 1 black

Terminal faston 6.35 2

Tie wrap >=24 cm 1

Spiral wrap 1 1

36cm


15cm

HEATSHRINK tube 1.6mm Clear

6 Pieces of 2 cm

Cable assembly:

Exact instructions on how to make this cable assembly are in the mounting

instructions part.

Be aware that the normal colour coding does not apply here!

WELLER2

To MB

J23 = BATT

+

-

20cm 10cm

5cm

+-

WELLER


Picture Description

ATTENTION! Be aware that a 12V battery has an enormous power (not in volts but in amps) that can damage the proton. Follow these instructions carefully!


On this picture – you can see that the red wire of the cable assembly connects to the GND or minus of the PCB and that the brown wire connects to the positive of the PCB. Be aware that the normal colour coding does not apply on this cable!!!

Strip the separate red and black wire over 1cm.

Solder the wires to the terminal fastons firmly


Put the red heatschrink tube over the brown wire and the black heatschrink tube over the red wire. The reason for this is to make the colour coding of the wires normal again (red = + and black = -)

Solder the two red wires together. Connect the two brown wires to the switch with the screw contacts.

Use spiral wrap to make a nice cable assembly of this.


Place the whole cable assembly trough the hole for the switch.

Press the switch firmly until it goes no further.

Mount the battery with a 24 cm tie wrap as on the picture. Connect the red wire (the wire with the red heatschrink tube round it) to the positive pole of the battery. Connect the black wire (the wire with the black heatschrink tube round it) to the negative pole of the battery.


Motor driver PCB

List of components:

Name Number Graphic

MD25 PCB 1

M3 x 10 bolts 4

M3x10

Nuts: M3 4

M3


4

Cable assembly 2 wires

1 2

Cable assembly 3 wires

2 3

Spiral wrap 1

1

15cm

10cm

HEATSHRINK tube 1.6mm Clear

3 Pieces of 2 cm


Cable assembly:



3

SDA

SCL

GND

15cmTO MB

J18 = MD25

WELLER

3

TO MD25


Picture Description

Remove the 2 jumpers. This puts the MD25 motor driver module in I2C mode.

Take the plexi base plate with 8 holes in it.


Mount the MD25 motor driver PCB to the base plate. Use:

4 M3x10 bolts

4 M3 nuts

4 3mm black spacers

2

To MB

J25=MPWR 11cm

Prepare a two wire cable as in the drawing. Be aware that again – normal colour coding does not apply here. Brown = 12V and red = Gnd.

Screw the 2 wire cable into the Header. ATTENTION: RED = +12V = FRONT SIDE BROWN = GND = BACK SIDE

Connect the 3 wire cable assembly to the 3 pin male connector on the MD25 PCB as on the picture. Place Spiral wrap round both cables.


Audio PCB

List of components:

Name Number Graphic

1

7 pin header 1

4 pin header 1

M3 x 8 BOLT 6

M3x8

12mm Hex Nylon black M3 standoffs

3



Picture Description

Place the 7 pin header and the 4 pin header in the holes as on this picture.

WELLER

Flip the Audio PCB and solder the 7 pin header and the 4 pin header to the PCB. Pay attention that these headers should be soldered on the PCB in a 90° angle!


Screw the 3 Hex Nylon black M3 standoffs with 3 M3x8mm bolts to the audio PCB as on the picture. 3 is enough – the 7 pin connector is in the way of the 4th standoff.

The 7 pin and 4 pin headers should pit nicely to the 7 pin and 4 pin connectors at the bottom of the Body PCB. (Body PCB is also referred to as Motherboard PCB) Use 3 M3x8 mm bolts to connect the audio PCB to the Motherboard or Body PCB.


Mother board PCB List of components:

Name Number Graphic

Motherboard PCB (also referred to as Body PCB)

1

M3 x 8 BOLT 8

M3x8

20mm Hex Nylon black M3 standoffs

4


Picture Description


Connecting all the cables


Picture Description

MD25 I2C J18 Connect the 3 wire cable coming from the MD25 motor driver module to J18 of the Body PCB.

MD25 POWER J25 Connect the 2 wire cable coming from the MD25 motor driver module to J25 of the Body PCB.

Slide the Plexi plate in the lowest slot. MOTORS Connect both motors to the 2 connectors on the MD25 motor driver module. Left motor to the left connector, right motor to the right connector.


SWITCH RED J35 SWITCH BLACK J17 Connect the 2 wire cables coming from the red and black push buttons respectively to J35 and J17 of the Body PCB.

SHARP IR LEFT J5 SHARP IR FRONT J10 SHARP IR RIGHT J12 Connect the 3 wire cables coming from the left, front and right Sharp IR sensors respectively to J5, J10 and J12 of the Body PCB.

LINEFOLLOW J3 Connect the 5 wire cable coming from the linesensor PCB to J3 of the Body PCB.


BATTERY POWER J23 Connect the 2 wire cable coming from the Battery and Switch to J23 of the Body PCB.

TEST BATTERY POWER Turn the Main switch on – If all 3 leds light up = power is OK!

LCD J11 Connect the 4 wire cable coming from the LCD to J11 of the Body PCB.


SPEAKER J29 Connect the 2 wire cable coming from the Speaker to J29 of the Body PCB.

HEAD 4 wire J20 HEAD 2 wire J4 Connect the 4 wire cable coming from the HEAD to J20 of the Body PCB. Connect the 2 wire cable coming from the HEAD to J4 of the Body PCB.

SERVO HEAD UP/DN J30 SERVO HEAD LFT/RGT J31 Connect the 3 wire cable coming from the UP/DOWN servo to J30. Connect the 3 wire cable coming from the LEFT/RIGHT servo to J31. Be aware of the exact polarity. Red = 6V Black = GND Yellow = Signal.


SERVO GRIP LEFT J33 SERVO GRIP RIGHT J34 Connect the 3 wire cable coming from the LEFT servo to J33. Connect the 3 wire cable coming from the RIGHT servo to J34. Be aware of the exact polarity. Red = 6V Black = GND Yellow = Signal.


PIC board + programmer

List of components:

Name Number Graphic

PIC ADD-ON Board 1

PICKIT2 NOT SUPPLIED BY ELEKTOR!! You could order this at Farnell or any other electronics supplier.

1

6 pin male connector 1

6 wire cable assembly 1

6


Spiral wrap 1

25cm


6 Pieces of 2 cm

Cable assembly:



WELLER

66

MALE Connector to

fit into PICKIT2

FEMALE CONNECTOR to fit

into MALE connector on PIC

add on board (PROTON)

FEMALE Connector


Picture Description

Mount the PIC Add-on board as on the picture. Take care that all pins are in the correct holes.


VPP/MCLRVDD = 5V

VSS = GNDICSPDAT/PGDICSPCLK/PGCAux–not used

The 6 pins of the white connector have all the necessary pins to program the PIC in High Voltage programming mode. HVP is the most common way of programming PIC microcontrollers. The cheapest programmers are PICKIT2 and PICKIT3, but als In circuit debuggers as the ICD3 etc use these 5 pins to program the PIC.

VPP/MCLRVDD = 5V

VSS = GNDICSPDAT/PGDICSPCLK/PGCAux–not used

Connecting a PICKIT2 “in circuit programmer” to the PIC add-on board should be done in this way.

WELLER

66

MALE Connector to

fit into PICKIT2

FEMALE CONNECTOR to fit

into MALE connector on PIC

add on board (PROTON)

FEMALE Connector

This is a drawing of the cable assembly that connects the PICKIT2 and the PROTON PIC board.

This picture shows how to connect a PICKIT2 programmer to the proton PIC board.


CONNECTION SCHEME PIC ADD ON BOARD


AVR board + programmer

List of components:

Name Number Graphic

AVR ADD-ON Board 1

AVRISPMK2 This in circuit programmer is not supplied by Elektor. It is for sale at any electronics supplier.

1



Picture Description

Mount the AVR Add-on board as on the picture. Take care that all pins are in the correct holes.

Connect the AVRISPMK2 programmer to the 6 pin header on the AVR add-on board. Any other programmer that uses these 6 pins for in circuit programming (Most others do!) can be used.

Pay special attention to the unusual way the connector fits into the 6 pin header.


Layout 6 pin AVRISP Header


CONNECTION SCHEME AVR ADD ON BOARD


MASTER DEMO PROGRAM The proton is delivered with a PIC and/or an AVR microcontroller add-on board.

These microcontrollers are pre-programmed by Elektor with a “master demo program”. (No worries

is you erase this program – this “mater demo program” is downloadable from the Elektor/Proton site

for free.)

This “master demo program” is actually a set of 9 demo programs that can be selected by the red

and black push buttons. The function of the selected program and that of the push buttons is

visualised on the LCD.

The 9 programs make users able to test the hardware and connections of all the different sensors

and actuators of the Proton robot.

program functionality

1 Led and buzzer test on motherboard

2 Servo test neck

3 MP3 and WAV player test

4 Test of RGB leds in the eyes

5 Set of different test programs for the

motors and encoders

6 Test of the 3 IR line follow sensors

7 Test of the 3 SHARP IR distance

sensors

8 Test of the ultrasonic distance sensor

in the nose of the head

9 Test of the Gripper module

The schematic on the next page visualises the 9 different programs and their functionality.


Master Demo Program

This file is already in the PIC or

AVR when you receive the

Proton.

The Flowcode and Hex file of this

program are open source and

can be downloaded for free from

the Elektor website.


BLOCK SCHEMATIC

Assembly manual Elektor Proton · PDF fileELEKTOR PROTON ROBOT ASSEMBLY MANUAL V1.2 Page 3 How...

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Transcript of Assembly manual Elektor Proton · PDF fileELEKTOR PROTON ROBOT ASSEMBLY MANUAL V1.2 Page 3 How...